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R-21AT
SERVICE MANUAL
SX802R21ATPKK
COMMERCIAL MICROWAVE OVEN
1000W/ R-21AT
ON DEF NO. X2 CHECK
MODEL
R-21AT
In interests of user-safety the oven should be restored to its original condition and only parts identical to those specified should be used.
TABLE OF CONTENTS
Page SERVICING ................................................................................................................. INSIDE FRONT COVER CAUTION, MICROWAVE RADIATION ............................................................................................................. 1 WARNING .......................................................................................................................................................... 1 PRODUCT SPECIFICATIONS ......................................................................................................................... 2 GENERAL INFORMATION ................................................................................................................................ 2 APPEARANCE VIEW ....................................................................................................................................... 3 OPERATION SEQUENCE ................................................................................................................................ 4 FUNCTION OF IMPORTANT COMPONENTS ................................................................................................ 5 TROUBLESHOOTING GUIDE .......................................................................................................................... 6 TEST PROCEDURE ......................................................................................................................................... 7 TOUCH CONTROL PANEL ASSEMBLY ........................................................................................................ 13 COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE ........................................................... 20 MICROWAVE MEASUREMENT .................................................................................................................... 25 WIRING DIAGRAM ......................................................................................................................................... 26 PICTORIAL DIAGRAM ................................................................................................................................... 27 CONTROL PANEL CIRCUIT ........................................................................................................................... 28 PRINTED WIRING BOARD ............................................................................................................................. 29 PARTS LIST ................................................................................................................................................... 30
SHARP CORPORATION
R-21AT
SERVICING
WARNING TO SERVICE PERSONNEL
Microwave ovens contain circuitry capable of producing very high voltage and current. Contact with following parts will result in electrocution. High voltage capacitor, High voltage transformer, Magnetron, High voltage rectifier, High voltage fuse, High voltage harness. REMEMBER TO CHECK 3D 1) Disconnect the supply. 2) Door opened, and wedged open. 3) Discharge high voltage capacitor. WARNING: AGAINST THE CHARGE OF THE HIGH-VOLTAGE CAPACITOR. The high-voltage capacitor remains charged about 60 seconds after the oven has been switched off. Wait for 60 seconds and then short-circuit the connection of the high-voltage capacitor (that is, of the connecting lead of the high-voltage rectifier) against the chassis using a screwdriver with an insulated handle. Sharp recommend that wherever possible fault-finding is carried out with the supply disconnected. In some cases, it may be necessary to connect the supply with the cover removed to carry out fault investigation in the circuitry. In such cases, the high voltage circuit should be disabled as described below to reduce the hazards:Carry out 3D checks (see above) Disconnect the supply leads from the high voltage transformer, making a note of the polarity. Insulate the connectors, ensuring they are positioned away from the transformer and fastened there. Connect any relevant test equipment e.g. voltmeter. Reconnect the oven to the supply, then close the door. Note the results of the test, taking care to keep clear of the operational oven. Carry out 3D checks (see above). Reconnect the leads to the transformer. Take care to observe correct polarity. Carry out 4R checks (see below). Microwave ovens should not be used without load. To test for the presence of microwave energy within a cavity, place a cup of cold water on the ceramic shelf, close the door and set the microwave timer for one (1) minute, set the power level to HIGH (100%) and push the start key. When the one (1) minute has elapsed (timer at zero) carefully check that the water is now hot. AFTER REPAIR REMEMBER TO CHECK 4R 1) 2) 3) 4) Reconnect all leads removed from components during testing. Replace the outer case (cabinet). Reconnect the supply. Run the oven. Check all functions.
When all service work is completed and the oven is fully assembled, the microwave power output should be checked and microwave leakage test should be carried out. IMPORTANT: If the oven becomes inoperative because of a blown fuse M10A Fuse, check the monitored 1st. interlock switch and monitor switch before replacing the fuse M10A. WARNING: WIRING / RE-WIRING Before carrying out any work; carry out 3D checks. 1) Disconnect the power supply. 2) Open the door and wedge open. 3) Discharge the high voltage capacitor. RE-WIRING 1) Wires must not touch: a) High voltage parts: b) Parts that become hot. c) Sharp edges d) Movable parts 2) Positive lock connectors are fitted correctly. 3) Wires are connected correctly as per pictorial diagram. 4) Now wire leads are trapped by the outer wrap.
R-21AT
SERVICE MANUAL
PRODUCT SPECIFICATIONS
GENERAL INFORMATION COMMERCIAL MICROWAVE OVEN R-21AT APPEARANCE VIEW
GENERAL IMPORTANT INFORMATION This Manual has been prepared to provide Sharp Corp. Service engineers with Operation and Service Information. It is recommended that service engineers carefully study the entire text of this manual, so they will be qualified to render satisfactory customer service.
CAUTION MICROWAVE RADIATION
OPERATING SEQUENCE
FUNCTION OF IMPORTANT COMPONENTS
SERVICING AND TROUBLESHOOTING GUIDE
Service engineers should not be exposed to the microwave energy which may radiate from the magnetron or other microwave generating devices if it is improperly used or connected. All input and output microwave connections, waveguides, flanges and gaskets must be secured. Never operate the device without a microwave energy absorbing load attached. Never look into an open waveguide or antenna while the device is energized.
TEST PROCEDURE
TOUCH CONTROL PANEL
WARNING Never operate the oven until the following points are ensured. (A) The door is tightly closed. (B) The door brackets and hinges are not defective. (C) The door packing is not damaged. (D) The door is not deformed or warped. (E) There is not any other visible damage with the oven. Servicing and repair work must be carried out only by trained service engineers. All the parts marked "*" on parts list are used at voltages more than 250V. Removal of the outer wrap gives access to potentials above 250V. All the parts marked "" on parts list may cause undue microwave exposure, by themselves, or when they are damaged, loosened or removed.
COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE
MICROWAVE MEASUREMENT
WIRING DIAGRAM
PARTS LIST
SHARP CORPORATION OSAKA, JAPAN
1
R-21AT
PRODUCT DESCRIPTION
SPECIFICATION
ITEM
Power Requirements
DESCRIPTION
230 - 240 Volts 50 Hertz Single phase, 3 wire earthed 1000 W nominal of RF microwave energy (measured by method of IEC 705) Operating frequency 2450 MHz Width 520 mm Height 309 mm including foot Depth 406 mm Width 351 mm Height 211 mm Depth 372 mm Touch Control System Timer (0 - 99 minutes and 99 seconds) Microwave Power for Variable Cooking Repetition Rate; P-HI ........................................... Full power throughout the cooking time P-90 ............................................................. approx. 90% of Full Power P-80 ............................................................. approx. 80% of Full Power P-70 ............................................................. approx. 70% of Full Power P-60 ............................................................. approx. 60% of Full Power P-50 ............................................................. approx. 50% of Full Power P-40 ............................................................. approx. 40% of Full Power P-30 ............................................................. approx. 30% of Full Power P-20 ............................................................. approx. 20% of Full Power P-10 ............................................................. approx. 10% of Full Power P-0 ............................................. No power throughout the cooking time DOUBLE QUANTITY pad EXPRESS DEFROST pad Number pads SELECT TIME pad STOP/CLEAR pad SELECT POWER pad START pad SET pad CHECK pad SIGNAL pad Approx. 18 kg
Power Output Case Dimensions
Cooking Cavity Dimensions
Control Complement
Set Weight
GENERAL INFORMATION
WARNING THIS APPLIANCE MUST BE EARTHED
IMPORTANT THE WIRES IN THIS MAINS LEAD ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE: GREEN-AND-YELLOW BLUE BROWN : EARTH : NEUTRAL : LIVE
2
R-21AT
APPEARANCE VIEW
OVEN 1. Oven light 2. Ceramic shelf 3. Control panel 9 4. Cavity face plate 5. Door latch openings 6. Door latches 7. Door hinges 8. Door seals and sealing surfaces 9. Door handle 10.Oven door with see-through window 11.Air ventilation cover and openings 12.Power supply cord 13.Air intake openings 14.Outer case cabinet TOUCH CONTROL PANEL
10
7
1
12 11
2 13 14 6 8 4 5 3
Digital Readout DOUBLE QUANTITY pad EXPRESS DEFROST pad Number pads for time and memory programming 5. SELECT TIME pad 6. STOP/CLEAR pad; touch to stop operation of oven and clear remaining heating time 7. SELECAT POWER pad for setting variable power level 8. START pad; touch to operate oven after door is closed and time is set 9. SET pad for setting memory 10.CHECK pad for checking memory 11.SIGNAL pad for setting signal sound
1. 2. 3. 4.
1
ON DEF NO. X2 CHECK
2
3
4
5 7 9 10
6 8 11
3
R-21AT
OPERATION SEQUENCE
OFF CONDITION
Closing the door activates the 1st. latch switch, 2nd. latch switch and stop switch. IMPORTANT: When the oven door is closed, the contacts COM-NC of the monitor switch must be open. When the microwave oven is plugged in a wall outlet (230 - 240V 50Hz), the line voltage is supplied to the noise filter and the control unit. Figure O-1 on page 26 1. The oven display will show . . 6-1. When the oven door is opened during or after the cycle of a cooking program, the 1st. interlock switch, latch switch and 2nd. interlock relay control switch must open their contacts first. After that the contacts (COM-NC) of the monitor switch can be closed. 6-2. When the oven door is closed, the contacts (COMNC) of the monitor switch must be opened. After that the contacts of the 1st. interlock switch, latch switch and 2nd. interlock relay control switch are closed. 6-3. When the oven door is opened and the contacts of the 1st. latch switch, 2nd. latch switch and the relay RY2 remain closed, the fuse M10A will blow, because the monitor switch is closed and a short circuit is caused.
MICROWAVE COOKING CONDITION
Program desired cooking time by touching SELECT TIME pad and the NUMBER pads. When the START pad is touched, the following operations occur: Figure O-2 on page 26 RELAY RY-2 RY-3 CONNECTED COMPONENTS power transformer oven lamp/antenna motor/fan motor
POWER LEVEL P-0 TO P-90 COOKING
When Variable Cooking Power is programmed, the line voltage is supplied to the power transformer intermittently through the contacts of relay (RY-2) which is operated by the control unit within a 32 second time base. Microwave power operation is as follows: VARI-MODE Power 10(P-HI) (100% power) Power 9(P-90) (approx. 90% power) Power 8(P-80) (approx. 80% power) Power 7(P-70) (approx. 70% power) Power 6(P-60) (approx. 60% power) Power 5(P-50) (approx. 50% power) Power 4(P-40) (approx. 40% power) Power 3(P-30) (approx. 30% power) Power 2(P-20) (approx. 20% power) Power 1(P-10) (approx. 10% power) Power 0(P-0) (0% power) Note: ON TIME 32 sec. 30 sec. 26 sec. 24 sec. 22 sec. 18 sec. 16 sec. 12 sec. 8 sec. 6 sec. 0 sec. OFF TIME 0 sec. 2 sec. 6 sec. 8 sec. 10 sec. 14 sec. 16 sec. 20 sec. 24 sec. 26 sec. 32 sec.
1. The line voltage is supplied to the primary winding of the high voltage transformer. The voltage is converted to about 3.3 volts A.C. output on the filament winding and high voltage of approximately 2300 volts A.C. on the secondary winding. 2. The filament winding voltage (3.3 volts) heats the magnetron filament and the high voltage (2000 volts) is sent to the voltage doubling circuit, where it is doubled to negative voltage of approximately 4000 volts D.C.. 3. The 2450 MHz microwave energy produced in the magnetron generates a wave length of 12.24 cm. This energy is channelled through the waveguide (transport channel) into the oven cavity, where the food is placed to be cooked. 4. When the cooking time is up, a signal tone is heard and the relays RY2 + RY3 go back to their home position. The circuits to the oven lamp, high voltage transformer, fan motor and antenna motor are cut off. 5. When the oven door is opened during a cooking cycle, the switches come to the following condition.
Switch Contact Condition During Oven Door Cooking Open(No cooking) Closed Opened Closed Opened Closed Opened Opened Closed
1st. interlock switch Latch switch 2nd. interlock relay control switch Monitor Switch
COM-NO COM-NO COM-NO COM-NC
The ON/OFF time ratio does not correspond with the percentage of microwave power, because approx. 2 seconds are needed for heating of the magnetron filament.
The circuit to the high voltage transformer, fan motor, oven lamp and antenna motor are cut off when the 1st. interlock switch, latch switch and 2nd. interlock relay control switch are made open. Shown in the display is remaining time. 6. MONITOR SWITCH CIRCUIT The monitor switch is mechanically controlled by the oven door, and monitors the operation of the 1st. interlock switch.
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R-21AT
FUNCTION OF IMPORTANT COMPONENTS
DOOR OPEN MECHANISM
The door is opened by grasping the door handle, refer to Figure D-1. When the door handle is grasped, the handle lever is pulled. And then the upper and lower latch heads are moved upward by the handle lever, and they are released from the latch hook. Now the door will open.
HIGH VOLTAGE FUSE 0.75A
The high voltage fuse blows when the high voltage rectifier or the magnetron is shorted.
THERMAL CUT-OUT 145°C (MAGNETRON)
This thermal cut-out protects the magnetron against overheating. If the temperature goes up higher than 145°C because the fan motor is interrupted or the ventilation openings are blocked, the thermal cut-out will open and line voltages to the high voltage transformer will be cut off and the operation of the magnetron will be stopped. The thermal cut-out will not resume.
Handle Lever
Latch Head Latch Hook
THERMAL CUT-OUT 125°C (OVEN)
Door Handle Latch Lever Latch Switch Lever A 1st. Interlock Switch
Latch Switch Lever B Latch Head Latch Switch Lever C Monitor Switch 2nd. Interlock Relay Control Switch Latch Switch
The thermal cut-out located on the top of the oven cavity is designed to prevent damage to the oven if the food in the oven catches fire due to over heating produced by improper setting of the cooking time or failure of control unit. Under normal operation, the oven thermal cut-out remains closed. However, when abnormally high temperatures are reached within the oven cavity, the oven thermal cut-out will open at 125°C causing the oven to shut down. The thermal cut-out will not resume.
MONITOR RESISTOR
The monitor resistor prevents the fuse M10A bursting when the fuse M10A blows due to the operation of the monitor switch.
Figure D-1. Door Open Mechanism
1ST. INTERLOCK SWITCH, LATCH SWITCH AND 2ND. INTERLOCK RELAY CONTROL SWITCH
1. When the oven door is closed, the contacts (COM-NO) of each switch must be closed. 2. When the oven door is opened, the contacts (COMNO) of each switch must be opened.
NOISE FILTER
The noise filter assembly prevents radio frequency interference that might flow back in the power circuit.
ANTENNA MOTOR
The antenna motor rotates the stirrer antenna located on the bottom of the oven cavity, so that the food on the ceramic shelf is cooked evenly during cooking. The antenna motor may turn in either direction.
MONITOR SWITCH
1. When the door is closed, the contacts (COM-NC) must be opened. 2. When the door is opened, the contacts (COM-NC) must be closed. 3. If the oven door is opened and the contacts (COM-NO) of the 1st. interlock switch fail to open, the fuse M10A blows immediately after closing the contacts (COMNC) of the monitor switch. CAUTION: BEFORE REPLACING A BLOWN FUSE M10A TEST THE 1ST. INTERLOCK SWITCH, MONITOR SWITCH AND MONITOR RESISTOR FOR PROPER OPERATION. (REFER TO CHAPTER "TEST PROCEDURE").
COOLING FAN MOTOR
The cooling fan motor drives a blade which draws external cool air. This cool air is directed through the air vanes surrounding the magnetron and cools the magnetron. This air is channelled through the oven cavity to remove steam and vapors given off from the heating food. It is then exhausted through the exhausting air vents at the oven cavity.
FUSE M10A 250V
1. If the wire harness or electrical components are shortcircuited, this fuse blows to prevent an electric shock or fire hazard. 2. This fuse blows when the 1st. interlock switch remain closed with the oven door open and when the contacts (COM-NC) of monitor switch closes.
5
R-21AT
TROUBLESHOOTING GUIDE
When troubleshooting the microwave oven, it is helpful to follow the Sequence of Operation in performing the checks. Many of the possible causes of trouble will require that a specific test be performed. These tests are given a procedure letter which will be found in the "Test Procedure" section.
TEST PROCEDURE
A B C D E E E E F G H I
I
J
K L M M N CK RE RE RECK CK CKCK
2ND. INTERLOCK RELAY CONTROL SWITCH
HIGH VOLTAGE TRANSFORMER
EXCEED MAX. HEATING TIME
SHORT OR OPENED WIRING
HIGH VOLTAGE CAPACITOR 1ST. INTERLOCK SWITCH
SHORTED IN POWER CORD
H.V. RECTIFIER ASSEMBLY
CONDITION
PROBLEM
Home fuse or circuit breaker blows when power cord is plugged into wall outlet.
OFF CONDITION
Fuse M10A blows when power cord is plugged into wall receptacle. . does not appear in display when power cord is first plugged into wall outlet. Oven lamp does not light when door is opened. Oven lamp lights but fan motor and antenna motor do not operate.
COOKING CONDITION
Oven does not go into cook cycle when START pad is touched. Oven seems to be operating but little or no heat is produced in oven load. (Food incompletely cooked or not cooked at all at end of cook cycle.) Oven goes into a cook cycle but extremely uneven heating is produced in oven load (food). Oven does not cook properly when programmed for Cooking Power 5 mode. (Operates properly on Cooking Power 10 (HIGH) mode.)
ERROR MODE
"EE9" Maximum time is exceeded.
6
LOW VOLTAGE
LATCH SWITCH
MAGNETRON
KEY UNIT RELAY (RY2)
RELAY (RY3)
POSSIBLE CASE AND DEFECTIVE PARTS
DIRTY OVEN CAVITY MISADJUSTMENT SWITCH
FOIL PATTERN ON P.W.B.
TOUCH CONTROL PANEL
OVEN LAMP OR SOCKET
FUSE M10A NOISE FILTER COOLING FAN MOTOR
WRONG OPERATION
HIGH VOLTAGE FUSE
THERMAL CUT-OUT
MONITOR SWITCH
ANTENNA MOTOR
R-21AT
TEST PROCEDURES PROCEDURE LETTER A MAGNETRON TEST COMPONENT TEST
NEVER TOUCH ANY PART IN THE CIRCUIT WITH YOUR HAND OR AN INSULATED TOOL WHILE THE OVEN IS IN OPERATION. CARRY OUT 3D CHECKS. Isolate the magnetron from high voltage circuit by removing all leads connected to filament terminal. To test for an open circuit filament use an ohmmeter to make a continuity test between the magnetron filament terminals, the meter should show a reading of less than 1 ohm. To test for short filament to anode condition, connect ohmmeter between one of the filament terminals and the case of the magnetron (ground). This test should be indicated an infinite resistance. If a low or zero resistance reading is obtained then the magnetron should be replaced.
MICROWAVE OUTPUT POWER (1 litre load)
The following test procedure should be carried out with the microwave oven in a fully assembled condition (outer case fitted). Microwave output power from the magnetron can be measured by way of IEC 705, i.e. it is measured by how much power the water load can absorb. To measure the microwave output power in the microwave oven, the relation of calorie and watt is used. When P(W) heating works for t(second), approximately P x t/4.187 calorie is generated. On the other hand, if the temperature of the water with V(ml) rises T (°C) during this microwave heating period, the calorie of the water is V x T. The formula is as follows; P x t / 4.187 = V x T P (W) = 4.187 x V x T / t Our condition for water load is as follows: Room temperature ........... around 20°C Power supply Voltage .............. Rated voltage Water load.................................. 1000 g Initial temperature .............................. 10±2°C Heating time .............................. 42 sec. P = 100 x T Measuring condition: 1. Container The water container must be a cylindrical borosilicate glass vessel having a maximum material thickness of 3 mm and an outside diameter of approximately 190 mm. 2. Temperature of the oven and vessel The oven and the empty vessel are at ambient temperature prior to the start the test. 3. Temperature of the water The initial temperature of the water is (10±2)°C. 4. Select the initial and final water temperature so that the maximum difference between the final water temperature and the ambient temperature is 5°C. 5. Select stirring devices and measuring instruments in order to minimize addition or removal of heat. 6. The graduation of the thermometer must be scaled by 0.1°C at minimum and be an accurate thermometer. 7. The water load must be (1000±5) g. 8. "t" is measured while the microwave generator is operating at full power. Magnetron filament heatup time is not included.
NOTE: The operation time of the microwave oven is "t + 2" sec. (2 sec. is magnetron filament heat-up time.)
Measuring method: 1. Measure the initial temperature of the water before the water is added to the vessel. (Example: The initial temperature T1 = 11°C) 2. Add the 1 litre water to the vessel. 3. Place the load on the centre of the shelf. 4. Operate the microwave oven at HIGH for the temperature of the water rises by a value T of (10 ± 2) K. 5. Stir the water to equalize temperature throughout the vessel. 6. Measure the final water temperature. (Example: The final temperature T2 = 21°C) 7. Calculate the microwave power output P in watts from above formula.
7
R-21AT
TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST Initial temperature .................................................................................................. T1 = 11°C Temperature after (42 + 2) = 44 sec ...................................................................... T2 = 21°C Temperature difference Cold-Warm ...................................................................... T1 = 10°C Measured output power The equation is "P = 100 x T" ................................................ P = 100 x 10°C = 1000 Watts
JUDGMENT: The measured output power should be at least ± 15 % of the rated output power. CAUTION: 1°C CORRESPONDS TO 100 WATTS. REPEAT MEASUREMENT IF THE POWER IS INSUFFICIENT.
1000g 1000g 1000g
T1°C
Heat up for 44 sec B HIGH VOLTAGE TRANSFORMER TEST WARNING:
T2°C
High voltage and large currents are present at the secondary winding and filament winding of the high voltage transformer. It is very dangerous to work near this part when the oven is on. NEVER make any voltage measurements of the high-voltage circuits, including the magnetron filament.
CARRY OUT 3D CHECKS. Disconnect the leads to the primary winding of the high voltage transformer. Disconnect the filament and secondary winding connections from the rest of the HV circuitry. Using an ohmmeter, set on a low range, it is possible to check the continuity of all three windings. The following readings should be obtained:a. Primary winding ................................ approximately 1.3 b. Secondary winding ............................ approximately 86 c. Filament winding......................................... less than 1 If the readings obtained are not stated as above, then the high voltage transformer is probably faulty and should be replaced. CARRY OUT 4R CHECKS. C HIGH VOLTAGE RECTIFIER ASSEMBLY TEST
B C
CARRY OUT 3D CHECKS.
HIGH VOLTAGE RECTIFIER
Isolate the high voltage rectifier assembly from the HV circuit. The high voltage rectifier can be tested using an ohmmeter set to its highest range. Connect the ohmmeter across the terminal B+C of the high voltage rectifier and note the reading obtained. Reverse the meter leads and note this second reading. The normal resistance is infinite in one direction and more than 100 k in the other direction. CARRY OUT 4R CHECKS. NOTE: FOR MEASUREMENT OF THE RESISTANCE OF THE RECTIFIER, THE BATTERIES OF THE MEASURING INSTRUMENT MUST HAVE A VOLTAGE AT LEAST 6 VOLTS, BECAUSE OTHERWISE AN INFINITE RESISTANCE MIGHT BE SHOWN IN BOTH DIRECTIONS. D HIGH VOLTAGE CAPACITOR TEST CARRY OUT 3D CHECKS. A. Isolate the high voltage capacitor from the circuit. B. Continuity check must be carried out with measuring instrument which is set to the highest resistance range. C. A normal capacitor shows continuity for a short time (kick) and then a resistance of about 10M after
8
R-21AT
TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST it has been charged. D. A short-circuited capacitor shows continuity all the time. E. An open capacitor constantly shows a resistance about 10 M because of its internal 10M resistance. F. When the internal wire is opened in the high voltage capacitor shows an infinite resistance. G. The resistance across all the terminals and the chassis must be infinite when the capacitor is normal. If incorrect reading are obtained, the high voltage capacitor must be replaced. CARRY OUT 4R CHECKS. E SWITCH TEST CARRY OUT 3D CHECKS. Isolate the switch to be tested and using an ohmmeter check between the terminals as described in the following table. Table: Terminal Connection of Switch
Plunger Operation
Released Depressed
COM to NO
Open circuit Short circuit
COM to NC
Short circuit Open circuit
COM; Common terminal, NO; Normally open terminal NC; Normally close terminal
If incorrect readings are obtained, make the necessary switch adjustment or replace the switch. CARRY OUT 4R CHECKS. F THERMAL CUT-OUT TEST
CARRY OUT 3D CHECKS. Disconnect the leads from the terminals of the thermal cut-out. Then using an ohmmeter, make a continuity test across the two terminals as described in the below. Table: Thermal Cut-out Test
Parts Name Thermal cut-out 125°C Thermal cut-out 145°C Temperature of "ON" condition (closed circuit). (°C) This is not resetable type. This is not resetable type. Temperature of "OFF" condition (open circuit). (°C) Above 125°C Above 145°C Indication of ohmmeter (When room temperature is approx. 20°C.) Closed circuit Closed circuit
If incorrect readings are obtained, replace the thermal cut-out. An open circuit thermal cut-out (MG) indicates that the magnetron has overheated, this may be due to resistricted ventilation, cooling fan failure or a fault condition within the magnetron or HV. circuit. An open circuit thermal cut-out (OVEN) indicates that the food in the oven cavity may catch fire, this may be due to over heating produced by improper setting of the cooking timer or failure of the control panel.
CARRY OUT 4R CHECKS.
G
BLOWN FUSE M10A
CARRY OUT 3D CHECKS.
If the fuse M10A is blown when the door is opened, check the 1st. interlock switch, monitor switch and monitor resistor. If the fuse M10A is blown, there could be a short or ground in electrical parts or wire harness. Check them and replace the defective parts or repair the wire harness.
CARRY OUT 4R CHECKS. CAUTION: Only replace fuse M10A with the correct value replacement.
9
R-21AT
TEST PROCEDURES PROCEDURE LETTER H NOISE FILTER TEST COMPONENT TEST
N FUSE M10A L
CARRY OUT 3D CHECKS. Disconnect the leads from the terminals of noise filter. Using an ohmmeter, check between the terminals as described in the following table.
MEASURING POINTS Between N and L Between terminal N and WHITE Between terminal L and RED INDICATION OF OHMMETER Approx. 680 k Short circuit Short circuit
DISCHARGE RESISTOR 680 k
NOISE FILTER
NOISE SUPPRESSION COIL
LINE CROSS CAPACITOR 0.068µF/ AC 250V
If incorrect readings are absorbed, replace the noise filter unit. CARRY OUT 4R CHECKS.
LINE BYPASS CAPACITOR 0.0033µF/ AC 250V
LINE BYPASS CAPACITOR 0.0033µF/ AC 250V
DISCHARGE RESISTOR 10M
I
MOTOR WINDING TEST CARRY OUT 3D CHECKS. Disconnect the leads from the motor. Using an ohmmeter, check the resistance between the two terminals as described in the table below.
Table: Resistance of Motor Motors Resistance Fan motor Approximately 219 Antenna motor Approximately 11 k If incorrect readings are obtained, replace the motor. CARRY OUT 4R CHECKS.
J
HIGH VOLTAGE FUSE TST CARRY OUT 3D CHECKS. If the high voltage fuse is blown, there could be a short in the high voltage rectifier or the magnetron. Check them and replace the defective parts and the high voltage fuse. CARRY OUT 4R CHECKS.
CAUTION: Only replace high voltage fuse with the correct value replacement.
K
TOUCH CONTROL PANEL ASSEMBLY TEST The touch control panel consists of circuits including semiconductors such as LSI, ICs, etc. Therefore, unlike conventional microwave ovens, proper maintenance can not be performed with only a voltmeter and ohmmeter. In this service manual, the touch control panel assembly is divided into two units, Control Unit and Key Unit and troubleshooting by replacement is described according to the symptoms indicated. 1. Key Unit Note : Check key unit ribbon connection before replacement. The following symptoms indicate a defective key unit. Replace the key unit. a) When touching the pads, a certain pad produces no signal at all. b) When touching a number pad, two figures or more are displayed. c) When touching the pads, sometimes a pad produces no signal. 2. Control Panel The following symptoms indicate a defective control unit. Before replacing the control unit. perform the key unit test (Procedure L) to determine if control unit is faulty. 2-1 In connection with pads a) When touching the pads, a certain group of pads do not produce a signal. b) When touching the pads, no pads produce a signal. 2-2 In connection with indicators a) At a certain digit, all or some segments do not light up. b) At a certain digit, brightness is low. c) Only one indicator does not light up. d) The corresponding segments of all digits do not light up; or they continue to light up.
10
R-21AT
TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST e) Wrong figure appears. f) A certain group of indicators do not light up. g) The figure of all digits flicker. 2-3 Other possible troubles caused by defective control unit. a) Buzzer does not sound or continues to sound. b) Clock does not operate properly. c) Cooking is not possible. L KEY UNIT TEST If the display fails to clear when the STOP/CLEAR pad is depressed, first verify the flat ribbon cable is marking good contact, verify that the door sensing switch (stop switch) operates properly; that is the contacts are closed when the door is closed and open when the door is open. If the door sensing switch (stop switch) is good, disconnect the flat ribbon cable that connects the key unit to the control unit and make sure the door sensing switch is closed (either close the door or short the door sensing switch connecter). Use the Key unit matrix indicated on the control panel schematic and place a jumper wire between the pins that correspond to the STOP/CLEAR pad marking momentary contact. If the control unit responds by clearing with a beep the key unit is faulty and must be replaced. If the control unit does not respond, it is a faulty and must be replaced. If a specific pad does not respond, the above method may be used (after clearing the control unit) to determine if the control unit or key pad is at fault.
G1 G9 G10 G11
20
G2
G3
17
G4
G5
SELECT POWER SELECT TIME
15
G6
DOUBLE QUANTITY EXPRESS DEFROST
13
G7
START STOP/ CLEAR
11
G8
SET CHECK SIGNAL
7 8 9 0
18
19
5 6
3 4
1 2
16
14
12
G12
CARRY OUT 4R CHECKS.
M
RELAY TEST CARRY OUT 3D CHECKS. Remove the outer case and check voltage between Pin Nos. 3 and 7 of the 3 pin connector (A) on the control unit with an A.C. voltmeter. The meter should indicate 230-240 volts, if not check oven circuit. Relay Test Check voltage at the relay coil with a D.C. voltmeter during the microwave cooking operation. DC. voltage indicated .......... Defective relay. DC. voltage not indicated .... Check diode which is connected to the relay coil. If diode is good, control unit is defective.
RELAY SYMBOL RY2 RY3 OPERATIONAL VOLTAGE Approx. 18.0V D.C. Approx. 18.0V D.C. CONNECTED COMPONENTS High voltage transformer Oven lamp / Antenna motor / Fan motor
CARRY OUT 4R CHECKS.
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TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST N PROCEDURES TO BE TAKEN WHEN THE FOIL PATTERN ON THE PRINTED WIRING BOARD (PWB) IS OPEN To protect the electronic circuits, this model is provided with a fine foil pattern added to the input circuit on the PWB, this foil pattern acts as a fuse. If the foil pattern is open, follow the troubleshooting guide given below for repair. Problem: POWER ON, indicator does not light up. CARRY OUT 3D CHECKS.
STEPS
1 2 3 4
OCCURRENCE
The rated AC voltage is not present at Power terminal of CPU connector (CN-A). The rated AC voltage is present at primary side of low voltage transformer. Only pattern at "a" is broken. Pattern at "a" and "b" are broken.
CAUSE OR CORRECTION
Check supply voltage and oven power cord. Low voltage transformer or secondary circuit defective. Check and repair. *Insert jumper wire J1 and solder. (CARRY OUT 3D CHECKS BEFORE REPAIR) *Insert the coil RCILF2003YAZZ between "c" and "d". (CARRY OUT 3D CHECKS BEFORE REPAIR)
NOTE: *At the time of these repairs, make a visual inspection of the varistor for burning damage and examine the transformer with tester for the presence of layer short circuit (check primary coil resistance). If any abnormal condition is detected, replace the defective parts.
(J2)
(TB1)
7
(17)
(CT1)
c
b a
(VRS2)
d
(J1) VRS1 P
POWER
12
CARRY OUT 4R CHECKS.
12
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TOUCH CONTROL PANEL ASSEMBLY
OUTLINE OF TOUCH CONTROL PANEL The touch control section consists of the following units as shown in the touch control panel circuit. (1) Control Unit (2) Key Unit The principal functions of these units and the signals communicated among them are explained below. 1. Control Unit Signal of key touch and oven function control are all processed by one microcomputer. 1) Power Supply Circuit This circuit changes output voltage at the secondary side of the low voltage (T1) transformer to voltages required at each part by full wave rectifying circuit, constant voltage circuit, etc.. 2) ACL Circuit This is an Auto-clear Circuit, i.e., a reset circuit, which enables IC1 to be activated from initial state. 3) Power SYNC Signal Generating Circuit This is a circuit for generating power SYNC signal by virtue of the secondary side output of transformer T1. This signal is used for a basic frequency to time processing and so on. 4) Clock Circuit This is a circuit for controlling clock frequency required for operating IC1. 5) IC1 (Main Processor) This is a one-chip microcomputer, responsible for controlling the entire control unit. 6) IC2 (Memory Processor) This is a memory IC, responsible for memory function. 7) IC3 This is a IC for driving light emitting diode. 8) Display Circuit This is a circuit for driving light emitting diode by IC1 output. 9) Key Input Circuit This is a circuit for transmitting key input information to IC1. 10) Sound-body Driving Circuit This is a circuit for driving sound body by IC1 output. 11) Relay Driving Circuit This is a circuit for driving output relay by IC1 output. 12) Door Sensing Switch Circuit This is a circuit for driving IC1 to detect door opening/ closing. 2. Key Unit The key unit is composed of a matrix circuit in which when a key it touched, one of signals P30--P34 generated by the LSI, is passed through the key and returned to the LSI as one of signals P24--P27. This model has 20 Memory pads. When the oven is shipped, Memory pad 1 to 10 are set as follows: fig.1. Memory No. 1 2 3 4 5 6 7 8 9 0 Cook Time 10 sec. 20 sec. 30 sec. 45 sec. 1 min. 1 min. 15 sec. 1 min. 30 sec. 2 min. 2 min. 30 sec. 3 min. (fig. 1) This model has a double quantity pad. When the oven is shipped, Magnification "1.7" is preset in the double quantity pad. This model has an express defrost pad. When the oven is shipped, express defrost is set as follows: fig.2. 1 STAGE
FORMULA POWER P = 0.2T 60 %
Output Power 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
2 STAGE
P = 0.15T 40 %
3 STAGE
P = 0.65T 20 %
T : Total cooling time (fig. 2) When 1/2 total cooking time is passed, the signal will sound and "CHECK" indicator will flash
DESCRIPTION OF LSI LSI(IZA897DR) The I/O signal of the LSI(IZA897DR) is detailed in the following table. Pin No. 1 2/3 4 5-6 Signal VCC VEE/AVSS VREF AN7-AN6 I/O IN IN IN IN Description Power source voltage: +5V. VC voltage of power source circuit input. Connected to GND Connected to VC. (+5V) Terminal not used.
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Pin No. 7-8 9-10 11
Signal AN5-AN4 AN3-AN2 AN1
I/O IN IN IN
Description Terminal to change functions according to the model. Signal in accordance with the model in operation is applied to set up its function. Terminal not used. Input signal which communicates the door open/close information to LSI. Door closed; "L" level signal (0V). Door opened; "H" level signal (+5V). Terminal not used. Magnetron high-voltage circuit driving signal. To turn on and off the cook relay. In 100% power level operation, "H" level during cooking; "L" level otherwise. In other power level operation (90,80,70,60,50,40,30,20,10 or 0%), "H" and "L" level is repeated according to power level.
Power level 100% 90% 80% 70% 60% 50% ON OFF 32sec. 0sec. 30sec. 26sec. 24sec. 22sec. 18sec. 2sec. 6sec. 8sec. 10sec. 14sec. Power level 40% 30% 20% 10% 0% ON OFF 16sec. 16sec. 12sec. 8sec. 6sec. 0sec. 20sec. 24sec. 26sec. 32sec.
ON
12 13
AN0 P55
IN OUT
+5V
OFF 32 sec.
GND
14-15 16-18 19
P54-P53 P52-P50 P47
OUT IN OUT
Terminal not used. Terminal not used. Signal to sound buzzer. This signal is to control the 2.5kHz continuous signal through IC3. A: key touch sound. B: Guidance sound. C: Completion sound.
0.12 sec +5V A GND 1.2 sec B GND 2.4 sec +5V C GND 1.2 sec +5V T
200µsec.
200µsec.
20
P46
OUT
Oven lamp, Fan motor and Antenna motor driving signal. (Square Waveform : 50Hz) To turn on and off the shut-off relay (RY3). The Square waveform voltage is delivered to the RY3 driving circuit and relays(RY2, COOK RE20 msec LAY) control circuit.
During cooking H L
21
P45
OUT
Digit selection signal. The relation between digit signal and digit are as follows: Digit signal Digit P42 ..................... 1st. P43 .................... 2nd. P44 ..................... 3rd. P45 ..................... 4th. Normally, one pulse is output in every ß period, and input to the grid of the lightemitting diode.
H ß(50Hz) L +5V P42 GND
P43 P44 P45
22-24 25
P44-P42 INT1
OUT IN
Digit selection signal. Signal similar to P45. Signal synchronized with commercial power source frequency. This is basic timing for all time processing of LSI.
20 msec H : +5V
L : GND
26
P40
IN
Connected to GND through resistor.
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Pin No. 27
Signal RESET
I/O IN
Description Auto clear terminal. Signal is input to reset the LSI to the initial state when power is supplied. Temporarily set to "L" level the moment power is supplied, at this time the LSI is reset. Thereafter set at "H" level. Memory (EEPROM) clock output. Memory (EEPROM) data input/output. Internal clock oscillation frequency setting input. The internal clock frequency is set by inserting the ceramic filter oscillation circuit with respect to XOUT terminal. Internal clock oscillation frequency control output. Output to control oscillation input of XIN. Connected to GND. Signal coming from touch key. When either one of G-12 line keys on key matrix is touched, a corresponding signal out of P30, P31, P32, P33, P34 will be input into P27. When no key is touched, the signal is held at "L" level. Signal similar to P27. When either one of G-11 line keys on key matrix is touched, a corresponding signal will be input into P26. Signal similar to P27. When either one of G-10 line keys on key matrix is touched, a corresponding signal will be input into P25. Signal similar to P27. When either one of G-9 line keys on key matrix is touched, a corresponding signal will be input into P24. Terminal not used. Segment data signals. The relation between signals and indicators are as follows:
Signal Segment Signal Segment
ß(50Hz) +5V GND
28 29 30
P71 P70 XIN
OUT IN/OUT IN
31 32 33
XOUT VSS P27
OUT IN IN
34
P26
IN
35
P25
IN
36
P24
IN
37-38 39-40
P23-P22 P21-P20
OUT OUT
P21,P20 P17.P16 P15,P14 P13,P12 P11,P10 P07,P06 41-48 49-56 57-59 60 P17-P10 P07-P00 P37-P35 P34 OUT OUT OUT OUT
.......... 1 .......... 2 .......... 3 .......... 4 .......... 5 .......... 6
P05,P04 ............. 7 P03,P02 ............. 8 P01,P00 ............. 9
Segment data signal. Signal similar to P21. Segment data signal. Signal similar to P21. Terminal not used. Key strobe signal. Signal applied to touch-key section. A pulse signal is input to P27, P26, P25 and P24 terminals while one of G4 line keys on key matrix is touched. Key strobe signal. Signal applied to touch-key section. A pulse signal is input to P27, P26, P25 and P24 terminals while one of G5 line keys on key matrix is touched. Key strobe signal. Signal applied to touch-key section. A pulse signal is input to P27, P26, P25 and P24 terminals while one of G6 line keys on key matrix is touched. Key strobe signal. Signal applied to touch-key section. A pulse signal is input to P27, P26, P25 and P24 terminals while one of G7 line keys on key matrix is touched. Key strobe signal. Signal applied to touch-key section. A pulse signal is input to P27, P26, P25 and P24 terminals while one of G8 line keys on key matrix is touched.
15
61
P33
OUT
62
P32
OUT
63
P31
OUT
64
P30
OUT
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2-2 Memory IC (IC2)
X24C02P is a 2K-bit, serial memory, enabling CMOS to be erased/written electrically. This memory is constructed with 256 registers x 8bits, enabling individual access, read and write operations to be performed. Details of input/output signal for IC2 are as shown in the following diagram.
FUNCTIONAL DIAGRAM
(3) Vcc (4) Vss START CYCLE H.V. GENERATION TIMING & CONTROL
TOP VIEW
(5) SDA
START STOP LOGIC CONTROL LOGIC SLAVE ADDRESS REGISTER COMPARATOR LOAD INC XDEC 64
A0 A1 A2 VSS
1 2 3 4
8 7 6 5
VCC TEST SCL
R/W (6) SCL
E 2PROM 256 x 8
WORD ADDRESS COUNTER
1 5 3
64 YDEC 8 DATA REGISTER Dout
SDA
CK PIN Dout ACK
Table 1. Relation between Pin Nos, and Signals Pin No. 1-3 4 5 6 7 8 Signal A0-A2 VSS SDA SCL TEST VCC I/O IN IN IN/OUT IN IN IN Connected to +5V. Connected to GND. Serial data input/output : input/outputs data to IC1. Clock signal input : input/outputs sireal data at every one pulse. Connected to GND. Connected to +5V. Description
When the memory IC (IC2) or control unit is exchanged, input the relay timing to the memory IC (IC2), referring to the "How to input the relay timing". Otherwise the oven will make a big noise when starting. How to input the relay timing ... Flashing / PAD (Door close) CHECK CHECK DISPLAY . . . 82 68 (user total count) CHECK CHECK No. INDICATOR ... 0.1sec BUZZER PHONE
SIGNAL SIGNAL DOUBLE QUANTITY 7 (after 1 sec.) SET 3. 8. 4. 9 SET CHECK
34 5 6 (service total count upper figure 3456XX) 7 38 38 38 . 69 0 49 49 x4 No.
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TOUCH CONTROL PANEL SERVICING
1. Precautions for Handling Electronic Components This unit uses CMOS LSI in the integral part of the circuits. When handling these parts, the following precautions should be strictly followed. CMOS LSI have extremely high impedance at its input and output terminals. For this reason, it is easily influenced by the surrounding high voltage power source, static electricity charge in clothes, etc. and sometimes it is not fully protected by the built-in protection circuit. In order to protect CMOS LSI. 1) When storing and transporting, thoroughly wrap them in aluminium foil. Also wrap all PW boards containing them in aluminium foil. 2) When soldering, ground the technician as shown in the figure and use grounded soldering iron and work table.
approx. 1M ohm
2. Shapes of Electronic Components
3
2
1 E CB
IC KIA7805P1
Transistor DTA123ES DTB143ES DTC143ES DTD143ES
3. Servicing of Touch Control Panel We describe the procedures to permit servicing of the touch control panel of the microwave oven and the precautions you must take when doing so. To perform the servicing, power to the touch control panel is available either from the power line of the oven itself or from an external power source. (1) Servicing the touch control panel with power supply of the oven: CAUTION: THE HIGH VOLTAGE TRANSFORMER OF THE MICROWAVE OVEN IS STILL LIVE DURING SERVICING PRESENTS A HAZARD. Therefore, before checking the performance of the touch control panel, 1) Disconnect the power supply cord, and then remove outer case. 2) Open the door and block it open. 3) Discharge high voltage capacitor. 4) Disconnect the leads to the primary of the power transformer. 5) Ensure that these leads remain isolated from other components and oven chassis by using insulation tape. 6) After that procedure, re-connect the power supply cord. After checking the performance of the touch control panel, 1) Disconnect the power supply cord. 2) Open the door and block it open. 3) Re-connect the leads to the primary of the power
17
transformer. 4) Re-install the outer case (cabinet). 5) Re-connect the power supply cord after the outer case is installed. 6) Run the oven and check all functions. A. On some models, the power supply cord between the touch control panel and the oven itself is so short that the two can't be separated. For those models, check and repair all the controls (sensor-related ones included) of the touch control panel while keeping it connected to the oven. B. On some models, the power supply cord between the touch control panel and the oven proper is long enough that they may be separated from each other. For those models, therefore, it is possible to check and repair the controls of the touch control panel while keeping it apart from the oven proper; in this case you must short both ends of the door sensing switch (on PWB) of the touch control panel with a jumper, which brings about an operational state that is equivalent to the oven door being closed. As for the sensor-related controls of the touch control panel, checking them is possible if dummy resistor(s) with resistance equal to that of the controls are used. (2) Servicing the touch control panel with power supply from an external power source: Disconnect the touch control panel completely from the oven proper, and short both ends of the door sensing switch (on PWB) of the touch control panel, which brings about an operational state that is equivalent to the oven door being closed. Connect an external power source to the power input terminal of the touch control panel, then it is possible to check and repair the controls of the touch control panel it is also possible to check the sensor-related controls of the touch control panel by using the dummy resistor(s). 4. Servicing Tools Tools required to service the touch control panel assembly. 1) Soldering iron: 30W (It is recommended to use a soldering iron with a grounding terminal.) 2) Oscilloscope: Single beam, frequency range: DC10MHz type or more advanced model. 3) Others: Hand tools 5. Other Precautions 1) Before turning on the power source of the control unit, remove the aluminium foil applied for preventing static electricity. 2) Connect the connectors of the key unit to the control unit being sure that the lead wires are not twisted. 3) After aluminium foil is removed, be careful that abnormal voltage due to static electricity etc. is not applied to the input or output terminals. 4) Attach connectors, electrolytic capacitors, etc. to PWB, making sure that all connections are tight. 5) Be sure to use specified components where high precision is required.
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PROCEDURE FOR CHECKING/CLEARING SERVICE COUNTS OF MICROWAVE OVEN
The following procedure enables the servicer to obtain the total using times (cook cycles) since the microwave oven is purchased and the total operation time (hours) since the microwave oven is purchased. The maximum capacity of the total using is 999,999 times, and the maximum capacity of total operation time is 999,999 hours. 1) Practice for checking total using times (Ex. 345678 times). ... Flashing / ... 0.1sec BUZZER
PAD (Door close) CHECK CHECK DISPLAY . . . 82 68 (user total count) SIGNAL SIGNAL DOUBLE QUANTITY 3456XX 1 (No 1) (after 1 sec.) 2 (No 2) (after 1 sec.) CHECK . 1 34 56
(service total count upper figure)
3) Practice for inputting total using times (Ex. 310000 times). ... Flashing / ... 0.1sec BUZZER
PAD (Door close) CHECK CHECK SIGNAL SIGNAL DOUBLE QUANTITY 2 (after 1 sec.) DISPLAY . . . 82 68 (user total count) INDICATOR PHONE
CHECK No. CHECK
34 56
(service total count upper figure)
3456XX 2 78
(service total count lower figure)
INDICATOR PHONE No.
CHECK No. CHECK 1 (after 1 sec.) SET 3,1,0,0 SET 2 (after 1 sec.) SET 0 SET
XXXX78 1 34 56 0 31 00 31 00 2 78 0 0 0
(service total count 310000 set)
No.
x4
34 56
(service total count upper figure)
No.
No.
2 78
(service total count lower figure)
No.
CHECK
.
4) Practice for inputting total operation time (Ex. 1234 hours). ... Flashing /
PAD (Door close) CHECK CHECK SIGNAL SIGNAL DOUBLE QUANTITY DISPLAY . . . 82 68 (user total count)
... 0.1sec BUZZER
INDICATOR PHONE
2) Practice for checking total operation time (Ex. 4567 hours). ... Flashing / ... 0.1sec BUZZER
PAD (Door close) CHECK CHECK DISPLAY . . . 82 68 (user total count) INDICATOR PHONE
CHECK No. CHECK
34 56
(service total count upper figure)
CHECK No. CHECK
3456XX 9 (after 1 sec.) SET 1,2 SET 0 (after 1 sec.) SET 3,4 SET 9 45 0 12 12 10 67 0 34 34
(Total operation time 1234 hours set)
No.
SIGNAL SIGNAL DOUBLE QUANTITY 34 56
(service total count upper figure)
x2
No.
3456XX 9 (No 9) (after 1 sec.) 0 (No 0) (after 1 sec.) CHECK . 9 45
(Total operation time upper figure)
No.
x2
0 67
(Total operation time lower figure)
No.
CHECK
.
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5) Practice for cancelling total using times and total operation time (user and service) and all other counter. ... Flashing / ... 0.1sec BUZZER
PAD (Door close) SET SET (within 2.0sec.) DOUBLE QUANTITY CHECK SINGLE SET DISPLAY . . . . . . . . . INDICATOR PHONE
KEY 0 1 : 9 START
DISPLAY 0 1 : 9 A
PAUSE End of each stage After 10% of total cooking time is passed : After 90% of total cooking time is passed There is no pause
No.
2) To check the constants of Express defrost.
DOUBLE PAD CHECK EXPRESS DEFROST
" " : Flicker /
DISPLAY . . 0.20 (A) 0 ( +-B ) P - 60 ( PL ) 0.15 (A) 0 ( +-B ) P - 40 ( PL ) 5 ( pause time ) P - 20 ( PL ) x2 ( repeat ) .
: 0.1 sec BUZZER
INDICATOR PHONE
"No." CHECK DEF
OTHER SETTING AND CHECKING PROCEDURE 1. EXPRESS DEFROST T = STG1 + STG 2 + STG3 STG = A x T + B 1) To set the constants of Express defrost. Ex. 0.20T, 60% at 1st stage 0.15T, 40% at 2nd stage 0.65T, 20% at 3rd stage " " : Flicker / : 0.1 sec BUZZER
(
)
PAD ORDER (Door close) SET SET (within 2 sec.) #1 START EXPRESS DEF 2,0 #2 SELECT TIME 0
DISPLAY . . . . 0.00 DEF. 0.20 DEF (A) 0 DEF 0 DEF (+ - B) DEF PDEF P - 60 0.00 DEF 0.15 DEF (A) 0 DEF 0 DEF (+ - B) DEF PDEF P - 40 0 DEF 5 DEF DEF PDEF P - 20 . DEF .
PHONE
"NO"
CHECK
SELECT POWER 6 SELECT TIME 1,5 SELECT TIME 0
3) To set user counts Practice for inputting total number of using times (Ex. 3100 times), and using times of Memory 1 (Ex. 100 times). " " : Flicker / : 0.1 sec BUZZER
PAD (Door close) x2 CHECK CHECK
DOUBLE QUANTITY
DISPLAY . . . 82 68 (user total count) 0 31 00 31 00
(user total count 3100 set)
INDICATOR PHONE
CHECK No. CHECK
SIGNAL SET 3,1,0,0 SET #A 1
x4
SELECT POWER 4 SELECT TIME #3 5 SIGNAL 2 SET SET
1 1 32 (memory 1 count) 0 1 00 1 00
(memory 1 count 100 set)
No.
(after 1 sec.) SET 1,0,0 SET
x3
CHECK
.
#1 : No key entry signal. #2 : To set -B, touch the select power key twice. #3 : Ex. defrost is paused after 50% of cooking time has lapsed when 5 key is entered, otherwise it is paused at the end of each stage.
NOTE: 1 : To input using times of other memory, touch necessary Memory key at above step #A. 2 : To input using times of manual cooking, touch SELECT TIME key at above step #A. 3 : To input using times of Express Defrost, touch EXPRESS DEFROST key at above step #A.
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COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE
WARNING: Avoid possible exposure to microwave energy. Please follow the instructions below before operating the oven. 1. Disconnect the oven from power supply. 2. Visually check the door and cavity face plate for damage (dents, cracks, signs of arcing etc.). Carry out any remedial work that is necessary before operating the oven. Do not operate the oven if any of the following conditions exist; 1. Door does not close firmly. 2. Door hinge, support or latch hook is damaged. 3. The door gasket or seal is damaged. 4. The door is bent or warped. 5. There are defective parts in the door interlock system. 6. There are defective parts in the microwave generating and transmission assembly. 7. There is visible damage to the oven. Do not operate the oven: 1. Without the RF gasket (Magnetron). 2. If the wave guide or oven cavity are not intact. 3. If the door is not closed. 4. If the outer case (cabinet) is not fitted.
Please refer to `OVEN PARTS, CABINET PARTS, CONTROL PANEL PARTS, DOOR PARTS', when carrying out any of the following removal procedures:
OUTER CASE REMOVAL
To remove the outer case, proceed as follows. 1. Disconnect oven from power supply. 2. Open the oven door and wedge it open. 3. Remove the five (5) screws from rear and along the side edge of case. 4. Slide the entire case back about 3cm to free it from retaining clips on the cavity face plate. 5. Lift the entire case from the oven. 6. Discharge the H.V. capacitor before carrying out any further work. 7. Do not operate the oven with the outer case removed. N.B.; Step 1, 2 and 8 form the basis of the 3D checks. CAUTION: 1. DISCONNECT OVEN FROM POWER SUP PLY BEFORE REMOVING OUTER CASE. 2. DISCHARGE THE HIGH VOLTAGE CAPACITOR BEFORE TOUCHING ANY OVEN COMPONENTS OR WIRING.
HIGH VOLTAGE TRANSFORMER REMOVAL
1. CARRY OUT 3D CHECKS. 2. Disconnect the filament leads of high voltage transformer from high voltage capacitor and the magnetron. 3. Disconnect the H.V. fuse from the high voltage transformer. 4. Disconnect the main wire harness from the high voltage transformer. 5. Remove the four (4) screws holding the transformer to base plate. 6. Remove the transformer. 7. Now the high voltage transformer is free.
HIGH VOLTAGE CAPACITOR, HIGH VOLTAGE FUSE AND HIGH VOLTAGE RECTIFIER ASSEMBLY REMOVAL
To remove the components, proceed as follows. 1. CARRY OUT 3D CHECKS. 2. Disconnect H.V. wire of the high voltage rectifier assembly from the magnetron. 3. Disconnect the filament lead of the high voltage transformer from the high voltage capacitor. 4. Remove one (1) screw holding earth side terminal of the high voltage rectifier assembly. 5. Disconnect high voltage fuse and terminal of high voltage rectifier assembly from the high voltage capacitor. 6. Now, the high voltage rectifier assembly should be free. 7. Disconnect the high voltage fuse from the high voltage transformer. 8. Now, the high voltage fuse is free. 9. Remove one (1) screw holding the capacitor holder to the oven cavity rear plate. 10.Remove one (1) screw holding the fan duct to the oven cavity rear plate. 11.Release the capacitor holder from the fan duct. 12.Remove the capacitor from the capacitor holder. 13.Now, the capacitor should be free. CAUTION: WHEN REPLACING HIGH VOLTAGE RECTIFIER ASSEMBLY, ENSURE THAT THE CATHODE (EARTH) CONNECTION IS SECURELY FIXED TO THE CAPACITOR HOLDER AND OVEN CAVITY REAR PLATE WITH AN EARTHING SCREW.
MAGNETRON REMOVAL
1. CARRY OUT 3D CHECKS. 2. Disconnect the high voltage wire of the high voltage
20
rectifier assembly and filament lead of the transformer from the magnetron.
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3. Remove the one (1) screw holding the air guide to the magnetron and remove the air guide. 4. Remove the one (1) screw holding the chassis support to the magnetron. 5. Carefully remove four (4) screws holding magnetron to waveguide, when removing the screws hold the magnetron to prevent it from falling.
6. Remove the magnetron from the waveguide with care so the magnetron antenna is not hit by any metal object around the antenna. CAUTION: WHEN REPLACING THE MAGNETRON, BE SURE THE R.F. GASKET IS IN PLACE AND THE MAGNETRON MOUNTING SCREWS ARE TIGHTENED SECURELY.
CONTROL PANEL ASSEMBLY REMOVAL
CONTROL PANEL ASSEMBLY 1. CARRY OUT 3D CHECKS. 2. Disconnect the main wire harness from the control unit. 3. Remove the one (1) screw holding the control panel assembly to the oven cavity front plate. 4. Lift up the control panel assembly. 5. Now, the control panel assembly is free. CONTROL UNIT 6. Disconnect the flat ribbon cable from the connector CNG. 7. Remove the six (6) screws holding the control unit to the control panel frame. 8. Release the two (2) tabs of the control panel frame holding the control unit to the control panel frame. 9. Now, the control unit is free. NOTE: 1. Before attaching a new key unit, wipe off remaining adhesive on the control panel frame surfaces completely with a soft cloth soaked in alcohol. 2. When attaching the key unit to the control panel frame, adjust the upper edge and right edge of the key unit to the correct position of control panel frame. 3. Stick the key unit firmly to the control panel frame by rubbing with a soft cloth so not to cause scratches.
OVEN LAMP AND LAMP SOCKET REMOVAL
CARRY OUT 3D CHECKS. Screw the oven lamp from the oven lamp socket off. Now, the oven lamp is free. Lift up the oven lamp socket from air intake duct. Pull the wire leads from the oven lamp socket by pushing the terminal hole of the oven lamp socket with the small flat type screw driver. 6. Now, the oven lamp socket is free. 1. 2. 3. 4. 5.
Oven lamp socket Terminal Wire lead
Terminal hole Flate type small screw driver
Figure C-1. Oven lamp socket
POSITIVE LOCK® CONNECTOR (NO-CASE TYPE) REMOVAL
Terminal
1. CARRY OUT 3D CHECKS. 2. Push the lever of positive lock® connector. 3. Pull down on the positive lock ® connector. CAUTION: WHEN CONNECTING THE POSITIVE LOCK ® CONNECTORS TO THE TERMINALS, INSTALL THE POSITIVE LOCK ® CONNECTOR SO THAT THE LEVER FACES YOU
Positive lock® connector 1 Push Lever
2 Pull down
Figure C-2 Positive lock® connector
ANTENNA MOTOR REMOVAL
1. Disconnect the oven from the power supply. 2. Remove the one (1) screw holding the base plate cover to the base plate and remove the base plate cover. 3. Disconnect the wire leads from the antenna motor and remove the one (1) screw holding the antenna motor. 4. Remove the antenna motor shaft from the antenna motor. 5. Now, the antenna motor is free.
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FAN MOTOR REPLACEMENT
REMOVAL
1. CARRY OUT 3D CHECKS. 2. Remove the one (1) screw holding the noise filter to the chassis support. 3. Release the noise filter from the tab on the fan duct. 4. Disconnect the wire leads from the fan motor. 5. Remove the one (1) screw holding the capacitor holder to the oven cavity rear plate. 6. Remove the one (1) screw holding the fan duct to the oven cavity rear plate. 7. Remove the fan duct from the oven. 8. Remove the fan blade from the fan motor shaft according to the following procedure. 9. Hold the edge of the rotor of the fan motor by using a pair of groove joint pliers. CAUTION: * Make sure that no metal pieces enter the gap between the rotor and the stator of the fan motor because the rotor is easily shaven by pliers and metal pieces may be produced. * Do not touch the pliers to the coil of the fan motor because the coil may be cut or injured. * Do not disfigure the bracket by touching with the pliers. 10.Remove the fan blade from the shaft of the fan motor by pulling and rotating the fan blade with your hand. 11. Now, the fan blade will be free.
Coil Groove joint pliers
CAUTION: * Do not reuse the removed fan blade because the hole (for shaft) may be larger than normal. 12.Remove the two (2) screws holding the fan motor to the fan duct. 13.Now, the fan motor is free. INSTALLATION 1. Install the fan motor to the fan duct with the two (2) screws. 2. Install the fan blade to the fan motor shaft according to the following procedure. 3. Hold the center of the bracket which supports the shaft of the fan motor on the flat table. 4. Install the fan blade to the shaft of fan motor by pushing the fan blade with a small, light weight, ball peen hammer or rubber mallet. CAUTION: * Do not hit the fan blade hard when installing because the bracket may be disfigured. * Make sure that the fan blade rotates smooth after installation. * Make sure that the axis of the shaft is not slanted. 5. Install the fan duct to the oven cavity rear plate with the one (1) screw. 6. Install the capacitor holder to the oven cavity rear plate with the one (1) screw. 7. Install the noise filter to the fan duct and the chassis support with the one (1) screw. 8. Re-connect the wire leads to the fan motor.
Shaft
Stator Gap Bracket Rotor
Shaft Axis Stator Rotor
These are the positions that should be pinched with pliers Table
Center of bracket
Rear view
Side view
POWER SUPPLY CORD REPLACEMENT
Removal
1. CARRY OUT 3D CHECKS. 2. Remove the one (1) screw holding the green/yellow wire to the cavity rear plate. 3. Disconnect the leads of the power supply cord from the noise filter, referring to the Figure C-3(a). 4. Release the power supply cord from the oven cavity rear plate. 5. Now, the power supply cord is free.
Oven Cavity Back Plate Screw Green/Yelow Wire Brown Wire
L RED WHT
Re-install
1. Insert the moulding cord stopper of power supply cord into the square hole of the oven cavity rear plate, referring to the Figure C-3(b). 2. Install the earth wire lead of power supply cord to the cavity rear plate with one (1) screw and tight the screw. 3. Connect the brown and blue wire leads of power supply cord to the noise filter correctly, referring to the Pictorial Diagram.
Moulding Cord Stopper Power Supply Cord Oven Cavity Rear Plate Square Hole
Power Supply Cord
Chassis Support
Bule Wire Noise Filter
N
Figure C-3 (a) Replacement of Power Supply Cord
22
Figure C-3(b). Power Supply Cord Replacement
R-21AT
1ST. INTERLOCK SWITCH, LATCH SWITCH, 2ND. INTERLOCK RELAY CONTROL SWITCH, AND MONITOR SWITCH REMOVAL
1. CARRY OUT 3D CHECKS. 2. Remove the control panel assembly referring to "CONTROL PANEL ASSEMBLY REMOVAL". 3. Disconnect the leads from all switches. 4. Remove the two (2) screws holding the latch hook to the oven cavity. 5. Remove the latch hook. 6. Push the retaining tab outward slightly and remove the switch. Re-install 1. Re-install each switch in its place. The 2nd. interlock relay control switch and the latch switch are in the lower position and the 1st. interlock switch is in the upper position. The monitor switch is in the middle position. 2. Re-connect wire leads to each switch. Refer to pictorial diagram. 3. Secure latch hook (with two (2) mounting screws) to oven flange. 4. Make sure that the monitor switch is operating properly and check continuity of the monitor circuit. Refer to chapter "Test Procedure" and Adjustment procedure.
Latch Hook
Tabs 1st. Interlock Switch
Tab Monitor Switch Tab Tab Tab 2nd. Interlock Relay Control Switch (Oven side) Latch Switch (Cabinet side)
Figure C-4. Switches
1ST. INTERLOCK SWITCH, LATCH SWITCH, 2ND. INTERLOCK RELAY CONTROL SWITCH, AND MONITOR SWITCH ADJUSTMENT
If the 1st. interlock switch, latch switch, 2nd. interlock relay control switch and monitor switch do not operate properly due to a mis-adjustment, the following adjustment should be made. 1. CARRY OUT 3D CHECKS.