TurboChef NGC-1007 Service Manual Download Page 86

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IR Element and Catalytic Converter Parts

116. 101312

Snap Ring

117. 102449

Washer, Shim

118. NGC-3003 IR Element

119. NGC-1116 Shield, Microwave

120. 101688

Screw, #8 x 1/2” Sht Metal PTH

121. NGC-1030 Clip, Catalytic Converter

(Non-SBK)

NGC-1233 Clip, Catalytic Converter

(SBK)

122. NGC-1012 Catalytic Converter

FIGURE 39: IR ELEMENT AND CATALYTIC CONVERTER PARTS AND ASSEMBLY

Chapter 8: IR Element and Catalytic Converter - Page 52

116

117

118

119

120

121

122

119

118

122

SERVICE PARTS AND ILLUSTRATIONS

Wire Harness Replacement P/N

Low Voltage Harness

123. 100185

Old Switch Setup

NGC-1418 New Switch Setup

Line Voltage Harness

124. NGC-1150-1 North America

NGC-1150-2 UK, Ireland, Brazil

NGC-1150-3 Eu, Asia, Pacific, Au, Japan

Magnetron Wire

125. 100186

All NGC Ovens

Power Cord

126. 100187

USA

100194

NGC ED - Europe, Asia, Pacific

100195

UK, Ireland, Brazil

103187

NGC EW- Europe, Asia, Pacific

103195

Australia

NGC-1383 Japan 3Ph

NGC-1390 Japan 1Ph

Summary of Contents for NGC-1007

Page 1: ...Accelerating the World of Cooking TurboChef Service Manual FOR THE TURBOCHEF NGC TORNADO OVEN 800 90TURBO Part Number NGC 1007 Revision D September 2007...

Page 2: ...For further information call 800 90TURBO 1 214 379 6000 Accelerating the World of Cooking...

Page 3: ...t is switched off NEVER attempt to touch the element during operation while the oven is warm or while the oven is cooling down x DO NOT store flammable vapors or liquids such as gasoline in the vicini...

Page 4: ...stic and Intl Electrical Specifications 1 2 Power Input 2 Delivery and Product Placement 2 Lifting and Placing the Oven 2 Built In Installation 2 Installation Near Open Heat Source 3 Oven Restraint Ki...

Page 5: ...o Check a Magnetron for Open Shorted Filament 33 How to Check a High Voltage Transformer or Filament Transformer 33 High Voltage and Filament Transformer Resistance Table 33 Microwave System Troublesh...

Page 6: ...el Enclosure and Parts 66 Figure 18 Monitor Circuit Shown in Failsafe State 67 Figure 20 Microwave System Parts 67 Figure 21 Microwave System Parts 68 Figure 22 Wave Guide Cover Wave Guide Removal and...

Page 7: ...has a damaged cord or plug is not working properly or has been damaged or dropped See POWER CORD REPLACEMENT page ii x DO NOT cover or block any openings on the appliance x DO NOT store this applianc...

Page 8: ...s a grounding wire with a grounding plug which must be plugged into an outlet that is properly installed and grounded Consult a qualified electrician or serviceman if uncertain about the ability to fo...

Page 9: ...Installation Specifications and Maintenance...

Page 10: ...AGE SENSOR TECHNOLOGY Voltage 208 240 VAC 60 Hz 1 phase Amperage Nameplate rating 30 Amp 3 wire including ground Cordset 10 gauge 3 conductor 5 foot cordset Plug NEMA 6 30 1 SPECS AND DIMENSIONS Dimen...

Page 11: ...MENT Remove oven from carton Immediately note any damage and contact shipping company within 24 hours in order to file a claim TurboChef is not responsible if the product is damaged in shipment Remove...

Page 12: ...owing Verify oven location has a minimum 6 152 mm clearance on top and minimum 2 51 mm of clearance on each side If the oven is being placed near a grill or stove there must be a divider between the o...

Page 13: ...the bottom oven a Remove the two screws that hold the top panel to the back of the oven see bottom arrows on Figure 4 b Align the holes on the stacking bracket with the holes on the oven and reinstall...

Page 14: ...m Element Be sure the bottom element is cool prior to lifting WARNING The bottom element operates at appx 1000 F 537 C Step 5 Remove Particles and Spray Oven Interior with TurboChef Oven Cleaner Using...

Page 15: ...Theory of Operation...

Page 16: ...pendent heat transfer mechanism is individually identified For instance if an oven is experiencing difficulties browning the food focus on CONVECTION SYSTEM and or BOTTOM IR AND CCV Focus on MICROWAVE...

Page 17: ...on a per recipe basis IRSI is the set temperature of the IR element during the READY STATE or idle IRSI setting can be adjusted in the TEST MODE page 16 Actual Temperature Cook Cavity TCC The actual...

Page 18: ...event time percentages for a recipe must equal 100 Percentage Air An event subset that specifies the relative amount of impingement airflow speed of convection motor dur ing an event Valid between 10...

Page 19: ...Fault Codes...

Page 20: ...d display F1 BLOWER Upon turning on the oven the control will attempt to restart the motor If the restart is suc cessful the fault code will be cleared The fault is also cleared from the display at th...

Page 21: ...control detects continuity on the open thermocouple circuit F8 Heat Low Fault is not logged in counter Displays during WARM UP or SELF TEST if the cook cavity tempera ture TCC fails to rise at least...

Page 22: ...The Control System...

Page 23: ...K3 SSR DUAL BOARD CONTROL I O KEYPAD VFD DISPLAY IR THERMOCOUPLE EC THERMOCOUPLE CC THERMOCOUPLE SUPPLY POWER 24VDC IR ELEMENT COMMAND CONVECTION HEATER COMMAND MAG HV COMMAND COMMAND MAG FILAMENT MO...

Page 24: ...or When the door opens the order is P S M IR Thermocouple Type K Thermocouple Embedded in the IR ele ment the IR thermocouple measures the inter nal sheath temperature of the IR element Valid IR set p...

Page 25: ...1 The STEST key initiates a self test to test all major components of the oven including door switches To run the self test press the corresponding soft key once Press the BACK key to return to the OV...

Page 26: ...incorrect temperature has been entered consult the factory before changing this value STATUS INDICATORS See Figures 9 and 10 on page 15 P Primary switch closed or open S Secondary switch closed or ope...

Page 27: ...otal duration of the cook cycle Enter the desired time and press ENTER b IR element temperature IRSP The temperature the lower radiant element will maintain during the entire cook cycle Valid temperat...

Page 28: ...Enable the Done Screen to Cook an item longer after the end of a cook cycle Save an adjusted cook time only if Time Screen is also enabled Time Screen To enable disable the Time Screen Figure 16 see t...

Page 29: ...codes are not available on some ovens Oven must be in Off or Cooling Down mode USER CONFIGURABLE OPTIONS ACCESS CODES The following codes allow access to each function screen listed To enable disable...

Page 30: ...ammed 4 NGC 3023 Display Svc Kit includes Items 5 6 and 7 5 101954 Spacer 1 2 Lg Aluminum 6 100193 3 Pin Power Cable 7 100184 26 Pin Ribbon Cable 8 NGC 1110 1 Keypad NGC Standard NGC 1110 2 Keypad NGC...

Page 31: ...trol DOES beep when any Key on the Keypad is pressed Check all connections between the I O control board and display Correct any loose connections If connections are OK and 5 VDC is present on the J3...

Page 32: ...chanical relay is in good working order If relay is OK refer to pages 34 35 F3 MAGNETRON CURRENT LOW for detailed troubleshooting F8 Heat Rise Low NOTE This message occurs in WARM UP and SELF TEST if...

Page 33: ...ss the MGTRON key to actuate the microwave While holding down the MGTRON key watch the CC and IR temperatures If either temperature bounces substantially there may be a noise EMI problem To correct th...

Page 34: ...The Microwave System...

Page 35: ...when the oven door opens the control will turn off the microwave If the monitor switch opens before the primary or sec ondary switches abnormal operation the monitor switch de energizes the monitor re...

Page 36: ...plus the charged high voltage capacitor supply down to 4800 volts to the magnetron when the voltage goes negative high voltage diode is back biased 4 The magnetron converts negative input voltage and...

Page 37: ...ransformer 2 per oven 1 per kit Europe Asia Pacific Australia UK Ireland Mexico Brazil NGC 3061 3 Filament Transformer 2 per oven 1 per kit Japan 16 100083 Mag Cooling Fan 17 101273 K3 Monitor Relay 1...

Page 38: ...ow in case of an over current scenario such as a high voltage transformer or capacitor failure The fuse also blows if the Monitor Circuit trips the failsafe High Voltage Capacitors Capacitor rating is...

Page 39: ...eplacing the covers To remove the wave guide covers reference Figure 22 and follow the steps below 1 Locate the fourteen 14 8 sheet metal screws securing the broken wave guide cover If the screw heads...

Page 40: ...it 4 Remove the two 2 right and left most screws Item 30 that secure the wave guide to the oven floor 5 The wave guide should now be loose enough to easily slide out from the right side of the oven NO...

Page 41: ...st be 220 VAC Latin America 200 VAC Japan or 230 VAC International MEASURING RF LEAKAGE FOR MICROWAVE SAFETY An RF microwave leakage test must be performed at the conclusion of the following service t...

Page 42: ...voltage from becoming posi tive thus as the high voltage winding of the trans former goes to 2400 VPK the high voltage capacitor is charged to 2400 volts When the high voltage wind ing starts to go t...

Page 43: ...rcuit 4 Connect the ohmmeter between the capacitor terminals The ohmmeter should momentarily indicate a low impedance and then slowly return to infinite resistance 5 Reverse the ohmmeter leads and rep...

Page 44: ...m the primary side of the HV transformers and looping through the black plastic current trans former on the main control board and back to the HV transformers 4 Press and hold the MGTRON soft key on t...

Page 45: ...the bottom right side of the wiring harness When the MGTRON key is pressed and held 24VDC should be present on pins 1 5 Reference the schematics pages 55 63 for physical location of pins on QC3 conne...

Page 46: ...n and replace the diodes Diodes OK Unplug the oven and replace the defective magnetron Magnetron Circuit is Drawing Excessive Current Measure resistance of high voltage capacitor s Resistance should s...

Page 47: ...The Oven Door...

Page 48: ...tom of the left and right hinge assemblies Insert a screw or nail into the holes to keep the hinges open while removing the oven door 3 Locate and remove the 38 screws 3 each side 4 Remove the plastic...

Page 49: ...d to finish closing it it is out of adjustment NOTE See Figure 26 page 37 Items 43 46 for illus tration of hardware WARNING Check for excessive Microwave Leakage after adjusting the Cook Door See page...

Page 50: ...ody is 0 02 0 5mm Figure 29 7 Restore power to the oven Allow the oven to warm to its set temperature 8 Allow the oven to remain at the set temperature for ten 10 minutes after warm up before making a...

Page 51: ...ow the steps below 1 Ensure the oven door is adjusted Refer to ADJUST ING THE COOK DOOR on page 38 2 Turn on oven and bring it to the set temperature WARNING Oven surfaces are HOT Use extreme caution...

Page 52: ...31 Monitor Switch Adjustment and Assembly Old Switch Setup FIGURE 30 Door Switch Assembly and Parts Old Switch Setup 58 61 57 1 53 63 59 54 60 55 62 2 56 x2 68 67 68 64 66 68 67 69 65 REF x2 THE OVEN...

Page 53: ...e included with Item 74 adjust switch lever position to a maximum allowable distance of 0 030 0 762 mm 6 Open and close the door several times to verify the switch gap PRIMARY SWITCH ADJUSTMENT AND PA...

Page 54: ...en press ENTER 8 Open the oven door and verify P S and M disengage in sequence 9 Close the oven door and verify the M S and P engage in sequence 10 Energize the Microwave System and open the door 11 V...

Page 55: ...te EX PO SU RE TO EX CE SS IV E M IC RO W AV E EN ER GY PR EC AU TI ON S A AF IN D EV IT ER UN E EX PO SI TI ON PR EC AU TI ON S FO R SA FE US E TO AV OI D PO SS IB LE 1 Ob jec t cau ght in Do or d e...

Page 56: ...luminum tape Item 98 x DO NOT block openings at bottom 3 Item 94 insulation not shown for clarity 4 Door should be flat without twisting or warpage after tightening all hardware 5 Refer to the chart t...

Page 57: ...or Toggle doesn t rotate freely or smoothly Replace any worn parts Clean assembly and re lubricate all rotating parts Be sure to grease the torsion spring See Figure 30 Actuator and toggle OK Check ad...

Page 58: ...The Convection Circuit...

Page 59: ...operate the convection motor described above The motor controller is controlled on command from the I O control board and a 0 10VDC speed command from the I O control board High Limit Thermostat The...

Page 60: ...ION CIRCUIT BLOWER MOTOR PARTS Figure 38 102 101688 Screw 8 x 1 2 PTH 103 NGC 1081 Cover Motor 104 100906 Nut 1 4 20 Flange 105 NGC 1025 Assy Blower Motor 106 NGC 3007 Kit Fan Blade 107 NGC 1024 Seali...

Page 61: ...SSR K4 defective Unplug oven and replace K4 OK Unplug oven and verify all wiring Verify P1 voltage on I O board is 5 0VDC 0 02 see Figure 40 page 54 F2 Cook Temperature Low 1 Verify Cook Door Operati...

Page 62: ...nnect control wiring b Ground OR 9 to chassis to remove backlight on A c Keeping OR 9 grounded check terminals on the control wiring plug for 0 10 VDC control voltage reference drawing of QC3 plug on...

Page 63: ...IR Element and Catalytic Converter...

Page 64: ...nctions by substantially lowering the combustion temperature of grease entrained in the air path to approximately the same temperature of the airflow thus the grease burns and breaks down into CO2 and...

Page 65: ...order to get the terminals and lead wires into the cavity and through the mounting holes CAUTION Do not allow the thermocouple lead wires to kink They are solid wire and will break 3 Once the IR elem...

Page 66: ...Schematics and Schematic Components...

Page 67: ...ens only Low Voltage Components Display VFD I O Control Board Keypad NGC Oven Switch Primary Interlock Switch Secondary Interlock Switch Monitor Safety Thermocouple CC Thermocouple EC Thermostat Magne...

Page 68: ...I O BOARD SCHEMATIC 54 FIGURE 40 I O Control Board and Test Point Locations...

Page 69: ...BL155 BL160 BR290 BL150 BR260 BR260 OR270 OR270 BR280 BL155 BR285 OR275 BR280 BL340 OR440 BR450 OR360 BL370 BL355 BL350 M2HV M1HV M2FC M1FC M2CD M2FA M1FA M2F M1F VOLTAGE MODULE BL000 BR000 O R 13 B K...

Page 70: ...6 7 2 K2 B MAG OUT 3 4 1 2 3 4 1 F FA FAN MAG 1 3 4 2 4 3 2 1 A B B A B A E MI FILTER 1 P HASE V SUPPLY V POWER 24VDC L N K1 FILAMENT K2 ANODE K3 MONITOR EC FAN NO C OT2 120 F 1 3 2 V AC IN I O C OMMO...

Page 71: ...12 RED 29 32 1 HT 38 21 11 31 MANUAL RESET OT1 B RD 19 P IN1 P IN2 P IN3 P IN5 P IN4 P IN6 RD 19 WH 2 WH 27 P IN1 P IN3 P IN4 P IN5 P IN2 P IN6 9 7 1 4 3 6 1 7 9 6 3 4 OR 11 BK 23 RD 16 R D 16 RD 24 B...

Page 72: ...D 29 32 1 HT 38 21 11 31 MANUAL RESET OT1 B RD 19 P IN1 P IN2 P IN3 P IN5 P IN4 P IN6 RD 19 WH 2 WH 27 P IN1 P IN3 P IN4 P IN5 P IN2 P IN6 9 7 1 4 3 6 1 7 9 6 3 4 OR 11 BK 23 RD 16 R D 16 RD 24 BK 25...

Page 73: ...F I G U R E 45 NGC Brazil Tornado Schematic NGC BRAZIL SCHEMATIC 63...

Page 74: ...Service Parts and Illustrations...

Page 75: ...LE SUPPLY POWER 24VDC IR ELEMENT COMMAND CONVECTION HEATER COMMAND MAG HV COMMAND COMMAND MAG FILAMENT MONITOR INTERLOCK INTERLOCK INTERLOCK 24VDC 24VDC 24VDC COMMON CMD COMMON 24VDC PRIMARY SWITCH SE...

Page 76: ...100508 Smart Card Blank Varies Smart Card Programmed 4 NGC 3023 Display Svc Kit includes Items 5 6 and 7 5 101954 Spacer 1 2 Lg Aluminum 6 100193 3 Pin Power Cable 7 100184 26 Pin Ribbon Cable 8 NGC 1...

Page 77: ...NGC 3017 Wave Guide Rear 23 NGC 3016 Wave Guide Front See Comprehensive Part List page 79 11 NGC 3062 1 HV Transformer 2 per oven 1 per kit USA Latin America Korea NGC 3062 2 HV Transformer 2 per oven...

Page 78: ...ave Guide Cover Parts 29 NGC 3036 Kit Wave Guide Cover Includes Item 31 and sealant 30 101666 Screws 8 32 x 1 2 Cap 31 101701 Screws 8 SST 32 NGC 1047 Support Frame 33 102809 Screws 8 32 x 3 8 CSK 100...

Page 79: ...Cook Door Parts 38 102809 8 32 x 3 8 PFH CSK 39 NGC 3067 Assy Oven Door Traditional NGC 3067 2 Assy Oven Door SBK 40 NGC 1061 Hinge Block 41 102804 Right Hinge 42 102805 Left Hinge 43 101381 10 32 x...

Page 80: ...WITCH ASSEMBLY AND PARTS Chapter 6 The Oven Door Page 41 SERVICE PARTS AND ILLUSTRATIONS FIGURE 29 PRIMARY AND SECONDARY INTERLOCKS ADJUSTMENT AND PARTS OLD SWITCH SETUP Chapter 6 The Oven Door Page 4...

Page 81: ...e 41 68 67 68 64 66 68 67 69 65 REF x2 75 71 72 73 74 APPLY HI TEMP GREASE TO AREA 70 FIGURE 32 PRIMARY INTERLOCK ADJUSTMENT AND PARTS NEW SWITCH SETUP Chapter 6 The Oven Door Page 42 Primary Safety S...

Page 82: ...NEW SWITCH SETUP Chapter 6 The Oven Door Page 43 Secondary and Monitor Safety Switch Parts 77 102804 Hinge Right 78 102012 Switch Limit Micro x2 79 NGC 1126 Plate Door Switch 80 101914 Standoff 8 32 F...

Page 83: ...ru e la por te 2 Do or tha t doe s not clo se pro per ly d e tan che ite son t bris es DA NG ER EU SE AU X M IC RO O ND ES Ne ten tez pas de fair fon ctio nne r cet fou r 2 Si la por te ne se ferm e p...

Page 84: ...COM ENABLE I O COM STATUS OK I O COM L2 L1 OR 9 BL530 BL500 OR540 BL510 K5 K4 B1 B2 A1 A2 SSR HT520 WH 28 WH 30 RD 19 BR600 1 2 HX ELEMENT 3300 WATTS 13 1 OHMS BOTTOM IR 3000 WATTS 14 4 OHMS BOTTOM I...

Page 85: ...6000 Not shown for clarity FIGURE 38 CONVECTION CIRCUIT ASSEMBLY AND PARTS Chapter 7 Convection Circuit Page 48 NO TIC E This devi cecom plies with Part 18ofthe FCC Rule s Ope ratio nissubj ect tothe...

Page 86: ...apter 8 IR Element and Catalytic Converter Page 52 116 x4 117 118 119 120 121 122 119 118 122 76 SERVICE PARTS AND ILLUSTRATIONS Wire Harness Replacement P N Low Voltage Harness 123 100185 Old Switch...

Page 87: ...131 101688 Screw 8 Serrated Phillips TRHD CRES 132 102921 Screw 8 32 x 3 8 PPHD SEM Int Tooth SS 133 NGC 1071 2 Cover Bottom Front 134 100785 Leg NGC Black Plastic 100781 Leg NGC Stainless Steel 135 1...

Page 88: ...ft Side 146 NGC 1213 2 Cover Right Side 147 NGC 1211 Cover Top 148 102756 Screw 8 x 1 2 Lg TORX HD Security 149 101691 Screw 8 Serrated Phillips TRHD CRES 150 102922 Screw 8 32 x 3 8 PPHD SEM Int Toot...

Page 89: ...Comprehensive Part List...

Page 90: ...estic 103180 None Cleaner TurboChef Oven International 103380 None Cleaner Wave Guide Cover Domestic 103183 None Cleaner Wave Guide Cover International 103383 None Clip Catalytic Converter Standard NG...

Page 91: ...GC 3011 38 Hinge Left 102805 26 Hinge Right 102804 26 31 33 34 Insulation Door 1 NGC 1125 1 35 Insulation Door 2 NGC 1125 2 35 Insulator Adhesive NGC 1163 21 Keypad OUT NGC 1110 4 17 Keypad Standard N...

Page 92: ...netron Fan Standard USA NGC 3030 1 20 Relay K7 Magnetron Fan Standard Europe Asia Pacific MPh NGC 3030 4 20 Relay K7 Magnetron Fan Standard Europe SPh NGC 3030 7 20 Relay K7 Magnetron Fan Standard Lat...

Page 93: ...t Frame NGC 1047 22 Switch Door Assembly NGC 3033 29 32 Switch Door Component 102012 29 30 31 32 33 34 Tape Aluminum 102698 35 Thermocouple Electrical Compartment EC 700 1199 None Thermocouple Cook Ca...

Page 94: ...elerating the World of Cooking Headquarters Six Concourse Parkway Suite 1900 Atlanta Georgia 30328 678 987 1700 PHONE 678 987 1750 FAX TURBOCHEF COM Global Operations 4240 International Parkway Suite...

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