TurboChef D1 User manual

TurboChef

INCORPORATED
Service Manual
for
Model D Ovens
Models Covered in this Manual:
D1 Domestic
D1A Domestic D1-EC European
D1B Domestic D1B-EC European Please See Inside for Important
D2 Domestic D2-EC European Steps before Operating Oven.
D2B Domestic D2B-EC European
Customer Service Toll Free Number [phone]
Copyright February 15, 1995 TurboChef, Inc., All Rights Reserved
Revision A February 16, 1996
Revision B February 27, 1997

TABLE OF CONTENTS
Contents Page
IMPORTANT SAFETY INSTRUCTIONS - READ FIRST . . . . . . . . . . . . . . 4, 5
RF INTERFERENCE CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6
GROUNDING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER CORD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Model Identification and Ratings . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.0 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Glossary of Common Terms . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Basic Operation Instructions (Version R Software) . . . . . . . . . 11
2.3 Developing Cook Settings and Programming . . . . . . . . . . . . 13
2.4 Control Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Basic Maintenance Procedure - Care and Cleaning . . . . . . 19
3.2 Self Test and On-Line Error Messages . . . . . . . . . . . . . . . . . 19
3.3 Self Test Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4 On-Line Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.0 CONVECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 Blower Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2 Blower Motor Controller Tests . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Blower Defective Messages . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.4 Blower Motor Controller Defective Messages . . . . . . . . . . . . 26
4.5 Blower Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.7 Heat Exchanger Defective Messages . . . . . . . . . . . . . . . . . 32
5.0 MICROWAVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1 Measuring Microwave Radiation Leakage . . . . . . . . . . . . . . . 33
5.2 How to Turn Magnetrons On/Off for Testing. . . . . . . . . . . . . . . 34
5.3 Microwave Component Locations. . . . . . . . . . . . . . . . . . . . . . . 35
5.4 Microwave Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5 Magnetron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.6 High Voltage Magnetron Transformer . . . . . . . . . . . . . . . . . 38
5.7 High Voltage Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.8 High Voltage Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.9 Microwave Mode Stirrer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.10 Magnetron Over-temperature Switch . . . . . . . . . . . . . . . . . . 41
5.11 RF Output Monitor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.0 COOK DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.1 Cook Door and Bearing Assembly . . . . . . . . . . . . . . . . . . . . 42
6.2 Cook Door and Interlock Switch Adjustments . . . . . . . . . . . . 43

7.0 FILTER DOOR SWITCH LOCATION / ASSEMBLY . . . . . . . . . . . . 44
8.0 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.1 Electrical Enclosure Assembly . . . . . . . . . . . . . . . . . . . . . . 45
8.2 Electrical Enclosure Diagnostic Message . . . . . . . . . . . . . . 46
8.3 Display and Keypad Assembly . . . . . . . . . . . . . . . . . . . . . . 46
9.0 MAG. FAN/COOLING FAN/TRANSFORMERS/DIODES/CAPS . . . . 47
10.0 WHERE AND HOW TO OBTAIN PARTS . . . . . . . . . . . . . . . . . . . . 48
10.1 How to Order Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.2 Returning Critical Components . . . . . . . . . . . . . . . . . . . . . . . 49
10.3 Substitution of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.0 CASE HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11.1 Common Door Related Problems . . . . . . . . . . . . . . . . . . . . 50
11.2 Miscellaneous Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.0 DIAGNOSTIC INFORMATION (Including Schematics) . . . . . . . . . 52
13.0 LIMITED WARRANTY FOR “D” SERIES OVENS. . . . . . . . . . . . . . . 61
APPENDIX A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INTERCONNECT BETWEEN OVEN AND MODEM . . . . . . . . . . . . 62
DIRECT CONNECT BETWEEN OVEN AND PC . . . . . . . . . . . . . . . 62

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 4 of 62
IMPORTANT SAFETY INSTRUCTIONS
WHEN USING ELECTRICAL APPLIANCES, BASIC SAFETY
PRECAUTIONS SHOULD BE FOLLOWED, INCLUDING THE FOLLOWING:
WARNING - To reduce the risk of burns, electric shock, fire, injury to persons or exposure
to excessive microwave energy:
1. Read all instructions before using the appliance.
2. Read and follow the specific “PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING
TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY” found on page 5.
3. This appliance must be grounded. Connect only to properly grounded outlet. See “GROUNDING
INSTRUCTIONS” found on page 6.
4. Install or locate this appliance only in accordance with the provided installation instructions.
5. Some products such as whole eggs and sealed containers - for example, closed glass jars - may explode
and SHOULD NOT be heated in this oven.
6. Use this appliance only for its intended use as described in the owner’s manual. DO NOT use corrosive
chemicals or vapors in this appliance. This type of oven is specifically designed to heat, cook, or dry
food. It is NOT designed for industrial or laboratory use.
7. Children SHOULD NOT use this appliance.
8. DO NOT operate this appliance if it has a damaged cord or plug, if it is not working properly, or if it has
been damaged or dropped. See “POWER SUPPLY CORD REPLACEMENT” found on page 6.
9. This appliance should be serviced only by qualified service personnel
10. DO NOT cover or block any openings on the appliance.
11. DO NOT store this appliance outdoors. DO NOT use this product near water - for example, near a
kitchen sink, in a wet basement, or near a swimming pool, and the like.
12. DO NOT immerse cord or plug in water.
13. Keep cord away; from heated surfaces.
14. DO NOT let cord hang over edge of table or counter.
15. DO NOT use a water jet for cleaning.
16. See “Basic Maintenance Procedures - Care and Cleaning” provided in this manual.
17. To reduce the risk of fire in the oven cavity:
a) DO NOT overcook food. Carefully attend appliance if paper, plastic, or other combustible materials
are placed inside the oven to facilitate cooking.
b) Remove wire twist-ties from paper or plastic bag in oven.
c) If materials inside the oven should ignite, keep oven door closed, turn oven off, and disconnect the
power cord, or shut off power at the fuse or circuit breaker panel.
d) DO NOT use the cavity for storage purposes. DO NOT leave paper products, cooking utensils, or
food in the cavity when not in use.
SAVE THESE INSTRUCTIONS

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 5 of 62
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING
SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE
MICROWAVE ENERGY
1. DO NOT attempt to operate this oven with the door open since open-door operation
can result in harmful exposure to microwave energy. It is important not to defeat or
tamper with the safety interlocks.
2. DO NOT place any object between the oven front face and the door or allow soil or
cleaner residue to accumulate on the sealing surfaces.
3. Make the following safety checks on all ovens to be serviced before activating the
magnetron or other microwave source, and make repairs as necessary:
a) Interlock operation.
b) Proper door closing.
c) Door (bent).
d) Hinges and latches (broken or loosened).
e) Door seals and sealing surfaces (arcing, wear, and other damage).
f) Evidence of dropping or abuse.
4. Before turning on microwave power for any service test or inspection within the
microwave generating compartments, check the magnetron, wave guide, or
transmission line, and cavity for proper alignment, integrity, and connection.
5. Any defective or mis-aligned components in the interlock, monitor, door seal, and
microwave generation and transmission systems must be repaired, replaced, or
adjusted by procedures described in this manual before the oven is released to the
owner.
6. The oven SHOULD NOT be adjusted or repaired by anyone except properly qualified
service personnel.
7. A microwave leakage check to verify compliance with the Federal Performance
Standard MUST BE performed on each oven prior to release to the owner.
SAVE THESE INSTRUCTIONS

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 6 of 62
RF INTERFERENCE CONSIDERATIONS
This oven generates radio frequency signals. This device has been tested and
determined to be in compliance with applicable part of FCC part 18 requirements and to
the protection requirements of Council Directive 89/336/EEC on the approximation of the
laws of the Member States relating to electromagnetic compatibility at the time of
manufacture. However, some other equipment may exhibit sensitivity to signals below
these limits resulting in interference with that equipment.
If your equipment experiences interference, the following steps should be considered:
1. Increase the physical separation between this oven and the sensitive equipment.
2. If the sensitive device can be grounded, do so following accepted grounding practices.
3. If battery powered microphones are being affected, insure that the batteries are fully
charged.
4. Keep sensitive equipment on electrically separate circuits, if possible.
5. DO NOT route intercom wires, microphone wires, or speaker cables near oven.
GROUNDING INSTRUCTIONS
This appliance MUST BE grounded. In the event of an electrical short circuit, grounding
reduces the risk of electric shock by providing an escape wire for the electric current. This
appliance is equipped with a cord having a grounding wire with a grounding plug. The
plug must be plugged into an outlet that is properly installed and grounded.
WARNING - Improper use of the grounding can result in a risk of electric shock.
Consult a qualified electrician or serviceman if the grounding instructions are not
completely understood, or if doubt exists as to whether the appliance is properly
grounded.
DO NOT use an extension cord. If the power supply cord is too short, have a qualified
electrician or serviceman install an outlet near the appliance.
POWER SUPPLY CORD REPLACEMENT
If the power supply cord is damaged, it MUST BE replaced by the manufacturer or its
service agent or a similarly qualified person in order to avoid a hazard.
SAVE THESE INSTRUCTIONS

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 7 of 62
1.0 INSTALLATION
1.1 Model Identification and Rating
MODEL NUMBER AND NAMEPLATE INFORMATION is located on the nameplate
label on the rear cover of the oven.
NOTE: An electrical schematic is supplied with the oven. It is located in the
back of the Display Panel in an envelope. An electrical schematic is also
provided in the Owner’s Manual for the oven. Please return the schematic to
the storage envelope for future use.
SERIAL NUMBER IDENTIFICATION is located on a serial number label attached
underneath the lower right corner of the oven frame.
The following provides an identification of serial numbers assigned by TurboChef to
specific currently manufactured oven types, and a brief description of the ovens.
D-1 Oven (Domestic) Serial Numbers 10001 through 10055.
First of this series was produced in April 1994. Cook Chamber, Frame,
Door and outer covers made of stainless steel.
D1-A Oven (Domestic) Serial Numbers 10056 through 10092.
Same basic oven as the D-1. Door was changed from stainless steel to
nickel-plated aluminum, to lighten it for easier operation and removal.
The machined door flange on the previous model became a formed part.
D2-EC Oven (European) Serial Numbers 10141 through 10210.
Extension of D1-A. The height of the cook chamber increased from 4” to
5.25” to allow cooking of a greater variety of foods. Heater element
terminals extend through the top cover of the heat exchanger rather than
the left side, for easier assembly. A secondary audio alarm has been
added to improve volume at cook cycle completion. A D-Sub 9 pin
connector is brought to the rear of the oven for computerized
downloading of recipes. Power wiring is WYE connected, 50 Hz.
D2B Oven (Domestic) Serial Numbers 10101 through 10120, 100101 →
→→
→,
, 300101 →
→→
→, 400101 →
→→
→.
This domestic version has the height of the cook chamber increased from
4” to 5.25” to allow cooking of a greater variety of foods. The electrical
control box moved from the front of the oven to the right side. Heater
element terminals extend through the top cover of the heat exchanger
rather than the left side, for easier assembly. A secondary audio alarm
has been added to improve volume at cook cycle completion. A D-Sub 9
pin connector is brought to the rear of the oven for computerized
downloading of recipes. (Same as D2B-EC except power wiring is delta
connected, 60 Hz.)
D2B-EC Oven (European) Serial Numbers 10211 through 10220, 10221(First CE
Qualified) through 10446, 110101 →
→→
→, 310101 →
→→
→, 410101 →
→→
→.
Same as the D2B Oven, except power wiring is WYE connected, 50 Hz.

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 8 of 62
1.2 INSTALLATION INSTRUCTIONS
1.2.1 Contractor Requirements
TurboChef ovens must be installed by a qualified food service equipment contractor,
dealer or service agency. The installation must be made in conjunction with an
understanding of applicable CE, UL, NSF, and FDA requirements and appropriate local
codes.
Before starting installation, the owner/installer should understand and agree upon:
a) The installation policies of TurboChef Inc.
b) The installation plan based on overview and preparation.
c) The responsibility for testing, instruction of proper operation, use & care, and
preventative maintenance.
WARNING
a) DEATH, INJURY, AND EQUIPMENT DAMAGE could result from improper installation
of the TurboChef oven or installation of a unit which has been damaged during
shipment or storage. Either of these conditions could void the equipment warranty.
b) DO NOT INSTALL a TurboChef oven suspected of damage.
c) INSTALL the TurboChef oven according to the policies and procedures outlined in this
manual.
1.2.2 Installation Precautions
TurboChef Inc. designs and manufactures equipment to comply with applicable CE,
UL, FDA, and FCC requirements. All equipment is designed and certified for safe
operation when installed in accordance with local and or national codes. Many local
codes exist, and it is the responsibility of the owner and installer to comply with these
codes.
In no event shall the manufacturer assume any liability for damages or injury resulting
from installations which are not in compliance with the instructions and codes listed
above. The manufacturer shall not assume liability for damage or injury resulting from
improper installation of equipment including temporary or unstable work stations or
counter tops.
The counter top or work surface must be able to support the weight of 650 pounds and
should not exceed 30 inches in height.
The oven should be installed level front to back and side to side. The oven legs may
be bolted to the counter top if desired and must be bolted if it is placed on a rolling cart.

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 9 of 62
1.3 Specifications
1.3.1 Physical characteristics:
D1 Models D2 Models
Width: 31.5” 31.5”
Height: 39.0” 41.3”
Depth: 35.5” 35.5”
Weight: 534 lb. 540 lb.
1.3.2 Electrical Characteristics:
Characteristic Domestic Models EC Models
Voltage: 208-240 Volts AC, 60 Hz 400-415 Volts AC, 50 Hz
Phases: Three Phase, 3~ Three Phase Wye, 3N~
Connections: 4 wire (incl. ground) 5-wire (incl. ground)
Current: 33-35 Amp 18 Amp
Power Usage (Maximums):
Convection Oven: 9 Kw 9 Kw
Microwave Oven: 4 Kw 4 Kw
Microwave Frequency: 2450 MHz 2450 MHz
Connector Type: NEMA 15-50 IEC 309 - 32 Amp
The unit is supplied with a 4’ power cord that includes a male connector. The outlet
box, receptacle and wall plate are to be furnished by the installing contractor.

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 10 of 62
2.0 OPERATING INSTRUCTIONS
2.1 Glossary of Common Terms
Air - Percent of convection air flow during a cook event.
Constant Parameter - The constant parameter, Cook Temperature Set Point, is used
by all Cook Settings.
Cook Chamber - Cavity in which the food products are cooked.
Cook Cycle - Time of operation for a Cook Setting.
Cook Setting - Recipe. The food product cooking process. It consists of duration,
percentage of the hot air flow (AIR) required and microwave (TW)
required.
Cook Mode - Execute the Cook setting instructions for selected food product.
Cooking Product - The food product to be cooked in the oven.
Cook Event – Segment of a cook cycle, up to four events can be used for each cycle.
COOL-DOWN Mode - Turns OFF all oven components except the cooling fan.
CURE Mode - Used to cure RTV sealant on waveguide plug.
Display - Primary interface to relay messages to the operator.
Duration - Time, in seconds, of a single cook event.
EDIT Mode - Mode used to adjust the Cook Setting parameters.
Keypad - Primary interface for the operator to control the oven.
HEAT - Selects the cook temperature set point in EDIT mode.
LED - Individual light indicators numbered 1 through 16 to show component status.
MAINTenance Mode - Mode used by authorized service personnel to check the
operation of oven components.
Mode - The software environment which allows certain operations to occur. There are
several modes, NORMAL, COOK, DIAGNOSTIC, EDIT and
MAINTenance, in which the oven can operate.
NORMAL Operation Mode - Mode used to perform the "NORMAL" oven operations,
such as, monitor the key pad for requests to cook or change mode, and
maintain the oven at the Cook Temperature Set Point.
Parameter - A Cook Setting consists of two different kinds of parameters. Those which
stay constant during a Cook Setting execution and those which can vary
during different events of a Cook Setting.
Radio Frequency (RF) - The term used to describe the microwave emissions.
Recipe - Cook Setting. The food product cooking plan. It will consist of up to four
Cook Events, each of which consists of duration, percentage usage of the
hot air flow (AIR) required and microwave (TW) required.
RESUME - Continues Cook Cycle if interrupted such as by opening oven door.
TW - Percent of Microwave used during a Cook Event.
WARM-UP Mode - Mode that brings the oven up to the Cook Temperature Set Point.

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 11 of 62
2.2 Basic Operating Instructions for Model D Ovens.(Version R
software)
Power On
The power switch is on the lower right side, towards the front when you are facing the
oven. Pull the power switch toward the top of the machine to turn on.
Self Test/Warm Up
1. The machine will go through a self-check to verify that the critical components
(magnetrons, heat exchanger and blower) are operational. (If the oven displays the
message “Cooling Down”, Depress the “Warm Up” key to start.)
CAUTION: Self Test results are unpredictable if the oven door or filter door are not closed
prior to or opened during the self test.
2. If any of the critical components are malfunctioning, the machine will stop at the end
of the component test displaying a message identifying the faulty component. Refer
to Troubleshooting Section for message definition.
3. When the self-check is complete and satisfactory, the machine will start warming up
and display "WARMING UP, HX Temp …". The HX Temp is the temperature of the
heat exchanger. When the HX temperature exceeds a value determined by the
cook temperature set point, the blower begins circulating air and the display
indicates “CC Temp/HX Temp” on the lower line. The CC Temp is the temperature
in the oven cook chamber. When the CC temperature reaches the cook
temperature set point, warm-up is complete. The Warm Up should take
approximately 30 minutes (shorter if the machine has not cooled down completely).
4. When the oven is ready to cook, it will display:
SelectRecipe Or SelectRecipe
CC480°HX 571°If in Diagnostic Mode Heat 480/571°
Running A Recipe/Cook Setting
CAUTION: DO NOT operate the oven without food or a suitable microwave load in the
cook chamber. This may damage the oven.
CAUTION: DO NOT operate oven with metal in the cook chamber. This will damage
the oven.
1. Open cooking chamber door by pulling the handle up, then pull the handle outward
until the door opens.
2. Place the food product in the appropriate position on the cooking platter.
3. Close cooking chamber door by pushing forward on the handle until the door shuts,
then push the handle down to latch into place.
4. Press the desired food (group) Cook Setting button.

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5. Press a button numbered 1 to 6 (subgroup) for food quantity or special food
definition. The display indicates the food group/subgroup name and cook time
seconds (counting down).
6. When the cooking cycle is complete, the oven will beep and the display will indicate
"PLEASE REMOVE FOOD FROM OVEN". Remove the food product from the
oven. Note: Food will continue to cook with radiant and convection energy when left
in the oven due to the high cook chamber temperature.
7. The cook cycle is now ready to begin again.
Notes:
• If for any reason you want to stop the cooking cycle, press the “STOP” button at any
time. The user may close the door and press "RESUME" for the Cook Setting to
continue.
• If the oven door or filter door is opened during a cook cycle, the oven will
automatically stop the current Cook Setting. The user may close the door and press
“RESUME” for the Cook Setting to continue.
• If the “DARKER” key is depressed, 25% of the last cooking event is added as
additional cook time.
• Protection against exposure to microwave energy: Safety interlocks in the oven
doors prevent or terminate microwave operation when either the oven door or filter
door is open.
Power Off
The power switch is on the lower right side, toward the front when you are facing the
oven. Push the power switch toward the bottom of the machine to de-energize.
OTHER OVEN OPERATIONS
Cool Down
An alternative to turning the power switch OFF when cooking is finished for the day is
the "COOL DOWN" mode. This mode turns off all the major components but still allows
the cooling fan to operate to keep the internal temperatures of the oven electrical parts
down while the oven is cooling. To select "COOL DOWN" press the "COOL DOWN"
button followed by the "ENTER" button. Opening the oven door will shorten the cool
down time.
Warm Up
To remove the oven from "COOL DOWN" and return to the ready to cook state, press
the "WARM UP" button. Make sure the oven and filter doors are securely closed.
Remember, the oven may take up to 30 minutes to warm up.
Stop Key
The "STOP" key can be utilized to stop the Cook Setting at any point in the cook cycle.
The Cook Setting may be continued by pressing the "RESUME" key. The "STOP" key
is also used to exit other modes such as "EDIT" or "MAINTENANCE".

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Darker Key
The "DARKER" key may be used to cook the food an additional 25% of the last cooking
event. This may be useful to brown the food product or make the product well done.
Resume Key
The "RESUME" key allows a Cook Setting which was interrupted by the "STOP" key or
opening the oven door to continue.
MAINTenance, Edit, and Heat Keys
Described in the section on DEVELOPING COOK SETTINGS AND PROGRAMMING.
2.3 Developing Cook Settings and Programming
2.3.1 How to Develop your Cook Settings
Cooking with a TurboChef oven is different and exciting! It delivers hot food faster, at a
higher quality than other ovens available today.
TurboChef uses both hot air and microwave energy to cook food. If you have
experience with either a convection oven or microwave oven you will see similarities
and significant differences. The key to creating good cook settings for your food is to
understand the following rules of thumb. When you get a list of cook settings you are
happy with, write them down and store the list in a safe place.
1. TurboChef uses a moving shroud of hot air to surround the food. This locks in the
food’s moisture.
2. The hot air provides coloring and crispness of most foods. The higher the air
velocity, the faster heat energy is transferred to the exterior surface of the food.
3. The microwave provides heat to the center of the food. Don’t try to do all the
cooking with microwave!
4. The weight of food determines the total time required to cook. The more weight, the
longer the time required. (Most medium thick crust pizzas cook in about 100
seconds.)
5. Be careful to balance the use of microwave on thick or frozen products. A tendency
will develop to overcook the edges before reaching the desired internal temperature.
6. Microwave seems to work best in the early stages of cooking, then use hot air to
finish the cooking. Although a continuous lower level of microwave is beneficial for
thick or frozen foods.
7. Color seems to develop mostly at the end of the cooking cycle. Higher velocity air in
the later stages of cooking will strongly control the food’s color.
Don’t be afraid to experiment! Write down your current cook settings and then start
testing. You can always go back to the old cook settings in a few seconds. Enjoy the
power and flexibility of your TurboChef System.

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 14 of 62
2.3.2 Reviewing Existing Cook Settings
NOTE: The EDIT feature is not available on some of the EC oven versions. COOK
and HEAT settings must be input through the RS 232 connector on the control card.
1. Press the EDIT key, key in the Access Number (PIN) and press ENTER.
2. Press the Recipe GROUP key you wish to review and observe the group name.
3. Press ENTER.
4. Press a SUBGROUP key, key 1 through key 6, and the subgroup name appears to
the right of the GROUP name.
5. Press ENTER and observe the Duration in seconds, the percentage of hot air flow
(Air), and the percentage of microwave (TW) for the first event of the cook cycle.
6. Press ENTER and the second event parameters are displayed. The Cook Setting
ends when an event with zero time duration is encountered or all four events are
used. If the first event of a Cook Setting has a duration of zero time, no Cook
Setting is defined.
7. Press EDIT to return to step 2.
8. Press HEAT and observe the cook temperature set point. The cook temperature
set point applies to all GROUP/SUBGROUP cook settings.
9. Press STOP to return to normal operation.
2.3.3 Editing Cook Settings
NOTE: The EDIT feature is not available on some of the EC oven versions. COOK
and HEAT settings must be input through the RS 232 connector on the control card.
1. Press the EDIT key, enter Access Number (PIN) and Press ENTER.
2. Press the Recipe GROUP name key of the Cook Setting you wish to edit.
3. Edit the food group name using the left/right arrow keys to position the blinking
cursor. Nine characters are available for the food group name. Repeat pressing an
alpha/numeric key until the needed letter or number appears. The up/down arrow
keys select upper case or lower case letters. Use the right arrow key to advance to
the next character position. The SP key replaces a character with a space and
advances to the next character position. Press ENTER when the new name is
complete. Note: When the existing information is correct, simply press ENTER to
store the information and move to the next display.
4. Press a SUBGROUP key number, 1 through 6, to indicate quantity or special food
definition.
5. As described in Step 3, likewise edit the subgroup name. Press ENTER.
6. Observe the three parameters for cook event 1. The blinking cursor indicates the
Event Duration is selected for editing. Use the left/right arrow keys to select the
other parameters, blower power (AIR) or microwave power (TW).

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 15 of 62
7. Using the numeric section of the keypad, key in the correct time or percentage and
press ENTER. The blinking cursor will advance to the next parameter. Note: You
must press ENTER to replace previous settings with new settings. Be careful not to
change a setting and move the blinking cursor without pressing ENTER to save the
setting.
8. If a setting is not changed and ENTER is pressed, the display will advance to the
next event. Use the up/down arrow keys to select any of the 4 events to edit or
review.
9. When 4 events are not required for the cook setting, set the duration of the first
unused event to 0. Note: If the duration of event #1 is set to 0, the
GROUP/SUBGROUP selection has no cook setting and displays “NO RECIPE
ENTERED” when selected.
10.Valid event duration time is 1 to 255 seconds. However, the combined duration of
all events, i.e., the total Cook Setting cook time, should not exceed 999 seconds.
Valid blower power (AIR) is 20% to 100% in 5% increments. Valid microwave power
(TW) is 0%, 50%, or 100%.
11.Anytime you wish to select a different Cook Setting to edit, press EDIT and return to
step 2.
12.To review or edit the Cook Temperature Set Point, press HEAT. Enter a new
temperature from the numeric keys and press ENTER. Note: The same Cook
Temperature Set Point applies to all GROUP/SUBGROUP Cook Settings.
13.When editing is complete, press STOP to return to normal cook mode.
2.3.4 Maintenance Operations
The MAINTenance mode allows you to manually control the various hardware
components of the oven and display operational information
Press the MAINTenance key, enter access number (PIN) and press ENTER.
1. VER key alternately displays the version of the oven operating system (hardware
and software) and the oven recipe version if loaded by the TurboComm utility.
2. HTR key turns the Heat Exchanger On and Off. If the heat exchanger is over the
maximum allowed temperature (Approximately 700 degrees F), the heaters can not
be turned on. An over temperature thermostat also prevents heater runaway. LED
11 indicates heaters are selected (Note: early “B” versions do not use LED 11.) and
LED 16 indicates current is flowing to the heaters. This key also resets the COOK
TEMP TOO LOW message.
CAUTION: DO NOT leave the heaters on for long periods, as the oven will rapidly
heat to maximum allowed temperature (Approximately 700°
°°
°F(371°C)).

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 16 of 62
3. %BLO key increases the convection air flow in 10% increments. Repeat pressing
key to select new air speeds. When the air flow is 100%, the next key press resets
air flow to 0%. If the blower is Off (LED 7 is not illuminated) the %BLO key is
ignored.
4. BLR key turns the convection air blower On or Off. LED 7 indicates the status of
the blower motor speed controller. The blower will return to controlled operation
when MAINTenance is exited. This key also resets the BMSC DEFECTIVE
message.
5. M1 key energizes magnetron 1 when the key is held depressed. To conserve
power, the Heat Exchanger is turned OFF when the key is pressed. The display
provides an un-calibrated indication of the power level in the microwave waveguide
cavity. The power reading varies with the motion of the microwave stirrer blade.
The magnetron turns OFF when the key is released. This key also resets the Mag
RF FLUC LOW and Mag CURRENT LOW messages.
CAUTION: DO NOT hold the key more than 5 seconds without a cooking product
or suitable microwave load in the oven.
6. M2 key energizes magnetron 2 as described in step 5.
CAUTION: DO NOT hold the key more than 5 seconds without a cooking product
or suitable microwave load in the oven.
7. M12 key energizes both magnetrons 1 and 2 as described in step 5.
CAUTION: DO NOT hold the key more than 5 seconds without a cooking product
or suitable microwave load in the oven.
8. PIN key allows for entry of an alternate personal identification number for accessing
EDIT and MAINTenance modes. If TurboComm is implemented, the PIN will also
reset the “New Settings” message. Enter from 1 to 4 numbers or letters and press
ENTER. Be sure to keep a record of the PIN you choose. Note: this function resets
the previous PIN number.
9. CCC key displays the Cook Cycle Count. Press key a second time and a message
prompts to press SP/CLR (Group 14 key/MICRO) to reset the count to zero.
10.EC key displays the temperature of the electronics compartment. If the EC
thermocouple is open or missing, “EC THERMO OPEN” is displayed. The EC
temperature should not exceed 140°F(60°C) under normal conditions.

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 17 of 62
11.WARM key causes the MAINTenance mode to be exited and the WARM-UP mode
to be selected without executing SELF-TEST.
12.DIAG key performs two functions. The first press displays the heat exchanger rate
of temperature rise, degrees per minute. This number is used by the oven
operating system to replace heat lost during cooking and maintain cook temperature
when the oven is idle. If MAINTenance mode is exited after the first press, a
diagnostic display is presented during cook and heat maintenance cycles. The
display shows all parameters, RF power, percent air flow, CC and HX temperature,
and the accumulated and target BTU during cooking for each event.
The second press indicates if the temperature rise was measured or defaulted to
the last known measurement. The measurement is taken during oven warm up
when the initial cook chamber temperature is less than one half the cook
temperature set point. To keep the normal display, exit MAINTenance after the key
press showing the measured or default message.
13.IAF key selects the amount of air flow when the oven is idle (not Cooking). When
IAF is first pressed, the current Idle Air Flow is displayed. The IAF range is 0% to
50% in 5% increments. Repeat pressing the IAF key to select a new air flow. Then
press ENTER to set the new IAF.
14.CURE key places the oven in a state for curing RTV sealant. All oven functions
except the Heat Exchanger are turned Off. The HX is maintained at 200 degrees F.
A 6 hour count down is started with the display updated each second to show the
remaining time. At the end of 6 hours, the oven automatically enters the Cool Down
state (the Heat Exchanger is turned Off). Press Warm Up to return to normal
operation. During the cure count down, press any key and enter a valid PIN to
return to MAINTenance.
15.SN key is used to enter the oven serial number. The first time SN is pressed the
current serial number is displayed. A second press clears the serial number field
and awaits entry of a new number. Up to 6 numbers may be entered. The serial
number is updated when ENTER is pressed.
16.FF key is used to display and reset oven fault flag counters. Repeat pressing the
FF key to display the 6 faults, BMSC Status, Low Cook Temperature, Low Mag
Current, Low RF Fluctuation, Mag Thermo Switch, and EC Over Temperature. The
counters increment from 0 to 255 and roll over to 0. To reset a counter, repeat
pressing FF to select the fault and press SP/CLR.
Press the MAINTenance or STOP key to return to normal cooking operation. The
magnetrons and heaters are turned OFF, the blower controller is returned to the ON or
operational state and the air flow is set to the IAF setting before returning to normal
cooking operation.

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 18 of 62
2.3.5 Replacing Keypad Menu Label Strips
1. Remove menu label strips by inserting a small pointed object, such as a wooden
toothpick, under the keypad film and pull out until the strip appears and can be
removed by hand. Use caution in order to avoid damaging keys, cutting the keypad
film or scratching the stainless steel panel.
2. Install a new menu strip by holding the keypad slot open with a small pointed object
and sliding the new menu strip into place. Again, use caution to avoid cutting the
keypad film or scratching the stainless steel panel.
2.4 Control Panel Layout
2.4.1 Keypad Layout
Group A
VER
Group E
M1
Group J
CCC
Subgroup 1
IAF ABC1
Subgroup 2
SN DEF2
Subgroup 3
GHI3
MAINT
STOP
Group B
HTR
Group F
M2
Group K
EC
Subgroup 4
CURE JKL4
Subgroup 5
FF MNO5
Subgroup 6
PQR6
EDIT
WARM
UP
Group C
% BLR
Group G
M12
Group L
WARM ⇑
Group N
STU7
Group P
VW8
Group R
XYZ9
HEAT DARKER
Group D
BLR ⇐
Group H
PIN ⇒
Group M
DIAG ⇓
MICRO
SP/CLR
AIR+MICRO
0
AIR
ENTER
COOL
DOWN
RESUME
NOTE: Subscripts used in MAINTenance and EDIT modes only.
2.4.2 Status LED Indicator Layout
Cook Door Primary 1 ••9
Cook Door Secondary 2 ••10
Cook Door Monitor 3 ••11 Heat Exchanger *
Filter Door Primary 4 ••12 Magnetron 1 Temperature OK†
Filter Door Secondary 5 ••13 Magnetron 2 Temperature OK†
Filter Door Monitor 6 ••14 Magnetron 1 On
Blower Running 7 ••15 Magnetron 2 On
8
••16 Heat On
When light is on, item is active.
* LED 11 is not connected on early “B” Version Ovens, LED 11 is connected on ovens with
Serial Numbers greater than 100,000.
† LED’s 12 and 13 are connected on “B” Version Ovens only.

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 19 of 62
3.0 TROUBLESHOOTING
3.1 Basic Maintenance Procedures - Care and Cleaning
Oven cleanliness must be maintained to insure proper cooking. In particular the
following areas should be checked.
1. In order to improve food color and crispness, check for convection air blockage in:
a) Chamber Basket.
b) Grease Filter (In Filter Box).
c) Holes in roof of Oven Cooking Cavity.
d) Holes in Cooking Platter.
2. To maintain 100% microwave power, frequently clean all carbon deposits from:
a) Cook Platter.
b) Waveguide Cap
c) Inside of Oven Cooking Cavity.
3. To insure the lifetime of the oven:
a) Do not operate with metal in the Oven Cooking Cavity.
b) Do not operate with a damaged or missing Waveguide Cap.
c) Do not operate with a clogged cooling air filter.
3.2 Self Test and On-Line Error Messages
3.2.1 SELF TEST - Defective Messages (Rev R Software).
Refer to 3.3 Self Test Flow Chart to determine logic tests performed.
Note: When a “… Defective” Message is encountered, the operator may press any key
to continue the self-test. The software will track this fault for future verification.
Displayed Message GoTo Page
1. “BMSC DEFECTIVE” 4.3 25
2. “HX Heat Thermo OPEN” 4.7 32
3. “HX Heat °F RISE LOW” 4.7 32
4. “CC Heat Thermo OPEN” 4.7 32
5. “CC Heat °F RISE LOW” 4.7 32
6. “Mag 1 (2) CURRENT LOW” 5.4 36
7. “Mag 1 (2) RF FLUC LOW” 5.4 36
8. “Mag 1 (2) THERMO SW” 5.4 36
9. “Oven Door Open” 6.2 43
10.“Filter Door Open” 7.0 44
11.“Keypad DEFECTIVE” 8.3 46

TurboChef, Inc. 700-0655.DOC Rev B February 15, 1997 Page 20 of 62
3.2.2 ON LINE (while cooking) - Diagnostic Messages (Rev R Software).
Refer to 3.4 On-Line Flow Chart to determine logic tests performed.
Note: Only “Cook Temp Too Low” and “BMSC DEFECTIVE” cause a cook cycle to
terminate. Magnetron failures as well as cook temperature variances cause cook cycle
time extensions (shortening) to compensate for lost (increased) available cooking
energy. Each time another cook cycle is started, the faults are reset and retested.
Displayed Message GoTo Page
1. “BMSC DEFECTlVE” 4.3 25
2. “COOK TEMP TOO LOW” 4.7 32
3. “EC Temp ___ °F” 8.2 46
4. “Mag CURRENT LOW” 5.4 36
5. “Mag RF FLUC LOW” 5.4 36
6. “Mag THERMO SW” 5.4 36