TurboChef i5 User manual

Accelerating the World of CookingTM
Service Manual
FOR THE TURBOCHEF i5 RAPID COOK OVEN

For further information, call
800.90TURBO
or
+1 214.379.6000

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.

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
Daily Maintenance 7
Oven Controls and Cooking
Oven Controls 9
Cooking 10
Mode 1: Oven Off 10
Mode 2: Temperature Select 11
Mode 3: Warming Up 11
Mode 4: Soak 11
Mode 5: Ready to Cook or “Idle” 11
Mode 6: Adjust Time 11
Mode 7: Cooking 12
Mode 8: Remove Food from Oven 12
Mode 9: Cook More 12
Mode 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 13
Table of Contents

Resetting the Oven 14
Turning Oven Options On/Off 14
Setting the Language 14
Setting the Date/Time 14
Test Mode - Testing Oven Parts 15
Test Mode - Status Indicators 15
Test Mode - Fault Log 15
Test Mode - Turning On/Off Diagnostic Mode 15
Test Mode - Self Test 16
Test Mode - Manufacturing Mode 16
Microwave Leakage Test (How to Use Oven for Testing) 16
Microwave Power Test 16
Burn-In 16
Serial Number Edit 17
Changing Temperature Measurement Setting 17
Self Test 17
Erase/Default Oven Settings 17
Loading a Menu 17
Updating the Software 18
Edit Mode
Overview of the Edit Mode 19
Single vs. Multiple Temperature Mode 19
Changing Set Temperatures 20
Changing Food Group/Recipe Name 20
Changing Recipe Settings 21
Oven Systems
Overview of the Convection System 23
Blower Motor (Bottom) 23
Blower Motor (Top) 23
Blower Motor Controller (BMSC) 23
Heater Element 23
Jetplate (Bottom) 23
Jetplate (Top) 23
Stirrer Motor and Assembly 23
Troubleshooting 24
Overview of the Oven Door 24
Removing/Reinstalling the Oven Door 24
Adjusting the Oven Door 24
Interlock Switches 26
Adjusting the Door Switches 26
Hinges and Counter-Balance Assembly 26
Adjusting the Counter-Balance Assembly 26
Measuring RF Leakage for Microwave Safety 27
Troubleshooting 28

Overview of the Microwave System 29
Capacitors 29
Testing a Capacitor 29
Filament Transformers 29
Wiring the Filament Transformers 29
High-Voltage Transformers 30
Wiring the High-Voltage Transformers 30
Testing a Filament or High-Voltage Transformer 30
High-Voltage Diodes 30
Testing a High-Voltage Diode 31
Magnetrons 32
Testing a Magnetron for an Open/Shorted Filament 32
Stirrer Motor and Assembly 32
Wave Guides 32
Troubleshooting 32
Overview of the Control System 33
Control Board 33
Display 33
Electrical Compartment Cooling Fans 33
Electrical Compartment Cooling Fan Thermostat 33
Electrical Compartment Thermocouple 33
EMI Filter 33
Fuses 33
High-Limit Thermostat 34
Keypad 34
Magnetron Cooling Fans 34
Magnetron Thermostats 34
Power Supply 34
Relay - K1 Filament 34
Relay - K2 Anode 34
Relay - K3 Monitor 34
Relay - K6 Voltage 34
Relay - K7 Magnetron Cooling Fan 35
Relay - K8 Stirrer Motor 35
RTD 35
Smart Card Reader 35
Solid State Relay - K4/K5 Heater 35
Speaker 35
USB Port 35
Voltage Sensor 35
Wire Harness 35
Troubleshooting 35
Overview of the Filtering System 36
Catalytic Converter 36
Drain Pan 36
Air Filter 36
Vent Catalyst 36
Troubleshooting 36

Troubleshooting
Overview of Troubleshooting 37
Fault Code Descriptions 37
Fault Code Troubleshooting - F1 Blower Running Status Bad 39
Fault Code Troubleshooting - F2 Cook Temperature Low 40
Fault Code Troubleshooting - F3 Magnetron Current Low 41
Fault Code Troubleshooting - F4 Door Monitor Defective 42
Fault Code Troubleshooting - F5 Magnetron Over Temperature 42
Fault Code Troubleshooting - F6 Electrical Compartment Temperature High 43
Fault Code Troubleshooting - F7 Open RTD 43
Fault Code Troubleshooting - F8 Heat Rise Low 44
Non-Fault Code Troubleshooting - No Keypad Input 45
Non-Fault Code Troubleshooting - “Door Open” Message when Door is Closed 45
Non-Fault Code Troubleshooting - No Display (Screen is Blank) 46
Non-Fault Code Troubleshooting - Food Not Cooking Properly 47
Non-Fault Code Troubleshooting - “Read Fail” Message when Loading a Menu 48
Non-Fault Code Troubleshooting - “Write Fail” Message when Loading a Menu 49
Non-Fault Code Troubleshooting - “Defective Media” Message When Oven is
Plugged in or Restarted 50
Oven Schematic 51
Appendix - Replacing Oven Components
Comprehensive Table of Oven Components A-1
Replacing Items - No Cover Removal Required A-3
Replacing Items - Opening Top Cover Required A-5
Replacing Items - Removing Top Cover Required A-7
Replacing Items - Removing Left Side Cover Required A-9
Replacing Items - Removing Right Side Cover Required A-11
Replacing Items - Removing/Opening Multiple Covers Required A-12

i
Safety Instructions
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
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 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 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.
RF Interference Considerations
The i5 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 electro-
magnetic 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
The i5 rapid cook oven combines precisely-
controlled impinged air and microwave energy to
create higher heat transfer rates than conventional
ovens. Top-launched microwave and impinged air
are stirred to further ensure even heat distribution,
while impinged air enters the cavity from the top
and bottom, generated by dual independently-
controlled blower motors. The combination of this
technology with the size of the cook cavity allows
for higher throughput than other batch ovens.
This manual includes instructions for servicing,
troubleshooting, installing, cleaning, and operating
the i5 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
Dimensions
Oven Dimensions
Height: 24.3” (618 mm)
Width: 27.2” (691 mm)
Depth (door closed): 28.25” (718 mm)
Depth (door open): 43.4” (1102 mm)
Weight: 275 lbs (125 kg)
Cook Cavity Dimensions
Height: 10” (254 mm)
Width: 24” (610 mm)
Depth: 16” (406 mm)
Volume: 2.22 ft3(63 liters)
Clearances
Top: 16” (406 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 handles for lifting
Interior
- 304 stainless steel interior
- Fully-insulated cook chamber
- Removable rack with dual setting option
- Top and bottom jetplates
24.3”
(618 mm)
27.2”
(691 mm)
31.1”
(790 mm)
28.25”
(718 mm)
43.4”
(1102 mm)
Figure 1: i5 Oven Dimensions

2 SPECIFICATIONS AND INSTALLATION
Single Phase
i5 US model (i5-9500-1)
Voltage: 208/240 VAC*
Frequency: 60 Hz
Current: 48 amps
Max Input: 9500/11500 watts
Plug: NEMA 6-50P
i5 UK model (i5-9500-2-UK)
Voltage: 230 VAC
Frequency: 50 Hz
Current: 48 amps
Max Input: 10000 watts
Plug: IEC 309, 3-pin
i5 BK model (i5-9500-6-BK)
Voltage: 220 VAC
Frequency: 60 Hz
Current: 48 amps
Max Input: 10000 watts
Plug: IEC 309, 3-pin
i5 LA model (i5-9500-7-LA)
Voltage: 220 VAC
Frequency: 60 Hz
Current: 48 amps
Max Input: 10000 watts
Plug: NEMA 6-50P
i5 JK model (i5-9500-8-JK) - 50 Hz
(i5-9500-10-JK) - 60 Hz
Voltage: 200 VAC
Frequency: 50 or 60 Hz
Current: 46 amps
Max Input: 9000 watts
Plug: PSE-marked, 3-blade
* North America models include a voltage sensor
which detects 208 or 240 VAC. The voltage
sensor does not compensate for lack-of or over-
voltage installations.
Multi Phase
i5 EW model (i5-9500-4-EW)
Voltage: 400 VAC
Frequency: 50 Hz
Current: 19 amps
Max Input: 10000 watts
Plug: IEC 309, 5-pin
i5 AU model (i5-9500-5-AU)
Voltage: 400 VAC
Frequency: 50 Hz
Current: 19 amps
Max Input: 10000 watts
Plug: Clipsal 5-pin
i5 KW model (i5-9500-12-KW)
Voltage: 400 VAC
Frequency: 60 Hz
Current: 19 amps
Max Input: 10000 watts
Plug: IEC 309, 5-pin
i5 ED model (i5-9500-3-ED)
Voltage: 230 VAC
Frequency: 50 Hz
Current: 28 amps
Max Input: 10000 watts
Plug: IEC 309, 4-pin
i5 SD model (i5-9500-13-SD)
Voltage: 230 VAC
Frequency: 60 Hz
Current: 28 amps
Max Input: 10000 watts
Plug: IEC 309, 4-pin
i5 JD model (i5-9500-9-JD) - 50 Hz
(i5-9500-11-JD) - 60 Hz
Voltage: 200 VAC
Frequency: 50 or 60 Hz
Current: 25 amps
Max Input: 10000 watts
Plug: PSE-marked, 4-blade
Electrical Specifications
TurboChef recommends a Type D circuit breaker for all installations outside the US.

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. Discard any
packaging.
Lifting and Placing the Oven
WARNING: Oven weighs approximately
275 lbs (125 kg). Never lift with fewer than
two people.
WARNING: Lift only using the provided
hand grips. Never lift the oven by the door
handle or by its base.
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 16”
(406 mm) clearance for the top.
1. Position one or more persons at the front and
rear of the oven.
2. Place hands into grips (see Figure 2) and lift.
3. Place the oven on a surface that is at least 30”
(762 mm) deep and capable of supporting
280 lbs (127 kg). If installing onto an oven
cart, make sure the wheels/casters are locked.
4. Install the oven rack or other provided
cooking surface.
5. 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 (24.3” or
618 mm).
- Verify oven location has a minimum 16” (406
mm) clearance on top and minimum 2” (51
mm) of clearance on each side.
Optional Installation Items
See Figure 5, page 5.
TurboChef Oven Cart
- Part Number: NGC-1217-3
- Height: 32” (813 mm)
- Width: 27.8” (706 mm)
- Depth: 26.625” (676 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
ChefComm Pro is a PC program for developing
and maintaining menus and recipes. To purchase
ChefComm Pro and a card reader, contact
customer service at 800.90TURBO or
[phone].
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 preset 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).
Figure 3: Selecting Voltage
208 VAC
SELECT VOLTAGE:
240 VAC

SPECIFICATIONS AND INSTALLATION
5
27.8” (706 mm)
32.0”
(813 mm)
26.625” (676 mm)
Figure 5: Oven Cart Dimensions
Grill
Partition
24.3” (618 mm)
Above Counter Top
TurboChef
i5 Oven
6”
(152 mm)
Minimum
12”
(305 mm)
Minimum
Deep Fryer
Counter Top / Table
Partition
24.3” (618 mm)
Above Counter Top
Figure 4: Installation Near Open Heat Source

6 SPECIFICATIONS AND INSTALLATION
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Daily Maintenance

DAILY MAINTENANCE
7
Step 1: Prepare the Oven
WARNING: Oven operates at approximately 450°F (232°C) and may cause
injury if not allowed to cool properly.
- Turn off the oven by pressing the On/Off key.
- Slightly open the oven door. Cooling takes approximately 40 minutes.
-DO NOT attempt to clean the oven until the oven displays “Oven Off”.
Step 2: Remove and Clean the Wire Rack
WARNING: Be sure the oven interior is cool before you remove the wire rack.
- Wash, rinse, and sanitize the wire rack.
Step 3: Remove and Clean the Lower Jetplate
- Unscrew the two thumb screws on the lower jetplate.
- Lift the lower jetplate by gripping the thumb screws.
- Remove the lower jetplate.
- Wash, rinse, and sanitize the lower jetplate.
Step 4: Remove and Clean the Lower Air Diverter
- Remove the lower air diverter.
- Wash, rinse, and sanitize the lower air diverter.
WARNING: DO NOT discard the lower air diverter. The oven will not work
without the lower air diverter installed.
Step 5: Wipe the Oven Interior
- Wipe any large particles from the oven interior with a damp towel.
Step 6: Clean the Oven Interior
- Spray oven cleaner onto the top, bottom, and sides of the oven interior.
CAUTION: DO NOT spray oven cleaner into the perforation on the back
oven wall. Doing so can damage critical oven components, resulting in a
non-warranty service call.
- Allow Oven Cleaner to penetrate stains for five minutes.
- Clean the oven interior with a nylon scrub pad.
Daily Maintenance
The following steps will help maintain your i5 Oven.
Use only TurboChef Oven Cleaner and Oven Guard.
The use of any other cleaning products can damage
critical oven components, resulting in a
non-warranty service call.
Supplies and Equipment
- TurboChef Oven Cleaner (Part Number: 103180)
- TurboChef Oven Guard (Part Number: 103181)
- Nylon scrub pad, cleaning towel, disposable gloves,
protective eyewear, dust mask (optional), *pair of
tongs wrapped with towel (optional - see step 11)
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6

8 DAILY MAINTENANCE
Step 7: Clean and Dry the Oven Door
CAUTION: DO NOT spray oven cleaner directly onto the oven door gasket
(reference “A” in adjacent photo) or saturate it with water.
CAUTION: DO NOT scrub or attempt to clean the oven door gasket. Doing
so may cause the oven door to misalign, resulting in a non-warranty service call.
- Clean oven door with oven cleaner and a nylon scrub pad.
- Wipe the oven door with a damp towel.
Step 8: Rinse the Oven Interior
CAUTION: DO NOT use a hose or water jet for cleaning. Doing so can
damage critical oven components, resulting in a non-warranty service call.
- Rinse the oven interior with clean water.
- Dry the oven interior with a clean towel.
Step 9: Apply TurboChef Oven Guard
- Spray Oven Guard onto a clean towel.
- Wipe the oven’s interior walls and the inside of the oven door.
CAUTION: DO NOT apply Oven Guard to the oven door gasket. Doing so
may damage the gasket, resulting in a non-warranty service call.
Step 10: Reinstall Components
- Reinstall the lower air diverter.
- Reinstall the lower jetplate. Screw in the two thumb screws to lock the lower
jetplate in place.
- Reinstall the wire rack.
- Close the oven door.
Step 11: Clean the Drain Pan
- Remove the drain pan entirely from the bottom of the oven.
- Wipe down* the inside of the area the drain pan fits within.
- Empty, clean, and reinstall the drain pan.
CAUTION: Ensure the drain pan’s outer edge is flush with the door panel (i.e.
not sticking out). Failure to do so will damage the oven door, resulting in a
non-warranty service call.
Step 12: Clean the Oven Exterior
- Wipe the oven exterior with a clean, damp towel.
CAUTION: DO NOT spray chemicals into any openings, such as the louvers
on the side panels or the rear vent catalyst housing. Doing so can damage
critical oven components, resulting in a non-warranty service call.
Step 13: Clean the Air Filter (once a week)
- Remove the air filter from the back panel.
- Wash in dishwasher or rinse with hot water.
-DO NOT use a water jet. Doing so will shorten the life of the filter.
- Reinstall the air filter.
CAUTION: DO NOT operate the oven without the air filter in place.
A
Step 7
Step 8
Step 9
Step 10
Step 11
Step 12
Step 13