TurboChef i3 User manual

TM
Service Manual
FOR THE TURBOCHEF i3TM RAPID COOK OVEN
© 2009-2010 TurboChef Technologies, Inc.

For further information, call
1-800-90TURBO
or
[phone]

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 baking
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.
©2009-2010 TurboChef Technologies, Inc.

Important Safety Instructions
General Safety Information i
Reducing Fire Risk i
Grounding Instructions ii
Power Cord Replacement ii
Precautions to be Observed Before and During Servicing to Avoid
Possible Exposure to Excessive Microwave Energy ii
RF Interference Considerations ii
Specifications and Installation
Theory of Operation 1
Certifications 1
Dimensions 1
Oven Construction 1
Electrical Specifications 2
Unpacking Instructions 3
Lifting and Placing the Oven 3
Installation Near Open Heat Source 4
Optional Installation Items 4
Voltage Selection 4
Ventilation Requirements 4
Daily Maintenance 7
Oven Controls and Cooking
Oven Controls 9
Cooking 10
Step 1: Turn the Oven On 10
Step 2: Select Cook Temperature 10
Step 3: Warming Up 10
Step 4: Soaking 11
Step 5: Ready to Cook or “Idle” 11
Step 6: Adjusting the Time 11
Step 7: Cooking 11
Step 8: Remove Food from Oven 12
Step 9: Additional Cooking Options 12
Step 10: Cooling Down 12
Info Mode
Overview of the Info Mode 13
Viewing Cook Counter/Time Logs 13
Viewing the Fault Log 13
Viewing the Service Numbers 14
Table of Contents

Options Screen 14
Setting the Language 14
Setting the Date/Time 14
Adjusting the Volume 15
Setting the F2 Alarm 15
Making a Copy of the Oven Menu 15
Updating the Oven Menu 15
Updating the Oven Firmware 15
Resetting the Oven 15
Test Mode - Testing Oven Parts 16
Top and Bottom Blower 16
Heaters 16
Magnetron Test 16
Stirrer 16
Status Indicators 16
Fault Log 16
Turning Diagnostic Mode On/Off 16
Manufacturing Mode 17
Microwave Leakage Test 17
Microwave Power Test 17
Burn-In 17
Serial Number Edit 17
Changing Temperature Measurement Setting 17
Self Test 17
Volt On 18
Erase/Default Oven Settings 18
Edit Mode
Overview of the Edit Mode 19
Changing Set Temperatures 19
Changing Food Group/Item Name 20
Changing Recipe Settings 20
Oven Systems
Convection System 21
Blower Motor (Bottom) 21
Blower Motor (Top) 21
Blower Motor Speed Controller (BMSC) 21
Heater Elements 21
Jetplate (Bottom) 21
Jetplate (Top) 21
Top Jetplate Insert 21
Stirrer Motor and Assembly 22

Convection System Troubleshooting 22
Oven Door 22
Removing/Reinstalling the Oven Door 22
Adjusting the Oven Door 22
Interlock Switches 24
Adjusting the Door Switches 24
Hinges and Counter-Balance Assembly 24
Adjusting the Counter-Balance Assembly 24
Measuring RF Leakage for Microwave Safety 25
Oven Door Troubleshooting 26
Microwave System 27
Capacitors 27
Testing a Capacitor 27
Filament Transformers 27
Wiring the Filament Transformers 27
High-Voltage Transformers 28
Wiring the High-Voltage Transformers 28
Testing a Filament or High-Voltage Transformer 28
High-Voltage Diodes 28
Testing a High-Voltage Diode 29
Magnetrons 30
Testing a Magnetron for an Open/Shorted Filament 30
Stirrer Motor and Assembly 30
Wave Guides 30
Microwave System Troubleshooting 30
Control System 31
Control Board 31
Display 31
Electrical Compartment Cooling Fans 31
Electrical Compartment Cooling Fan Thermostat 31
Electrical Compartment Thermocouple 31
EMI Filter 31
Fuses 31
High-Limit Thermostat 32
Keypad 32
Magnetron Cooling Fan 32
Magnetron Thermostats 32
Power Supply 32
Relay - K1 Filament 32
Relay - K2 Anode 32
Relay - K3 Monitor 32
Relay - K6 Voltage 32
Relay - K7 Magnetron Cooling Fan 33
Relay - K8 Stirrer Motor 33

RTD 33
Smart Card Reader 33
Solid State Relay - K4/K5 Heater 33
Speaker 33
USB Port 33
Wire Harness 33
Voltage Sensor 34
Control System Troubleshooting 34
Filtering System 34
Catalytic Converter 34
Drain Pan 34
Air Filter 34
Vent Catalyst 34
Filtering System Troubleshooting 34
Troubleshooting
Overview of Troubleshooting 35
Fault Code Descriptions 35
Fault Code Troubleshooting - F1 Blower Running Status Bad 37
Fault Code Troubleshooting - F2 Cook Temperature Low 38
Fault Code Troubleshooting - F3 Magnetron Current Low 39
Fault Code Troubleshooting - F4 Door Monitor Defective 40
Fault Code Troubleshooting - F5 Magnetron Over Temperature 40
Fault Code Troubleshooting - F6 Electrical Compartment Temperature High 41
Fault Code Troubleshooting - F7 Open RTD 41
Fault Code Troubleshooting - F8 Heat Low 42
Fault Code Troubleshooting - F9 Cook Cavity Temperature High 42
Non-Fault Code Troubleshooting - No Keypad Input 43
Non-Fault Code Troubleshooting - “Cook Door Open” Message when Door is Closed 43
Non-Fault Code Troubleshooting - No Display (Screen is Blank) 44
Non-Fault Code Troubleshooting - Food Not Cooking Properly 45
Non-Fault Code Troubleshooting - “Read Fail” Message when Loading a Menu 46
Non-Fault Code Troubleshooting - “Write Fail” Message when Loading a Menu 47
Non-Fault Code Troubleshooting - “Defective Media” Message When Oven is
Plugged in or Restarted 48
Oven Schematic 49
Appendix - Replacing Oven Components
Replacing Oven Components A-1
No Cover Removal Required A-2
Opening Top Cover Required A-4
Removing Top Cover Required A-5
Removing Left Side Cover Required A-8
Removing Right Side Cover Required A-10
Removing Right and Left Covers Required A-11

i
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
Read all instructions before using this appliance.
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.
This appliance must be grounded. Connect only to properly grounded outlet. See "Grounding
Instructions" found on page ii.
Install or locate this appliance only in accordance with the provided installation instructions.
Some products such as whole eggs and sealed containers (e.g., closed glass jars) may explode and
should not be heated in this oven.
Use this appliance only for its intended uses as described in this manual.
This appliance should be serviced only by qualified service personnel. Contact the nearest authorized
service facility for examination, repair, or adjustment.
Keep cord away from heated surfaces.
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. THIS COULD RESULT IN VERY HOT LIQUIDS SUDDENLY
BOILING OVER WHEN THE CONTAINER IS DISTURBED OR A UTENSIL IS INSERTED
INTO THE LIQUID.
XDO NOT allow children to use this appliance.
XDO NOT use corrosive chemicals or vapors in this appliance - it is not designed for industrial or
laboratory use.
XDO NOT 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 found on page ii.
XDO NOT cover or block any openings on this appliance.
XDO NOT store this appliance outdoors.
XDO NOT use this product near water (e.g., near a kitchen sink, in a wet basement, near a swimming pool).
XDO NOT immerse cord or plug in water.
XDO NOT let cord hang over the edge of table or counter.
XDO NOT use a water jet for cleaning. See the Maintenance section (pages 7-8) for proper cleaning
procedures.
Reducing Fire Risk
Remove wire twist-ties from paper or plastic bags used to facilitate cooking in the oven.
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.
If smoke is observed, switch off or unplug the oven. Keep the door closed to stifle any flames.
XDO NOT use the cook cavity for storage purposes.
XDO NOT overcook food. Carefully attend to the oven if paper, plastic, or other combustible materials are
placed inside the oven to facilitate cooking.
XDO NOT leave paper products, cooking utensils, or food in the cavity when not in use.
SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS

Grounding Instructions
This appliance must be grounded. In the event of an electrical short circuit, grounding reduces the risk of elec-
tric 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 doubt exists as to whether the appliance is properly grounded.
XDO NOT 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
If the power cord is damaged, it must only be replaced by the manufacturer, its service agent, or a
similarly-qualified person.
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 pages 25-26 for leakage test procedures.
RF Interference Considerations
The i3 oven generates radio frequency signals. This device has been tested and was determined to be in
compliance 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:
Increase the physical separation between this oven and the sensitive equipment.
If the sensitive device can be grounded, do so following accepted grounding practices.
If battery-powered microphones are being affected, ensure that the batteries are fully charged.
Keep sensitive equipment on separate electrical circuits if possible.
Route intercom wires, microphone wires, speaker cables, etc. away from the oven.
ii SAFETY INSTRUCTIONS

Specifications and Installation

SPECIFICATIONS AND INSTALLATION
1
Theory of Operation
Utilizing TurboChef’s patented technology to rapidly
cook food without compromising quality, the i3 oven
provides superior cooking performance while
requiring minimal space and energy consumption.
The control system precisely coordinates independent
top and bottom impinged airflow with microwave to
deliver superior quality and throughput. The top-
launched microwave system allows for use of most
standard metal pans, and integral catalytic converters
allow for UL®-certified ventless operation (see page 4
for details and limitations).
This manual includes instructions for servicing,
troubleshooting, installing, cleaning, and operating
the i3 oven. If you have questions that are not
addressed in this manual, contact Technical Service
(800.90TURBO, [phone]) or your
Authorized Distributor.
Certifications
cULus, UL EPH, TÜV, CE, FDA
UL 710B (KNLZ) listed for ventless operation.
Dimensions
Oven Dimensions
Height: 21.25” (540 mm)
Width: 24.5” (622 mm)
Depth (footprint): 25.75” (654 mm)
Depth (door closed): 31.25” (794 mm)
Depth (door open): 39.65” (1007 mm)
Weight: 245 lb. (111 kg)
Cook Cavity Dimensions
Height: 6.9” (175 mm)
Width: 19.4” (493 mm)
Depth: 14.75” (375 mm)
Volume: 1.14 ft3(32.3 liters)
Clearances
Top: 19” (483 mm)
Sides: 2” (51 mm)
Oven Construction
Exterior
- Two-tone stainless steel front, top, and sides
- 304 stainless steel removable grease pan
- Ergonomic door handle
- Rubber seal for surface mounting
- Side hand grips for lifting
Interior
- 304 stainless steel interior
- Fully-insulated cook chamber
- Oven rack removable for cleaning
- Top and bottom jetplates
21.25”
(540 mm)
24.5”
(622 mm)
31.25”
(794 mm)
28.25”
(718 mm)
39.65”
(1007 mm)
Figure 1: i3 Oven Dimensions

2 SPECIFICATIONS AND INSTALLATION
Multi Phase
i3 DL (USA) model (i3-9500-14-DL)*
208/240 VAC, 60 Hz, 24 amps
Max Input: 8600/9900 watts
Plug: NEMA 15-30P
i3 BD model (i3-9500-16-BD)
220 VAC, 60 Hz, 24 amps
Max Input: 9100 watts
Plug: IEC 309, 4-pin
i3 LD model (i3-9500-15-LD)
220 VAC, 60 Hz, 24 amps
Max Input: 9100 watts
Plug: NEMA 15-30P
i3 EW model (i3-9500-4-EW)
400 VAC, 50 Hz, 14 amps
Max Input: 9500 watts
Plug: IEC 309, 5-pin
i3 AU model (i3-9500-5-AU)
400 VAC, 50 Hz, 14 amps
Max Input: 9500 watts
Plug: Clipsal 5-pin
i3 KW model (i3-9500-12-KW)
400 VAC, 60 Hz, 14 amps
Max Input: 9500 watts
Plug: IEC 309, 5-pin
i3 ED model (i3-9500-3-ED)
230 VAC, 50 Hz, 24 amps
Max Input: 9500 watts
Plug: IEC 309, 4-pin
i3 SD model (i3-9500-13-SD)
230 VAC, 60 Hz, 24 amps
Max Input: 9200 watts
Plug: IEC 309, 4-pin
i3 JD model (i3-9500-9-JD) - 50 Hz
(i3-9500-11-JD) - 60 Hz
200 VAC, 50 or 60 Hz, 23 amps
Max Input: 8000 watts
Plug: PSE-marked, 4-blade
Electrical Specifications
TurboChef recommends a Type D circuit breaker for all installations outside the US.
* North America models include a voltage sensor that detects 208 or 240 VAC. The voltage sensor does
not compensate for lack-of or over-voltage installations.
Single Phase
i3 US model (i3-9500-1)*
208/240 VAC, 60 Hz, 40 amps
Max Input: 8300/9600 watts
Plug: NEMA 6-50P, 8/3
i3 BK model (i3-9500-6-BK)
220 VAC, 60 Hz, 40 amps
Max Input: 8800 watts
Plug: IEC 309, 3-pin
i3 LA model (i3-9500-7-LA)
220 VAC, 60 Hz, 40 amps
Max Input: 8800 watts
Plug: NEMA 6-50P
i3 UK model (i3-9500-2-UK)
230 VAC, 50 Hz, 40 amps
Max Input: 9200 watts
Plug: IEC 309, 3-pin
i3 JK model (i3-9500-8-JK) - 50 Hz
(i3-9500-10-JK) - 60 Hz
200 VAC, 50 or 60 Hz, 40 amps
Max Input: 8000 watts
Plug: PSE-marked, 3-blade

SPECIFICATIONS AND INSTALLATION
3
Figure 2: Hand Grip Locations
Unpacking Instructions
1. Remove oven from packaging.
2. Before discarding packaging, check
thoroughly for accessories, consumables,
and literature.
3. Discard packaging.
4. Check cook cavity thoroughly for accessories,
consumables, and literature.
5. Discard any packaging in cook cavity.
Lifting and Placing the Oven
WARNING: Oven weighs approximately
245 lb. (111 kg). Never lift with fewer than
two people.
WARNING: Lift the oven only by using the
provided hand grips. Never lift the oven by the
door handle.
WARNING: The oven must be properly
placed on a table or countertop 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 19”
(483 mm) clearance for the top.
1. Prepare a surface that is at least 30” (762 mm)
deep and capable of supporting 250 lb. (113 kg).
If installing onto an oven cart, make sure the
wheels/casters are locked.
2. Position one or more persons at the front and
rear of the oven.
3. Place hands into grips (see Figure 2) and lift.
4. Place the oven on the prepared surface or cart,
ensuring no edges are hanging off the sides.
5. Install the oven rack.
6. Plug in the oven.
NOTE: The oven is primarily serviced through its
top. DO NOT install shelving directly over the unit.
The operator will be responsible for service charges
incurred as a result of added time required to access
the top of the oven.
Install or locate this appliance only in accordance with the instructions below.

4 SPECIFICATIONS AND INSTALLATION
Installation Near Open Heat Source
See Figure 4, page 5.
When placing a TurboChef oven near an open heat
source, strictly adhere to the following:
- 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 (21.25” or
540 mm).
- Verify the oven location has a minimum 19” (483
mm) clearance on top and a minimum 2” (51
mm) of clearance on each side.
Optional Installation Items
See Figure 5, page 5.
TurboChef Oven Cart
- Part Number: NGC-1217-2
- Height: 17.3” (439 mm)
- Width: 27.8” (706 mm)
- Depth: 26.625” (676 mm)
TurboChef Stacking Stand
- Part Number: i5-9369
- Height: 44.6” (1133 mm)
- Width: 32.5” (826 mm)
- Depth: 26.5” (673 mm)
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 (CON-7006)
ChefComm Pro empowers any user of a TurboChef
oven to easily and efficiently create menu settings on a
computer and transfer them to an oven via smart card
or USB device.
ChefComm Limited (CON-7016)
ChefComm Limited is a “read-and-transfer only” ver-
sion of ChefComm Pro that helps ensure carefully-
crafted settings are easy to distribute globally, while
providing the peace of mind that they will not be
altered.
Voltage Selection
For North America oven models, the oven will detect
208 or 240 incoming voltage.
The initial voltage selection is typically completed
before the oven is used by the customer. However, if
incoming voltage for the store is different than the pre-
set voltage, the operator will be required to select
either 208 or 240 after pressing the On/Off key to
turn on the oven. The correct voltage will be enlarged
on the screen, identifying which option to select (see
Figure 3 below).
Ventilation Requirements
The TurboChef model i3 oven has been approved by
Underwriter’s Laboratory for ventless operation (UL
710B, 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.
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.
Figure 3: Selecting Voltage
208 VAC
SELECT VOLTAGE:
240 VAC

SPECIFICATIONS AND INSTALLATION
5
59.7” (1516 mm)
(handle)
32.5” (826 mm)
(handle)
35.5” (706 mm)
28.6” (726 mm)
4.5”
(114 mm)
30.0” (762 mm)
31.5” (800 mm)
32.5” (826 mm)
44.6” (1133 mm)
17.3”
(439 mm)
15.8”
(401 mm)
20.5” (521 mm)
26.5” (673 mm)
21.25” (540 mm)
Figure 5: Oven Cart and Stacking Stand Dimensions
Grill
Partition
21.25” (540 mm)
Above Counter Top
TurboChef
i3 Oven
6”
(152 mm)
Minimum
12”
(305 mm)
Minimum
Deep Fryer
Counter Top / Table
Partition
21.25” (540 mm)
Above Counter Top
Figure 4: Installation Near Open Heat Source

6 SPECIFICATIONS AND INSTALLATION
This page intentionally
left blank.

Daily Maintenance