TurboChef 2020 manual

Accelerating the World of Cookin g TM S er vic e M anual FOR THE TURBOCHEF 2020 HIGH h CONVE Y OR O VEN © 2008 T ur boChef T echnolog ies , I nc .[...]

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F or fur ther infor mation, call 800.90TURBO or +1 214.379.6000[...]

The information contained in this manual is impor tant for the pr oper installation, use, maintenance, and r epair of this o v en. F ollo w these pr ocedur es and instr uctions to help ensur e satisfactor y baking r esults and y ears of tr ouble-fr ee ser vice. E rr ors – descriptiv e, typographic, or pictorial – ar e subject to corr ection. S [...]

T able of C on t en ts S af et y I nf or ma tion I mpor tant S afety I nformation – P lease R ead F irst i G eneral S afety I nformation i R educing F ir e Risk i P r ev enting Ov en D amage ii G r ounding I nstr uctions ii P ow er Cor d R eplacement ii Specifica tions and installa tion D imensions 1 E lectrical S pecifications 1 P ackaging 2 Cer[...]

I nitiating a B urn-I n T est 20 E rasing Ov en S ettings 20 V ie wing the S erial N umber 20 Ov en S y st ems The Contr ol S ystem 21 Contr ol Boar d 21 D isplay 21 EMI F ilter 21 F uses 21 H igh-Limit Thermostat 21 K eypad 21 P ow er S upply - 24VDC 21 R elays, K6 (H eaters) and K7 (Conv ey or D ir ection) 21 R elay , S olid S tate - K5/K4 H eate[...]

SAFE T Y INFORM A TION I mpor tan t S af et y I nf or ma tion – P lease R ead F irst I mpr oper installation, adjustment, alteration, ser vice, or maintenance of this equipment can cause pr oper ty damage, injur y , or death. Thor oughly r ead the installation, operating, and maintenance instr uctions befor e installing or ser vicing this equipme[...]

ii SAFE T Y INFORM A TION Pr ev en ting O v en Damage o When ser vicing this appliance, do not tear insulation to get to components. Rather , find the edge of the insulation and r emo v e the tape that holds it in place. o Clean the o v en daily . o Clean the o v en only with T urboChef Ov en Cleaner . o x DO NO T clean with a water jet. o x DO NO [...]

Specifica tions and I nstalla tion[...]

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SPECIFIC A TIONS AND INST ALLA TION 1 Dimensions Ex t er ior H eight 13.0” (330 mm) -- with legs 17.0” (432 mm) W idth 48.3” (1227 mm) -- with extensions 60.1” (1527 mm) D epth 35.7” (907 mm) C on v ey or Length 48.3” (1227 mm) W idth (S ingle) 20.0” (508 mm) W idth (50/50) 9.5” / 9.5” (241 mm / 241 mm) W idth (70/30) 15” / 4”[...]

2 SPECIFIC A TIONS AND INST ALLA TION P ack ag ing All o v ens ar e packaged in a double-wall corr ugated bo x with integrated wooden skids. All international o v ens shipped via Air or Less than Container Loads ar e packaged in wooden crates. C er tifica tions O v en C onstruc tion - 430 stainless steel fr ont, top , sides, and back - Cool to touc[...]

SPECIFIC A TIONS AND INST ALLA TION 3 The sur face on which the o v en is placed must be at least 30” (762 mm) deep and capable of suppor ting 200 lbs. (90.7 kg) per o v en. The manufactur er shall not assume liability for damage or injur y r esulting fr om the impr oper installation of this equipment, including temporar y or unstable wor k stati[...]

4 SPECIFIC A TIONS AND INST ALLA TION I nstalla tion Near Open Hea t S our c e S ee F igur e 7. When placing a T urboChef o v en near an open heat sour ce, strictly adher e to the follo wing: - I f the o v en is being placed near a grill or sto v e, a divider must exist betw een the o v en and the open heat sour ce, with a minimum of 6” (152 mm) [...]

Cleaning - Daily and W eek ly[...]

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CLEANING 5 = W ash, rinse, sanitiz e. (U se only T urboChef- appr ov ed cleaner , par t number 103180). = Completely dr y with clean to w el. IDLE BACK OFF E M E R G E N C Y S T O P Hi gh h C on vey or by TurboC hef TM IDLE BACK OFF E M E R G E N C Y S T O P Hi gh h C on vey or by TurboC hef TM IDLE BACK OFF E M E R G E N C Y S T O P Hi gh h C on v[...]

6 CLEANING W ARNING: Always disconnect po w er befor e cleaning or ser vicing the o v en. IDLE BACK OFF E M E R G E N C Y S T O P Hi gh h Co nv eyo r by TurboC hef T M IDLE BACK OFF E M E R G E N C Y S T O P Hi gh h Co nv eyo r by TurboC hef T M IDLE BACK OFF E M E R G E N C Y S T O P Hi gh h Co nv eyo r by TurboC hef T M COOKING BEL T 10:00 BREAKF[...]

CLEANING 7 1. 2. 3. 4. 5. Step 3: Remov e I nner Oven Components 1 2 2 1 1 2 1 1 2. 4. Step 4: Clean Oven Componen ts 1. 3. 5. 6. 7. Replace lters if damaged or torn.[...]

8 1. 2. 3. 4. Step 5: Replace Oven C omponents 1 2 2 1 2 6. 7. 8. 9. 5. Latch Step 7: Ready the Oven for U se 1. 2. Step 6: V er ify Chain T ension Acceptable - Chain ( A) is tight and easily clears crumb tray holder (B) A B Call service to have link remov ed - Chain (A) is loose and risks contact with crumb tray holder (B) A B See detail below . S[...]

S tandar d O v en Oper a tion[...]

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ST AND ARD OVEN OPER A TION 9 O v en C on tr ols F igur e 8. 1. Displa y The display sho ws curr ent o v en operation and/or user pr ogramming information. 2. S of t Key s S ix soft keys ar e on the o v en contr ols, thr ee on the left (L1, L2, L3, wher e L1 = top) and thr ee on the right (R1, R2, R3, wher e R1 = top). P r ess a soft key to select [...]

C ook ing a P r oduc t This section explains ho w to cook a food pr oduct b y describing the “ standar d operation ” modes thr ough which the o v en pr ogr esses (F igur e 9). - MODE 1: Ov en O ff - MODE 2: B elt S peed S elect - MODE 3: W arming - MODE 4: S oaking - MODE 5: Cooking - MODE 6: Cooling D o wn - MODE 7: I dle NO TE: MODE 7 is not [...]

ST AND ARD OVEN OPER A TION 11 M ode 3: W ar ming M ode during which the o v en warms to the pr eset cooking temperatur e defined b y the cooking pr ofile that was selected. H appens When... - A selection is made fr om MODE 2, and the o v en ’ s temperatur e at the beginning of warmup was not within (less than) 25°F (14°C) of the o v en ’ s s[...]

12 ST AND ARD OVEN OPER A TION E diting a C ook ing P r ofile T o edit a cooking pr ofile, the o v en must be in the COOKING MODE , and the full edit or flex option must be enabled for each option y ou want to edit. F or mor e information on selecting betw een full edit, rigid, and flex options for each editable setting, see E dit M odes S elect Sc[...]

ST AND ARD OVEN OPER A TION 13 BEL T R 10:00 T OP AIR 80 % <--- ---> PROFILE 1 A djusting the B elt Speed The H igh h Conv ey or Ov en can accommodate either one or two conv ey or belts. The o v en will automatically detect the number of conv ey or belts installed and display the option to change the speed of each conv ey or belt independentl[...]

14 ST AND ARD OVEN OPER A TION T his page int entionally lef t blank .[...]

O v en M odes[...]

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OVEN MODES C onfig M ode The CONFIG MODE (F igur e 12) ser v es four main purposes: 1. T o access the smar t car d scr een. 2. T o access the fault count scr een. 3. T o access the SETUP MODE . 4. T o access the TEST MODE (ser vice use only). T o access the CONFIG MODE , pr ess the up key fr om the O VEN OFF MODE . Smar t C ar d S cr een (L oading [...]

16 DEGS F EDIT/RIGID/FLEX ENGLISH SETUP MENU INFO F igur e 17: S etup M ode Chang ing the Displa y T emper a tur e The o v en can display the temperatur e in either Celsius or F ahr enheit units. T o change the display temperatur e, pr ess L1 in SETUP MODE (F igur e 17). E dit M odes S elec t S cr een The edit modes select scr een (F igur e 19) all[...]

NO TE: I f the update is unsuccessful, the display will r emain off and the o v en will beep one long, lo w tone. I f this occurs, r epeat the abo v e pr ocedur e. I f the update fails multiple times, a smar t car d may be damaged. P lease note that the o v en will be inoperable until a successful update is per formed. As such, T urboChef r einfor [...]

18 OVEN MODES Acc essing the B elt C on tr ol S cr een F r om TEST MODE scr een 1 (F igur e 21, page 17), pr ess L2 to access the belt contr ol scr een (F igur e 25). U se this mode to v erify the belts wor k corr ectly . The number after the belt speed sho ws the pulses r ead b y the HES. The per centage is the amount of driv e being asked of the [...]

OVEN MODES 19 B ott om Displa y Line The bottom display line sho ws enabled inputs and outputs on the contr ol boar d. The numbers 1-10 indicate the differ ent bottom display line, which ar e explained belo w . NO TE: A “-” or “_” display ed on the bottom display line denotes v alues that ar e in the off mode or closed. 1 “R” r epr esen[...]

20 I nitia ting a Bur n-I n T est NO TE: B urn-in tests ar e for manufacturing use only . DO NO T initiate a burn-in test unless expr essly instr ucted b y T urboChef . T o initiate a burn-in test, P r ess L2 (F igur e 22, page 17) on scr een 2 of the TEST MODE . The burn-in test (F igur e 28) r uns the o v en for 45 minutes to ensur e corr ect o v[...]

O v en S y st ems[...]

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21 OVEN SY STEMS T he C on tr ol S y st em This section contains information about the follo wing components: - Contr ol Boar d - D isplay - EMI F ilter - F uses - H igh-limit Thermostat - K eypad - P ow er S upply , 24VDC - R elay (K6 - H eaters) - R elay (K7 - Conv ey or D ir ection) - R elay , S olid S tate - R TD - S mar t Car d R eader - S pea[...]

22 OVEN SY STEMS T esting P r oc edur e 1. D isconnect line v oltage to the unit. 2. T ake a r esistance r eading of the coil. 3. I f coil r esistance is corr ect (585 W ): a) A pply line v oltage to the unit. b) Check for 24 VDC at the coil of the r elay when the unit is calling for heat. c) Check the state of the contacts. -I f the normally open [...]

23 OVEN SY STEMS T he C on v ey or S y st em This section contains information about the follo wing components, as w ell as testing pr ocedur es: - G ear D riv e (Conv ey or M otor) - G ear D riv e (Conv ey or M otor) S peed Contr oller (CMSC) G ear Dr iv e ( C on v ey or M ot or) The conv ey or motor is a 1610 RPM, 3-phase motor with a built-in H [...]

24 OVEN SY STEMS A cc essing P ar amet ers W ARNING: DO NO T per form this pr ocedur e unless instr ucted b y T urboChef . Changing the parameters to other than those pr eset b y T urboChef can damage critical o v en components. NO TE: “M otor Rated S peed ” (07) is RPM of motor befor e gearbo x, not after . 1. O pen the right end bell (page A-[...]

T r oubleshooting[...]

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25 TR OUBLESHOO TING Ov er view of T r oubleshooting This section contains information on the follo wing: - F ault code descriptions - F ault code tr oubleshooting - N on-fault code tr oubleshooting F ault C ode D escr iptions F ault codes ar e logged in a fault counter (page 15) for tr oubleshooting. U pon completing the ser vice call and r estori[...]

26 F ault C ode and D escr iption W hen A c tiv e R ef er t o ... W ar ming Idle C ook ing T est F1: Blo w er F ailur e a a a a P ages 27-28 F2: L o w T emp D ur ing C ook a P age 29 F4: Emer genc y S t op a a a a N/A F5: C C O v er T emp a a a P age 30 F6: EC O v er T emp a a a a P age 31 F7: R TD F ailur e a a a a P age 32 F8: H igh Limit T r ip [...]

27 TR OUBLESHOO TING F ault C ode T r oubleshooting F r om TEST MODE , y ou can test separate o v en components to help diagnose an issue. T o access TEST MODE , see page 17. T r oubleshooting: F1:BL OWER F A UL T A ccess the TEST MODE . (page 17) Ar e the status indicators at location 7 and 8 pr esent (page 18)? NO YES 7 8 O pen Left E nd B ell. I[...]

28 TR OUBLESHOO TING Blo w er M ot or T r oubleshooting NO TE: Continued fr om page 27. 1. V erify motor spins fr eely . - M otor seiz ed: U nplug o v en and corr ect obstr uction or r eplace motor . - M otor spins fr eely: V erify motor windings (see F igur e 36, page 27). 2. V erify motor windings ar e OK. M easur e the r esistance betw een windi[...]

TR OUBLESHOO TING 29 T r oubleshooting: F2: L OW C OOK TEMP R estar t the o v en, access the TEST MODE , and turn on both the top and bottom blo w ers. Ar e the status indi - cators at location 6, 7, 8, and 9 pr esent (pages 18-19)? O pen the right end bell. NO F ix wiring/connections. I s wir e harness pr operly connected? NO F ix connection. T es[...]

30 TR OUBLESHOO TING NO YES YES NO R emo v e the obstr uction. T r oubleshoot F1 fault (pages 27-28). R eplace the defectiv e heater(s). T est the R TD (page 22 for r esistance/ temperatur e char t). I s the R TD damaged or defectiv e (page 22)? NO R eplace the I/O contr ol boar d (page A-8). YES YES T r oubleshooting: F5: C C OVER TEMP I s anythin[...]

31 TR OUBLESHOO TING T r oubleshooting: F6: EC OVER TEMP Ar e the air filters on the back of the o v en clean? NO Clean the air filter(s) (page 7). YES I s the o v en hot? NO YES A ccess TEST MODE (page 17). I s the sta - tus indicator at position “b ” (page 18) less than 65? NO R eplace the I/O contr ol boar d (page A-8). O pen the left and ri[...]

32 TR OUBLESHOO TING T r oubleshooting: F8: HIGH LIMIT TRIPPED I s the high limit thermostat tripped (page 21)? R eset and determine why it tripped - o v er temp , blo w er failur e, etc. Check if the high limit pr obe or R TD is damaged or defec - tiv e, r eplace if needed (page A-8). NO YES T r oubleshooting: F7: R TD F A UL T O pen the right end[...]

33 TR OUBLESHOO TING T r oubleshooting: F9: BEL T F A UL T ( T otal B elt Run F ailur e) Ar e ther e any obstr uctions that ar e blocking the conv ey or ’ s mo v ement or is the conv ey or belt damaged? R emo v e obstr uction or r eplace/r epair the conv ey or and r estar t the o v en. I s the F9 fault code still pr esent? YES R emo v e the chain[...]

34 TR OUBLESHOO TING T r oubleshooting: C ooling S y st em Issue I s the o v en in an ar ea of moderate temperatur e (120ºF [49ºC] or cooler)? D oes the o v en hav e r oom to v entilate (not tightly enclosed b y other appliances or fixtur es)? R elocate o v en to cooler ar ea. M ov e o v en to open ar ea or r emo v e items that ar e in close pr o[...]

TR OUBLESHOO TING 35 T r oubleshooting: F ood Not C ook ing P r oper ly D oes the pr oblem occur for all pr ogrammed r ecipes? F or example, ar e all r ecipes under - cooked/o v er cooked/etc.? I s the food item in the corr ect star ting state (e.g., fr oz en, fr esh, etc.)? I s the corr ect amount of food (por tion) being cooked? E nsur e the food[...]

36 TR OUBLESHOO TING I s the keypad cable pr operly connected to the contr ol boar d? T r oubleshooting: No Keypad I nput R eplace the keypad (page A-8). I f the pr oblem persists, or if beeps occur when buttons ar e pr essed but commands do not r egis - ter on the display , r eplace the contr ol boar d (page A-8). Corr ect wiring. YES NO T r ouble[...]

S chema tics[...]

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SCHEM A TICS 37 (CON-7002) (NGC-3023) (HHC-4120) (HHC-6517-2) (HHC-6630-2) (TC3-0433) (HHC-4120) (HHC-6630-2) (102075) (NGC-3005) FRONT HCT-4162 208 V AC BACK HCT-4161 208 V AC[...]

8 7 6 5 4 DASH NO A KEYPAD 14 2 1 P4 2 1 P6 - - 2 1 J6 - - - - 14 14 - - - - - - - - - PRODUCTION 3 USED ON NEXT ASSY APPLICATION QA 2 CODE IDENT NO NONE D SIZE SCALE DRAWING NO KEY 1 3 SCHEMATIC, HHC-2020 VFD DISPLAY , 3PH, WYE, 380-415 VAC, 60 HZ/50 DATE SIGNATURE ENGINEER DRAWN CHECKED TITLE A R B C D B C D NOTES: 8 5 4 REVISIONS LTR DESCRIPTION[...]

SCHEM A TICS 39[...]

CMSC P ARAME TERS 40 SCHEM A TICS[...]

Ap pendix - R eplacing O v en C omponen ts[...]

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A -1 APPENDIX - REPLA CING OVEN C OMPONENT S R eplacing O v en C omponen ts W ARNING: B efor e r emo ving or r eplacing any o v en component, thor oughly r ead the safety instr uctions found at the fr ont of this manual and Ov en S ystems (pages 21-24). A dher e to all pr ecautions and warnings outlined in these sections, as failur e to do so could[...]

A -2 P ar t D etails ... L oca t e the P ar t Her e ... I t em P ar t Number Q t y . P er O v en O utside of End B ells (P age A -4) L ef t End B ell (P age A -6) R igh t End B ell (P age A -8) Hea t er C ov er HC T -4032 1 a Jetpla te HC T -4099 2 a Keypad HHC-1234 1 a L eg 100785 4 a P lenum HC T -4020 2 a P o w er C or d HC T -4116-3 (NEM A 15-5[...]

A -3 APPENDIX - REPLA CING OVEN C OMPONENT S T his page int entionally lef t blank .[...]

A -4 APPENDIX - REPLA CING OVEN C OMPONENT S Shelf T ray Shelf T ray Chain (behind guar d) and Chainguar d , R igh t C on v ey or C rumb T ray C rumb T ray Chainguar d , L ef t (not sho wn) G ear M ot or C o v er Ha t ch Ha t ch La t ch E y elid Hea t er Channel P lenums Jetpla t es Ha t ch Sup por t , T op P lenum Hanger R eplacing I t ems - O uts[...]

APPENDIX - REPLA CING OVEN C OMPONENT S I t em P ar t Number Har dw ar e D escr iption Har dw ar e P ar t Number(s) A ir F ilt er HC T -4067 None None Back P anel HC T -4105 S cr ew , #10-32 x .5, PPH, INT T ooth, SS 101460 (x2) Chain, C on v ey or HC T -4143 None None Chainguar d , L ef t HC T -4038 None None Chainguar d , R igh t HC T -4041 None [...]

A -6 APPENDIX - REPLA CING OVEN C OMPONENT S R eplacing I t ems - L ef t End B ell W ARNING: B efor e r emo ving or r eplacing any o v en component, thor oughly r ead the safety instr uctions found at the fr ont of this manual and Ov en S ystems (pages 21-24). A dher e to all pr ecautions and warnings outlined in these sections, as failur e to do s[...]

A -7 APPENDIX - REPLA CING OVEN C OMPONENT S Blo w er M ot or C on tr oller R ela y , S olid S ta te , K4/K5 R ela y , M echanical , K6 F use Block 20 A mp F use , Class C C F igur e A -6: L ef t End B ell C omponen ts , Back P anel R emo v ed I t em P ar t Number Har dw ar e D escr iption Har dw ar e P ar t Number(s) Blo w er M ot or A ssembly HC [...]

A -8 P o w er Sup ply and Br acket Displa y , VFD C ar d R eader C on tr ol B oar d Speaker EMI F ilt er F igur e A -8: R igh t End B ell C omponen ts , Back P anel R emo v ed APPENDIX - REPLA CING OVEN C OMPONENT S R eplacing I t ems - R igh t End B ell W ARNING: B efor e r emo ving or r eplacing any o v en component, thor oughly r ead the safety [...]

A -9 APPENDIX - REPLA CING OVEN C OMPONENT S I t em P ar t Number Har dw ar e D escr iption Har dw ar e P ar t Number(s) Blo w er M ot or A ssembly HC T -4205 Nut , 1/4-20, S er rat ed HEX F lange , P la t ed S t eel S cr ew , #10-32 x 5/8, SK T HD , PL T S tandoff , #10-32 x I, F/F , 3/8 HEX, PL T Spac er , #10 (.192) x 3/8 OD X 7/16, AL S cr ew ,[...]

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F or ser vice or infor mation: WITHIN NOR TH AMERICA CALL C ustomer S er vice at 800.90 TURBO or OUT SIDE NOR TH AMERICA CALL +1 214-379-6000 or Y our A uthoriz ed D istributor P ar t N umber: HCT -4202/R evision B/J uly 2008 Countr y Code: NA/EU Accelerating the World of Cookin g TM Corpor ate H eadquar ters S ix Concourse Pkwy , S uite 1900 A tla[...]