TurboChef Encore Touch Rapid User manual

TM
CAUTION: Read the instructions before using the machine.
©2015 TurboChef Technologies, Inc.
Service Manual
   TM    

The information contained in this manual is important for the proper installation, use, maintenance,
and repair of this oven. Follow these procedures and instructions to help ensure satisfactory cooking
results and years of trouble-free service.
Errors – descriptive, typographic, or pictorial – are subject to correction. Specifications are subject to
change without notice.
Please carefully read this manual and retain it for future reference.
For further information, call
800.90TURBO
or
+1 214.379.6000

Important Safety Instructions
General Safety Information i
Reducing Fire Risk i
Grounding Instructions ii
Power Cord Replacement or Removal ii
Precautions to be Observed Before and During Servicing to Avoid Possible Exposure to
Excessive Microwave Energy ii
RF Interference Considerations iii
Protective Earth (Ground) Symbol iii
Equipotential Bonding Symbol iii
Specifications and Installation
Theory of Operation 1
New Features 1
Dimensions 1
Certifications 2
Oven Construction 2
Electrical Specifications 2
Installation 2
Unpacking Instructions 2
Installation Warnings - Read Before Lifting Oven 2
Installing the Oven 3
Installation Near Open Heat Source 3
Oven Restraint Kit 4
ChefComm Pro® 4
ChefComm LimitedTM 4
Date and Time Prompt 4
Voltage Selection 4
Ventilation 4
Cleaning
Daily Maintenance 5-6
Quarterly Maintenance 7
Oven Controls and Cooking
Oven Controls 9
Menu Cook Mode 10
Manual Cook Mode 13
Continued on next page...
Table of Contents

Info Mode
Information Screen 15
Serial Number 15
Menu Version 15
Sage Firmware Version 15
Phoenix Firmware Version 15
Service Number 15
Voltage - View Incoming 15
Tutorials 15
Counters Screen 15
Cook Counter 15
Total Cook Time 15
Magnetron Time 15
Total Time (oven on) 15
Fault Log 15
Power Cycles 15
Options Screen 15
Editing / 15
Cook More / 15
Load Menu / 15
Light Ring / 16
VAC / 16
Demo Mode / 16
Manual Cooking / 16
Diagnostic Mode / 16
F2 Bypass / 16
Cooking Stone / 16
Settings Screen 16
Temperature / 16
Language 17
Ethernet 17
Sound Volume 17
Set Date 17
Set Time 17
Auto On / 18
Auto Off / 18
Service Screen 18
Fault Log 18
Counters and Timers 19

Test Mode 19
Magnetron Test 19
Top Heater Test 19
Bottom Heater Test 19
Control Blower Speed 20
Manufacturing (Mfg) Screen 20
Oven Model 20
Serial Number 20
Load Menu from USB or Smart Card 21
Save Menu to USB or Smart Card 21
Firmware Update 22
Edit Mode
Edit Set Temperature 23
Edit Bottom Temperature Offset 23
Access Edit Items Screen 24
Name a Group 24
Delete a Group 25
Move a Group 25
Item Editing Options 26
Edit Settings 27
Name Item 29
Add from Cookbook 29
Change Group 30
Move Item 30
Delete Item 31
Oven Systems
Impingement System 33
Blower Motor 33
Blower Motor Speed Controller (BMSC) 33
Heater - Top 33
Heater - Bottom 33
High Limit Thermostat 33
Jetplate - Bottom 33
RTD - Top and Bottom 33
Solid State Relay - K4/K5 Heaters 33
Troubleshooting 33
Continued on next page...

Oven Door 34
Removing/Reinstalling the Oven Door 34
Adjusting the Oven Door 34
Interlock Switches 35
Relay - K3 Monitor 35
Adjusting the Primary, Secondary, and Monitor Switches 35
Measuring RF Leakage for Microwave Safety 36
Troubleshooting 36
Microwave System 37
Capacitors 37
Testing a Capacitor 37
Filament Transformers 37
Wiring the Filament Transformers 37
High-Voltage Transformers 38
Wiring the High-Voltage Transformers 38
Testing a Filament or High-Voltage Transformer 38
High-Voltage Diodes 38
Testing a High-Voltage Diode 39
Magnetrons 39
Magnetron Cooling Fans 39
Magnetron Thermostats 40
Testing a Magnetron for an Open/Shorted Filament 40
Relay - K1 Filament 40
Relay - K2 Anode 40
Relay - K7 Cooling Fans 40
Waveguides 40
Troubleshooting 40
Control System 41
Control Board (SAGE) 41
Display and UI Control Board (Phoenix) 41
Ethernet Extension Cable 41
LED Light Ring 41
MicroSD 41
Speaker 41
USB/Smart Card Reader 41
Troubleshooting 41

Power Components 42
Electrical Compartment Cooling Fan 42
Electrical Compartment Thermostat 42
Electrical Compartment Thermocouple 42
EMI Filter 42
Fuses 42
Power Supply 42
Relay - K6 Voltage 42
Relay - K7 All Cooling Fans 42
Voltage Sensor 43
Wire Harnesses 43
Troubleshooting 43
Filtering System 43
Catalytic Converter 43
Air Filter 43
Vent Catalyst 43
Troubleshooting 43
Troubleshooting
Overview of Troubleshooting 45
Fault Code Descriptions 45
F1 Blower Running Status Bad 47
F2 Cook Temperature Low 48
F3 Magnetron Current Low 49
F4 Door Monitor Defective 50
F5 Magnetron Over Temperature 50
F6 Electrical Compartment Temperature High 51
F7 RTD Open 51
F8 Heat Low 52
F9 Cook Cavity Temperature High 52
F10 Communication Failure 53
F12 Firmware Reboot 53
“Cook Door Open” Message when Door is Closed 54
No Display (Screen is Blank) 55
Touch Screen is Locked Up or Unresponsive 56
Oven Keeps Cooling Down, will not Warm Up 57
Menu will not Load - Smart Card 57
Menu will not Load - USB 58
Firmware will not Update 59
Food Not Cooking Properly 60
Steam Present During or After Cooking 61
Speaker not Beeping 61
Continued on next page...

Oven Schematic and Wire Harnesses
Relay Schematic 63
Oven Schematic 64
Wire Harness: Heater 65
Wire Harness: Cooling Fans 65
Wire Harness: HV Microwave Circuit 1 66
Wire Harness: HV Microwave Circuit 2 66
Wire Harness: Low Voltage 66
Wire Harness: Main Line Voltage 67-68
Encore 2 Appendix - Replacing Oven Components
Replacing Oven Components A-1
Oven Exterior A-2
Impingement System A-4
Microwave System A-6
Oven Door and Related Parts A-8
Control System A-10
Power Components A-12 – A-15

i
SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS
WARNING: When operating this oven, strictly adhere to the following safety precautions to
reduce the risk of burns, electric shock, fire, injury, damage to oven or property near oven, or
possible exposure to excessive microwave energy.
GENERAL SAFETY INFORMATION
a Read all instructions before using this appliance.
a Read and follow the specific “Precautions to be Observed Before and During Servicing to Avoid Possible
Exposure to Excessive Microwave Energy” found on page ii.
a This appliance must be grounded. Connect only to a properly grounded outlet. See “Grounding
Instructions” on page ii.
a Install or locate this appliance only in accordance with the provided installation instructions.
a This appliance should be serviced by qualified service personnel only. Contact the nearest authorized
service facility for examination, repair, or adjustment.
a Keep the cord away from heated surfaces.
a Liquids, such as water, coffee, or tea are able to be overheated beyond the boiling point without
appearing to be boiling. Visible bubbling or boiling when the container is removed from the microwave
oven is not always present.           
           .
a : The contents of feeding bottles and baby food jars must be stirred or shaken and the
temperature checked before consumption, in order to avoid burns (IEC 60335-2-90).
a Use this appliance only for its intended uses as described in this manual.
a Only use utensils that are suitable for use in microwave ovens (IEC 60335-2-90).
X   use corrosive chemicals or vapors in this appliance; it is not designed for industrial/laboratory use.
X :   heat liquids or other foods in sealed containers (e.g., jars, whole eggs, etc.) since
they are liable to explode.
X   allow children to use this appliance.
X   operate this appliance if it has a damaged cord or plug, is not working properly, or has been
damaged or dropped. See “Power Cord Replacement or Removal” found on page ii.
X   cover or block any openings on this appliance.
X   store this appliance outdoors.
X   use this product near water (e.g., near a kitchen sink, in a wet basement, near a swimming pool).
X   immerse the cord or plug in water.
X   let the cord hang over the edge of a table or counter.
X   use a water jet for cleaning. See pages 5-7 in this manual for proper cleaning procedures.
X   use this product without the bottom jetplate installed. The oven will not cook properly and
damage to the oven may occur.
X This appliance is not to be used by children or persons with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction.
X WARNING: Due to the nature of the appliance, the floors around it may be slippery.
REDUCING FIRE RISK
a Remove wire twist-ties from paper or plastic bags used to facilitate cooking in the oven.
a If materials inside the oven ignite, keep the oven door closed, turn the oven off, and disconnect the
power cord or shut off power at the fuse or circuit breaker panel.
a If smoke is observed, switch off or unplug the oven. Keep the door closed to stifle any flames.
X   use the cook cavity for storage purposes.
X   overcook food. Carefully attend to the oven if paper, plastic, or other combustible materials are
placed inside the oven to facilitate cooking.
X   leave paper products, cooking utensils, or food in the cavity when the oven is not in use.

ii SAFETY INSTRUCTIONS
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 oven is equipped with a cord that has
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 follow grounding
instructions or if in doubt as to whether the appliance is properly grounded.
X   use an extension cord. If the power cord is too short, have a qualified electrician or
serviceman install an outlet near the appliance.
WARNING:Improper grounding can result in risk of electric shock.
POWER CORD REPLACEMENT OR REMOVAL
If the power cord is damaged, it must be replaced by the manufacturer, its service agent, or a similarly
qualified person.
WARNING: If the oven is unplugged during service or maintenance, the user must be able to access and
see the plug at all times to ensure that the oven remains unplugged. The plug must remain near the oven
and cannot be placed behind another appliance or in another room.
PRECAUTIONS TO BE OBSERVED BEFORE
AND DURING SERVICING TO AVOID POSSIBLE
EXPOSURE TO EXCESSIVE MICROWAVE ENERGY
(a) Do not operate or allow the oven to be operated with the door open.
(b) Make the following safety checks on all ovens to be serviced before activating the magnetron or other
microwave source, and make repairs as necessary: (1) interlock operation, (2) proper door closing,
(3) seal and sealing surfaces (arcing, wear, and other damage), (4) damage to or loosening of hinges and
latches, (5) evidence of dropping or abuse.
(c) 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 connections.
(d) Any defective or misadjusted components in the interlock, monitor, door seal, and microwave
generation and transmission systems shall be repaired, replaced, or adjusted by procedures described
in this manual before the oven is released to the owner.
(e) A microwave leakage check to verify compliance with the Federal Performance Standard should be
performed on each oven prior to release to the owner. Refer to page 36 for leakage test procedures.
SAVE THESE INSTRUCTIONS

iii
SAFETY INSTRUCTIONS
RF INTERFERENCE CONSIDERATIONS
This oven generates radio frequency signals. This device has been tested and was determined to be in compli-
ance with applicable portions 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 equipment with sensitivity to signals below these
limits may experience interference.
If your equipment experiences interference:
a Increase the physical separation between this oven and the sensitive equipment.
a If the sensitive device can be grounded, do so following accepted grounding practices.
a If battery-powered microphones are being affected, ensure that the batteries are fully charged.
a Keep sensitive equipment on separate electrical circuits if possible.
a Route intercom wires, microphone wires, speaker cables, etc. away from the oven.
PROTECTIVE EARTH GROUND SYMBOL
This symbol identifies the terminal which is intended for connecting an external conductor for
protection against electric shock in case of a fault, or the terminal of a protective earth (ground)
electrode.
EQUIPOTENTIAL BONDING SYMBOL
This symbol identifies the terminals which, when connected together, bring the various parts of an
equipment or of a system to the same potential, not necesarily being the earth (ground) potential,
e.g. for local bonding.
SAVE THESE INSTRUCTIONS

iv SAFETY INSTRUCTIONS
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Specifications and
Installation

1
SPECIFICATIONS AND INSTALLATION
Theory of Operation
The TurboChef Encore Touch oven uses radiant heat in
combination with high-speed air impingement and side-
launched microwave to cook food rapidly without com-
promising quality. Performance and menu versatility are
maximized due to flexible top and bottom temperature
settings and the ability to set the amount of microwave
and air in different phases of each recipe.
This manual includes instructions for installing, clean-
ing, operating, and servicing the oven. If you have
questions that are not addressed in this manual,
contact Customer Support at 800.90TURBO (USA) or
+1 214.379.6000 (International), or your Authorized
Distributor.
New Features
The Encore touch offers the same great cooking
performance but with many new features including:
- Capacitive touch screen with industrial-grade
tempered glass cover
- Manual mode for on-the-fly cooking
- Add from cookbook option that allows a user to
access and save TurboChef cookbook recipes
- Up to 10 selectable languages
- Integrated tutorials for daily operation
and maintenance
- Enhanced data logging for troubleshooting
assistance and learning which products are
being cooked and when
- New menu editing tools and USB/smart
card detection
Dimensions
Oven Dimensions
Height - Single Oven
with legs: 23” (584 mm)
without legs: 19” (483 mm)
Height - Stacked Ovens
lower oven with legs: 42” (1067 mm)
lower oven without legs: 38” (965 mm)
Width: 21.4” (544 mm)
Depth
footprint: 25.85” (657 mm)
door closed: 29.95” (761 mm)
door open: 36.31” (922 mm)
Weight: 185 lb. (84 kg)
Cook Cavity Dimensions
Height: 6.0” (152 mm)
Width: 15.5” (394 mm)
Depth: 14.5” (368 mm)
Volume: 0.78 ft3(22.1 liters)
Clearances
Top: 5” (127 mm)
Sides: 2” (51 mm)
21.4” (544 mm)
19”
(483 mm)
32.7” (831 mm)
30.2” (767 mm)
28.6” (726 mm)
Figure 1: Oven Dimensions

2SPECIFICATIONS AND INSTALLATION
Certifications
cULus, UL EPH, TÜV, CE, FDA
Oven Construction
Exterior
- Powder coated, corrosion-resistant stainless steel
outer wrap.
- Stainless steel front panels and door
- Cool-to-touch exterior; all surfaces below 122°F
(50°C)
- Ergonomic door handle
Interior
- 201/304 stainless steel
- Fully welded and insulated cook chamber
- Removable rack and lower jetplate
Electrical Specifications
TurboChef recommends a Type D circuit breaker
for all installations outside the United States.
Single Phase (6200 watts)
US/Canada: 208/240 VAC*, 60 Hz, 30 A
Europe/Asia (UK): 230 VAC, 50 Hz, 30 A
Brazil (BK): 220 VAC, 60 Hz, 30 A
Latin America (LA): 220 VAC, 60 Hz, 30 A
Japan (JK): 200 VAC, 50 or 60 Hz, 30 A
Multiphase (6200 watts)
Europe/Asia Wye (EW): 400 VAC, 50 Hz, 16 A
Europe/Asia Delta (ED): 230 VAC, 50 Hz, 30 A
Japan Delta (JD): 200 VAC, 50 or 60 Hz, 30 A
Korea/Middle East Wye (KW): 400 VAC, 60 Hz, 16 A
Korea/Middle East Delta (SD): 230 VAC, 60 Hz, 30 A
* US/Canada models include a voltage sensor
that detects 208 or 240 VAC, but does not
compensate for lack-of or over-voltage installations.
Installation
Install or locate this appliance only in accordance
with the instructions below.
Unpacking Instructions
1. Remove the oven from its packaging.
2. Before throwing the packaging away, check it
thoroughly for accessories and literature.
NOTE: Keeping the packaging is recommended in
case the oven may be shipped to another location.
3. Check the cook cavity thoroughly for
packaging, accessories, and literature.
4. Discard any packaging in the cook cavity.
Installation Warnings - Read Before Lifting Oven
WARNING: The oven weighs approximately
185 lb. (84 kg). Never lift with fewer than
two people.
WARNING: Never lift the oven by the door
handle. Doing so will cause the door to mis-
align, resulting in a non-warranty service call.
WARNING: The oven must be properly
placed on a food station at all times.
TurboChef will not recognize a fallen oven as
a warrantable claim and is not liable for any
injuries that may result.
WARNING: This oven is not intended for
built-in installation (i.e., installing the oven in
any structure that surrounds the oven by five
or more sides). Be sure to provide a minimum
of 2” (51 mm) clearance for all sides and 5”
(127 mm) clearance for the top.
WARNING: This oven is not intended to be
stacked without appropriate hardware.
Contact TurboChef for details.
WARNING: Never stack ovens more than
two high.

3
SPECIFICATIONS AND INSTALLATION
Installing the Oven
1. Prepare a surface capable of supporting
190 lb. (86 kg) or 380 lb. (172 kg) if stacking.
The surface must be 27.45” (697 mm) deep.
2. If installing onto an oven cart:
a. Ensure the oven cart casters are locked.
b. Ensure the oven legs are removed.
c. Drilling additional holes in the counter
surface/cart for stability is required if the
existing holes in the cart/surface do not
align with the leg holes of the oven. For
details, contact customer support at
800-90TURBO or [phone].
3. Position one or more persons at the front and
back of the oven.
4. Place hands under the oven and lift.
5. Place the oven on the prepared surface,
ensuring no edges are hanging off the sides.
6. If stacking two ovens:
a. See page 1 for dimensions.
b. Install the stacking bracket (part number
ENC-3001) to the lower oven.
c. Place the upper oven on top of the lower
oven.
d. Secure the bracket to the top oven.
7. Ensure the oven rack is properly installed to
each oven (attached to the bottom jetplate).
8. Plug in the oven.
NOTE: The oven is primarily serviced through
its sides and top. Shelving installed directly over the
unit may delay servicing. The owner will be respon-
sible for paying service costs for additional time spent
accessing the oven.
Installation Near Open Heat Source
When placing a TurboChef oven near an open heat
source (see Figure 2, below), strictly adhere to the fol-
lowing:
- If the oven is being placed near a grill or stove,
a divider must exist between the oven and the
open heat source, with a minimum of 6” (152
mm) between the oven and the divider.
- If the oven is being placed near a fryer, a
divider must exist between the oven and fryer,
with a minimum of 12” (305 mm) between
the oven and the divider.
- The height of the divider must be greater than
or equal to the height of the oven (see page 1).
- Verify the oven location has a minimum 5”
(127 mm) clearance on top and a minimum 2”
(51 mm) clearance on each side.
Grill
Partition
Height Equal to
Oven Height
Oven
6”
(152 mm)
Minimum
12”
(305 mm)
Minimum
Deep Fryer
Counter Top / Table
Partition
INLET AIR
E
X
H
A
U
S
T
E
X
H
A
U
S
T
Height Equal to
Oven Height
Figure 2: Installation Near Open Heat Source

4SPECIFICATIONS AND INSTALLATION
Oven Restraint Kit
Part Number: TC3-0242
WARNING: The Oven Restraint Kit
will not prevent the oven from falling
off a countertop if the oven is pulled off or
allowed to slide off the edge. Installation
instructions are included with the kit.
ChefComm Pro
Part Number: CON-7006
ChefComm Pro® lets you easily create menu
settings on a computer and upload them to
an oven via smart card or USB. For more
information, call TurboChef Customer Support
at 800.90TURBO or +1 214.379.6000.
ChefComm Limited
Part Number: CON-7016
ChefComm LimitedTM is a “read-and-upload only”
version of ChefComm Pro that helps ensure menu
settings are easy to distribute, while preventing
them from being changed at the store level.
Date and Time Prompt
The oven maintains a data log that contains
valuable information about the operation of the
oven, including faults, items cooked, and other
events. An accurate date and time are important
for the data log. If the oven loses the date and
time as a result of prolonged disconnection from
power, a prompt will alert the operator to set the
date and time. The prompt will only occur once.
If bypassed, the operator must update the date and
time from the Info Mode Settings screen (see page
17 for details.)
Voltage Selection
For North America oven models, the oven will
detect 208 or 240 incoming voltage.
If incoming voltage for the store is different than
the factory-preset voltage, the operator will be
required to select either 208 or 240. The correct
voltage will be enlarged on the screen, identifying
which option to touch (see Figure 3, below).
Ventilation
The TurboChef Encore oven has been approved
by Underwriter’s Laboratory for ventless operation
(UL KNLZ listing) for all food items except for
foods classified as “fatty raw proteins.” Such foods
include bone-in, skin-on chicken, raw hamburger
meat, raw bacon, raw sausage, steaks, etc. If
cooking these types of foods, consult local HVAC
codes and authorities to ensure compliance with
ventilation requirements.
To ensure continued compliance with all health,
building, and fire codes, you are required to
maintain clean and sanitary conditions around
your oven at all times.
NOTE: In no event shall the manufacturer assume
any liability for damages or injuries resulting from
installations which are not in compliance with the
instructions and codes previously listed. Failure to
comply with these instructions could result in the
issuance of a temporary cease and desist order from
the local health department until the environment
concerns are addressed.
Figure 3: Voltage Selection

Daily and Quarterly
Maintenance