Sharp CD2200M Service manual

TopPage RCD2200M SERVICE MANUAL S2801RCD22MP COMMERCIAL MICROWAVE OVEN MODELS R-CD1800M R-CD2200M In the interest of user-safety the oven should be restored to its original condition and only parts identical to those specified should be used. WARNING TO SERVICE PERSONNEL: Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts may result in a severe, possibly fatal, electrical shock. (High Voltage Capacitor, High Voltage Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..) CONTENTS PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY CHAPTER 1. WARNING TO SERVICE PERSONNEL CHAPTER 2. MICROWAVE MEASUREMENT PROCEDURE CHAPTER 7. TEST PROCEDURES CHAPTER 8. TOUCH CONTROL PANEL ASSEMBLY CHAPTER 9. PRECAUTIONS FOR USING LEADFREE SOLDER CHAPTER 3. FOREWORD AND WARNING CHAPTER 10. COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE CHAPTER 4. PRODUCT DESCRIPTION CHAPTER 11. CIRCUIT DIAGRAMS CHAPTER 5. OPERATION Parts List CHAPTER 6. TROUBLESHOOTING GUIDE This document has been published to be used for after sales service only. The contents are subject to change without notice. CONTENTS PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY CHAPTER 1. WARNING TO SERVICE PERSONNEL [1] Before Servicing.......................................... 1-1 [2] When the testing is completed,................... 1-1 [3] After repairing.............................................. 1-1 CHAPTER 2. MICROWAVE MEASUREMENT PROCEDURE CHAPTER 3. FOREWORD AND WARNING CHAPTER 4. PRODUCT DESCRIPTION [1] SPECIFICATIONS ...................................... 4-1 [2] GROUNDING INSTRUCTIONS.................. 4-1 [3] OVEN DIAGRAM ........................................ 4-2 CHAPTER 5. OPERATION [1] DESCRIPTION OF OPERATING SEQUENCE .................................................... 5-1 [2] OVEN SCHEMATIC .................................... 5-2 [3] DESCRIPTION AND FUNCTION OF COMPONENTS .......................................... 5-3 CHAPTER 6. TROUBLESHOOTING GUIDE CHAPTER 7. TEST PROCEDURES [1] A: MAGNETRON ASSEMBLY TEST .......... 7-1 [2] B: POWER TRANSFORMER TEST ........... 7-1 [3] C: HIGH VOLTAGE RECTIFIER (1) AND/OR (2) TEST ...................................... 7-1 [4] D: HIGH VOLTAGE CAPACITOR (1) AND/OR (2) TEST ...................................... 7-2 [5] E: SECONDARY INTERLOCK SWITCH (1) AND/OR (2) TEST ................................. 7-2 [6] F: PRIMARY INTERLOCK SYSTEM TEST........................................................... 7-2 [7] G: MONITOR SWITCH (1) AND/OR (2) TEST........................................................... 7-3 [8] H: BLOWN MINITOR FUSE TEST ............. 7-3 [9] I: FUSE 12A (1) (2) TEST ........................... 7-3 [10] J: TEMPERATURE FUSE TEST ................ 7-4 [11] K: MAGNETRON THERMISTOR TEST..... 7-4 [12] L: EXHAUST THERMISTOR TEST ............ 7-4 [13] M: NOISE FILTER TEST ............................ 7-5 [14] N: KEY UNIT TEST..................................... 7-5 [15] O: CONTROL UNIT TEST .......................... 7-6 [16] P: POWER UNIT TEST .............................. 7-6 [17] Q: RELAY UNIT TEST ................................ 7-6 [18] R: ANTENNA SENSOR TEST.................... 7-7 [19] S: MICROWAVE SENSOR TEST ............... 7-7 CHAPTER 8. TOUCH CONTROL PANEL ASSEMBLY [1] SPECIAL FUNCTION FOR SERVICING..... 8-1 [2] SERVICING FOR BRINTED WIRING BOARDS..................................................... 8-6 CHAPTER 9. PRECAUTIONS FOR USING LEADFREE SOLDER CHAPTER 10. COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE [1] WARNINGS .............................................. 10-1 [2] OUTER CASE AND REAR COVER REMOVAL...................................................... 10-1 [3] POWER TRANSFORMERS (1) AND/ OR (2) REMOVAL ..................................... 10-2 [4] MAGNETRONS (1) AND/OR (2) REMOVAL...................................................... 10-2 [5] MAGNETRON THERMISTOR ASSEMBLY REPLACEMENT ............................... 10-2 [6] HIGH VOLTAGE CAPACITOR AND HIGH VOLTAGE RECTIFIER ASSEMBLY REMOVAL ......................................... 10-2 [7] POWER SUPPLY CORD REPLACEMENT........................................................ 10-3 [8] HOW TO RELEASE THE POSITIVE LOCK CONNECTOR. ............................... 10-3 [9] EXHAUST FAN REMOVAL....................... 10-4 [10] FAN MOTORS REMOVAL ........................ 10-4 [11] ANTENNA MOTORS (UPPER AND LOWER) REMOVAL ................................. 10-4 [12] POWER UNIT REMOVAL......................... 10-4 [13] RELAY UNIT REMOVAL........................... 10-4 [14] CONTROL PANEL ASSEMBLY AND CONTROL UNIT REMOVAL..................... 10-4 [15] DOOR SENSING SWITCH/SECONDARY INTERLOCK SWITCHES (1), (2) AND MONITOR SWITCHES (1), (2) REPLACEMENT ............................................ 10-5 [16] DOOR SENSING SWITCH/SECONDARY INTERLOCK SWITCHES (1), (2) AND MONITOR SWITCHES (1), (2) ADJUSTMENT............................................... 10-5 [17] DOOR REPLACEMENT ........................... 10-6 [18] DOOR DISASSEMBLY ............................. 10-7 CHAPTER 11. CIRCUIT DIAGRAMS [1] Figure S-1. Pictorial Diagram .....................11-1 [2] Figure S-2. Switching Power Supply Unit Circuit.........................................................11-4 [3] Figure S-3. Relay Unit Circuit ....................11-5 [4] Figure S-4. Control Unit/ Antenna sensor/ Microwave Sensor Circuit ...................11-6 [5] Figure S-5. Printed Wiring Board ...............11-7 Parts List RCD2200M RCD2200M Service PRECAUTIONS TO BE OBSERVED BEFORE AND Manual DURING SERVICING 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 the Federal Performance Standard should be performed on each oven prior to release to the owner. BEFOR SERVICING BEFORE SERVICING Before servicing an operative unit, perform a microwave emission check as per the Microwave Measurement Procedure outlined in this service manual. If microwave emissions level is in excess of the specified limit, contact SHARP ELECTRONICS CORPORATION immediately @1-800-237-4277. If the unit operates with the door open, service person should 1) tell the user not to operate the oven and 2) contact SHARP ELECTRONICS CORPORATION and Food and Drug Administration's Center for Devices and Radiological Health immediately. Service personnel should inform SHARP ELECTRONICS CORPORATION of any certified unit found with emissions in excess of 4mW/cm2. The owner of the unit should be instructed not to use the unit until the oven has been brought into compliance. i RCD2200M Service Manual CHAPTER 1. WARNING TO SERVICE PERSONNEL RCD2200M Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts may result in a severe, possibly fatal, electrical shock. (Example) High Voltage Capacitor, High Voltage Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc.. Read the Service Manual carefully and follow all instructions. Don't Touch ! Danger High Voltage [2] When the testing is completed, [1] Before Servicing 1. Disconnect the power supply cord, and then remove outer case. 1. Disconnect the power supply cord case. , and then remove outer 2. Open the door and block it open. 3. Discharge high voltage capacitor. 2. Open the door and block it open. 4. Reconnect the leads to the primary of the power transformer. 3. Discharge high voltage capacitor. 5. Reinstall the outer case (cabinet). WARNING: RISK OF ELECTRIC SHOCK. DISCHARGE THE HIGHVOLTAGE CAPACITOR BEFORE SERVICING. 6. Reconnect the power supply cord after the outer case is installed. 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 the connecting lead of the high-voltage rectifier) against the chassis with the use of an insulated screwdriver. 7. Run the oven and check all functions. Whenever troubleshooting is performed the power supply must be disconnected. It may, in some cases, be necessary to connect the power supply after the outer case has been removed, in this event, 2. Reinstall the outer case (cabinet). [3] After repairing 1. Reconnect all leads removed from components during testing. 3. Reconnect the power supply cord after the outer case is installed. 4. Run the oven and check all functions. 1) Disconnect the power supply cord, and then remove outer case. Microwave ovens should not be run empty. To test for the presence of microwave energy within a cavity, place a cup of cold water on the oven turntable, close the door and set the power to HIGH and set the microwave timer for two (2) minutes. When the two minutes has elapsed (timer at zero) carefully check that the water is now hot. If the water remains cold carry out Before Servicing procedure and reexamine the connections to the component being tested. 2) Open the door and block it open. 3) Discharge high voltage capacitor. 4) 4.Disconnect the leads to the primary of the power transformer. 5) Ensure that the leads remain isolated from other components and oven chassis by using insulation tape. 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. 6) After that procedure, reconnect the power supply cord. 1–1 RCD2200M Service Manual CHAPTER 2. MICROWAVE MEASUREMENT PROCEDURE RCD2200M A. Requirements: 1) Microwave leakage limit (Power density limit): The power density of microwave radiation emitted by a microwave oven should not exceed 1mW/ cm2 at any point 5cm or more from the external surface of the oven, measured prior to acquisition by a purchaser, and thereafter (through the useful life of the oven), 5 mW/cm2 at any point 5cm or more from the external surface of the oven. 2) Safety interlock switches: Primary interlock relay and door sensing switch shall prevent microwave radiation emission in excess of the requirement as above mentioned, secondary interlock switch shall prevent microwave radiation emission in excess of 5 mW/cm2 at any point 5cm or more from the external surface of the oven. B. Preparation for testing: Before beginning the actual measurement of leakage, proceed as follows: 1) Make sure that the actual instrument is operating normally as specified in its instruction booklet. Important: Survey instruments that comply with the requirement for instrumentation as prescribed by the performance standard for microwave ovens, 21 CFR 1030.10(c)(3)(i), must be used for testing. 2) Place the oven tray in the oven cavity. 3) Place the load of 275±5 ml (9.8 oz) of tap water initially at 20±5°C (68°F) in the center of the oven cavity. The water container shall be a low form of 600 ml (20 oz) beaker with an inside diameter of approx. 8.5 cm (3-1/2 in.) and made of an electrically nonconductive material such as glass or plastic. The placing of this standard load in the oven is important not only to protect the oven, but also to insure that any leakage is measured accurately. 4) Set the cooking control on Full Power Cooking Mode 5) Close the door and select a cook cycle of several minutes. If the water begins to boil before the survey is completed, replace it with 275 ml of cool water. C. Leakage test: Closed-door leakage test (microwave measurement) 1) Grasp the probe of the survey instrument and hold it perpendicular to the gap between the door and the body of the oven. 2) Move the probe slowly, not faster than 1 in./sec. (2.5 cm/sec.) along the gap, watching for the maximum indication on the meter. 3) Check for leakage at the door screen, sheet metal seams and other accessible positions where the continuity of the metal has been breached (eg., around the switches, indicator, and vents). While testing for leakage around the door pull the door away from the front of the oven as far as is permitted by the closed latch assembly. 4) Measure carefully at the point of highest leakage and make sure that the highest leakage is no greater than 4mW/cm2, and that the secondary interlock switch and the primary interlock relay do turn the oven OFF before any door movement. NOTE: After servicing, record data on service invoice and microwave leakage report. 2–1 RCD2200M CHAPTER 3. FOREWORD AND WARNINGService RCD2200M Manual FOREWORD This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service Information for the SHARP MICROWAVE OVENS, R-CD2200M and R-CD1800M. It is recommended that service personnel carefully study the entire text of this manual so that they will be qualified to render satisfactory customer service. Check the interlock switches and the door seal carefully. Special attention should be given to avoid electrical shock and microwave radiation hazard. 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 personnel. DANGER Certain initial parts are intentionally not grounded and present a risk of electrical shock only during servicing. Service personnel - Do not contact the following parts while the appliance is energized; High Voltage Capacitor, Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness; If provided, Vent Hood, Fan assembly, Cooling Fan Motor. All the parts marked “ “ on parts list are used at voltages more than 250V. Removal of the outer wrap gives access to voltage above 250V. All the parts marked “*“ on parts list may cause undue microwave exposure, by themselves, or when they are damaged, loosened or removed. 3–1 RCD2200M CHAPTER 4. PRODUCT DESCRIPTION RCD2200M Service Manual [1] SPECIFICATIONS ITEM Power Requirements Power Consumption Power Output Outside Dimensions Cooking Cavity Dimensions Control Complement Weight Safety Standard DESCRIPTION R-CD1800M R-CD2200M Single phase 230/208V, 60Hz, A.C. only 3.2kW 2.7kW 230V-14A 230V-12.3A 208V-16A 208V-13.5A 1800W Operating frequency 2450 MHz 2200W Operating frequency 2450 MHz 17-1/2” (W) x 20-1/2” (D) x 13-5/8” (H) 445mm (W) x 520mm (D) x 346mm (H) (including feet) 14” (W) x 13” (D) x 7-1/8” (H) 355mm (W) x 326mm (D) x 177mm (H) Touch Control System Digital Display Ten number Pads STOP/CLEAR pad CUSTOM HELP pad START pad SELECT POWER pad (Power level: 0 to 100%) SELECT TIME pad DOUBLE/ TRIPLE QUANTITY pad EXPRESS DEFROST pad SET MEMORY pad Approx. 70 lbs/ 32 kg UL Listed. FCC Authorized DHHS Rules, CFR, Title 21, Chapter 1, Subchapter J NSF Certified, CSA [2] GROUNDING INSTRUCTIONS 1. GROUNDING INSTRUCTIONS This appliance must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This appliance is equipped with a cord having a grounding wire with a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with the National Electrical Code and local codes and ordinances. 2. WARNING Improper use of the grounding plug can result in a risk of electric shock. The electrical requirements are 230/208 Volt, 60 Hz, AC only, and 20 Amp or more fused electrical supply. It is recommended that a separate circuit serving only this appliance be provided. When installing this appliance, observe all applicable codes and ordinances. If it is necessary to use an extension cord, use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that will accept the plug on the appliance. The marked rating of the extension cord should be AC230/208 Volt 20 Amp. Consult a qualified electrician or serviceman if the grounding instructions are not completely understood or if doubt exists as to whether the appliance is properly grounded. Plug Conguration NEMA 6-20P R-CD2200M NEMA 6-15P R-CD1800M Radio or TV Interference Should there be any interference caused by the microwave oven to your radio or TV, check that the microwave oven is on a different electrical circuit, relocate the radio or TV as far away from the oven as feasible or check position and signal of receiving antenna. 4–1 RCD2200M [3] OVEN DIAGRAM 1. OVEN 1. Touch control panels 14 2. Door latch openings 1 10 3. Ceramic shelf 9 4. Splash cover 1 5. Oven light 12 6. Air intake filter 2 7. Air intake openings 4 18 3 5 11 7 15 13 8. Door seals and sealing surfaces 9. Door hinges 10. Oven door with see-through window 17 16 6 8 11. Door latches 15. Power supply cord 12. Door handle 16. Mounting plate 13. Service window for replacing the oven light bulb 17. Screw for mounting plate 14. Ventilation openings 18. Oven ceiling cover 2. TOUCH CONTROL PANEL 1 2 7 7 5 1. SELECT TIME pad 2. SELECT POWER pad 3. DOUBLE/TRIPLE QUANTITY pad 4. CUSTOM HELP pad 5. STOP/CLEAR pad 6. START pad 7. Ten number pads 8. EXPRESS DEFROST pad 9. SET MEMORY pad 4–2 6 3 4 8 9 5 6 RCD2200M CHAPTER 5. OPERATION RCD2200M Service Manual [1] DESCRIPTION OF OPERATING SEQUENCE The following is a description of component functions during oven operation. 1. OFF CONDITION 2. The shut-off relay (RY-4) contacts close completing circuits to turn on the oven lamp and antenna motors. (For details, refer to Figure O-1) 3. If the door remains open, 60 seconds later the control unit de-energizes shut-off relay (RY-4) turning off the oven lamp and antenna motors. Closing the door activates the door sensing switch and secondary interlock switches (1), (2). (In this condition, the monitor switches (1) & (2) contacts are opened.) When the oven is plugged in, and the rated voltage is supplied to the switching power supply unit through the noise filter, (figure O-1). The switching supply unit supplies D.C. voltage (approx. 24V) to the relay unit. And the display will show “ . “. 4. VARIABLE POWER COOKING When Variable Cooking Power is programmed, the rated voltage A.C. is supplied to the power transformer intermittently through the contacts of relay (RY-2, RY-3). Relays RY-2 and RY-3 are operated by the control unit within an interval 48 second time base. Microwave power operation is as follows: 2. COOKING CONDITION (For details, refer to Figure O-2) Press SELECT TIME pad. Enter cooking time by pressing the number pads. Press the SELECT POWER pad. Enter power level by pressing the number pad. When the START pad is pressed, the following operations occur: VARI-MODE 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 1. The contacts of relays are closed. And the oven lamp and the antenna motors connected to the relays are turned on (For details, refer to Figure O-2). 2. D.C. voltage is supplied to the fan motors, exhaust fan and exhaust motor from the control unit. 3. Rated voltage is supplied to the primary winding of the power transformer and is converted to about 3.17 volts output on the filament winding, and approximately 2240 volts on the high voltage winding. 4. The filament winding voltage heats the magnetron filament and the H.V. winding voltage is sent to a voltage doubler circuit. ON TIME 48 sec. 44 sec. 40 sec. 36 sec. 32 sec. 26 sec. 22 sec. 16 sec. 12 sec. 8 sec. 0 sec. OFF TIME 0 sec. 4 sec. 8 sec. 12 sec. 16 sec. 22 sec. 26 sec. 32 sec. 36 sec. 40 sec. 48 sec. NOTE: The ON/OFF time ratio does not exactly correspond with the percentage of microwave power, because approx. 3 seconds are needed for heating of the magnetron filament. 5. The microwave energy produced by the magnetron is channelled through the waveguide into the cavity feed-box, and then into the cavity where the food is placed to be cooked. 6. Upon completion of the cooking time, the oven will revert to the OFF condition. The fan motors, exhaust fan and the exhaust motor will operate at least for 1 minute. 5. TWO MAGNETRON OPERATION SYSTEM Two magnetrons (1), (2) are equipped in order to get higher microwave power output. The primary windings of the power transformers (1), (2) are connected so that each magnetron can be oscillated alternatively according to the frequency of the power supply. Refer to the Figure B-1. 7. When the door is opened during a cook cycle, monitor switches (1) & (2), door sensing switch, secondary interlock switches (1), (2) and primary interlock relay are activated with the following results. The circuits to the high voltage components are de-energized. OPERATION OF MAGNETRON 8. The monitor switch (1) is electrically monitoring the operation of the secondary interlock switch (1) and primary interlock relay, and monitor switch (2) is electrically monitoring the operation of the secondary interlock switch (2) and primary interlock relay, and monitor switches (1), (2) are mechanically associated with the door so that it will function in the following sequence. COMMERCIAL FREQUENCY (60HZ) POWER OUTPUT BY MAGNETRON 1 1) (1) When the door opens from a closed position, the contacts of the primary interlock relay and secondary interlock switches (1), (2) open. Then the monitor switch contacts close. POWER OUTPUT BY MAGNETRON 2 Figure B-1. Operation of Magnetron 2) (2) When the door is closed from the open position, the monitor switches (1), (2) contacts first open, and then the contacts of the secondary interlock switches (1), (2) close. If the secondary interlock switches (1), (2) and primary interlock relay fail with their contacts closed when the door is opened, the closing of the monitor switches (1), (2) contacts will form a short circuit through the monitor fuse, secondary interlock switches (1), (2) and primary interlock relay, causing the monitor fuse to blow. 3. DOOR OPEN CONDITION When the door is opened, the contacts of the door sensing switch open, initiating the following: 1. A signal is input to the control unit energizing the coil of shutoff relay (RY-4). 5–1 RCD2200M [2] OVEN SCHEMATIC 1. Off Condition SCHEMATIC NOTE: CONDITION OF OVEN 1. DOOR CLOSED 2. “ . “ APPEARS ON DISPLAY Figure O-1. Oven Schematic-Off Condition 2. Cooking Condition SCHEMATIC NOTE: CONDITION OF OVEN 1. DOOR CLOSED. 2. SELECT TIME PAD TUCHED.. 3. COOKING TIME PROGRAMMED. 4. START PAD TOUCHED. Figure O-2. Oven Schematic-Cooking Condition 5–2 RCD2200M [3] DESCRIPTION AND FUNCTION OF COMPONENTS 1. DOOR OPEN MECHANISM 3. If the door is opened, and the contacts of the primary interlock relay and secondary interlock switch of the same circuit fail to open, the monitor fuse blows simultaneously with closing of the monitor switch contacts of that circuit (1 or 2). 1. The handle lever is pulled. 2. The upper and lower latch heads are lifted up by the linked latch lever. CAUTION: BEFORE REPLACING A BLOWN MONITOR FUSE TEST THE DOOR SENSING SWITCH, PRIMARY INTERLOCK RELAY, SECONDARY INTERLOCK SWITCHES (1), (2), DOOR SENSING SWITCH AND MONITOR SWITCHES (1), (2) FOR PROPER OPERATION. (REFER TO CHAPTER “TEST PROCEDURE”). 3. The latch lever is lifted up by the handle lever. 4. Now both latch heads are lifted up, so they can be released from the latch hook. 5. Now the door can be opened. Latch lever NOTE: MONITOR FUSE AND SWITCH ARE REPLACED AS AN ASSEMBLY. Switch lever A 5. MONITOR FUSE Latch hook 1. The monitor fuse blows when the contacts (COM-NO) of the primary interlock relay (RY1) and secondary interlock switch remain closed with the oven door open and when the monitor switch closes. Monitor switch (2) Latch head Monitor switch (1) 2. If the wire harness or electrical components are short-circuited, this monitor fuse blows to prevent an electric shock or fire hazard. Switch lever B Secondary interlock switch (2) Handle lever 6. MAGNETRON TEMPERATURE FUSES (1), (2) Secondary interlock switch (1) Latch head The temperature fuses (1), (2) located on the top of the upper and lower waveguide, are designed to prevent damage to the magnetrons (1), (2). If an over heated condition develops in the tube due to blower motor failure, obstructed air ducts, dirty or blocked air intake, etc., the circuit to the magnetrons are interrupted. Under normal operation, the temperature fuses remains closed. However, when abnormally high temperatures are generated within the magnetron, the temperature fuse will open at 302°F (150°C) causing the microwave energy to stop. The defective temperature fuse must be replaced with new rated one. Door sensing switch Switch lever C Figure D-1. Door Open Mechanism 2. DOOR SENSING SWITCH The door sensing switch is activated by the latch head of the door and switch lever C. When the door is opened, the contacts of the switch open and interrupt the circuit to the coils of the primary interlock relay. The contacts of the primary relay then open and interrupt the circuit to the primary winding of the power transformers. 7. OVEN TEMPERATURE FUSE The temperature fuse, located on the side of the exhaust duct assembly, is designed to prevent damage to the oven by fire. If the food load is overcooked, by either error in cook time or defect in the control unit, the temperature fuse will open. Under normal operation, the oven temperature fuse remains closed. However, when abnormally high temperatures are generated within the oven cavity, the oven temperature fuse will open at 248°F (120°C), causing the oven to shut down. The defective temperature fuse must be replaced with new rated one. 3. SECONDARY INTERLOCK SWITCHES (1), (2) The secondary interlock switches (1), (2) are activated by the upper latch head of the door and switch lever B. When the door is opened, the contacts of the switch open and interrupt the circuit to the primary winding of the power transformers (1), (2). 8. EXHAUST THERMISTOR 4. MONITOR SWITCHES (1), (2) The exhaust thermistor is located on the side of the exhaust duct assembly. The temperature in the exhaust duct is detected through the resistance of the thermistor. If the temperature is high, the control panel will display”EE7” and the oven will stop to avoid overheating and catching fire. If the thermistor is open, the control panel will display “EE8” and the oven will stop. The monitor switches (1), (2) are mounted in the upper position of the latch hook. The monitor switches are activated by the upper latch head of the door and switch lever A. When the door is opened, the contacts of the monitor switches close. Monitor switch (1) is intended to render the oven inoperative by means of blowing the monitor fuse, when the contacts of the primary interlock relay and secondary interlock switch (1) fail to open when the door is opened. Monitor switch (2) is intended to render the oven inoperative by means of blowing the monitor fuse, when the contacts of the primary interlock relay and secondary interlock switch (2) fail to open when the door is opened. 9. MAGNETRON THERMISTOR The thermistor is a negative temperature coefficient type. The air temperature around the upper and lower magnetrons is detected through the resistance of the thermistor. If the temperature is high, the control panel will display “EE7” and the oven will stop to protect the magnetrons against overheat. If the magnetron thermistor is open, the control panel will display “EE8” and the oven will stop. Functions: With the door shut, the contacts of the door sensing switch and the secondary interlock switches (1), (2) are closed and the contacts of the monitor switches (1), (2) are open. 10. FAN MOTORS 1. When the door is opened, the contact of the door sensing switch and secondary interlock switches (1), (2) are opened first, then the contact of the monitor switches (1), (2) are closed. The fan motors drive blades which draw external cool air into the oven. This cool air is directed through the air vanes surrounding the magnetrons and cools the magnetrons. This air is channelled through the oven cavity to remove steam and vapours given off from the heating foods. It is then exhausted through the exhausting air vents at the oven cavity. 2. As the door goes to a closed position, the contacts of the monitor switches (1), (2) are opened first, then the contacts of the door sensing switch and the secondary interlock switches (1), (2) close. 5–3 RCD2200M During cooking, they operate. After cooking, they will operate at least for 1 minute and the maximum operating time is 4 minutes. When the temperature of the magnetron thermistor becomes bellow 110°C, the fan motors will stop. These two (2) fan motors are D.C. motors. 4. The large electric currents flow through the high voltage winding of the high voltage transformer. 11. EXHAUST MOTOR 6. The fuse 12A blows by the large electric currents. The exhaust motor is located on the side of the exhaust duct assembly. This motor drives a blade in the exhaust duct assembly. The driven blade draws the external cool air into the oven from the intake duct assembly. Then it sends the air out of the oven through the exhaust duct assembly. During cooking, the exhaust motor operates. After cooking, it will operate at least for 1 minute and the maximum operating time is 4 minutes. When the temperature of the exhaust thermistor becomes bellow 65°C, the exhaust motor will stop. This motor is D.C. motor. 7. The power supplying to the high voltage transformer is cut off. 5. The large electric currents beyond 12A flow through the primary winding of the high voltage transformer. 18. OVEN LAMP The oven cavity light illuminates the interior of the oven so that food being cooked can be examined visually through the door window without having to open the door. 19. NOISE FILTER The noise filter prevents the radio frequency interference that might flow back in the power circuit. NOTE: Do not disconnect the power supply from the exhaust motor when it is turned on. Or it may be out of order. 12. ANTENNA MOTORS The upper and lower antenna motors drive antennas to radiate the microwave. 13. EXHAUST FAN The exhaust fan is located to the rear cover. It sends the air (which is at the top of the oven cavity) out of the oven. This motor is D.C. motor. 14. ANTENNA SENSOR The antenna sensors are located to the top and bottom of the oven cavity. And they watch if the antennas are rotating or not. 15. MIROWAVE SENSOR The microwave sensor is located on the top of the oven cavity. And it watch if the microwave is radiated into the oven cavity or not. 16. FUSE 12A (1) (2) 1. If the wire harness or electrical components are short-circuited, this fuse blows to prevent an electric shock or fire hazard. 2. The fuse also blows when the asymmetric rectifier, H.V. rectifier, H.V. wire harness, H.V. capacitor, magnetron or secondary winding of high voltage transformer is shorted. 17. H.V. ASYMMETRIC RECTIFIER (1) (2) The H.V.asymmetric rectifiers (1) (2) are solid state devices that prevent current flow is both directions. And they prevent the temperature rise of the high voltage transformers (1) (2) by blowing the fuses 12A (1) (2) when the high voltage rectifiers (1) (2) are shorted. The rated peak reverse voltage of D1 of the asymmetric rectifier is 6 KV. The rated peak reverse voltage of D2 of the asymmetric rectifier is 1.7 KV. D1 and D2 of the asymmetric rectifier or high voltage rectifier are shorted when the each peak reverse voltage goes beyond the each rated peak reverse voltage. (The process of the blowing the fuse 12A.) D2 D1 ASYMMETRIC RECTIFIER HIGH VOLTAGE RECTIFIER NOTE: The H.V.asymmetric rectifier is assembled with the high voltage rectifier actually. 1. The high voltage rectifier is shorted by some fault when microwave cooking or dual cooking. 2. The peak reverse voltage of D2 of the rectifier goes beyond the rated peak reverse voltage 1.7 KV in the voltage doubler circuit. 3. D2 of the rectifier is shorted. 5–4 RCD2200M CHAPTER 6. TROUBLESHOOTING GUIDEService RCD2200M Manual Never touch any part in the circuit with your hand or an uninsulated tool while the power supply is connected. 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. IMPORTANT: If the oven becomes inoperative because of a blown monitor fuse, check the monitor switches (1), (2), primary interlock relay RY1, door sensing switch and secondary interlock switches (1), (2), before replacing the monitor fuse. If monitor fuse is replaced, the monitor switch (1) and/or (2) must also be replaced. Use part FFSBA033WRKZ as an assembly. IMPORTANT: Whenever troubleshooting is performed with the power supply cord disconnected. It may, in some cases, be necessary to connect the power supply cord after the outer case has been removed, in this event, 1. Disconnect the power supply cord, and then remove outer case. 2. Open the door and block it open. 3. Discharge two high voltage capacitors. 4. Disconnect the leads to the primaries of the two power transformers. 5. Ensure that the leads remain isolated from other components and oven chassis by using insulation tape. 6. After that procedure, reconnect the power supply cord. When the testing is completed 1. Disconnect the power supply cord, and then remove outer case. 2. Open the door and block it open. 3. Discharge two high voltage capacitors. 4. Reconnect the all leads removed from components during testing. 5. Reinstall the outer case (cabinet). 6. Reconnect the power supply cord after the outer case is installed. 7. Run the oven and check all functions. 6–1 6–2 COOKING CONDITION OFF CONDITION CONDITION Oven goes into a cook cycle but shuts down before and off cooking cycle. Oven does not go into cook cycle when START pad is touched. Low or no power is produced during cooking condition. (The food is heated incompletely or not heated at all.) Variable cooking does not operates properly, except HIGH power functions. Fan motor does not operate. Exhaust fan does not operate. Exhaust motor does not operate. Oven doen not go into cook cycle when START pad on the door is touched. Oven lamp and antenna motors do not go on in cook cycle. It seems that the output power is lower or higher than the rated one. Monitor fuse blows when power cord is plugged into wall receptacle. " . " does not appear in display when power cord is first plugged into wall receptacle. Oven lamp does not go on for 1 minute after door is opened. Home fuse blows when power cord is plugged into wall receptacle PROBLEM POSSIBLE CAUSE AND DEFECTIVE PARTS J OVEN TEMPERATURE FUSE H J MAGNETRON TEMP. FUSE (1), (2) F G MONITOR SWITCH (1), (2) A B C D E F I RELAY UNIT POWER UNIT KEY UNITS MAGNETRON THERMISTOR NOISE FILTER EXHAUST THERMISTOR FUSE 12A (1), (2) PRIMARY INTERLOCK SYSTEM MONITOR FUSE DOOR SENSING SWITCH SECONDARY INTERLOCK SWITCH (1), (2) HIGH VOLTAGE CAPACITOR (1), (2) H.V. RECTIFIER ASSEMBLY (1), (2) POWER TRANSFORMER (1), (2) MAGNETRON (1), (2) L K M N P Q O CONTROL UNIT TEST PROCEDURE RCD2200M LOW POWER SUPPLY VOLTAGE NO POWER AT OUTLET SHORT IN POWER SUPPLY CORD LOOSE WIRING AIR FLOW BLOCKED SWITCH UNIT. VOLTAGE SELECT RELAY (1), (2) EXHAUST MOTOR EXHAUST FAN FAN MOTORS OVEN LAMP OR SOCKET RCD2200M SPECIFICATION OF ERROR Outline When a basic performance and the function are ruined When the dangers of the state of the high temperature and the ignition, etc. are foreseen When you mistake the setting of the heating time When neither the power supply nor the environmental condition are proper When informing of the exchange time of parts EE 1 EE 2 EE 3 EE 4 EE 5 EE 7 EE 8 EE 9 EE 10 EE 11 EE 21 EE 31 EE 81 EE 83 EE 14 EE 24 EE 44 EE 54 EE 15 EE 25 EE 35 EE 16 EE 26 EE 17 EE 27 EE 18 EE 28 EE 38 EE 29 EE 19 EE 39 EE7 Operation stop Operation stop Display Only EE9 EE4, EE5, EE6 CC1, CC2, CC3, CC4 Exceeding of maxmum cooking time Burned food Relay unit Control unit Antenna sensor (1) (Upper) Antenna sensor (2) (Lower) Microwave sensor Low or High power supply voltage No load or small load operation Loose wiring Q O R R S Exhaust thermistor Fan motors Exhaust motor Antenna motor 1 and/or 2 Air flow blocked Content of error Displaying and heating stop Primary interlock system Fuse 12A 1 and/or 2 Magnetron temp. fuse 1 and/or 2 Magnetron thermistor 1 and/or 2 Error history display Magnetron 1and /or 2 POSSIBLE CAUSE AND DEFECTIVE PARTS Usual error display EE1 EE2 EE3 EE4 EE5 EE7 EE8 EE9 EE8 EE1 EE2 EE3 EE8 EE3 EE0 EE0 EE0 EE0 EE0 EE0 EE0 EE8 EE8 EE7 EE7 EE8 EE8 EE8 EE8 EE6 EE6 Display in operation usually EE0, EE1, EE2, EE3, EE8 A B D C E F I J K L Power transformer 1 & 2 High voltage capacitor 1 and /or 2 H.V.rectifier assembly 1 and/or 2 Secondary interlock switch 1 and/or TEST PROCEDURE Operation when error occurs Displaying and heating stop Failer of high voltage circuit 1 Failer of high voltage circuit 2 Failer of high voltage circuit 1&2 Too high of input voltage(+13%) Too low of input voltage(-13%) Food burned (temp., too high) Melted contacts of relays Over maximum cooking time EEPROM error Life end of magnetron 1 Life end of magnetron 2 Life end of magnetron 1&2 Life end of relays RY2/RY3 Over Current error MG1 Cooling Fan lock judge MG2 Cooling Fan lock judge Exhaust motor lock judge Life end of exhaust motor MG1 antenna rotation error MG2 antenna rotation error MG1/2 antenna rotation error MG1 thermistor open MG2 thermistor open MG1 temperature, too high MG2 temperature, too high Magnetron 1 Magnetron 2 Magnetron 1& 2 Exhaust thermistor open/short No food small food NOTE 1: If the power supply voltage is higher than 230V+13% (259.9V), EE4 will be displayed. If the power supply voltage is lower than 208V-13% (180.96V), EE5 will be displayed. NOTE 2: " " means that the parts should be replaced when EE11, EE21, EE31 or EE81 is indicated on the display. Display for maintenance CC1 CC2 CC3 CC4 { { { { Error history display – – – – Content of maintenance Check item MG1 exchange time information MG2 exchange time information Exhaust Fan motor exchange time information T/C unit exchange time information Using time of MG1 Using time of MG2 Using time of Exhaust motor Using number of times of RY2/RY3 6–3 Parts to be replaced MG1 MG2 Exhaust motor Relay unit RCD2200M CHAPTER 7. TEST PROCEDURES RCD2200M Service Manual [1] A: MAGNETRON ASSEMBLY TEST 1. Disconnect the power supply cord, and then remove outer case and rear cover. 2. Open the door and block it open. 3. Discharge high voltage capacitor. 4. To test for an open filament, isolate the magnetron from the high voltage circuit. A continuity check across the magnetron filament leads should indicate less than 1 ohm. 5. To test for a shorted magnetron, connect the ohmmeter leads between the magnetron filament leads and chassis ground. This test should indicate an infinite resistance. If there is little or no resistance the magnetron is grounded and must be replaced. 6. Reconnect all leads removed from components during testing. 7. Reinstall the rear cover and the outer case (cabinet). 8. Reconnect the power supply cord after the outer case is installed. 9. Run the oven and check all functions. 1. MICROWAVE OUTPUT POWER The following test procedure should be carried out with the microwave oven in a fully assembled condition (outer case fitted). HIGH VOLTAGES ARE PRESENT DURING THE COOK CYCLE, SO EXTREME CAUTION SHOULD BE OBSERVED. Power output of the magnetron can be measured by performing a water temperature rise test. This test should only be used if above tests do not indicate a faulty magnetron and there is no defect in the following components or wiring: silicon rectifier, high voltage capacitor and power transformer. This test will require a 16 ounce (453cc) measuring cup and an accurate mercury thermometer or thermocouple type temperature tester. For accurate results, the following procedure must be followed carefully: 1. Fill the measuring cup with 16 oz. (453cc) of tap water and measure the temperature of the water with a thermometer or thermocouple temperature tester. Stir the thermometer or thermocouple through the water until the temperature stabilizes. Record the temperature of the water. 2. Place the cup of water in the oven. Operate oven at 100% Power selecting more than 60 seconds cook time. Allow the water to heat for 60 seconds, measuring with a stop watch, second hand of a watch or the digital read-out countdown. 3. Remove the cup from the oven and again measure the temperature, making sure to stir the thermometer or thermocouple through the water until the maximum temperature is recorded. 4. Subtract the cold water temperature from the hot water temperature. The normal result should be 49 to 91.1°F (27.2 to 50.6°C) rise in temperature for R-CD18MP. The normal result should be 59 to 109.8°F (32.8 to 61°C) rise in temperature for R-CD22MP. If the water temperatures are accurately measured and tested for the required time period the test results will indicate if the magnetron tube has low power output (low rise in water temperature) which would extend cooking time or high power output (high rise in water temperature) which would reduce cooking time. Because cooking time can be adjusted to compensate for power output, the magnetron tube assembly should be replaced only if the water temperature rise test indicates a power output well beyond the normal limits. The test is only accurate if the power supply line voltage is 208/230 volts and the oven cavity is clean. . [2] B: POWER TRANSFORMER TEST 1. Disconnect the power supply cord, and then remove outer case and rear cover. 2. Open the door and block it open. 3. Discharge high voltage capacitor. 4. Disconnect the primary input terminals and measure the resistance of the transformer with an ohmmeter. Check for continuity of the coils with an ohmmeter. On the R x 1 scale, the resistance of the primary coil should be less than 1 ohm and the resistance of the high voltage coil should be approximately 58 ohms; the resistance of the filament coil should be less than 1 ohm. 5. Reconnect all leads removed from components during testing. 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the outer case is installed. 8. Run the oven and check all functions. (HIGH VOLTAGES ARE PRESENT AT THE HIGH VOLTAGE TERMINAL, SO DO NOT ATTEMPT TO MEASURE THE FILAMENT AND HIGH VOLTAGE.) [3] C: HIGH VOLTAGE RECTIFIER (1) AND/OR (2) TEST 1. HIGH VOLTAGE RECTIFIERFTEST 1. Disconnect the power supply cord, and then remove the outer case and the rear cover. 2. Open the door and block it open. 3. Discharge two high voltage capacitors. 7–1 RCD2200M 4. 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 100k ohms in the other direction. 5. Reconnect all leads removed from components during testing. 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the rear cover and the outer case are installed. 8. Run the oven and check all functions. A D2 B D1 ASYMMETRIC RECTIFIER C HIGH VOLTAGE RECTIFIER 2. ASYMMETRIC RECTIFIER TEST 1. Disconnect the power supply cord, and then remove outer case. 2. Open the door and block it open. 3. Discharge two high voltage capacitors. 4. Isolate the high voltage rectifier assembly from the HV circuit. The asymmetric rectifier can be tested using an ohmmeter set to its highest range across the terminals A+B of the asymmetric rectifier and note the reading obtained. Reverse the meter leads and note this second reading. If an open circuit is indicated in both directions then the asymmetric rectifier is good. If the asymmetric rectifier is shorted in either direction, then the asymmetric rectifier is faulty and must be replaced with high voltage rectifier. When the asymmetric rectifier is defective, check whether magnetron, high voltage rectifier, high voltage wire or filament winding of the high voltage transformer is shorted. 5. Reconnect all leads removed from components during testing. 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the rear cover and the outer case are installed. 8. Run the oven and check all functions. NOTE: Be sure to use an ohmmeter that will supply a forward bias voltage of more than 6.3 volts. [4] D: HIGH VOLTAGE CAPACITOR (1) AND/OR (2) TEST 1. Disconnect the power supply cord, and then remove outer case and rear cover. 2. Open the door and block it open. 3. Discharge high voltage capacitor. 4. If the capacitor is open, no high voltage will be available to the magnetron. Disconnect input leads and check for short or open between the terminals using an ohmmeter. Checking with a high ohm scale, if the high voltage capacitor is normal, the meter will indicate continuity for a short time and should indicate an open circuit once the capacitor is charged. If the above is not the case, check the capacitor with an ohmmeter to see if it is shorted between either of the terminals and case. If it is shorted, replace the capacitor. 5. Reconnect all leads removed from components during testing. 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the rear cover and the outer case are installed. 8. Run the oven and check all functions. [5] E: SECONDARY INTERLOCK SWITCH (1) AND/OR (2) TEST 1. Disconnect the power supply cord, and then remove outer case and rear cabinet. 2. Open the door and block it open. 3. Discharge high voltage capacitor. 4. Isolate the switch and connect the ohmmeter to the common (COM.) and normally open (NO) terminal of the switch. The meter should indicate an open circuit with the door open and a closed circuit with the door closed. If improper operation is indicated, replace the secondary interlock switch. 5. Reconnect all leads removed from components during testing. 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the rear cover and the outer case are installed. 8. Run the oven and check all functions. 7–2 RCD2200M [6] F: PRIMARY INTERLOCK SYSTEM TEST 1. DOOR SENSING SWITCH 1. Disconnect the power supply cord, and then remove outer case and rear cabinet. 2. Open the door and block it open. 3. Discharge high voltage capacitor. 4. Isolate the switch and connect the ohmmeter to the common (COM.) and normally open (NO) terminal of the switch. The meter should indicate an open circuit with the door open and a closed circuit with the door closed. If improper operation is indicated, replace the door sensing switch. 5. Reconnect all leads removed from components during testing. 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the rear cover and the outer case are installed. 8. Run the oven and check all functions. NOTE: If the door sensing switch contacts fail in the open position and the door is closed, the blower motor, stirrer motors and oven light will be activated by RY1. 2. PRIMARY INTERLOCK RELAY RY1 1. Disconnect the power supply cord, and then remove outer case and rear cabinet. 2. Open the door and block it open. 3. Discharge high voltage capacitor. 4. Disconnect two (2) wire leads from the male tab terminals of the Primary Interlock Relay RY1. Check the state of the relay contacts using a ohmmeter. The relay contacts should be open. If the relay contacts are closed, replace the circuit board entirely or the relay itself. 5. Reconnect all leads removed from components during testing. 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the rear cover and the outer case are installed. 8. Run the oven and check all functions. [7] G: MONITOR SWITCH (1) AND/OR (2) TEST 1. Disconnect the power supply cord, and then remove outer case and rear cabinet. 2. Open the door and block it open. 3. Discharge high voltage capacitor. 4. Before performing this test, make sure that the secondary interlock switches (1), (2) and the primary interlock relay RY1 are operating properly, according to the above Switch Test Procedure. Disconnect the wire lead from the monitor switches (1), (2) (COM) terminals. Check the monitor switches (1), (2) operation by using the ohmmeter as follows. When the door is open, the meter should indicate a closed circuit. When the monitor switch actuator is pushed by a screw driver through the upper latch hole on the front plate of the oven cavity with the door opened (in this condition the plunger of the monitor switch is pushed in), the meter should indicate an open circuit. If improper operation is indicated, the switch may be defective. After testing the monitor switches, reconnect the wire lead to the monitor switch (COM) terminals and check the continuity of the monitor circuit. 5. Reconnect all leads removed from components during testing. 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the rear cover and the outer case are installed. 8. Run the oven and check all functions. Screw Driver Latch hook Monitor switch (2) Monitor switch (1) Ohmmeter [8] H: BLOWN MINITOR FUSE TEST 1. Disconnect the power supply cord, and then remove outer case and rear cabinet. 2. Open the door and block it open. 7–3 RCD2200M 3. Discharge high voltage capacitor. 4. If the monitor fuse is blown when the door is opened, check the primary interlock relay RY1, secondary interlock switches (1), (2) and monitor switches (1), (2) according to the “TEST PROCEDURE” for those switches before replacing the blown monitor fuse. CAUTION: CAUTION: BEFORE REPLACING A BLOWN MONITOR FUSE, TEST THE PRIMARY INTERLOCK RELAY, SECONDARY INTERLOCK SWITCHES, DOOR SENSING SWITCH AND MONITOR SWITCHES FOR PROPER OPERATION. If the monitor fuse is blown by improper switch operation, the monitor fuse and monitor switch must be replaced with “monitor fuse and monitor switch assembly” part number FFS-BA033WRKZ, even if the monitor switch operates normally. The monitor fuse and monitor switch assembly is comprised of a 20 ampere fuse and switch. 5. Reconnect all leads removed from components during testing. 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the rear cover and the outer case are installed. 8. Run the oven and check all functions. [9] I: FUSE 12A (1) (2) TEST 1. Disconnect the power supply cord, and then remove outer case and rear cabinet. 2. Open the door and block it open. 3. Discharge high voltage capacitor. 4. If the fuse is blown, check the magnetron, high voltage capacitor, high voltage rectifier assembly, according to the “TEST PROCEDURE” before replacing the blown fuse. Then replace the fuse. 5. Reconnect all leads removed from components during testing. 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the rear cover and the outer case are installed. 8. Run the oven and check all functions. [10] J: TEMPERATURE FUSE TEST 1. Disconnect the power supply cord, and then remove outer case and rear cabinet. 2. Open the door and block it open. 3. Discharge high voltage capacitor. 4. A continuity check across the temperature fuse terminals should indicate a closed circuit unless the temperature of the temperature fuse reaches specified temperature as shown below. Open temperature Magnetron temperature fuse (1) Magnetron temperature fuse (2) Magnetron temperature fuse (1), (2) 150°C Oven temperature fuse 120°C Close temperature Display or Condition EE1 Non resetable type EE2 EE3 Non resetable type Oven shut off Check point Magnetron (1) Failure: Test magnetron (1) and fan motor. Magnetron (2) Failure: Test magnetron (2) and fan motor. Magnetron (1), (2) Failure: Test magnetron (1), (2). Check fan motor and ventilation opening. Food has been burned in oven. Temperature of oven inside is very high. 5. Reconnect all leads removed from components during testing. 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the rear cover and the outer case are installed. 8. Run the oven and check all functions. CAUTION: IF THE TEMPERATURE FUSE INDICATES AN OPEN CIRCUIT AT ROOM TEMPERATURE, REPLACE TEMPERATURE FUSE. [11] K: MAGNETRON THERMISTOR TEST 1. Disconnect the power supply cord, and then remove outer case and rear cabinet. 2. Open the door and block it open. 3. Discharge high voltage capacitor. 4. Disconnect the connector of the magnetron thermistor from the harness. Measure the resistance of the thermistor with an ohmmeter. Connect the ohmmeter leads to the connector of the thermistor. Room temperature 68°F (20°C) Resistance Approx. 750KΩ If the meter does not indicate above resistance, replace the thermistor. 5. Reconnect all leads removed from components during testing. 7–4 RCD2200M 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the rear cover and the outer case are installed. 8. Run the oven and check all functions. [12] L: EXHAUST THERMISTOR TEST The exhaust thermistor can be checked by using the Special function (SF-6). Check the exhaust thermistor, referring to the pages of the Exhaust thermistor check (SF-6). If the display shows “OH”, the exhaust thermistor is normal. If the display shows “no”, the exhaust thermistor is abnormal and it should be replaced. [13] M: NOISE FILTER TEST 1. Disconnect the power supply cord, and then remove outer case and rear cabinet. 2. Open the door and block it open. Source (White) Source (Black) NOISE FILTER DISCHARGE RESISTOR 470K 1/2W 3. Discharge high voltage capacitor. 4. Disconnect the lead wires from the terminal the noise filter. Using an ohmmeter, check between the terminals as described in the following table. If incorrect reading are obtained, replace the noise filter. LINE CROSS CAPACITOR 1.0μF / AC 250V FUSE 20A NOISE SUPPRESSION COIL 5. Reconnect all leads removed from components during testing. 6. Reinstall the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord after the rear cover and the outer case are installed. 8. Run the oven and check all functions. MEASURING POINT Between source terminals Between source (Black) and load (Black) terminals Between source (White) and load (White/Brown) terminals INDICATION OF OHMMETER Approx. 470KΩ Short circuit. Short circuit. LINE BYPASS CAPACITOR 0.0033μF / AC 125V LINE BYPASS CAPACITOR 0.0033μF / AC 125V Load (White/Brown) Load (Black) [14] N: KEY UNIT TEST 1. Disconnect the power supply cord, and then remove outer case and rear cabinet. 2. Open the door and block it open. 3. Discharge high voltage capacitor. 4. Check Key unit ribbon connection before replacement. 5. If key unit ribbon connection is normal, carry out the following procedures. 6. Re-install the rear cover and the outer case (cabinet). 7. Reconnect the power supply cord. 8. The following symptoms indicate a defective key unit. 1) When touching the pads, a certain pad produces no signal at all. 2) When touching a number pad, two figures or more are displayed. 3) When touching the pads, sometimes a pad produces no signal. 9. When you can not judge if the key unit is normal or not by using the item 8 above, carry out following test procedures. 1) Disconnect the power supply cord, and then remove outer case and rear cover. 2) Open the door and block it open. 5 3) Discharge two high voltage capacitors. 4 3 X2/X3 EXPRESS DEFROST 2 1 CN-M SELECT TIME SELECT POWER 6 4) Disconnect the leads to the primary of the power transformer. 1 4 3 2 8 8 5 6 7 9 9 0 STOP CLEAR 7 5) Ensure that these leads remain isolated from other components and oven chassis by using insulation tape. SET CUSTOM MEMORY HELP 6) Reconnect the power supply cord. START < KEY UNIT > 7) If the display fails to clear when the STOP/CLEAR pad is depressed, first verify the flat ribbon cable is making 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 connector). 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 making 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 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. 7–5 CN-Z 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 1 4 3 6 6 6 8 5 6 7 7 7 7 9 0 STOP CLEAR START CN-Q 8 CN-R < SW UNIT > 2 < DOOR KEY UNIT > RCD2200M 8) For the door key unit, check the open/short and/or connection of the switch unit and the harness, too. 10.If the Key unit is defective. 1) Disconnect the power supply cord, and then remove outer case and rear cover. 2) Open the door and block it open. 3) Discharge two high voltage capacitors. 4) Replace the Key unit. 5) Reconnect all leads removed from components during testing. 6) Re-install the rear cover and the outer case (cabinet). 7) Reconnect the power supply cord after the rear cover and the outer case are installed. 8) Run the oven and check all functions. [15] O: CONTROL UNIT TEST The following symptoms indicate a defective control unit. Before replacing the control unit, perform the Key units test (Procedure) to determine if control unit is faulty. Connect the power supply cord. And check for followings. 1. In connection with pads. 1) When touching the pads, a certain group of pads do not produce a signal. 2) When touching the pads, no pads produce a signal. 2. In connection with display 1) At a certain digit, all or some segments do not light up. 2) At a certain digit, brightness is low. 3) Only one indicator does not light. 4) The corresponding segments of all digits do not light up; or they continue to light up. 5) Wrong figure appears. 6) A certain group of indicators do not light up. 7) The figure of all digits flicker. 3. Other possible problems caused by defective control unit. 1) Buzzer does not sound or continues to sound. 2) Cooking is not possible. 4. If the protectors F1 and/or F2 on the control unit PWB are open, the control unit is defective. To check, carry out following procedures. i) Disconnect the power supply cord, and then remove outer case and rear cover. ii) Open the door and block it open. iii) Discharge two high voltage capacitors. iv) Remove the control unit from the control panel, referring to “CONTROL PANEL ASSEMBLY AND CONTROL UNIT REMOVAL”. v) Check the continuity of the protectors F1 and F2 on the control unit [16] P: POWER UNIT TEST 1. Check the out put voltage of power unit at CN21 as follows. i) Disconnect the power supply cord, and then remove outer case and rear cover. ii) Open the door and block it open. iii) Discharge two high voltage capacitors. iv) Disconnect the leads to the primary of the power transformer. v) Ensure that these leads remain isolated from other components and oven chassis by using insulation tape. vi) Check the voltage between Pin No1 and No2 of CN21. vii) The output voltage should be approx. 24V. viii) If not so, the power unit is defective. 2. Check the continuity of the fuse F1 and protector F21 on the power unit as follows. i) Disconnect the power supply cord, and then remove outer case and rear cover. ii) Open the door and block it open. iii) Discharge two high voltage capacitors. iv) Remove the power unit from the oven, referring to “POWER UNIT REMOVAL”. v) Check the continuity of the fuse F1 and the protector F21. 7–6 RCD2200M vi) If they are open, the power unit is defective [17] Q: RELAY UNIT TEST 1. Disconnect the power supply cord, and then remove outer case and rear cover. 2. Open the door and block it open. 3. Discharge two high voltage capacitors. 4. Remove the relay unit from the oven, referring to “RELAY UNIT REMOVAL”. 5. Check the continuity of the FUSE1 on the relay unit. 1) If it is open, the relay unit is defective. 6. Check the open and /or short of the transformer primary coil on the relay unit. 1) If it is open and /or short, it is defective. 7. Check the state of the relays contacts RY-1, RY-2 and RY-3 using an ohmmeter. 1) The relay contacts should be open. If not so, the relay unit is defective. [18] R: ANTENNA SENSOR TEST There is no test procedure for the antenna sensor. When the error history display shows EE15, EE25 or EE35, if the antenna motors, control unit and wiring are normal, the antenna sensor may be defective. [19] S: MICROWAVE SENSOR TEST There is no test procedure for the microwave sensor. When the error history display shows EE18, EE28 or EE38, if the magnetrons, control unit and wiring are normal, the microwave sensor may be defective. 7–7 RCD2200M Service Manual CHAPTER 8. TOUCH CONTROL PANEL ASSEMBLY RCD2200M [1] SPECIAL FUNCTION FOR SERVICING This oven has the special functions for servicing as shown in the table 1 ~ 4. By using the special function, service person can check the using time or the using number of times for the electrical parts. Also service person can check the AC supply voltage and /or set the standard voltage. When “SF-2” is selected, the display will show the total cooking number of times. Table 1. Total cooking number of times Set SF-2 Contents (decimal) Total cooking number of times Max. 9999(x100) times Data clear { New data set – The service person can check and /or carry out the contents as shown in the table 2. Table 2. Special function contents Check, clear and set of using time or number of times Error history Check of AC supply voltage Exhaust thermistor check Set standard voltage for production. Model name Making date of software key 2 4 5 6 7 CUSTOM HELP Display SF-2 SF-4 SF-5 SF-6 SF-7 cd XX (Model) XX XX (Date) XX XX (Time) After plug in Yes Yes NOTE: The function marked “yes” can be used only after the oven is plugged in again. 1. Check, clear and set of using time or number of times When the display shows “CC” and the number as shown in the table 3, 1) Before replacing the parts, check the using time or number of times about the parts. 2) If the using time or number of times go over the limit level, replace the defective parts. 3) After replacing the parts, clear the using time or number of times about the parts, referring to the table 4. Table 3. CC error Display “CC”, “1.” repeatedly “CC”, “2.” repeatedly “CC”, “3.” repeatedly “CC”, “4.” repeatedly “CC”, “1.2.4.” repeatedly Content Magnetron 1 (top) Magnetron 2 (bottom) Exhaust fan Need to change relay unit Some maintenance occurs same time Ex. Magnetron 1&2 and relay unit Limit level 1250 hour 1250 hour 3000 hour MG Relay 200000 times Action Display only Display only Display only Display only Display only The using time or using number of times can be checked or set by using the number pads after “SF-2” is set. Table 4. Using time or number of times about each part Contents (decimal) Using time of MG 1 (top) Using time of MG 2 (bottom) Using number of times of MG 1 (top) relay Using number of times of MG 2 (bottom) relay Total cooking time (hour. min.) Total cooking time (hundred hour) Using time of exhaust fan 10 key 1 2 3 4 5 6 7 Max. 9999 hours 9999 hours 999 (x 1000) times 999 (x 1000) times 99 hours 59min. 9999 hundred hours 9999 hours 8–1 Data clear { { { { { { { New data set { { – – – – { RCD2200M For example: Procedure to check the total cooking number of times (example, 957700 times) and using time (example, 1260 hours) of MG 1 and set 0 hours after MG1 is replaced. : no sound {: 0.1 second sound : 2.0 second sound ✩: [(0.04 sec. ON, 0.04 sec. OFF) x 3] x 4 beeps Operation (within 20 sec.) : (0.06 sec. ON, 0.06 sec. OFF) x 2 beeps : (0.1 sec. ON, 0.1 sec. OFF) x 10 beeps Display . . . . SF- SELECT POWER SET MEMORY START STOP/CLEAR Indicator SF2 9577 2 (after 1 sec.) Sound CHECK (total counter for serviced [x 100]) 1 SELECT TIME START 1260 0 SF-2 STOP/CLEAR 0 CHECK For example: Procedure to check the total cooking number of times (example, 957700 times) and clear it and check using time (example, 1260 hours) of MG 1 and set the using time (example, 1000 hours) of MG1. Operation (within 20 sec.) Display . . . . SF- SELECT POWER SET MEMORY START STOP/CLEAR Indicator SF2 9577 2 (after 1 sec.) Sound CHECK (total counter for serviced [x 100]) SELECT TIME START 0 SF-2 1 SELECT TIME 1,0,0,0 START 1260 0 1000 SF-2 STOP/CLEAR 0 CHECK x4 2. Error history (SF-4) You can check the most recent 10 error histories. For example: Procedure to check the error histories that have been memorized in memory 1, memory 2 and memory 9. Operation (within 20 sec.) SELECT POWER SET MEMORY START STOP/CLEAR 4 1 (latest error No.) 2 (1 time previous error) 9 (8 times previous error) #2 SELECT POWER Display . . . . SF- Indicator SF-4 #1 EE 1 EE 6 EE24 0 8–2 Sound RCD2200M #1 If there is no error “0" will be displayed. #2 If you touch SELECT POWER, all history are cleared. 3. Check of AC supply voltage (SF-5) You can check the current voltage of AC supply. For example: Procedure to check current voltage (In case of 230V +13%) For example: Procedure to check current voltage (In case of 230V) Operation SELECT POWER SET MEMORY START STOP/CLEAR (within 20 sec.) Operation Display Indicator Sound . . . . SF- (within 20 sec.) 5 230U 5 STOP/CLEAR 0 STOP/CLEAR Operation SELECT POWER SET MEMORY START STOP/CLEAR Operation Display Indicator Sound . . . . SF- (within 20 sec.) SELECT POWER SET MEMORY START STOP/CLEAR 5 208U 5 STOP/CLEAR EE4 0 For example: Procedure to check current voltage (In case of 208V -13%) For example: Procedure to check current voltage (In case of 208V) (within 20 sec.) SELECT POWER SET MEMORY START STOP/CLEAR Display Indicator Sound . . . . SF- STOP/CLEAR 0 Display Indicator Sound . . . . SFEE5 0 4. Exhaust thermistor check (SF-6) You can check if the exhaust thermistor works correctly or not by using this function. For example: In case the exhaust thermistor works correctly (275ml water load is necessary.), the display will show “OH” as follows. Operation plug in Display . Indicator Sound (within 20 sec.) (within 20 sec.) SELECT POWER . SET MEMORY START STOP/CLEAR . . SF- 6 START SF-6 5.00 (count down) or OH or (after 5 min.) STOP/CLEAR STOP/CLEAR ON SF-1 0 8–3 RCD2200M For example: In case the exhaust thermistor works incorrectly (275ml water load is necessary), the display will show “no” as follows. In that case, the exhaust thermistor should be checked or replaced. Operation plug in Display . Indicator Sound (within 20 sec.) SELECT POWER . SET MEMORY START STOP/CLEAR . . SF- (within 20 sec.) 6 START SF-6 5.00 (count down) ON no (after 5 min.) STOP/CLEAR STOP/CLEAR or SF-1 0 5. Set of standard voltage (SF-7) When the control unit or the relay unit is replaced, set the standard voltage, referring to following procedure. Because the control unit judges if the AC supply voltage is 230V or 208V by comparing with the standard voltage. The temporary standard voltage is set when the oven is shipped from the factory. But when the control unit is replaced to new one, it does not have the standard voltage. When the relay unit is replaced to new one, set the standard voltage too. Because the signal from the relay unit to detect the AC supply voltage has error of ±5%. The standard voltage can be set by using this function. For example: Procedure to set the standard voltage (in case input voltage is 230V ±1V) Operation plug in Display . Indicator Sound Flashing (within 20 sec.) SELECT POWER . SET MEMORY START STOP/CLEAR . . SF- (within 20 sec.) 7 START (after 1 sec.) STOP/CLEAR 230U (currnt voltage) 230U SF0 Image of the standard voltage is as follows; When the oven detects the AC supply voltage is 230V, the control unit calculates the standard voltage is 219V. Because 230V- 11v = 219V. When the oven detects the AC voltage is 208V, the control unit calculates that the standard voltage is 219V. Because 208V + 11V = 219v. NOTE: 11V is not exact. For example: In case that AC supply voltage is out of range from tentative memorized voltage (standard voltage ±13%), the display will show “----” as follows. At that time, the voltage of AC power may be not suitable or the control unit and /or the relay unit may be out of order. Operation plug in Display . Indicator (within 20 sec.) (within 20 sec.) SELECT POWER . SET MEMORY START STOP/CLEAR . . SF- 7 START STOP/CLEAR ---0 8–4 Sound RCD2200M For example: Procedure to set standard voltage at 230V area. This example shows how to set the standard voltage when the oven judge that the input voltage is 208V by mistake at 230V area. If the input voltage is not accurate at the place of customer, the standard voltage can be selected by using “0” key in the following procedure. Operation plug in Display . Indicator Sound Flashing (within 20 sec.) (within 20 sec.) SELECT POWER . SET MEMORY START STOP/CLEAR . . SF- 7 0 START (after 1 sec.) 208U (currnt voltage) 230U (select voltage) 230U SF0 STOP/CLEAR For example: Procedure to set standard voltage at 208V area. This example shows how to set the standard voltage when the oven judge that the input voltage is 230V by mistake at 208V area. If the input voltage is not accurate at the place of customer, the standard voltage can be selected by using “0” key in the following procedure. Operation plug in Display . Indicator Sound Indicator Sound Flashing (within 20 sec.) (within 20 sec.) SELECT POWER . SET MEMORY START STOP/CLEAR . . SF- 7 0 START (after 1 sec.) STOP/CLEAR 230U (currnt voltage) 208U (select voltage) 208U SF0 6. CUSTOM HELP You can check if the correct control unit is installed or not by using this function. Procedure to check the model name and making date of software. Operation plug in Display . (within 20 sec.) (within 20 sec.) SELECT POWER SET MEMORY START STOP/CLEAR CUSTOM HELP . . . SF#1cd-XX (model name) XXXX (date) STOP/CLEAR XXXX (time) 0 #1: The display will show “cd22”, “cd18” or “cd12”. “cd22” means model R-CD2200M and “cd18” means model R-CD1800M and “cd12” means model R-CD1200M. 8–5 RCD2200M [2] SERVICING FOR BRINTED WIRING BOARDS 1. Precautions for Handling Electronic Components b) On some models, the power supply cord between the printed wiring boards and the oven proper is long enough that they may be separated from each other. For those models, it is possible to check and repair the controls of the printed wiring boards 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 printed wiring boards with a jumper, which activates an operational state that is equivalent to the oven door being closed. As for the sensor-related controls of the printed wiring boards, checking them is possible if dummy resistor(s) with resistance equal to that of the controls are used. 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 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. 2. Servicing the printed wiring boards with power supply from an external power source: Disconnect the printed wiring boards completely from the oven proper, and short both ends of the door sensing switch (on PWB) of the printed wiring boards, which activates an operational state that is equivalent to the oven door being closed. Connect an external power source to the power input terminal of the printed wiring boards, then it is possible to check and repair the controls of the printed wiring boards it is also possible to check the sensor-related controls of the printed wiring boards by using the dummy resistor(s). approx. 1M ohm 2. Servicing of Printed Wiring Boards We describe the procedures to permit servicing of the printed wiring boards of the microwave oven and the precautions you must take when doing so. To perform the servicing, power to the printed wiring boards is available either from the power line of the oven itself or from an external power source. 3. Servicing Tools Tools required to service the printed wiring boards assembly. 1. Servicing the printed wiring boards with power supply of the oven: 1) Soldering iron: 60W CAUTION: THE HIGH VOLTAGE TRANSFORMER OF THE MICROWAVE OVEN IS STILL LIVE DURING SERVICING AND PRESENTS A HAZARD. (It is recommended to use a soldering iron with a grounding terminal.) 2) Oscilloscope: Single beam, frequency range: DC - 10MHz type or more advanced model. Therefore, before checking the performance of the printed wiring boards, 3) Others: Hand tools 1) Disconnect the power supply cord and then remove outer case and rear cover. 4. Other Precautions 2) Open the door and block it open. 3) Discharge two high voltage capacitors. 1) Before turning on the power source of the printed wiring boards, remove the aluminium foil applied for preventing static electricity. 4) Disconnect the leads to the primary of the two power transformers. 2) Connect the connector of the key unit to the printed wiring boards being sure that the lead wires are not twisted. 5) Ensure that these leads remain isolated from other components and oven chassis by using insulation tape. 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. 6) After that procedure, re-connect the power supply cord. 4) Attach connectors, electrolytic capacitors, etc. to PWB, making sure that all connections are tight. After checking the performance of the printed wiring boards, 1) Disconnect the power supply cord. 5) Be sure to use specified components where high precision is required. 2) Open the door and block it open. 3) Re-connect the leads to the primary of the two power transformers. 4) Re-install the rear cover and the outer case (cabinet). 5) Re-connect the power supply cord after the rear cover and the outer case is installed. 6) Run the oven and check all functions. a) On some models, the power supply cord between the printed wiring boards and the oven itself is so short that the they can’t be separated. For those models, check and repair all the printed wiring boards (sensor-related ones included) of the printed wiring boards while keeping it connected to the oven. 8–6 RCD2200M Manual SOLDER CHAPTER 9. PRECAUTIONS FOR USINGService LEAD-FREE RCD2200M Employing lead-free solder The “Main PWB” of this model employs lead-free solder. This is indicated by the “LF” symbol printed on the PWB and in the service manual. The suffix letter indicates the alloy type of the solder. Example: Indicates lead-free solder of tin, silver and copper Using lead-free wire solder When repairing a PWB with the “LF” symbol, only lead-free solder should be used. (Using normal tin/lead alloy solder may result in cold soldered joints and damage to printed patterns.) As the melting point of lead-free solder is approximately 40°C higher than tin/lead alloy solder, it is recommend that a dedicated bit is used, and that the iron temperature is adjusted accordingly. Soldering As the melting point of lead-free solder (Sn-Ag-Cu) is higher and has poorer wet ability, (flow), to prevent damage to the land of the PWB, extreme care should be taken not to leave the bit in contact with the PWB for an extended period of time. Remove the bit as soon as a good flow is achieved. The high content of tin in lead free solder will cause premature corrosion of the bit. To reduce wear on the bit, reduce the temperature or turn off the iron when it is not required. Leaving different types of solder on the bit will cause contamination of the different alloys, which will alter their characteristics, making good soldering more difficult. It will be necessary to clean and replace bits more often when using lead-free solder. To reduce bit wear, care should be taken to clean the bit thoroughly after each use. 9–1 RCD2200M Service AND Manual ADJUSTMENT PROCECHAPTER 10. COMPONENT REPLACEMENT RCD2200M DURE [1] WARNINGS WARNING AGAINST HIGH VOLTAGE: Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts may result in severe, possibly fatal, electric shock. (Example) High Voltage Capacitor, Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc.. WARNING: Avoid possible exposure to microwave energy. Please follow the instructions below before operating the oven. 1. Disconnect the power supply cord. 2. Make sure that a definite "click" can be heard when the microwave oven door is unlatched. (Hold the door in a closed position with one hand, then pull the door handle lever with the other, this causes the latch leads to rise, it is then possible to hear a "click" as the door switches operate.) 3. 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. WARNING FOR WIRING To prevent an electric shock, take the following precautions. 1. Before wiring, 1) Disconnect the power supply cord. 2) Open the door block it open. 3) Discharge the two high voltage capacitor and wait for 60 seconds. 2. Don't let the wire leads touch to the following parts; 1) High voltage parts: Magnetron, High voltage transformer, High voltage capacitor, High voltage rectifier assembly and High voltage wire. 2) Hot parts: Oven lamp, Magnetron, High voltage transformer and Oven cavity. 3) Sharp edge: Bottom plate, Oven cavity, Waveguide flange Chassis support and other metallic plate. 4) Movable parts (to prevent a fault) Blower fan blade, Blower fan motor, Switches, Switch levers, Antenna motor and Stirrer antennas. 3. Do not catch the wire leads in the outer case cabinet. 4. Insert the positive lock connector until its pin is locked and make sure that the wire leads do not come off even if the wire leads are pulled. 5. To prevent an error function, connect the wire leads correctly, referring to the Pictorial Diagram. Please refer to “OVEN PARTS, CABINET PARTS, CONTROL PANEL PARTS, DOOR PARTS”, when carrying out any of the following removal procedures: [2] OUTER CASE AND REAR COVER REMOVAL To remove the components, procedure as follows. 5. DISCHARGE TWO HIGH VOLTAGE CAPACITORS BEFORE TOUCHING ANY OVEN COMPONENTS OR WIRING. 1. Disconnect the power supply cord. 2. Remove the eleven (11) screws from the rear and along side the edge of the outer case. 6. 6. Now, outer case is free. NOTE: Do not lose the support angle at this time. 7. Remove the four (4) screws holding the magnetron exhaust cover to the rear cover. To remove rear cover: 3. Slide the case back about 1 inch (3 cm) to free it from the oven cavity. 8. Remove the magnetron exhaust cover from the rear cover. 4. Lift entire case from the unit. 9. Disconnect the connector of the fan motor from the connector of harness. 10 – 1 RCD2200M 12.Now, the rear cover with the fan motor and exhaust cover is free. 10.Remove the eight (8) screws holding the rear cover and exhaust cover to the bottom plate, power supply cord angle, intake duct and exhaust duct. NOTE: Do not forget to re-connect the wire leads to the exhaust fan when the rear cover and outer case cabinet are reinstalled. 11.Remove the rear cover with the fan motor and exhaust cover from the oven cavity. [3] POWER TRANSFORMERS (1) AND/OR (2) REMOVAL 5. Disconnect wire leads of power transformers (1) and/or (2) from magnetrons (1) and/or (2). 1. Disconnect the power supply cord and then remove outer case and rear cover, referring to “OUTER CASE AND REAR COVER REMOVAL”. 6. Disconnect wire leads of power transformers (1) and/or (2)from high voltage capacitors (1) and/or (2). 2. Open the oven door and block it open. 7. Remove two (2) screws holding each power transformer (1) and/or (2) to base plate. 3. Discharge two high voltage capacitors. 4. Disconnect the main wire harness from power transformers (1) and/or (2). 8. Remove the power transformers (1) and/or (2) from base plate. 9. Now, power transformers (1) and/or (2) are free. [4] MAGNETRONS (1) AND/OR (2) REMOVAL 1. Disconnect the power supply cord and then remove outer case and rear cover, referring to “OUTER CASE AND REAR COVER REMOVAL”. 9. Remove the four (4) screws holding each magnetron (1) and/or (2) to upper and/or lower waveguide. When removing the screws, hold the magnetron to prevent it from falling. 2. Open the oven door and block it open. 10.Remove the magnetrons (1) and/or (2) from upper and/or lower waveguide with care so magnetron antenna is not hit by any metal object around antenna. 3. Discharge two high voltage capacitors. 4. Disconnect the connector of the magnetron thermistor assembly from the connector of the harness. 11. Remove the two (2) screws holding the partition plate S to each magnetron (1) and/or (2). 5. Remove the magnetron thermistor assembly from magnetrons. 6. Disconnect wire leads from magnetrons (1) and/or (2). 12.Remove the two (2) partition plate S from each magnetron (1) and/ or (2). 7. Remove the two (2) screws holding the bottom cover to the bottom plate assembly. 13.Now, the magnetrons (1) and/or (2) are free. CAUTION: WHEN REPLACING MAGNETRON, BE SURE THE R.F. GASKET IS IN PLACE AND MOUNTING SCREWS ARE TIGHTENED SECURELY. 8. Remove the bottom cover from the bottom plate assembly. [5] MAGNETRON THERMISTOR ASSEMBLY REPLACEMENT 1. REMOVAL iii) And also the thermistor should be inserted center of the right and left walls of the magnetron. 1. Disconnect the power supply cord and then remove outer case and rear cover, referring to “OUTER CASE AND REAR COVER REMOVAL”. 2. Re-install the rear cover and outer case cabinet to the oven by reversing the procedures of “OUTER CASE AND REAR COVER REMOVAL”. 2. Open the oven door and block it open. NOTE: Do not forget to re-connect the wire leads to the fan motor. 3. Discharge two high voltage capacitors. Center 4. Disconnect the connector of the magnetron thermistor assembly from the capacitor of the harness. Magnetron 5. Remove the snap band of magnetron thermistor assembly from the hole of the partition cover by pulling out. 6. Remove the magnetron thermistor assembly from the two (2) magnetrons. Right wall 3rd. fin 2nd. fin 1st. fin 7. Now, the magnetron thermistor assembly is free. 2. REINSTALLATION Thermistor Left wall 1. Insert the magnetron thermistor assembly to the magnetron as shown in Figure C-1 and push it until the thermistor assembly stops. i) Tab The tabs of the magnetron thermistor assembly should be inserted between the 2nd. fin and 3rd. fin. Tab Magnetron thermistor assembly Figure C-1. Magnetron thermistor installation ii) The thermistor should be inserted between the 1st. fin and 2nd. fin. [6] HIGH VOLTAGE CAPACITOR AND HIGH VOLTAGE RECTIFIER ASSEMBLY REMOVAL 1. Disconnect the power supply cord and then remove outer case and rear cover, referring to “OUTER CASE AND REAR COVER REMOVAL”. 2. Open the oven door and block it open. 10 – 2 RCD2200M CAUTION: 1) DISCHARGE THE TWO HIGH VOLTAGE CAPACITOR BEFORE TOUCHING ANY OVEN COMPONENTS OR WIRING. 3. Discharge two high voltage capacitors. 4. Remove the two (2) screws holding the capacitor unit angle to the intake duct assembly or the exhaust duct assembly. 2) DO NOT REPLACE ONLY THE HIGH VOLTAGE RECTIFIER. IF IT IS DEFECTIVE, REPLACE THE HIGH VOLTAGE RECTIFIER ASSEMBLY. 5. Remove one (1) screw holding the capacitor band to capacitor unit angle. 6. Remove one (1) screw holding ground side terminals of high voltage rectifier assembly to the capacitor band. 3) WHEN REPLACING THE HIGH VOLTAGE RECTIFIER ASSEMBLY AND THE HIGH VOLTAGE CAPACITOR, THE GROUND SIDE TERMINAL OF THE HIGH VOLTAGE RECTIFIER MUST BE SECURED FIRMLY WITH A GROUNDING SCREW. 7. Remove the capacitor band from the high voltage capacitor. 8. Disconnect all wire leads from the high voltage capacitor. 9. Now, the capacitor (1) or (2) and the high voltage rectifier assembly are free. [7] POWER SUPPLY CORD REPLACEMENT 1. REMOVAL 4. Install the grounding wire of the power supply cord to the oven cavity with the one (1) screw. 1. Disconnect the power supply cord and then remove the outer case and the rear cover referring to “OUTER CASE AND REAR COVER REMOVAL”. 5. Connect the black wire lead of the power supply cord to the source side upper terminal of the noise filter. 6. Connect the white wire lead of the power supply cord to the source side lower terminal of the noise filter. 2. Open the oven door and block it open. 3. Discharge the two high voltage capacitors. 7. Reinstall the rear cover, the magnetron exhaust cover and the outer case cabinet and check that the oven is operating properly. 4. Remove the one (1) screw holding the grounding wire of the power supply cord to the oven cavity. Small line 5. Disconnect the wire leads of the power supply cord from the noise filter. 6. Remove the one (1) screw holding the power supply cord angle to the capacitor unit angle. 7. Remove the power supply cord angle with the power supply cord from the capacitor unit angle. Power supply cord Cord bushing 8. Nip the cord bushing with the bushing pliers and release it from the power supply cord angle. Figure C-2(a) Cord bushing position 9. Remove the cord bushing with the power supply cord from the power supply cord angle. Grounding wire of power supply cord Noise filter 10.Remove the cord bushing from the power supply cord. 11.Now, the power supply cord is free. 2. INSTALLATION Black wire lead of power supply cord 1. Install the cord bushing to the power supply cord so that the small line on the power supply cord surface comes to the end of the cord bushing as shown in the.Figure C-2. 2. Install the cord bushing (with the power supply cord) into the hole of the power supply cord angle with the bushing pliers. White wire lead of power supply cord 3. Reinstall the power supply cord angle to the capacitor unit angle with the one (1) screw. Figure C-2(b) Wiring to the noise filter [8] HOW TO RELEASE THE POSITIVE LOCK CONNECTOR. 1. Disconnect the power supply cord and then remove outer case and rear cover, referring to “OUTER CASE AND REAR COVER REMOVAL”. Terminal Positive lock connector R 1 2. Open the door and block it open. Push 3. Discharge high voltage capacitor. 4. Push the lever of positive lock® connector, pull down the connector from terminal. Lever 5. Now, the connector is free. CAUTION: THE POSITIVE LOCKR TERMINAL CAN NOT BE REMOVED BYJUST PULLING ON IT. THE LOCK LEVER MUST BE RELEASED TO REMOVE THE CONNECTOR FROM THE TERMINAL. 2 Pull down Figure C-3. How to release the positive lockR connector 10 – 3 RCD2200M [9] EXHAUST FAN REMOVAL 1. Disconnect the power supply cord and then remove the outer case and the rear cover, referring to “OUTER CASE AND REAR COVER REMOVAL”. 4. Make sure that the connector of the exhaust fan has been disconnected from the wire harness. 2. Open the oven door and block it open. 5. Remove the four (4) screws and the two (2) nuts holding the exhaust fan. 3. Discharge the two high voltage capacitors. 6. Now, the exhaust fan is free. [10] FAN MOTORS REMOVAL 5. Remove the three (3) screws holding the fan motor to the motor fixing angle and magnetron cool duct A. 1. Disconnect the power supply cord and then remove outer case and rear cover, referring to “OUTER CASE AND REAR COVER REMOVAL”. 6. Release the wire leads of the fan motor from the wire holder. 2. Open the oven door and block it open. 7. Remove the fan motor from the oven cavity. 3. Discharge two high voltage capacitors. 8. Now, the fan motor is free. 4. Disconnect the connector of the fan motor from the connector of the wire harness. [11] ANTENNA MOTORS (UPPER AND LOWER) REMOVAL 1. UPPER 7. Now, the antenna motor (upper) is free. 1. Disconnect the power supply cord and then remove outer case and rear cover, referring to “OUTER CASE AND REAR COVER REMOVAL”. 2. LOWER 2. Open the oven door and block it open. 2. Remove the two (2) screws holding the motor protect cover to the bottom plate assembly. 1. Disconnect the power supply coed. 3. Discharge two high voltage capacitors. 3. Remove the motor protect cover from the bottom plate assembly. 4. Disconnect the wire leads from the antenna motor (upper). 4. Disconnect the wire leads from the antenna motor (lower). 5. Remove the one (1) screw holding the antenna motor (upper) to the oven cavity. 5. Remove the one (1) screw holding the antenna motor (Lower) to the oven cavity. 6. Turn and lift up the antenna motor (upper). 6. Now, the antenna motor (lower) is free. [12] POWER UNIT REMOVAL 1. Disconnect the power supply cord and then remove the outer case, referring to “OUTER CASE AND REAR COVER REMOVAL”. 4. Disconnect all wire leads and connectors from the power unit. 2. Open the oven door and block it open. 5. Remove the four (4) screws holding the power unit to the PWB holder. 3. Discharge the two high voltage capacitors. 6. Now, the power unit is free. [13] RELAY UNIT REMOVAL 1. Disconnect the power supply cord and then remove the outer case, referring to “OUTER CASE AND REAR COVER REMOVAL”. 6. Remove the PWB holder with the power unit and the relay unit from the oven cavity. 2. Open the oven door and block it open. 7. Remove the six (6) screws holding the relay unit to the PWB holder. 3. Discharge the two high voltage capacitors. 8. Remove the relay unit from the PWB holder. 4. Disconnect all wire leads and connectors from the power unit and the relay unit. 9. Now, the relay unit is free. NOTE: When the relay unit is replaced, set the standard voltage referring to Special Function pages. 5. Remove the four (4) screws holding the PWB holder to the oven cavity top plate and the noise filter angle. [14] CONTROL PANEL ASSEMBLY AND CONTROL UNIT REMOVAL 1. Disconnect the power supply cord and then remove the outer case, referring to “OUTER CASE AND REAR COVER REMOVAL”. 8. Remove five (5) screws holding the control unit to the panel fixing plate. 2. Open the oven door and block it open. 9. Remove the CPU protect sheet from the control unit. 3. Discharge the two high voltage capacitors. 10.Now, the control unit is free. 4. Disconnect all connectors from the control unit. CAUTION: When installing the control unit into the control panel frame: 5. Remove the vinyl tape with a cushion attached to the oven cavity face plate and the control panel case. 1) Be careful not to damage any of the components on the control unit. 6. Remove three (3) screws holding the control panel to the oven cavity face plate. 2) When inserting key units ribbon cable through the frame, ensure it is not pinched or bent. 7. Now the control panel assembly is free. 10 – 4 RCD2200M NOTE: 1) Before attaching a new key unit, remove remaining adhesive on the panel fixing plate surfaces completely with a soft cloth soaked in alcohol. Cushion 2) When attaching the key unit to the panel fixing plate, adjust the lower edge and left edge of the key unit to the correct position of panel fixing plate. Vinyl tape (W 20mm x L 520mm) 3) Stick the key unit firmly to the panel fixing plate by rubbing with soft cloth to prevent scratching. Cavity front plate 4) When the control unit is replaced, set the standard voltage referring to Special function pages. Control panel case 5) Attach the vinyl tape and the cushion to the oven cavity face plate and the control panel case after the control panel assembly is installed. [15] DOOR SENSING SWITCH/SECONDARY INTERLOCK SWITCHES (1), (2) AND MONITOR SWITCHES (1), (2) REPLACEMENT 1. REMOVAL 2) Fasten both switches together to latch hook with one (1) screw and nut. 1. Disconnect the power supply cord and then remove the outer case, referring to “OUTER CASE AND REAR COVER REMOVAL”. NOTE: for Monitor switch and Fuse replacement 1) .Monitor switch and fuse should be replaced as an assembly. 2. Open the oven door and block it open. 3. Discharge the two high voltage capacitors. 2) When the monitor fuse is installed to the noise filter, make sure the fuse is held with the fuse clips certainly. 4. Disconnect all wire leads from the all switches. 5. Remove two (2) screws holding latch hook to oven flange. Fuse clips 6. Remove latch hook assembly from oven flange. 7. Remove the switch(es) in accordance with following procedure. DOOR SENSING SWITCH Push the two (2) tabs outward and pull switch forwards to release switch. Monitor fuse MONITOR SWITCHES OR SECONDARY INTERLOCK SWITCHES Remove one (1) screw and nut holding two switches together to latch hook. SECONDARY INTERLOCK SWITCHES 8. Now, switch(es) is now free. 1) Mount the two (2) switches side by side in the middle position of the latch hook. 2. REINSTALLATION 2) Fasten both switches together to latch hook with one (1) screw and nut. 1. Re-install the switch(es) in accordance with following procedure. DOOR SENSING SWITCH 2. Re-install latch hook assembly and fasten it to oven flange with two (2) screws. Mount the door sensing switch in the lower position of latch hook. MONITOR SWITCHES 3. Re-connect all wire leads to all switches, referring to pictorial diagram. Be careful to ensure proper connection of the wire leads. 1) Mount the two (2) switches side by side in the top position of the latch hook. 4. Make sure that the monitor switches (1), (2) and all other switches are operating properly. And check continuity of the monitor circuit. Refer to chapter “Test Procedure” and Adjustment procedure. [16] DOOR SENSING SWITCH/SECONDARY INTERLOCK SWITCHES (1), (2) AND MONITOR SWITCHES (1), (2) ADJUSTMENT 1. Adjustment procedure 5. With door closed, adjust latch hook by moving it back and forth, and up and down. In and out play of the door allowed by the upper and lower position of the latch hook should be less than 0.5mm. The vertical position of the latch hook should be adjusted so that the door sensing switch and secondary interlock switches (1), (2) are activated with the door closed. The horizontal position of the latch hook should be adjusted so that the monitor switches (1), (2) are activated with the door closed. 1. Disconnect the power supply cord and then remove the outer case, referring to “OUTER CASE AND REAR COVER REMOVAL”. 2. Open the oven door and block it open. 3. Discharge the two high voltage capacitors. If the door sensing switch, secondary interlock switches (1), (2) and monitor switches (1), (2) do not operate properly due to a misadjustment, the following adjustment should be made. 6. Secure the screws with washers firmly. 7. Check the operation of all switches. If all switches have not activated with the door closed, loosen two (2) screws and adjust the latch hook position. 4. Loosen the two (2) screws holding latch hook to the oven cavity front flange. 10 – 5 RCD2200M 2. After adjustment, check the following. 1. In and out play of door remains less than 0.5mm when in the latched position. Latch lever Switch lever A Latch hook 2. The door sensing switch and secondary interlock switches (1), (2) interrupt the circuit before the door can be opened. Monitor switch (2) 3. Monitor switches (1), (2) contacts close when door is opened. Latch head 4. Re-install outer case and check for microwave leakage around door with an approved microwave survey meter. (Refer to Microwave Measurement Procedure.) Monitor switch (1) Switch lever B Secondary interlock switch (2) Handle lever Secondary interlock switch (1) Latch head Door sensing switch Switch lever C Figure C-4. Latch Switch Adjustments [17] DOOR REPLACEMENT 1. REMOVAL 2. Adjust the door by moving it vertically so that the top of the door is parallel to the bottom of the control panel assembly. 1. Disconnect the power supply cord and then remove the outer case, referring to “OUTER CASE AND REAR COVER REMOVAL”. 3. Tighten the upper and lower oven hinge screws. 2. Open the oven door and block it open. 3.1. After adjustment, make sure of the following: 3. Discharge the two high voltage capacitors. 4. Disconnect the harness of the door assembly from the control unit. 1. Door latch heads smoothly catch the latch hook through the latch holes, and the latch head goes through the center of the latch hole. 5. Remove the two (2) screws holding each of the upper and lower hinges to the oven cavity. 2. Deviation of the door alignment from horizontal line of cavity face plate is to be less than 1.0mm. 6. Remove door assembly with upper and lower hinges by pulling it forward. 3. The door is positioned with its face depressed toward the cavity face plate. 7. Release upper and lower hinges and the hinge cover from door assembly. 4. Re-install outer case and check for microwave leakage around door with an approved microwave survey meter. (Refer to Microwave Measurement Procedure.) 8. Now, door assembly is free. NOTE: The door on a microwave oven is designed to act as an electronic seal preventing the leakage of microwave energy from oven cavity during cook cycle. NOTE: When individual parts are replaced, refer to “Door Disassembly”. This function does not require that door be air-tight, moisture (condensation)-tight or light-tight. Therefore, occasional appearance of moisture, light or sensing of gentle warm air movement around oven door is not abnormal and do not of themselves, indicate a leakage of microwave energy from oven cavity. If such were the case, your oven could not be equipped with a vent, the very purpose of which is to exhaust the vapor-laden air from the oven cavity. 2. REINSTALLATION 1. Install the hinge cover to the upper hinge. At this time, the harness of the door assembly should be passed through under the hinge cover. 2. Insert the upper and lower hinges into door hinge pins. 3. Insert the upper and lower hinges with door assembly into rectangular holes of oven cavity front plate. Screws 4. Make sure that the door is parallel with oven face lines (left and upper side line) and door latch heads pass through the latch holes correctly. Hinge cover Harness Outer case cabinet 5. Fasten upper and lower hinges firmly to oven cavity with two (2) screws on each hinge. NOTE: After any service to the door; Upper hinge 1) Make sure that door sensing switch, secondary interlock switches (1), (2) and monitor switches (1), (2) are operating properly. (Refer to chapter “Test Procedures”.). 2) An approved microwave survey meter should be used to assure compliance with proper microwave radiation emission limitation standards. Screws Lower hinge 3. DOOR ADJUSTMENT Latch heads Door adjustment is performed with the door properly installed and closed and while the oven hinges are loose. Figure C-5. Door Replacement 1. Loosen upper and lower hinges with phillips head screw driver. 10 – 6 RCD2200M [18] DOOR DISASSEMBLY 1. CHOKE COVER REMOVAL 3) Stick the key unit firmly to the key fixing plate by rubbing with soft cloth to prevent scratching. 1. Remove the door assembly from oven cavity, referring to “DOOR REMOVAL”. 4. SWITCH UNIT REMOVAL 2. Insert a putty knife (thickness of about 0.5mm) at the three (3) positions in gap between the choke cover and the door panel of the latch heads side as shown in the fig.C-6, to free engaging parts. After removing door panel; 1. Remove the five (5) screws holding the key fixing plate to the door frame. 3. Push the each four (4) positions of the upper side and lower side of chock cover by your finger as shown in the Fig.C-6, to free engaging parts. 2. Remove the key fixing plate from the door frame. 3. Remove the board cover from the key fixing plate. 4. Pull the chock cover rightward as shown in the fig.C-6, to free engaging parts. 4. Disconnect the flat ribbon cable of the key unit from the connector of the switch unit. NOTE: As the choke cover and door panel are engage at 14 places, do not force any particular part. 5. Disconnect the harness from the connector of the switch unit. 6. Remove the one (1) screw holding the switch unit to the key fixing plate. 5. Remove the choke cover carefully. (If choke cover is broken, replace with a new one.) 7. Now, the switch unit is free. NOTE: When carrying out any repair to the door, do not bend or warp the slit choke (tabs on the door panel assembly) to prevent microwave leakage. 5. FRONT DOOR GLASS REMOVAL After removing door panel; Push Push 1. Remove the one (1) screw holding the glass stopper to the door frame. Push Push Choke cover 2. Slide the front door glass leftward (latch heads side) and then slide it upward. Door handle 3. Release the upper edge of the front door glass from the tabs of the door frame. Door panel 4. Now, the front door glass is free. Latch heads 6. DOOR HANDLE, DOOR LEVER AND HANDLE COVER REMOVAL Putty knife Push Push Push Push After removing door panel; Figure C-6. Choke cover 1. Remove the latch spring from the latch angle assembly and the latch lever. 2. DOOR PANEL REMOVAL After removing choke cover; 2. Remove the one (1) screw holding the latch angle assembly to the door frame. 1. Remove the six (6) screws holding the door panel to the door frame. 3. Remove the four (4) screws holding the latch angle assembly to the door handle. 2. Release the harness from the hole of the door panel. 4. Now, the door handle is free. 3. Remove the door panel from the door frame by releasing the six (6) tabs of the door frame. 5. Remove the door lever from the latch heads. 3. KEY UNIT (IN DOOR ASSEMBLY) REMOVAL 7. Now, the door lever and the handle cover are free. After removing door panel; 7. UPPER AND LOWER LATCH HEADS REMOVAL 1. Remove the five (5) screws holding the key fixing plate to the door frame. After removing door panel; 6. Remove the door lever from the handle cover by releasing the tabs. 1. Remove the latch spring from the latch angle assembly and the latch lever. 2. Remove the key fixing plate from the door frame. 3. Remove the board cover from the key fixing plate. 2. Remove the one (1) screw holding the latch angle assembly to the door frame. 4. Disconnect the flat ribbon cable of the key unit from the connector of the switch unit. 3. Remove the four (4) screws holding the latch angle assembly to the door handle. 5. Remove the connectors installed at the edge of the key unit ribbon cable. 4. Now, the door handle is free. 6. Tear the key unit from the key fixing plate. 5. Remove the door lever from the latch heads. 7. Now, the key unit is free. 6. Remove the two (2) latch heads and the latch lever from the latch angle assembly together. NOTE: 1) Before attaching a new key unit, remove remaining adhesive on the key fixing plate surfaces completely with a soft cloth soaked in alcohol. 7. Remove the latch heads from the latch lever. 8. Now, the latch heads are free. 2) When attaching the key unit to the key fixing plate, adjust the upper edge and left edge of the key unit to the correct position of key fixing plate. 10 – 7 RCD2200M 8. DOOR CASE REMOVAL 9. NOTE FOR POSITION OF HARNESS AND PIPE After removing door panel; Before the door panel is reinstalled, make sure that the pipe should be positioned at the correct place. And the harness should pass through the holder of the door frame and the pipe, as shown in Fig.C-7. 1. Remove the five (5) screws holding the key fixing plate to the door frame. 2. Remove the key fixing plate from the door frame. 3. Remove the front door glass from the door frame, referring to “FRONT DOOR GLASS REMOVAL”. 4. Remove the door handle, the door lever with the handle cover from the door frame, referring to “DOOR HANDLE, DOOR LEVER AND HANDLE COVER REMOVAL”. Pipe 5. Remove the one (1) screw holding the latch angle assembly to the door frame. 6. Remove the latch angle assembly with the door latches from the door frame. 7. Bend up all nails of the door case. 8. Remove door case from the door frame. 9. Now, the door case is free Harness Holder Door frame Figure C-7. Inside of door 10 – 8 RCD2200M CHAPTER 11. CIRCUIT DIAGRAMS RCD2200M Service Manual [1] Figure S-1. Pictorial Diagram High voltage rectifier (1) High voltage capacitor (1) Magnetron (1) Magnetron temp.fuse (1) Gray/Gray Red Asymmetric rectifier (1) Magnetron (1) Power transformer (1) Magnetron thermistor (1) High voltage capacitor (2) High voltage capacitor (1) Power transformer (1) Magnetron thermistor (2) Black High voltage rectifier (2) Asymmetric rectifier (2) White Power transformer (2) Red (Red case) Main harness B Brown Blue (Blue case) Yellow (White case) Magnetron (2) Black (Blue case) Magnetron (2) Magnetron temp.fuse (2) Black (Blue case) Power transformer (2) Wiring of high voltage components REAR VIEW Main wire harness Red White/White White Blue/Blue Black Black Oven harness K CPU harness Green Black Brown/ White Oven lamp socket White Main wire harness Noise filter unit RIGHT SIDE VIEW LEFT SIDE VIEW 11 – 1 Blue RCD2200M Sensor harness White/Orange/Blue Connector CN-G Connector CN-Z Connector CN-H Sensor harness Connector CN-F Green/Yellow Microwave sensor Antenna sensor (1) CPU harness Key unit ribbon cable Red/Blue White/White Harness of exhaust thermistor Exhaust thermistor Brown/Red Exhaust thermistor Oven temp. fuse Main wire harness Antenna motor (1) Control unit Black Exhaust motor TOP VIEW CONTROL UNIT Current transformer CT1 Grounding position of power unit and door sensing switch Wire leads to cook relay Monitor switch (2) Voltage select relay (1) Voltage select relay (2) Monitor switch (1) Secondary interlock switch (2) Secondary interlock switch (1) GROUNDING POSITION AND CT1 Yellow (Blue case) Blue (Blue case) Brown Voltage select relay (1) Gray Main wire harness Gray Blue (Blue case) Red (Main wir harness) Main harness B Brown/White (Blue case) White/White DC harness 22 Brown Red Brown Voltage select relay (2) White White Blue (Main wir harness) Green/Green Orange White DC harness 22 Main harness B Door sensing switch LATCH SWITCHES Yellow Blue Brown Brown V.S. RELAYS 11 – 2 DC harness 22 RCD2200M 1 BRN 2 3 WHT CN1 Main wire harness NOTE: The red and blue wire leads to the cabinet side terminals of RY2 and RY3 should go through inside the core of CT1 Cook relay (1) RY2 BRN BRN RED Cook relay (2) RY3 BLU Primary interlock relay RY1 Main wire harness YLW YLW BRN BLK YLW BLK 1 GRN 2 RED DC harness 22 CN-E CT1 1 WHT 2 3 WHT CN-B DC harness 22 GRN 1 2 ORG 3 CN-C Grounding wire YLW YLW YLW YLW YLW YLW YLW YLW YLW YLW YLW YLW RED 13 12 11 10 9 8 7 6 5 4 3 2 1 1 BLK 2 3 RED 4 5 WHT CN-A CPU harness CN-D 2 RED 1 GRN CN21 DC harness 22 SWITCHING POWER SUPPLY UNIT RELAY UNIT 11 – 3 Main wire harness DC harness 22 Main wire harness 3 TH1 L1 Q1 FB1 R8 D5 R7 5 NC DRV 3 PC1B 3 4 IC1 VCC HV 6 8 D7 C6 C10 + D2 D4 D1 D3 2 VZ3 VZ2 R3 R4 R5 R6 R11 D6 2 D8 C11 R1 R2 C13 7 8 10 2 12 T1 VZ1 4 3 4,5 D21 C21 C14 R21 C22 + IC21 2 1 ZD21 R23 PC1A C23 L21 F21 C24 1 2 CN21 Output CD1 C9 + C8 R9 C5 + C1 C12 R22 1 F1 C7 7 CS 1 2 FB CN1 1 ADJ R10 GND 4 ZD1 ZD2 R24 R25 R26 11 – 4 R27 Input RCD2200M [2] Figure S-2. Switching Power Supply Unit Circuit RCD2200M [3] Figure S-3. Relay Unit Circuit 1 8 4 6 NOTE: IF NOT SPECIFIED : 1/4W J% T1 RTRNPA162DR : 1SS133 CN-D 1N4002x4 1 D-5 RY4 D-7 24V-2 D-2 ZD291 HZ12B1 510F PCJ-124D3M CN-E SW POWER UNIT GND-1 D244 OL D-12 RY4 AC1 3 O.L. AM1 AM2 V-SENS 470F R291 10K 5 AC230V/208V R292 R293 D294 C291 470uF/25V D293 T3.15A FUSE1 S10K300 CN-A D-6 D292 D291 VRS1 INT 24V 2 GND 1 F241 D-3 GND D-4 RY1 D-8 RY2 D-10 RY3 D-9 RY5,6 D-11 DOOR D-1 I-SENS D-13 Q241 KRA223M C241 DI24D1 10uF/50V RY1 D241 PRIMARY INTERLOCK RELAY 24V-1 DU24D1-1PR-CF D242 RY2 COOK RELAY (1) DU24D1-1PR-CF D243 RY3 COOK RELAY (2) RY5,6 3 2 1 D251 1N4002 24V D245 1N4002 CN-B RY5,6 CN-C DOOR SW 3 2 GND 1 DOOR SW MONITOR SW2 D295 D296 C296 10uF/50V D297 MONITOR SW1 D298 R296 33K R295 620F C295 CT1 11 – 5 ( ) : NOT INSERT PARTS : CHECK POINT F-4 F-6 F-19 F-17 RY2 RY3 H-1 H-2 H-3 1/4W 100 R161 13 14 15 16 12 8 7 Q41 18 Q43 KRC101S Q42 KRC101S Q44 6 5 R1100K14 IC101 7 3.32KD 3 + 4.7K C41 R104 1 IC101 4 KA358 8 19 10K R91 P34 P35 P36 P54 VCH 51KF 4.7K (D11) KRC101S R51 R103 2 1.8KF R101 2 R163 5 Q172 4 6 11 1/4W 10K KRC106S 3 11 11 10 (Q11) 1/4W 18K 4.7K R95 4.7K 4.7K R176 R175 Q162 KRC101S C91 R105 10K R107 10K R106 10K O 9 KIA7805AP IC11 G I AIN2 19 11 AIN3 9 11 29 P55 P52 P51 TC10 P53 4.7K R142 1 2 3 4 R31 1 2 <MICROWAVE SENSOR> SENSOR ASSEMBLY ANT401 R402 10K R157 R156 4.7K CN-N PT501 2 G-3 53 4.7K VCC TEST SCL SDA 4.7K 8 7 6 5 1 CN-G <ANT SENSOR> SENSING SW KTC3198 Q501 G-4 G-7 G-6 3 54 55 CN-K A0 A1 A2 VSS KTC3875 C121 KRA222S R33 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 Q181 KRA101S G-5 1 KRC101S 1M R99 CF1 CSTLS4M00G56-P18 KRC101S Q151 <ANT SENSOR> SENSING SW KTC3198 Q501 PT501 2 3 CN-N G-1 G-2 52 Q152 4.7K P81 P82 P83 P84 P85 P86 P87 COM3 COM2 COM1 COM0 V3 V2 V1 C1 C0 Q49 KRA102S Q46 21 11 29 BZ1 R49 1/4W 3.3K 22 Q48 IC1 50 G-8 G-9 NOT INSERT PARTS IR SENSOR G-10 51 KIA358 150KF IC181 R184 2 8 1 300KF R183 + 4 3 1K R185 10K R186 4.7K IC21 R21 PST422 A290 Q131 KRA101S R131 R132 F-26 GND-5 MAG TH1 48 F-24 TH1 (R134) (R133) MAG TH2 49 F-22 TH2 1.5KF R132 C132 C131 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 KRC101S P50 P47 P46 P45 P44 P43 P42 P41 P40 TC10 P36 P35 P34 P33 P32 DV0 Q47 NOT INSEART PART KRC101S < CONTROL UNIT > P43 P42 P41 P40 VCH (CN-X) R64-R69 1/4W 750×6 R66 Q66 R11 KRA102S Q161 KRC106S G 1/4W 10K R172 KTB1424 R171 D51 100 Q101 KRC101S R118 0 F2 R41 Q171 17 (R117) F-13 RY4 DOOR F-1 F-15 RY1 RY5, 6 F-21 I-SENS F-25 FANIN2 F-20 FAN+ F-16 FAN- F-12 FANIN1 F-18 FAN+ F-14 GND-2 F-7 GND-2 F-8 EX-IN PWM F-10 24V-2 CN-H AH SENSOR (RY5, 6) V.S. RELAY (1), (2) FAN MOTOR EXHAUST MOTOR F-11 V-SENS F-23 INT JP1 ) ( GND-1 F-9 C161 10u/50V F-3 C103 R47 24V-2 R52 C164 D52 180 C11 47u/35V D161 D162 ( ) R166 R165 ( ) C101 (R13) D91 C162 0.01u/ 50V 4.7K (C12) 15KF R108 D95 R102 (ZD11) (D103) R162 4.7K R174 4.7K R109 4.7K R164 P75 R173 (R113) C51 62KF R12 P80 C163 P74 D101 C13 AIN0 0.01u/ 50V C104 4.7KF P76 R110 P77 (R111) 0.1u/50V D102 KT5221-43 X6 23 24 R65 Q65 F1 AIN1 1K 1K F-5 D141 4.7K AIN4 1W 820 C14 C95 C105 (R141) R143 C31 0.01u/50V 4.7K 1K 1K C15 4.7K R155 C141 R154 R32 IC121 P82 1W 200 R153 R121 R123 P01 Q31 C32 C151 0.01u/ 50V 0.01u/50V R34 R151 47K 4.7K R98 10K P85 47K R122 4.7K R124 P84 2.2K C171 C106 25 26 27 R64 Q64 31 Q69 4 3 2 1 47 46 45 44 ( ) Q57 6 7 7 7 : NOT INSERT PARTS : KDS160 (CHIP) : 0.1u/50V (CHIP) : 1/10W J% (CHIP) Q56 Q66 35 Q55 Q65 36 STOP CLEAR 6 3 5 0 9 START STOP CLEAR 2 7 6 3 START 7 2 : 1SS133 (AX) CONTROL UNIT < DOOR KEY UNIT > 4 1 1 39 SET CUSTOM MEMORY HELP 2 40 29 11 G Q69-Q62 KRA102S ×8 Q58-Q52 KRC101S ×7 Q52 Q62 < KEY UNIT > 0 8 9 5 4 1 8 EXPRESS DEFROST 3 41 X2/X3 4 42 X5 Q53 Q63 38 Q54 Q64 37 R56-R63 1W 820 x8 KM5624-11-S24 R79-R83 4.7K < SW UNIT > CN-R 8 5 6 6 CN-Q 4 5 5 3 2 1 4 3 2 1 5 43 SELECT TIME SELECT POWER CN-M 34 Q67 4 3 2 1 9 8 7 6 33 LD1 CPU UNIT, SENSOR ASSEMBLY NOTE IF NOT SPECIFIED Q68 Q58 32 CN-Z < CPU UNIT > 4.7K X4 R71-R74 R74 R73 R72 R71 R75-R78 100K x4 IKID65004AFC61 C71-C74 330p/50V x4 C71 DV0 R181 R22 R69 Q69 D74 C72 24V-1 R137 300KF R68 Q68 C73 4.7K 180KF 1K C102 R115 C172 0.01u /50V 0.01u/ 50V C182 P02 1W 200 R152 C22 0.01u 4.7K C181 C16 4.7K R182 1K C21 D181 AIN5 C183 P81 R401 HSC278 330p/50V R51 D401 C401 P86 R67 Q67 D72 R75 P33 P32 AIN6 R136 P83 C152 0.01u/ 50V R501 10K 1/4W ) R501 10K 1/4W R78 P80 P77 P76 P75 P74 P73 P72 P71 P70 P67 P66 P65 P64 P63 P62 P61 P60 P57 P56 P55 P54 P53 P52 P51 4.7K P64 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 VSS 1 XIN 2 XOUT 3 TEST 4 VDD 5 P21 6 P22 7 RESE T8 P20 9 P00 10 P01 11 P02 12 AVDD 13 AVRE F14 AIN0 15 AIN1 16 AIN2 17 AIN3 18 AIN4 19 AIN5 20 AIN6 21 AIN7 22 AVSS 23 INT0 24 AIN7 4.7K R135 P62 R48 P35 P34 R79P44 D73 C74 P60 LD12 D70 CHECK LD11 D69 P65 R77 P57 D71 P73 P72 P71 P70 P67 P66 R76 P61 R80P45 P56 ON LD16 DEF LD15 NO. LD14 x2 LD13 x3 1 2 3 4 5 6 11 – 6 ( VDD TEST TXD RXD RESET VSS P63 COM1 COM2 COM3 COM4 A F B G C DP D E 12 11 10 9 8 7 6 5 4 3 2 1 R63 D68 D67 D66 D65 D64 D63 D62 D61 R62 R61 R60 R59 R58 R57 R56 R81P46 8 7 6 5 4 3 2 1 R82 P47 9 10 11 12 13 14 15 16 R83 P50 CN-F RCD2200M [4] Figure S-4. Control Unit/ Antenna sensor/ Microwave Sensor Circuit 10u/50V RCD2200M [5] Figure S-5. Printed Wiring Board CONTROL UNIT SWITCH UNIT RELAY UNIT MICROWAVE SENSOR SWITCHING POWER SUPPLY UNIT 11 – 7 ANTENNA SENSOR RCD2200M PartsGuide PARTS LIST COMMERCIAL MICROWAVE OVEN HOW TO ORDER REPLACEMENT PARTS To have your order filled promptly and correctly, please furnish the following information. 1. MODEL NUMBER 2. REF. NO. 3. PART NO. 4. DESCRIPTION MODELS R-CD1800M R-CD2200M Parts marked "*" may cause undue microwave exposure. Parts marked " " are used in voltage than 250V. CONTENTS [1] OVEN PARTS [2] DOOR AND CONTROL PANEL DOOR PROTECTION SHEET SPADPA204WRE0 ACCESSORY PAD SPADFA657WREZ PARTS INDEX TOP PAD ASSEMBLY FPADBA691WRKZ WRAP COVER SSAKHA034WRE0 INSTRUCTION BOOK TOUCH GUIDE BOTTOM PAD ASSEMBLY FPADBA692WRKZ PACKING CASE SPAKCE599WREZ [R-CD2200M] SPAKCE603WREZ [R-CD1800M] This document has been published to be used for after sales service only. The contents are subject to change without notice. RCD2200M [1] OVEN PARTS 7-15 6-13 7-21 4-63 4-12 7-21 4-34 2-3 2-2 4-64 7-15 2-2-1 7-25 x2 7-13 x2 4-63 7-21 4-11 7-21 6-15 4-48 7-21 1-18 4-48 4-60 2-8 Vinyl insulation tape: 20mm (W) x 520mm (L) Please get the vinyl insulation tape from a local vender 2-10 7-21 4-71 7-29 4-50 4-59 4-62 7-21 4-36 7-21 4-61 7-21 2-9 7-21 7-21 4-9 4-70 1-10 1-11 7-4 7-22 7-21 7-28 7-4 6-10 1-20 7-16 4-37 4-53 4-1 4-17 1-22 7-2 7-23 1-1 7-18 7-18 1-15 7-21 6-11 7-27 7-6 7-21 7-18 1-16 4-14 4-44 4-51 7-14 7-1 6-16 4-32 6-17 4-19 4-69 7-3 7-3 1-25 1-13 7-21 7-10 4-66 1-21 7-3 4-66 7-9 4-15 4-25 4-30 4-16 4-28 7-16 4-33 4-24 4-33 7-11 2-5 7-8 4-28 4-26 7-11 2-1 4-4 7-7 4-47 7-6 1-21 1-24 7-6 7-7 4-47 7-10 4-54 1-15 1-20 7-4 4-27 1-23 7-1 7-6 4-8 7-10 6-11 7-6 7-18 4-22 1-7 7-6 7-21 4-51 7-6 7-21 7-4 7-21 4-40 1-14 7-17 4-7 4-39 4-41 4-47 7-24 7-5 4-51 7-16 7-7 1-13 4-35 7-27 4-13 1-14 1-4 1-8 1-6 7-2 4-57 1-17 7-7 4-56 1-9 4-37 4-20 7-6 7-28 4-55 1-19 4-47 4-46 4-65 7-6 4-42 7-12 4-38 7-18 6-10 4-21 7-18 4-67 4-65 7-18 4-45 6-10 4-58 7-10 7-6 4-52 4-55 1-19 4-43 7-23 7-7 6-14 7-10 1-3 7-4 4-67 4-67 4-9 1-10 1-11 1-23 7-15 7-21 4-49 7-21 7-7 1-2 4-6 4-5 4-50 7-1 7-6 7-21 1-5 4-68 7-21 4-36 4-2 4-3 7-21 4-10 7-26 x2 7-21 2-1-1 2-1-2 1-12 4-31 7-8 2-4 7-20 1-12 7-21 7-21 4-18 4-23 2-7 4-18-2 4-40 4-18-1 4-18-3 2-6 2 7-19 2-6 2-7 RCD2200M NO. PARTS CODE PRICE NEW PART RANK MARK RANK DESCRIPTION [1] OVEN PARTS ! ! ! ! * ! * * ELECTRIC PARTS 1-1 FDTCTA239WRKZ 1-2 FMOT-A031WRKZ 1-3 QFS-TA015WRE0 1-4 DH-HZA017WRKZ 1-5 FACCDA120WREZ 1-5 FACCDA121WREZ 1-6 FPWBFA383WRKZ 1-7 RRLY-A046WRKZ 1-8 QFS-BA011WRE0 1-9 QFSHDA009WRE0 1-10 RC-QZA336WRZZ 1-10 RC-QZA347WRZZ 1-11 FH-DZA145WRZZ 1-12 QSW-MA085WRE0 1-13 FFS-BA033WRKZ AV BP AG AY BG BG AN AW AE AG AS AS AP AF -- Sensor assembly (Exhaust thermistor) Exhaust motor assembly Temperature fuse 120C (Oven) Magnetron thermistor assembly Power supply cord [RCD2200M] Power supply cord [RCD1800M] Noise filter Relay UL fuse 12A Fuse holder High voltage capacitor [RCD2200M] High voltage capacitor [RCD1800M] High voltag rectifier assembly Secondary interlock/Door sensing switches Monitor switch (V-5220Q) and fuse (20A) assembly RV-MZA357WRZZ BG Magnetron 1-15 QFS-TA014WRE0 1-16 QSOCLA026WRZZ 1-17 RLMPTA105WRZZ 1-18 RMOT-A016WRZZ 1-19 RMOT-A026WRZZ 1-20 RMOTDA238WRZZ 1-21 RTRN-A750WRZZ 1-22 DPWB-A570DRKZ 1-23 DPWB-A571DRKZ 1-24 DPWB-A565DRKZ 1-25 DPWB-A568DRKZ CABINET PARTS 2-1 DDAI-A214WRKZ 2-1-1 XNES740-32000 2-1-2 LX-BZA179WREZ 2-2 FFTASA076WRYZ 2-2-1 PCUSUA651WRPZ 2-3 GCABUB125WRPZ 2-4 GCOVHA526WRPZ 2-5 LANGKB285WRPZ 2-6 PSHEGA011WREZ 2-7 PSHEPB279WREZ 2-8 TMAPCA782WRRZ 2-9 PFPF-A299WREZ 2-10 PCUSGA756WRPZ OVEN PARTS 4-1 FCAS-A026WRYZ 4-2 DDUC-A071WRKZ 4-3 PCUSGA721WRPZ 4-4 LHLD-A314WRFZ 4-5 LANGQA694WRWZ 4-6 LBSHC0006YBE0 4-7 LANGQA699WRPZ 4-8 LANGQA707WRPZ 4-9 LBNDKA163WRPZ 4-10 GCOVAA399WRWZ 4-11 GCOVAA398WRTZ 4-12 PGIDHA069WRPZ 4-13 JKNBKA801WRFZ 4-14 PCOVPA479WRFZ 4-15 GCOVPA023WRPZ 4-16 PCOVPA515WRFZ 4-17 DDUC-A072WRKZ 4-18 FFIL-A014WRKZ 4-18-1 LX-BZA178WREZ 4-18-2 PFIL-A040WRYZ 4-18-3 XREUW40-06000 4-19 FGLSPA069WRFZ 4-20 FHNG-A370WRYZ 4-21 ************* 4-22 FPLT-A025WRYZ 4-23 FPLT-A026WRYZ 4-24 MLEVCA001WRFZ 4-25 MLEVPA279WRFZ 4-26 MLEVPA280WRFZ 4-27 MSPRCA165WREZ 4-28 MSPRCA166WREZ 4-30 PHOK-A164WRFZ 4-31 GCOVHA527WRPZ 4-32 GCOVPA020WRPZ 4-33 JKNBKA800WRFZ 4-34 LANGKB292WRPZ 4-35 LANGQA671WRPZ 4-36 LANGQA696WRPZ 4-37 LANGQA702WRPZ 4-38 LSUB-A137WRPZ AG AF AU AP BE AS BU BA BA BF BH Temperature fuse 150C (Magnetron) Oven lamp socket Oven lamp Fan motor (DC) (Exhaust fan) Fan motor Stirrer motor (Antenna motor) Power transformer Microwave sensor unit Antenna sensor unit Power unit (Switching power supply unit) Relay unit BM AC AL AM AD BN AH AG AM AH AF AL AD Bottom plate assembly Nut; 4mm x 3.2mm Special screw Oven lamp access cover Cushion Outer case cabinet Motor protect cover Cavity fixing plate Rubber sheet L Rubber sheet S Schematic diagram Damper sheet Cabinet cushion AR AV AG AN AM AD AK AF AK AS AW AF AS BB BF AY AV BA AM AW AA BT AT ** AZ BA AG AG AG AC AC AM AG AV AM AM AM AF AM AE Fan case assembly Exhaust duct assembly Cushion PWB holder AC cord angle Cord bushing Noise filter angle Relay fixing angle HV capacitor band MG exhaust cover Rear cover Exhaust cover Splash cover knob Splash cover Cover Frame Intake duct assembly air fillter unit Filter stopper R Air fillter Ring Oven tray assembly Upper hinge assy Oven cavity assembly (Not a replaceable part) Upper antenna assembly Lower antenna assembly Switch lever C Switch lever A Switch lever B Latch spring A Latch spring B Latch hook Bottom cover Antenna cover Antenna cover knob Support angle Lamp holder angle Capacitor unit angle Motor fixing angle Face support angle 1-14 3 RCD2200M NO. PARTS CODE PRICE NEW PART RANK MARK RANK DESCRIPTION [1] OVEN PARTS 4-39 MHNG-A592WRPZ 4-40 NSFTPA045WRFZ 4-41 PCLIC0018WRE0 4-42 PCOVPA480WRFZ 4-43 PCOVPA496WRFZ 4-44 PFILWA064WRPZ 4-45 PGLSPA720WREZ 4-46 PCUSGA761WRPZ 4-47 PSKR-A462WRPZ 4-48 GLEGPA033WRE0 4-49 GCOVPA022WRPZ 4-50 PCUSGA745WRPZ 4-51 PCUSGA750WRPZ 4-52 PCUSGA751WRPZ 4-53 PCUSGA752WRPZ 4-54 PCUSGA755WRPZ 4-55 PSKR-A464WRPZ 4-56 PDUC-B056WRFZ 4-57 PCUSGA757WRPZ 4-58 PDUC-B046WRPZ 4-59 PCUSGA742WRPZ 4-60 PCUSGA743WRPZ 4-61 PCUSGA744WRPZ 4-62 PCUSGA746WRPZ 4-63 PCUSGA747WRPZ 4-64 PCUSGA748WRPZ 4-65 PCUSGA758WRPZ 4-66 PCUSGA765WRPZ 4-67 PCUSGA766WRPZ 4-68 PCUSGA767WRPZ 4-69 PSHEPB323WREZ 4-70 PCOVPA523WRFZ 4-71 PCOVPA522WRFZ MISCELLANEOUS 6-10 LBNDKA166WREZ 6-11 LHLDWA063WREZ 6-13 TCAUAA303WRRZ 6-14 TCAUAA312WRRZ 6-15 TCAUAA313WRRZ 6-16 TCAUAA314WRRZ 6-17 TCAUAA315WRRZ SCREWS, NUTS AND WASHE 7-1 LX-NZ0061WRE0 7-2 XHPS740P08000 7-3 XEPS730P08XS0 7-4 XHPS740P08K00 7-5 XBTUW40P12000 7-6 XOTS740P08000 7-7 XHTS740P08000 7-8 XBPS730P28KS0 7-9 XNES730-24000 7-10 LX-BZA164WREZ 7-11 LX-BZA181WREZ 7-12 XETS740P08000 7-13 XHPS730P06000 7-14 LX-CZ0052WRE0 7-15 XNGUW40-24000 7-16 LX-BZA132WREZ 7-17 LX-BZA138WREZ 7-18 XETS740P10000 7-19 LX-CZA085WREZ 7-20 XHTWW40P08000 7-21 XOTWW40P08000 7-22 XFPWW30P06000 7-23 XCBWW30P08000 7-24 XCPS740P08000 7-25 XBPS740P35000 7-26 XNES740-32000 7-27 LX-BZA169WREZ 7-28 XOTWW40P10000 7-29 XCHWW40P08000 AP AN AB AG AK AF AH AE AF AA AG AD AC AC AD AF AK AN AF AK AF AF AF AG AD AF AN AC AC AC AF Lower hinge Antenna shaft Clip l Hinge cover Sensor cover Lamp filter Lamp glass Cushion Partition angle S Leg Partition cover Cushion B Lamp cushion Cav top cushion Cav face cushion Relay cushion Partition angle L Mag cool duct A Filter cushion Mag cool duct B Rear cushion A Rear cushion B Rear cushion C Rear cushion D Rear cushion E Rear cushion F Cav back sheet Cushion Cushion Cushion Insertion barrer Edge cap R Edge cap L AD AF AG AF AG AF AG Wire holder Wire holder caution label monitor caution hwc caution caution label user caution label AA AB AB AB AB AA AC AB AE AC AH AA AB AA AE AB AB AA AB AC AB AD AB AB AD AC AC AA AB Nut : 4mm x 3.2mm Screw : 4mm x 8mm Screw : 3mm x 8mm Screw : 4mm x 8mm Screw : 4mm x 12mm Screw : 4mm x 8mm Screw : 4mm x 8mm Screw : 3mm x 28mm nut : 3mm x 2.4mm HEX cup-screw Special screw Screw : 4mm x 8mm Screw : 3mm x 6mm Special screw Nut : 4mm x 2.4mm Special screw Special screw Screw : 4mm x 10mm Special screw Screw : 4mm x 8mm Screw: 4mm x 8mm Screw : 3mm x 6mm Screw : 3mm x 8mm Screw : 4mm x 8mm Screw : 4mm x 35mm Nut; 4mm x 3.2mm Special screw Screw : 4mm x 10mm Screw : 4mm x 8mm 4 RCD2200M [2] DOOR AND CONTROL PANEL PARTS 3-5 3-2 3-4 3-5 3-3-6 3-3-8 3-3-3 3-3-4 3-1 3-3-2 3-4 3-3-1 3-3-7 5-8 3-3-8 3-3-5 5-34 5-20 5-17 5-28 5-18 5-6 5-3 5-2 5-3-2 5-34 5-3-1 5-18 5-17 5-19 5-5 5-21 5-33 5-7 5-14 5-30 5-25 5-26 5-31 5-29 5-11 5-9 5-27 5-7 5-32 5-24 5-10 5-13 5-16 5-7 5-12 5-15 5-16 5-11 6-2 5-32 5-35 6-1 6-9 5-1 6-8 6-3 6-12 6-4 6-7 6-5 6-6 5 RCD2200M NO. PARTS CODE PRICE NEW PART RANK MARK RANK DESCRIPTION [2] DOOR AND CONTROL PANEL PARTS * * * * * * CONTROL PANEL PARTS 3-1 PSHEPB332WREZ 3-2 DPWB-A567DRKZ 3-2 DPWB-A574DRKZ 3-3-1 FUNTKB179WREZ 3-3-2 GCOVAA389WRPZ 3-3-3 GMADIA189WRFZ 3-3-4 GWAKPB142WRFZ 3-3-5 HDECQA372WRMZ 3-3-6 HDECQA373WRMZ 3-3-7 LANGQA676WRWZ 3-3-8 PCUSGA753WRPZ 3-4 PCUSGA754WRPZ 3-5 XCPS730P08XS0 DOOR PARTS 5-1 FANGKA225WRYZ 5-2 FDORFA436WRYZ 5-3 FCOV-A018WRKZ 5-3-1 GCOVAA392WRYZ 5-3-2 GWAK-A012WRFZ 5-5 LSTPPA261WRFZ 5-6 PGLSPA727WREZ 5-7 XEPS740P08000 5-8 GCOVHA525WRFZ 5-9 JHNDMA058WRMZ 5-10 JHNDMA062WRPZ 5-11 LSTPPA260WRFZ 5-12 MLEVFA091WRWZ 5-13 MSPRTA190WRE0 5-14 PCOVPA476WRFZ 5-15 PCOVPA477WRFZ 5-16 PCUSGA720WRPZ 5-17 PCUSGA736WRPZ 5-18 PCUSGA737WRPZ 5-19 PCUSGA738WRPZ 5-20 PPIPPA017WRFZ 5-21 PSHEPB325WREZ 5-24 HBDGCA127WRRZ 5-24 HBDGCA128WRRZ 5-25 MSPRCA174WREZ 5-26 DPWB-A569DRKZ 5-27 FUNTKB180WREZ 5-28 FW-VZC153WREZ 5-29 LANGTA440WRPZ 5-30 LRTNPA001DRZZ 5-31 LRTNPA002DRZZ 5-32 XBPS740P25K00 5-33 XCPS730P08XS0 5-34 XEPS740P10000 5-35 LX-RZ180AKRE0 MISCELLANEOUS 6-1 TCADRA030WRRZ 6-2 TINSEB153WRRZ 6-3 LHLDWA013WRE0 6-4 FW-VZC159WREZ 6-5 FW-VZC160WREZ 6-6 FW-VZC154WREZ 6-7 FW-VZC155WREZ 6-8 FW-VZC156WREZ 6-9 FW-VZC157WREZ 6-12 LHLDWA011WRE0 AN BQ BQ AU AR AL AK AL AL AP AF AC AC CPU protect sheet Control unit [RCD2200M] Control unit [RCD1800M] Key unit C/P case Display window Panel grille Panel cap R Panel cap L Panel fixing plate CP cushion A CP cushion B Screw : 3mm x 8mm AN BB BE BA AX AG AS AB AS BD AK AG AG AD AG AM AG AE AF AC AF AK AF AF AF BA AS AS AN AF AF AC AC AA AA Latch angle assembly Door panel sub assembly Door case assembly Door case Door frame Glass stopper Front door glass Screw : 4mm x 8mm Choke cover Door handle Hhandle lever Latch head Latch lever Latch spring Board cover Handle cover Latch ag cushion Door cushion L Door cushion S Harness cushion Pipe Key protect cover Door badge [RCD2200M] Door badge [RCD1800M] Earth spring Switch unit Key unit Harnes (Door key harness) Key fixing plate connector connector Screw : 4mm x 25mm Screw : 3mm x 8mm Screw : 4mm x 10mm Special ring AF AP AC BF AZ AX AG AG AR AB Touch guide Instruction book Purce lock Main wire harness Harnes (CPU harnes) Harnes (Main wire harness B) Harnes (Oven harness) Harnes (DC harness 22) Harness (Sensor harness) Purce lock M 6 RCD2200M INDEX PARTS CODE [ D ] DDAI-A214WRKZ DDUC-A071WRKZ DDUC-A072WRKZ DH-HZA017WRKZ DPWB-A565DRKZ DPWB-A567DRKZ DPWB-A568DRKZ DPWB-A569DRKZ DPWB-A570DRKZ DPWB-A571DRKZ DPWB-A574DRKZ [ F ] FACCDA120WREZ FACCDA121WREZ FANGKA225WRYZ FCAS-A026WRYZ FCOV-A018WRKZ FDORFA436WRYZ FDTCTA239WRKZ FFIL-A014WRKZ FFS-BA033WRKZ FFTASA076WRYZ FGLSPA069WRFZ FH-DZA145WRZZ FHNG-A370WRYZ FMOT-A031WRKZ FPLT-A025WRYZ FPLT-A026WRYZ FPWBFA383WRKZ FUNTKB179WREZ FUNTKB180WREZ FW-VZC153WREZ FW-VZC154WREZ FW-VZC155WREZ FW-VZC156WREZ FW-VZC157WREZ FW-VZC159WREZ FW-VZC160WREZ [ G ] GCABUB125WRPZ GCOVAA389WRPZ GCOVAA392WRYZ GCOVAA398WRTZ GCOVAA399WRWZ GCOVHA525WRFZ GCOVHA526WRPZ GCOVHA527WRPZ GCOVPA020WRPZ GCOVPA022WRPZ GCOVPA023WRPZ GLEGPA033WRE0 GMADIA189WRFZ GWAK-A012WRFZ GWAKPB142WRFZ [ H ] HBDGCA127WRRZ HBDGCA128WRRZ HDECQA372WRMZ HDECQA373WRMZ [ J ] JHNDMA058WRMZ JHNDMA062WRPZ JKNBKA800WRFZ JKNBKA801WRFZ [ L ] LANGKB285WRPZ LANGKB292WRPZ LANGQA671WRPZ LANGQA676WRWZ LANGQA694WRWZ LANGQA696WRPZ LANGQA699WRPZ LANGQA702WRPZ LANGQA707WRPZ LANGTA440WRPZ LBNDKA163WRPZ LBNDKA166WREZ LBSHC0006YBE0 No. PRICE NEW PART RANK MARK RANK 1-2-1 1-4-2 1-4-17 1-1-4 1-1-24 2-3-2 1-1-25 2-5-26 1-1-22 1-1-23 2-3-2 BM AV AV AY BF BQ BH BA BA BA BQ 1-1-5 1-1-5 2-5-1 1-4-1 2-5-3 2-5-2 1-1-1 1-4-18 1-1-13 1-2-2 1-4-19 1-1-11 1-4-20 1-1-2 1-4-22 1-4-23 1-1-6 2-3-3-1 2-5-27 2-5-28 2-6-6 2-6-7 2-6-8 2-6-9 2-6-4 2-6-5 BG BG AN AR BE BB AV BA -AM BT AP AT BP AZ BA AN AU AS AS AX AG AG AR BF AZ 1-2-3 2-3-3-2 2-5-3-1 1-4-11 1-4-10 2-5-8 1-2-4 1-4-31 1-4-32 1-4-49 1-4-15 1-4-48 2-3-3-3 2-5-3-2 2-3-3-4 BN AR BA AW AS AS AH AG AV AG BF AA AL AX AK 2-5-24 2-5-24 2-3-3-5 2-3-3-6 AF AF AL AL 2-5-9 2-5-10 1-4-33 1-4-13 BD AK AM AS 1-2-5 1-4-34 1-4-35 2-3-3-7 1-4-5 1-4-36 1-4-7 1-4-37 1-4-8 2-5-29 1-4-9 1-6-10 1-4-6 AG AM AM AP AM AF AK AM AF AN AK AD AD PARTS CODE LHLD-A314WRFZ LHLDWA011WRE0 LHLDWA013WRE0 LHLDWA063WREZ LRTNPA001DRZZ LRTNPA002DRZZ LSTPPA260WRFZ LSTPPA261WRFZ LSUB-A137WRPZ LX-BZA132WREZ LX-BZA138WREZ LX-BZA164WREZ LX-BZA169WREZ LX-BZA178WREZ LX-BZA179WREZ LX-BZA181WREZ LX-CZ0052WRE0 LX-CZA085WREZ LX-NZ0061WRE0 LX-RZ180AKRE0 [ M ] MHNG-A592WRPZ MLEVCA001WRFZ MLEVFA091WRWZ MLEVPA279WRFZ MLEVPA280WRFZ MSPRCA165WREZ MSPRCA166WREZ MSPRCA174WREZ MSPRTA190WRE0 [ N ] NSFTPA045WRFZ [ P ] PCLIC0018WRE0 PCOVPA476WRFZ PCOVPA477WRFZ PCOVPA479WRFZ PCOVPA480WRFZ PCOVPA496WRFZ PCOVPA515WRFZ PCOVPA522WRFZ PCOVPA523WRFZ PCUSGA720WRPZ PCUSGA721WRPZ PCUSGA736WRPZ PCUSGA737WRPZ PCUSGA738WRPZ PCUSGA742WRPZ PCUSGA743WRPZ PCUSGA744WRPZ PCUSGA745WRPZ PCUSGA746WRPZ PCUSGA747WRPZ PCUSGA748WRPZ PCUSGA750WRPZ PCUSGA751WRPZ PCUSGA752WRPZ PCUSGA753WRPZ PCUSGA754WRPZ PCUSGA755WRPZ PCUSGA756WRPZ PCUSGA757WRPZ PCUSGA758WRPZ PCUSGA761WRPZ PCUSGA765WRPZ PCUSGA766WRPZ PCUSGA767WRPZ PCUSUA651WRPZ PDUC-B046WRPZ PDUC-B056WRFZ PFIL-A040WRYZ PFILWA064WRPZ PFPF-A299WREZ PGIDHA069WRPZ PGLSPA720WREZ PGLSPA727WREZ PHOK-A164WRFZ PPIPPA017WRFZ PSHEGA011WREZ 7 No. PRICE NEW PART RANK MARK RANK 1-4-4 2-6-12 2-6-3 1-6-11 2-5-30 2-5-31 2-5-11 2-5-5 1-4-38 1-7-16 1-7-17 1-7-10 1-7-27 1-4-18-1 1-2-1-2 1-7-11 1-7-14 1-7-19 1-7-1 2-5-35 AN AB AC AF AF AF AG AG AE AB AB AC AC AM AL AH AA AB AA AA 1-4-39 1-4-24 2-5-12 1-4-25 1-4-26 1-4-27 1-4-28 2-5-25 2-5-13 AP AG AG AG AG AC AC AF AD 1-4-40 AN 1-4-41 2-5-14 2-5-15 1-4-14 1-4-42 1-4-43 1-4-16 1-4-71 1-4-70 2-5-16 1-4-3 2-5-17 2-5-18 2-5-19 1-4-59 1-4-60 1-4-61 1-4-50 1-4-62 1-4-63 1-4-64 1-4-51 1-4-52 1-4-53 2-3-3-8 2-3-4 1-4-54 1-2-10 1-4-57 1-4-65 1-4-46 1-4-66 1-4-67 1-4-68 1-2-2-1 1-4-58 1-4-56 1-4-18-2 1-4-44 1-2-9 1-4-12 1-4-45 2-5-6 1-4-30 2-5-20 1-2-6 AB AG AM BB AG AK AY AG AG AE AF AC AF AF AF AD AG AD AF AC AC AD AF AC AF AD AF AN AE AC AC AC AD AK AN AW AF AL AF AH AS AM AF AM RCD2200M PARTS CODE PSHEPB279WREZ PSHEPB323WREZ PSHEPB325WREZ PSHEPB332WREZ PSKR-A462WRPZ PSKR-A464WRPZ [ Q ] QFS-BA011WRE0 QFSHDA009WRE0 QFS-TA014WRE0 QFS-TA015WRE0 QSOCLA026WRZZ QSW-MA085WRE0 [ R ] RC-QZA336WRZZ RC-QZA347WRZZ RLMPTA105WRZZ RMOT-A016WRZZ RMOT-A026WRZZ RMOTDA238WRZZ RRLY-A046WRKZ RTRN-A750WRZZ RV-MZA357WRZZ [ T ] TCADRA030WRRZ TCAUAA303WRRZ TCAUAA312WRRZ TCAUAA313WRRZ TCAUAA314WRRZ TCAUAA315WRRZ TINSEB153WRRZ TMAPCA782WRRZ [ X ] XBPS730P28KS0 XBPS740P25K00 XBPS740P35000 XBTUW40P12000 XCBWW30P08000 XCHWW40P08000 XCPS730P08XS0 " XCPS740P08000 XEPS730P08XS0 XEPS740P08000 XEPS740P10000 XETS740P08000 XETS740P10000 XFPWW30P06000 XHPS730P06000 XHPS740P08000 XHPS740P08K00 XHTS740P08000 XHTWW40P08000 XNES730-24000 XNES740-32000 " XNGUW40-24000 XOTS740P08000 XOTWW40P08000 XOTWW40P10000 XREUW40-06000 No. PRICE NEW PART RANK MARK RANK 1-2-7 1-4-69 2-5-21 2-3-1 1-4-47 1-4-55 AH AF AK AN AF AK 1-1-8 1-1-9 1-1-15 1-1-3 1-1-16 1-1-12 AE AG AG AG AF AF 1-1-10 1-1-10 1-1-17 1-1-18 1-1-19 1-1-20 1-1-7 1-1-21 1-1-14 AS AS AU AP BE AS AW BU BG 2-6-1 1-6-13 1-6-14 1-6-15 1-6-16 1-6-17 2-6-2 1-2-8 AF AG AF AG AF AG AP AF 1-7-8 2-5-32 1-7-25 1-7-5 1-7-23 1-7-29 2-3-5 2-5-33 1-7-24 1-7-3 2-5-7 2-5-34 1-7-12 1-7-18 1-7-22 1-7-13 1-7-2 1-7-4 1-7-7 1-7-20 1-7-9 1-7-26 1-2-1-1 1-7-15 1-7-6 1-7-21 1-7-28 1-4-18-3 AB AC AD AB AB AB AC AC AB AB AB AA AA AA AD AB AB AB AC AC AE AC AC AE AA AB AA AA 8 EndPage COPYRIGHT © 2008 BY SHARP CORPORATION ALL RIGHTS RESERVED. No part of this publication may be reproduced, stored in retrieval systems, or transmitted in anyform or by any means, electronic, mechanical, photocopying, recording, or other wise, without prior written permission of the publisher.
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