SERVICE MANUAL
Microwave Oven
HMB402
HMB405
HMB406
B/S/H/ assumes no responsibility for any repairs
made on our products by anyone other than
authorized Bosch service technicians.
5551 Mc Fadden · Huntington Beach, California 92649 · 1-800-735-4328
58300000003827
ARA
R080015E, Edition 1,
Rev.EN
1 A
APRIL 2004
SAFETY PRECAUTIONS
This device is to be serviced only by properly qualified service personnel.
Consult the service manual for proper service procedures to assure continued safety operation and for precautions to be
taken to avoid possible exposure to excessive microwave energy.
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 CSA should be performed on each oven prior to
release to the owner.
CONTENTS
(Page)
SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Inside front cover
SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
CAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
INSTALLATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
OPERATING INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
FEATURES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
CONTROL PANEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
SCHEMATIC DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
CIRCUIT DESCRIPTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
SERVICE INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
TOOLS AND MEASURING INSTRUMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
MICROWAVE LEAKAGE TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
MEASUREMENT OF MICROWAVE POWER OUTPUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
DISASSEMBLY AND ADJUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
INTERLOCK CONTINUITY TEST- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
COMPONENT TEST PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
TROUBLE SHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
WIRING DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
REPLACEMENT PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
SCHEMATIC DIAGRAM OF P.C.B. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
PRINTED CIRCUIT BOARD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-2
P.C.B. PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1
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SPECIFICATIONS
MODEL NO.
HMB402, HMB405, HMB406
Rated Power Consumption
1,500 W
Output
1100 W (*IEC60705 Rating standard)
Frequency
2,450 MHz
Power Supply
120 V AC, 60 Hz
Magnetron Cooling
Forced Air Cooling
Microwave Stirring
Turntable
Rectification
Rectification Voltage Doubler Half-Wave
Door Sealing
Choke Cover and Choke System
Safety Devices
Thermostat:
Open at 90°c ± 5°c
Close at 75°c ± 5°c
Fuse(20A)
Primary Interlock Switch
Secondary Interlock Switch
Interlock Monitor Switch
2M246
1.05 µF, 2.1 KV AC
350 mA, 9.0 KV
125 V, 20 W
Tempered Safety Glass
237/8” x 1913/16” x 139/16”
1717/32” x 1821/32” x 107/8”
2.1 Cu.ft
Owner’s Manual, Easy Use Chart
Glass Turntable, Rotating Ring
Magnetron
High Voltage Capacitor
High Voltage Diode
Cavity Lamp
Tray
Overall Dimensions (W x D x H)
Oven Cavity Size (W x D x H)
Effective Capacity of Oven Cavity
Accessories
SWITCH CHART
SWITCH MODE
CONDITIONS
DOOR OPEN
DOOR CLOSED
PRIMARY
INTERLOCK
SWITCH
COM
NO
SECONDARY
INTERLOCK
SWITCH
COM
NO
•
•
NOTE: Use the above switch chart with circuit diagram on page 4-2.
“•” represents the connection of the terminal of each switch.
1-1
INTERLOCK
MONITOR
SWITCH
COM
NC
•
CAUTIONS
Unlike other appliances, the microwave oven is
high-voltage and high-current equipment.
Though it is free from danger in ordinary use,
extreme care should be taken during repair.
MICROWAVE RADIATION
Personnel should not be exposed to the
microwave energy which may radiate from the
magnetron or other microwave generating
device if it is improperly used or connection.
All input and output microwave connections,
waveguide, flange, and gasket must be secure
never operate the device without a microwave
energy absorbing load attached.
Never look into an open waveguide or antenna
while the device is energized.
• DO NOT operate on a 2-wire extension cord during
repair and use.
• NEVER TOUCH any oven components or wiring during
operation.
• BEFORE TOUCHING any parts of the oven, always
remove the power plug from the outlet.
• For about 30 seconds after the oven stops, an electric
charge remains in the high voltage capacitor. When
replacing or checking, you must discharge the high
voltage capacitor by shorting across the two terminals
with an insulated screwdriver.
• Proper operation of the microwave oven requires that
the magnetron be assembled to the waveguide and
cavity. Never operate the magnetron unless it is
properly installed.
• Be sure that the magnetron gasket is properly
installed around the dome of the tube whenever
installing the magnetron.
ANTENNA
Gasket
COOLING FIN
FILAMENT
TERMINALS
MAGNETRON
CHASSIS GROUND
MAGNETRON
• Remove your watches whenever working close to or
replacing the Magnetron.
• DO NOT touch any parts of the control panel circuit. A
resulting static electric discharge may damage this
P.C.B.
• NEVER operate the oven with no load.
• NEVER injure the door seal and front plate of the oven
cavity.
• NEVER put iron tools on the magnetron.
• NEVER put anything into the latch hole and the
interlock switches area.
THE OVEN IS TO BE SERVICED ONLY
BY PROPERLY QUALIFIED SERVICE
PERSONNEL.
2-1
INSTALLATIONS
BEFORE YOU BEGIN, READ THE FOLLOWING INSTRUCTIONS COMPLETELY AND CAREFULLY.
INSTALLING
GROUNDING INSTRUCTIONS
1. Empty the microwave oven and clean inside it with
a soft, damp cloth. Check for damage such as
misaligned door, damage around the door or dents
inside the cavity or on the exterior.
For personal safety, this appliance must be fully
grounded at all times.
In the event of an electrical short circuit, grounding
reduces the risk of electrical shock.
The plug must be plugged into an outlet that is
properly installed and grounded.
2. Put the oven on a counter, table, or shelf that is
strong enough to hold the oven and the food and
utensils you put in it. (The control panel side of the
oven is the heavy side. Use care when handling.)
WARNING
Improper use of the grounding plug can result in a
risk of electric shock.
Do not, under any circumstances, cut or remove
the third ground prong from the power cord plug.
3. Do not block the vent and the air intake openings.
Blocking vent or air intake openings can cause
damage to the oven and poor cooking results.
Make sure the microwave oven legs are in place to
ensure proper air flow.
4. The oven should not be installed in any area where
heat and steam are generated, because they may
damage the electronic or mechanical parts of the
unit.
Do not install the oven next to a conventional
surface unit or above a conventional wall oven.
PREFERRED METHOD
ENSURE PROPER GROUND
EXISTS BEFORE USE
5. Use microwave oven in an ambient temperature
less than 104°F(40°C).
6. Place the microwave oven on a sturdy and flat
surface at least 10 cm(4 inches) from the wall.
7. Place the microwave oven as far away as possible
from TV, RADIO, COMPUTER, etc., to prevent
interference.
10cm
3-1
OPERATING INSTRUCTIONS
FEATURES
Oven Front Plate
Window Door Screen
Door Seal
Display Window
Control Panel
Door Open Button
Safety Door Lock System
Turntable
Turntable Roller Rest
CONTROL PANEL
1. DISPLAY: Displays the timer, the time of day, cooking time,
power level being used and cooking functions selected.
2. PERSONAL CHOICE: Touch this pad to change the oven’s
default settings for sound, clock, scroll speed, lbs/kg.
3. QUICK DEFROST: This function lets you defrost quickly for
up to 1 pound of frozen food. Three food choices are
available and the oven will automatically set the defrosting
time for each food.
4. AUTO DEFROST: This feature allows defrosting of meat,
poultry and fish with weight selection of 0.1 to 6.0 pounds.
5. TIMER: This feature uses no microwave energy; it functions
as a kitchen timer.
6. AUTO COOK: This feature allows you to cook food without
entering a cook time or power. Six food choices are available
with this mode.
7. + / – PADS: Press to add or subtract 10 seconds during
AUTO COOK or timed cook programs.
8. PLUS TIME: A great time-saver for quick cooking. Press to
add 30-second increments and cook without pressing
START.
9. POPCORN: The oven will pop corn automatically using the
sensor.
10. REHEAT: This feature allows you to reheat pre-cooked
room-temperature or refrigerated foods with-out selecting
cooking times or power levels.
11. SMART SENSOR: Cook most of your favorite foods
without having to select cooking times and power levels.
Ten food categories are available.
12. CLOCK: This is a 12-hour clock and can be switched from
AM to PM.
13. COOK TIME: Allows you to program a specific cook time
and power level.
14. POWER LEVEL: Ten power levels are available, from low
to high.
15. NUMBER PADS: Used for selecting food category, time
and power level.
16. START: Begins operation.
17. STOP/CLEAR: Clear display or stop operation.
4-1
4-2
NOTICE: SINCE THIS IS BASIC SCHEMATIC DIAGRAM, THE VALUES OF COMPONENTS AND
SOME PARTIAL CONNECTIONS ARE SUBJECT TO CHANGE FOR IMPROVEMENT.
IMPORTANT SAFETY NOTE: THE SHADED AREAS ON THIS SCHEMATIC DIAGRAM INCORPORATE SPECIAL FEATURES
IMPORTANT FOR PROTECTION FROM MICROWAVE RADIATION, FIRE, ELECTRICAL SHOCK, AND
HAZARDS. WHEN SERVICING IT IS ESSENTIAL THAT ONLY MANUFACTURER’S SPECIFIED PARTS
BE USED FOR THE CRITICAL COMPONENTS IN THE SHADED AREAS OF THE SCHEMATIC DIAGRAM.
SCHEMATIC DIAGRAM
CIRCUIT DESCRIPTION
• A high voltage of approximately 2100 volts AC is
generated in the secondary of the high voltage
transformer which is increased by the action of the high
voltage diode and charging of the high voltage
capacitor.
• The negative 4,000 Volts DC is applied to the filament
of the magnetron.
GENERAL DETAILS
• The low voltage transformer supplies the necessary
voltage to the micom controller when power cord is
plugged in.
• When the door is closed, the primary switch is ON, the
secondary switch is ON, and the monitor switch opens
(contact COM and NO).
WHEN THE OVEN IS SET AT ANY LEVEL
EXCEPT MAXIMUM.
WHEN SELECTING COOKING POWER
LEVEL AND TIME
• The micom controller controls the ON-OFF time of
relay 2 by the applied signal to vary the average output
power of microwave oven as POWER LEVEL.
(refer to page 1-1)
• One complete cycle of relay 2 is 22 seconds.
• The micom controller memorizes the function you set.
• The time you set appears in the display window.
• Each indicator light turns on to indicate that the stage
has been set.
WHEN THE DOOR IS OPENED DURING
COOKING
WHEN TOUCHING THE START PAD
• The coil of the relay is energized by the micom
controller.
• Power input is supplied to the high voltage transformer
through the fuse to the primary switch and relay 2.
• Turntable rotates.
• Both the primary switch and relay 2 cut off the primary
winding voltage of the high voltage transformer.
• ON-OFF of relay 2 is coupled electrically with opening
and closing of the secondary switch.
• When the door is opened, the secondary switch is
opened and when the door is closed, the secondary
switch is closed.
• The cooking time stops counting down.
• Relay stops functioning.
• As the door is opened, if the contact of primary switch
and relay2 and/or secondary switch fail to open, the
fuse opens due to the large current surge caused by
the monitor switch activation, which in turn stops
magnetron oscillation.
N
MONITOR
SWITCH
LL
H.V.
TRANSFORMER
FUSE
PRIMARY
SWITCH RELAY 2
SECONDARY
SWITCH
N
MICOM CONTROLLER
MONITOR
SWITCH
LL
• The fan motor rotates and cools the magnetron by
blowing the air (coming from the intake on the baseplate).
• The air is also directed into the oven to exhaust the
vapor in the oven through the upper plate.
• Cooking time starts counting down.
• 3.3 volts AC is generated from the filament winding of
the high voltage transformer. This 3.3 volts is applied to
the magnetron to heat the magnetron filament through
two noise-preventing choke coils.
H.V.
TRANSFORMER
FUSE
PRIMARY
SWITCH RELAY 2
MICOM CONTROLLER
4-3
SECONDARY
SWITCH
SERVICE INFORMATION
TOOLS AND MEASURING INSTRUMENTS
NECESSARY TOOLS
NECESSARY MEASURING INSTRUMENTS
Tools normally used for TV servicing are sufficient.
Standard tools are listed below.
• Diagonal pliers
• Long nose pliers
• Phillips screwdriver
• Flat blade screwdriver
• Wrench (size 5mm)
• Nutdriver (size 5mm)
• Adjustable wrench
• Soldering iron
• Solder
• Vinyl insulation tape
• Polishing cloth
• TESTER (VOLTS-DC, AC, Ohmmeter)
• Microwave survey meter
- Holaday HI-1500
HI-1501
- Narda 8100
8200
• Inch scale
• 600 cc non conductive material beaker (glass or plastic),
inside diameter: approx. 8.5 cm (31/2 in.)
• Cylindrical and made of borosilicate glass vessel.
max. thickness: 3 mm
outside diameter: approx. 190mm
height: approx. 90mm
• Glass thermometer: 100°C or 212°F (1 deg scale)
MICROWAVE LEAKAGE TEST
CAUTIONS
MEASURING MICROWAVE ENERGY
LEAKAGE
• Be sure to check microwave leakage prior to
servicing the oven if the oven is operative prior to
servicing.
• The service personnel should inform the
manufacture importer, or assembler of any
certified oven unit found to have a microwave
emission level in excess of 5 mW/cm2 and should
repair any unit found to have excessive emission levels
at no cost to the owner and should ascertain the cause
of the excessive leakage. The service personnel
should instruct the owner not to use the unit until the
oven has been brought into compliance.
• If the oven operates with the door open, the service
personnel should:
- Tell the user not to operate the oven.
- Contact the manufacturer.
• The service personnel should check all surface and
vent openings for microwave leakage.
• Check for microwave leakage after every servicing.
The power density of the microwave radiation leakage
emitted by the microwave oven should not exceed
4 mW/cm2. Always start measuring of an unknown field
to assure safety for operating personnel from radiation
leakage.
• Pour 275±15cc of 20±5°C(68±9°F) water in a beaker
which is graduated to 600 cc, and place the beaker
on the center of the turntable.
• Set the energy leakage monitor to 2,450 MHz and
use it following the manufacturer's recommended
test procedure to assure correct result.
• When measuring the leakage, always use the 2inch (5cm) spacer supplied with the probe.
• Operate the oven at its maximum output.
• Measure the microwave radiation using and
electromagnetic radiation monitor by holding the
probe perpendicular to the surface being measured
Move probe along shaded area
Probe scanning speed
Less than 2.5 cm/sec
( 1in/sec)
5-1
MEASUREMENT WITH OUTER CASE
REMOVED
NOTES WHEN MEASURING
• Do not exceed meter full scale deflection.
• The test probe must be removed no faster than
1 inch/sec (2.5 cm/sec) along the shaded area,
otherwise a false reading may result.
• The test probe must be held with the grip portion of the
handle.
A false reading may result if the operator's hand is
between the handle and the probe.
• When testing near a corner of the door, keep the probe
perpendicular to the surface making sure the probe
horizontally along the oven surface; this may possibly
cause probe damage.
• When you replace the magnetron, measure for
microwave energy leakage before the outer case is
installed and after all necessary components are
replaced or adjusted.
Special care should be taken in measuring the
following parts. (Circled area of Fig. below)
- Around the magnetron
- The waveguide
WARNING : AVOID CONTACTING ANY
HIGH VOLTAGE PARTS
RECORD KEEPING AND NOTIFICATION
AFTER MEASUREMENT
• After adjustment and repair of any microwave energy
interruption or microwave energy blocking device,
record the measured values for future reference. Also
enter the information on the service invoice.
• The microwave energy leakage should not be more
than 4 mW/cm.sq. after determining that all parts are in
good condition, functioning properly and genuine
replacement parts which are listed in this manual have
been used.
• At least once a year, have the electromagnetic energy
leakage monitor checked for calibration by its
manufacturer.
MEASUREMENT WITH A FULLY
ASSEMBLED OVEN
• After all components, including the outer case, are fully
assembled, measure for microwave energy leakage
around the door viewing window, the exhaust opening,
and air inlet openings.
• Microwave energy leakage must not exceed the values
prescribed below.
NOTE: Leakage with the outer case removed less than
5 mW/cm.sq. Leakage for a fully assembled
oven (Before the latch switch (primary) is
interrupted) with the door in a slightly opened
position-less than 2 mW/cm.sq.
5-2
MEASUREMENT OF MICROWAVE POWER OUTPUT
• Microwave power output measurement is made with
the microwave oven supplied at its rated voltage and
operated at its maximum microwave power setting with
a load of (1000±5) g of potable water.
• The water is contained in a cylindrical borosilicate glass
vessel having a maximum material thickness of 3 mm
and an outside diameter of approximately 190mm.
• The oven and the empty vessel are at ambient
temperature prior to the start of the test.
• The initial temperature (T1) of the water is (10±2)°C It
is measured immediately before the water is added to
the vessel. After addition of the water to the vessel,
the load is immediately placed on the center of the
turntable which is in the lowest position and the
microwave power switched on.
• The time T for the temperature of the water to rise by a
value ∆ T of (10±2)°K is measured, where T is the time
in seconds and ∆T is the temperature rise. The initial
and final water temperatures are selected so that the
maximum difference between the final water
temperature and the ambient temperature is 5°K.
• The microwave power output P in watts is calculated
from the following formula :
P=
4187 x (∆T)
T
is measured while the microwave generator is
operating at full power. Magnetron filament heat-up
time is not included. (about 3 sec)
• The water is stirred to equalize temperature throughout
the vessel, prior to measuring the final water
temperature.
• Stirring devices and measuring instruments are
selected in order to minimize addition or removal of
heat.
WATER LOAD
TURNTABLE
DISASSEMBLY AND ADJUSTMENT
A. OUTER CASE REMOVAL
Remove the screw
1) Disconnect the power supply cord from the outlet.
2) Remove the screws from the rear of the case.
The outer case must be moved backward to be lifted
off.
securing screw
B. POWER SUPPLY CORD
1) Remove the outer case.
2) Disconnect two terminals, and remove one screw of
the ground terminal.
ground screw
C. CONTROL PANEL ASSEMBLY
1) Open the door.
2) Disconnect the leadwire from RELAY(RY2) of the
PCB SUB ASS’Y.
3) Lift up and pull out control panel assembly carefully
from the cavity.
4) Disconnect the leadwire from connector(CN1) of the
PCB SUB ASS’Y.
Lift up and pull out control panel
CAUTION: DISCHARGE THE HIGH VOLTAGE
CAPACITOR BEFORE SERVICING
(refer to page 2-1)
5-3
D. PCB ASSEMBLY REMOVAL
Remove choke cover
1) Remove the control panel assembly from the
cavity. (Refer to control panel assembly removal
on previous page.)
2) Remove screws which hold the PCB SUB ASS’Y to
the control panel.
3) Disconnect the flat cable from the PCB SUB
ASS’Y and take off the PCB SUB ASS’Y
Control Panel
PCB Sub Asm
Key Membrance
Remove door
Door seal plate
Release
Lever
Button Spring
Door Open Button
E. DOOR MAIN ASSEMBLY REMOVAL
1) Open the door.
2) Remove the choke cover very carefully with a flat-blade
screwdriver.
CAUTION : Be careful not to damage door seal plate
with the screwdriver.
3) Lift up and push the door.
Spacer
NOTE:
1. After replacing the door, be sure to check that the
primary switch, monitor switch, and secondary switch
operate normally.
2. After replacing the door, check for microwave energy
leakage with a survey meter. Microwave energy must
be below the limit of 4 mW/cm. (with a 275 ml water
load)
3. When mounting the door assembly to the oven
assembly, be sure to adjust the door assembly parallel
to the chassis. Also adjust so the door has no play
between the inner door surface and oven frame
assembly. If the door assembly is not mounted
properly, microwaves may leak from the clearance
between the door and the oven.
5-4
F. AIR DUCT ASSEMBLY REMOVAL
I. FAN MOTOR ASSEMBLY REMOVAL
1) Disconnect the leadwire from lamp and MGT thermostat.
2) Remove the mounting screw to the magnetron.
1) Discharge the high voltage capacitor.
2) Disconnect the leadwire from fan motor, noise filter
and high voltage capacitor.
3) Remove the two screws holding the suction guide
Ass’y to the oven cavity and remove the high voltage
diode earth screw.
4) Remove the screw of the capacitor bracket.
5) Remove the two screws holding the fan motor Ass’y to
the suction guide Ass’y.
G. MAGNETRON REMOVAL
1) Disconnect the leadwire from the magnetron.
2) Carefully remove the mounting screws holding the
magnetron and the waveguide.
3) Remove the magnetron Ass’y until the tube is clear
from the waveguide.
NOTE:
1. When removing the magnetron, make sure its dome
does not hit any adjacent parts, or it may be damaged.
2. When replacing the magnetron, be sure to install
the magnetron gasket in the correct position and be
sure that the gasket is in good condition.
3. After replacing the magnetron, check for microwave
leakage with a survey meter around the magnetron.
Microwave energy must be below the limit of 5
mW/cm2. (With a 275 ml. water load).
Make sure that gasket is rigidly attached to the
magnetron. To prevent microwave leakage, tighten
the mounting screws properly, making sure there is
no gap between the waveguide and the magnetron.
J. HIGH VOLTAGE CAPACITOR AND
DIODE REMOVAL
1) Discharge the high voltage capacitor.
2) Disconnect the leadwire from the fan motor, noise
filter and high voltage capacitor.
3) Remove the screw holding the suction guide Ass’y to
the oven cavity and remove the high voltage diode
earth screw.
4) Remove the screw holding the high voltage capacitor
bracket.
Fan Motor
Ass’y
Air Duct
Suction
Guide
Magnetron
H.V.
Capacitor
Waveguide
Dome
Waveguide
Bracket
Magnetron
Gasket
Magnetron
H.V.
Diode
H. HIGH VOLTAGE TRANSFORMER
REMOVAL
1) Discharge the high voltage capacitor.
2) Disconnect the leadwire from magnetron, high voltage
transformer, and capacitor.
3) Remove the screw holding the high voltage
transformer to the base-plate.
5-5
K. REMOVING THE TURNTABLE MOTOR
M. INTERLOCK SYSTEM
1) Remove the glass turntable.
2) Remove the rotating ring ass’y by hand.
3) Remove the turntable motor cover.
The turntable base cover is easily removed by
pinching the six parts with wire cutting pliers.
4) Disconnect the leadwire from the turntable motor
terminals.
5) Remove the screw securing the turntable motor to
the oven cavity assembly.
6) After repairing the motor, rotate the removed
turntable motor cover.
7) Fit the turntable motor cover's projecting part to the
base plate slit.
1) INTERLOCK MECHANISM
The door lock mechanism is a device which has
been specially designed to eliminate completely
microwave activity when the door is opened during
cooking and thus to prevent the danger resulting
from the microwave leakage.
2) MOUNTING OF THE PRIMARY/MONITOR/
SECONDARY SWITCHES TO THE LATCH
BOARD
ADJUSTMENT
DIRECTION
NOTE:
1. Remove the wire lead from the turntable motor
VERY CAREFULLY.
2. Be sure to grasp the connector, not the wires,
when removing.
SECONDARY
SWITCH
MONITOR
SWITCH
PRIMARY
SWITCH
3) INSTALLATION AND ADJUSTMENT OF THE
LATCH BOARD TO THE OVEN ASSEMBLY
• Mount the latch board to the oven assembly.
• Adjust the latch board in the arrow direction so that
oven door will not have any play in it when the door
is closed.
• Tighten the mounting screw.
• Check for play in the door by pushing the door
release button. Door movement should be less
than 0.5 mm. (1/64 inch)
Don't push the door release button while making this
adjustment. Make sure that the latch moves
smoothly after adjustment is completed and that the
screws are tight. Make sure the primary, monitor,
and secondary switches operate properly by
following the continuity test procedure.
Wire Leads
Turntable Motor
L. REMOVING SENSOR
1) Disconnect the leadwire from PCB Assembly.
2) Remove a screw securing the sensor duct.
5-6
INTERLOCK CONTINUITY TEST
WARNING : FOR CONTINUED PROTECTION AGAINST EXCESSIVE RADIATION
EMISSION, REPLACE ONLY WITH IDENTICAL REPLACEMENT PARTS.
TYPE NO. SZM-V 16-FA-63 OR VP-533A-OF FOR PRIMARY SWITCH
TYPE NO. SZM-V 16-FA-62 OR VP-532A-OF FOR MONITOR SWITCH
TYPE NO. SZM-V 16-FA-63 OR VP-533A-OF FOR SECONDARY SWITCH
B. SECONDARY INTERLOCK SWITCH TEST
A. PRIMARY INTERLOCK SWITCH TEST
Disconnect the wire lead from the secondary
switch.
Connect the ohmmeter leads to the common
(COM) and normally open (NO) terminals of the
switch. The meter should indicate a open circuit in
the door open condition. When the door is closed,
meter should indicate an closed circuit. When the
secondary switch operation is abnormal, make the
necessary adjustment or replace the switch only
with the same type of switch.
When the door release button is depressed slowly
with the door closed, an audible click should be
heard at the same time or successively at
intervals. When the button is released slowly, the
latches should activate the switches with an
audible click.
If the latches do not activate the switches when
the door is closed, the switches should be a
adjusted in accordance with the adjustment
procedure. Disconnect the wire lead from the
primary switch. Connect the ohmmeter leads to
the common (COM) and normally open (NO)
terminal of the switch. The meter should indicate
an open circuit in the door open condition.
When the door is closed, the meter should
indicate a closed circuit.
When the primary switch operation is abnormal,
make the necessary adjustment or replace the
switch only with the same type of switch.
COMPONENTS
SWITCHES
(Wire leads removed)
C. MONITOR SWITCH TEST
Disconnect the wire lead from the monitor switch.
Connect the ohmmeter leads to the common
(COM) and normally closed (NC) terminals of the
switch. The meter should indicate closed circuit in
the door open condition. When the door is closed,
meter should indicate an open circuit. When the
monitor switch operation is abnormal, replace with
the same type of switch.
NOTE: After repairing the door or the interlock
system, it is necessary to do this continuity
test before operating the oven.
TEST PROCEDURE
Check for continuity of the
switch with an Ohm-meter
Primary
Switch
Monitor
Switch
RESULTS
Door
open
Door
closed
NO
COM
NC
COM
Secondary
Switch
NO
COM
NOTE : After checking for the continuity of switches, make sure that they are
connected correctly.
5-7
COMPONENT TEST PROCEDURE
CAUTIONS
1. DISCONNECT THE POWER SUPPLY CORD FROM THE OUTLET WHENEVER REMOVING THE
OUTER CASE FROM THE UNIT. PROCEED WITH THE TEST ONLY AFTER DISCHARGING THE HIGH
VOLTAGE CAPACITOR AND REMOVING THE WIRE LEADS FROM THE PRIMARY WINDING OF THE
HIGH VOLTAGE TRANSFORMER. (SEE PAGE 2-1)
2. ALL OPERATIONAL CHECKS WITH MICROWAVE ENERGY MUST BE DONE WITH A LOAD (1 LITER
OF WATER IN CONTAINER) IN THE OVEN.
COMPONENTS
HIGH VOLTAGE
TRANSFORMER
(Wire leads removed)
TEST PROCEDURE
RESULTS
FILAMENT
WINDING
TERMINAL
SECONDARY
TERMINAL
PRIMARY
TERMINAL
1. Measure the resistance.
(Ohm-meter scale: Rx1 and Rx100)
• Primary winding
• Secondary winding
• Filament winding
Approx.: 0.2 ~ 0.4 ohm
Approx.: 60 ~ 90 ohm
Less than: 1 ohm
2. Measure the resistance.
(Ohm-meter scale: Rx1000)
• Primary winding to ground
• Filament winding to ground
Normal: Infinite
Normal: Infinite
MAGNETRON
(Wire leads removed)
1. Measure the resistance.
(Ohm-meter scale: Rx1)
• Filament terminal
Normal: Less than 1 ohm
2. Measure the resistance.
(Ohm-meter scale: Rx1000)
• Filament to chassis
Normal: Infinite
5-8
COMPONENTS
TEST PROCEDURE
RESULTS
Antenna
Gasket
Chassis
Filament
NOTE: When testing the magnetron, be sure to install the magnetron gasket
in the correct position and be sure that the gasket is in good condition.
HIGH VOLTAGE
CAPACITOR
HIGH VOLTAGE
DIODE
NOTE :
Some inexpensive meters
may indicate infinite
resistance in both direction.
Measure the resistance.
(Ohm-meter scale: Rx1000)
• Terminal to terminal.
Normal: Momentarily indicates
several ohms, and
then gradually returns
to infinite.
Measure the resistance.
(Ohm-meter scale: Rx1000)
• Terminal to case.
Normal: Infinite.
Measure the continuity (Forward).
(Ohm-meter scale: Rx10000)
Normal: Continuity.
Abnormal: Infinite.
Measure the continuity (Reverse).
(Ohm-meter scale: Rx10000)
Normal: Infinite.
Abnormal: Continuity.
5-9
COMPONENTS
RELAY 2
TEST PROCEDURE
RESULTS
Check for continuity of relay 2 with an
ohm-meter.
(Remove wire leads from relay 2 and
operate the unit.)
Relay 2
FAN MOTOR
(Wire leads removed)
POWER
LEVEL
1
2
3
4
5
6
7
8
9
10
4 sec
6 sec
8 sec
10 sec
12 sec
14 sec
16 sec
18 sec
20 sec
22 sec
18 sec
16 sec
14 sec
12 sec
10 sec
8 sec
6 sec
4 sec
2 sec
0 sec
Normal:
A: Approx. 85 ~ 100 ohm.
B: Approx. 10 ~ 25 ohm.
Measure the resistance.
(Ohm-meter scale: R x 1)
Abnormal: Infinite or several
ohm.
B
A
TURNTABLE
MOTOR
(Wire leads removed)
Measure the resistance.
(Ohm-meter scale: R x 1 )
Normal: Approx.100~150 ohm
Abnormal: Infinite or several
ohm.
SENSOR
1) Disconnect sensor connector from
micom computer board.
2) Measure resistance terminal to terminal
(ohm meter scale: R X 1000)
Normal: Approximately
BK - RD: 5.1 Kohm
RD - WH: 2.1 Kohm
BK - WH: 2.1 Kohm
1
2
3
BK
RD
WH
NOTE : • A MICROWAVE LEAKAGE TEST MUST ALWAYS BE PERFORMED
WHEN THE UNIT IS SERVICED FOR ANY REASON.
• MAKE SURE THE WIRE LEADS ARE IN THE CORRECT POSITION.
• WHEN REMOVING THE WIRE LEADS FROM THE PARTS, BE SURE
TO GRASP THE CONNECTOR, NOT THE WIRES.
F-code
F-4
Abnormal: Infinite or several.
* Sensor cooking condition
1. Oven should be plugged in at
least 5 minutes before sensor
cooking.
2. Room temperature should not
exceed 95°F .
3. Be sure the exterior of the
cooking container and the
interior of the oven are dry.
Wipe each off with paper towel.
4. The oven will not generate
microwave energy for the first
28 seconds of the sensor
cooking cycle.
Cause
When self-heating time of humidity sensor exceeds 64 seconds or
if zero balancing voltage does not rise to 2.5 [volt]
Only "CLEAR" key is permitted to enter.
5-10
TROUBLE SHOOTING
WHEN YOU GET A COMPLAINT FROM YOUR CUSTOMER, EVALUATE THE COMPLAINT CAREFULLY. IF
THE FOLLOWING SYMPTOMS APPLY, PLEASE INSTRUCT THE CUSTOMER IN THE PROPER USE OF THE
MICROWAVE OVEN. THIS CAN ELIMINATE AN UNNECESSARY SERVICE CALL.
CAUTIONS
1. Check grounding before checking for trouble.
2. Be careful of the high voltage circuit.
3. Discharge the high voltage capacitor. (See page 2-1)
4. When checking the continuity of the switches or of the high voltage transformer, disconnect one lead wire
from these parts and then check continuity with the AC plug removed. To do otherwise may result in a
false reading or damage to your meter.
5. Do not touch any part of the circuit on the PCB since static electric discharge may damage this control
panel.
Always touch yourself to ground while working on this panel to discharge any static charge built up in your
body. (Micom model only)
CONDITION
CAUSE
REMEDY
Microwave oven
does not work.
Inserting many plugs into one
outlet and using them at the
same time.
(blown fuse or breaker)
Avoid using other electrical
appliances when you use the
microwave oven.
Microwave oven plug is not
inserted tightly.
Insert microwave oven plug
securely.
Low AC input voltage.
Use the microwave oven at
adequate line voltage.
Food temperature is too low.
This may not be a defect.
It is possible that the food
should be cooked for a
longer time period.
Using metallic ware and
allowing it to touch the oven
wall.
Do not use metallic ware for
cooking except where noted
in the cooking guide.
Ceramic ware trimmed in
gold or silver powder is used.
Do not use any type of
cookware with metallic
trimming.
Inconsistent intensity of
microwave by their
characteristics.
1. Use plastic wrap or lid.
2. Stir once or twice while
cooking soup, cocoa or
milk, etc.
Output power is too low.
Sparks occur.
Uneven cooking.
5-11
(TROUBLE 1) The following visual conditions indicate a probable defective control circuit.
1. Incomplete segments.
• Segment missing.
• Partial segment missing.
• Digit flickering (NOTE: Slight flickering is normal.)
2. Colon does not turn on or blink.
3. A distinct change in the brightness of one or more numbers in display.
4. One or more digits in the display are not lighting.
5. Display indicates a number different from one touched, for example, key in 5 and 3 appears in the display.
6. Specific numbers (for example 7 or 9) will not display when key pad is touched.
7. Display does not count down with time blinking or up with clock operation.
8. Display obviously jumps in time while counting down.
9. Display counts down too fast while cooking.
10. Each indicator light does not turn on after setting cooking cycle.
11. Display time of day does not reappear when cooking is finished.
CONDITION
CHECK
1. No input can be
programmed.
Check the connection between
membrane key
assembly and
PCB assembly.
Continuity
Defective PCB
assembly.
Replace PCB
assembly.
No continuity
Loose
connection.
Connect them
tightly.
Replace key
membrane
assembly and
check operation.
Everything works
as specified.
Defective key
membrane
assembly.
Replace key
membrane
assembly.
Defective PCB
assembly.
Replace PCB
assembly.
2. Some inputs
cannot be
programmed.
3. Display shows a
number or figure
different from one
touched.
RESULT
Still have trouble.
4. Random
programming
when touching
other pads.
5. Display is fixed
at some figure
and can not
accept any
input.
5-12
CAUSE
REMEDY
(TROUBLE 2) Oven does not operate at all, Display window does not display any figures,
and no input is accepted.
CONDITION
1. Fuse blows.
CHECK
Check continuity
of monitor
switch (with
door closed).
RESULT
Continuity.
CAUSE
REMEDY
Malfunction of the
monitor switch.
Replace fuse,
primary, monitor,
secondary
switches, and
RELAY(RY2) of
P.C.B Assembly.
Shorted contact at
the primary switch.
Replace fuse,
primary, monitor,
secondary
switches, and
RELAY(RY2) of
P.C.B Assembly.
No continuity.
Replace fuse
Check continuity
of primary
switch (with
door opened).
Continuity.
Check continuity
of secondary
switch (with
door opened).
Continuity.
Disconnect one
side of the wire
lead connected
from transformer
to the high
voltage
capacitor and
operate the unit.
No continuity.
Malfunction of
secondary switch.
No continuity.
Replace fuse,
primary, monitor,
secondary
switches, and
RELAY(RY2) of
P.C.B Assembly.
Normal.
Defective high
voltage capacitor.
Replace high
voltage capacitor.
Fuse blows again
Defective high voltage transformer.
Replace high voltage transformer.
NOTE : All these switches must be replaced at the same time. Refer to page 5-7, 5-8
2. Fuse does not
blow.
Check continuity
of thermostat.
No continuity.
Defective
thermostat.
Replace
thermostat.
Defective power
supply cord.
Replace power
supply cord.
Continuity.
Check continuity
of power supply
cord.
No continuity.
5-13
(TROUBLE 3) Display shows all figures set, but oven does not start cooking while desired
program times are set and START pad is touched.
CONDITION
CHECK
1. Setting time
does not count
down when
touching START
pad.
Check continuity
of secondary
switch (with
door closed).
2. Fan motor or
oven lamp do
not turn on.
RESULT
No continuity.
CAUSE
REMEDY
Defective
secondary switch.
Replace
secondary switch.
Continuity.
Check the connection between
CN1 connector
and PCB
assembly.
Continuity
Defective PCB
assembly.
Replace PCB
assembly.
No continuity
Loose connection.
Connect them
tightly.
Check fan motor.
Abnormal
Defective fan motor.
Replace fan motor.
Check oven lamp.
Abnormal
Defective oven lamp.
Replace oven lamp.
Normal
(TROUBLE 4) Oven seems to be operating but little heat is produced in oven load.
CONDITION
Output is low
CHECK
Check the
power source
voltage.
RESULT
CAUSE
REMEDY
Lower than 90% of
rating voltage.
Decrease in power
source voltage
with load.
Suggest customer
contact local
electric power
utility co. or
qualified
electrician.
Defective PCB
assembly.
Replace PCB
assembly.
Defective
magnetron.
Replace
magnetron.
Normal
Disconnect the
wire leads from
relay 2 and
check on and off
time with
multitester.
Measure the
output power.
Abnormal
Normal
Abnormal
NOTE : Simple test of power output-conducted by heating one liter water for one min. if available.
Minimum 8.5°C temperature rise is normal condition.
5-14
(TROUBLE 5) No microwave oscillation even though oven lamp and fan motor run.
(Display operates properly)
CONDITION
No microwave
oscillation.
CHECK
Disconnect the
wire leads from
relay 2 and
check continuity
of relay 2.
(Operate the unit)
Check high voltage transformer
RESULT
No continuity.
CAUSE
REMEDY
Defective PCB
assembly.
Replace PCB
assembly.
Defective high
voltage
transformer.
Replace high
voltage
transformer.
Defective high
voltage capacitor.
Replace high
voltage capacitor.
Defective high
voltage diode.
Replace high
voltage diode.
Defective
magnetron.
Replace
magnetron.
Continuity.
Abnormal
Normal
Check high voltage capacitor.
Abnormal
Normal
Check high voltage diode.
Abnormal
Normal
Check
magnetron.
Abnormal
NOTE : • Make sure the wire leads correct position.
• When Removing the wire leads from the parts, be sure to grasp the connector, not the wires.
• When removing the magnetron, be sure to install the magnetron gasket in the correct position
and in good condition.
Output is full power
when you set lower
power level.
Disconnect the
wire leads from
relay 2 and check
continuity relay 2.
(Operate the unit)
Abnormal.
5-15
Defective PCB
assembly.
Replace PCB
assembly.
For Model
HMB402
HMB405
HMB406
K
R
W
K
W
K
K
YG
G W
W
B
K
G
B
W
B
PK
R
G
K
W
R
W
K
W
R
K
W
K
Black
B
Blue
G
Green
R
Red
W
White
PK
Pink
Yellow-Green
YG
6-1
THIS IS THE LAST PAGE OF THIS MANUAL
6-2