Sharp R-405KS-T Service Manual

R405KST

SERVICE MANUAL

MICROWAVE OVEN

NIGHT LIGHT POPCORN

1

4

7

2

5

8

0

STOP

CLEAR

START

COOK

DEFROST

REHEAT

SOFTEN

MELT WARM

3

6

9

MODEL R-405KS-T

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..)

PRECAUTIONS TO BE OBSERVED BEFORE AND

DURING SERVICING TO AVOID POSSIBLE EXPO-

SURE TO EXCESSIVE MICROWAVE ENERGY

CHAPTER 1. WARNING TO SERVICE PERSONNEL

CHAPTER 2. MICROWAVE MEASUREMENT PRO-

CEDURE

CHAPTER 3. FOREWORD AND WARNING

CHAPTER 4. PRODUCT DESCRIPTION

CHAPTER 5. GENERAL INFORMATION

CHAPTER 6. OPERATION

CHAPTER 7. TROUBLESHOOTING GUIDE

CONTENTS

CHAPTER 8. TEST PROCEDURES

CHAPTER 9. TOUCH CONTROL PANEL ASSEMBLY

CHAPTER 10. PRECAUTIONS FOR USING LEAD-

FREE SOLDER

CHAPTER 11. COMPONENT REPLACEMENT AND

ADJUSTMENT PROCEDURE

CHAPTER 12. CIRCUIT DIAGRAMS

Parts List

SHARP CORPORATION

This document has been published to be used for after sales service only.

The contents are subject to change without notice.


DURING SERVICING TO AVOID POSSIBLE EXPO-

SURE TO EXCESSIVE MICROWAVE ENERGY


[2] When the testing is completed, ..................1-1

CHAPTER 2. MICROWAVE MEASUREMENT PRO-

CEDURE

[1] Requirements: ............................................2-1

CONTENTS

[10] Procedure I: NOISE FILTER TEST............. 8-4

[11] Procedure J: TOUCH CONTROL PANEL

ASSEMBLY TEST....................................... 8-4

[12] Procedure K: KEY UNIT TEST ................... 8-5

[13] Procedure L: RELAY TEST......................... 8-5

[14] Procedure M: DEFROST TEST.................. 8-6

[15] Procedure N: FOIL PATTERN ON THE

PRINTED WIRING BOARD TEST.............. 8-6

CHAPTER 9. TOUCH CONTROL PANEL ASSEM-

BLY


[1] FOREWORD ..............................................3-1

[2] WARNING ..................................................3-1

[3] DANGER ....................................................3-1


[1] SPECIFICATIONS ......................................4-1



[1] DESCRIPTION OF OPERATING SE-

QUENCE ...................................................6-1

[3] DESCRIPTION AND FUNCTION OF

COMPONENTS..........................................6-3



[1] Procedure A: MAGNETRON ASSEMBLY

TEST ..........................................................8-1

TEST ..........................................................8-1

[3] Procedure C: HIGH VOLTAGE RECTIFI-

ER TEST ....................................................8-1

[4] Procedure D: HIGH VOLTAGE CAPACI-

TOR TEST ..................................................8-2

[5] Procedure E: TEMPERATURE FUSE OR

THERMAL CUT-OUT TEST .......................8-2

[6] Procedure F: PRIMARY INTERLOCK

SWITCH TEST ...........................................8-2

[7] Procedure F: SECONDARY INTERLOCK

SYSTEM TEST...........................................8-3

[8] Procedure G: MONITOR SWITCH TEST.....8-3

[9] Procedure H: BLOWN MONITOR FUSE

TEST ..........................................................8-4

[3] SERVICING FOR TOUCH CONTROL

PANEL ........................................................ 9-4

CHAPTER 10. PRECAUTIONS FOR USING LEAD-

FREE SOLDER

[2] Using lead-free wire solder ....................... 10-1

[3] Soldering................................................... 10-1

CHAPTER 11. COMPONENT REPLACEMENT AND

ADJUSTMENT PROCEDURE

[1] WARNINGS ...............................................11-1

[2] OUTER CASE REMOVAL .........................11-2

[4] HIGH VOLTAGE RECTIFIER AND HIGH

VOLTAGE CAPACITOR REMOVAL ..........11-2

[6] OVEN LAMP REMOVAL............................11-3

[7] POSITIVE LOCK CONNECTOR (NO-

CASE TYPE) REMOVAL ...........................11-3

[8] CONTROL PANEL ASSEMBLY REMOV-

AL ..............................................................11-3

[9] GRAPHIC SHEET AND MEMBRANE

SWITCH REPLACEMENT.........................11-3

[10] TURNTABLE MOTOR REMOVAL .............11-4

[11] COOLING FAN MOTOR REMOVAL..........11-4

[12] DOOR SENSING SWITCH/PRIMARY IN-

TERLOCK SWITCH AND MONITOR

SWITCH REMOVAL ..................................11-5

[13] DOOR SENSING SWITCH/PRIMARY IN-

TERLOCK SWITCH AND MONITOR

SWITCH ADJUSTMENT ...........................11-5

[14] DOOR REPLACEMENT ............................11-5


[2] Control Panel Circuit (Figure S-2)............. 12-2

[3] Printed Wiring Board (Figure S-3) ............ 12-3

Parts List

R405KST

POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY


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

(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 until the oven has been brought into compliance.

i

R405KST


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.

[1] Before Servicing

1. Disconnect the power supply cord case.

2. Open the door and block it open.

3. Discharge high voltage capacitor.

, and then remove outer

WARNING: RISK OF ELECTRIC SHOCK. DISCHARGE THE HIGH-

VOLTAGE CAPACITOR BEFORE SERVICING.

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.

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,

1) Disconnect the power supply cord, and then remove outer case.

2) Open the door and block it open.

3) Discharge high voltage capacitor.

4) 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.

6) After that procedure, reconnect the power supply cord.

Don't Touch !

Danger High Voltage

[2] When the testing is completed,

1. Disconnect the power supply cord, and then remove outer case.



4. Reconnect the leads to the primary of the power transformer.

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.

[3] After repairing

1. Reconnect all leads removed from components during testing.




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.

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.

1 – 1

R405KST

CHAPTER 2. MICROWAVE MEASUREMENT PROCEDURE

[1] Requirements:

1. Microwave leakage limit (Power density limit): The power density of microwave radiation emitted by a microwave oven should not exceed 1mW/ cm 2 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/cm 2 at any point 5cm or more from the external surface of the oven.

2. Safety interlock switches:

Primary interlock switch shall prevent microwave radiation emission in excess of the requirement as above mentioned. Secondary interlock relay and door sensing switch shall prevent microwave radiation emission in excess of 5 mW/cm 2 at any point 5cm or more from the external surface of the oven.

[2] 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.

[3] 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/cm 2 , and that the secondary interlock relay and the primary interlock switch do turn the oven OFF before any door movement.

NOTE: After servicing, record data on service invoice and microwave leakage report.

2 – 1

R405KST


[1] FOREWORD

This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service Information for the SHARP

MICROWAVE OVEN, R-405KS-T.

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.

[2] 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 no other visible damage with the oven.

Servicing and repair work must be carried out only by trained service personnel.

[3] 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


Service Manual

[1] SPECIFICATIONS

ITEM

Power Requirements

Power Consumption

Power Output

Outside Dimensions

Cooking Cavity Dimensions

(1.4 Cubic feet)

Control Complement

Oven Cavity Light

Safety Standard

DESCRIPTION

120 Volts

60 Hertz

Single phase, 3 wire grounded

1600W / Approx. 13.5 Amperes

1100 W nominal of RF microwave energy (IEC Test procedure)

Operating frequency 2450 MHz

Width 21-5/8"

Height 12-3/8"

Depth 17-5/8"

Width 15-3/8" NOTE: Internal capacity is calculated by measuring

Height 9-3/8" maximum width, depth and height.

Depth 16-3/4" Actual capacity for holding food is less.

Touch Control System

Clock (1:00 - 12:59)

Timer (0 - 99 minutes 99 seconds)

Microwave Power for Variable Cooking

Repetition Rate;

P-HI -------------------- Full power throughout the cooking time

P-90 -------------------- approx. 90% of FULL Power









P-0 ---------------------- No power throughout the cooking time

POPCORN pad

NIGHT LIGHT pad

MINUTE PLUS pad

Cook pad

Defrost pad

Reheat pad

Number selection pads

Power Level pad

Timer/Clock pad

Stop/Clear pad

START pad

Melt, Soften, Warm pads

Yes

UL listed FCC Authorized

DHHS Rules, CFR, Title 21, Chapter 1, Subchapter J

R405KST

4 – 1

R405KST


Service Manual

[1] GROUNDING INSTRUCTIONS

This oven is equipped with a three prong grounding plug. It must be plugged into a wall receptacle that is properly installed and grounded in accordance with the National Electrical Code and local codes and ordinances.

In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current.

WARNING: Improper use of the grounding plug can result in a risk of electric shock.

Electrical Requirements

The electrical requirements are a 120 volt 60 Hz, AC only, 15 or 20 amp. 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. A short power-supply cord is provided to reduce risks of becoming entangled in or tripping over a longer cord. Where a two-pronged wallreceptacle is encountered, it is the personal responsibility and obligation of the customer to contact a qualified electrician and have it replaced with a properly grounded three-pronged wall receptacle or have a grounding adapter properly grounded and polarized. If the extension cord must be used, it should be a 3-wire, 15 amp. or higher rated cord. Do not drape over a countertop or table where it can be pulled on by children or tripped over accidentally.

CAUTION: DO NOT UNDER ANY CIRCUMSTANCES CUT OR REMOVE THE ROUND

GROUNDING PRONG FROM THIS PLUG.

Grounded

Receptacle Box

3-Pronged

Plug

Grounding Pin

3-Pronged Receptacle

[2] OVEN DIAGRAM

1. OVEN

1. One touch door open button.

Push to open door.

2. Door latches.

The oven will not operate unless the door is securely closed.

3. Removable turntable support

4. Removable turntable.

The turntable will rotate clockwise or counterclockwise.

5. Oven lamp.

It will light when oven is operating or door is opened.

6. Oven door with see-through window

2

7. Ventilation openings. (Rear)

8. Auto-Touch control panel.

9. Time display: Digital display, 99 minutes, 99 seconds.

10.Waveguide cover:

11.Power supply cord.

6

3

10

5

4

9

8

1

7

11

5 – 1

R405KST

2. TOUCH CONTROL PANEL

NIGHT LIGHT POPCORN

1 2

4

7

5

8

0

STOP

CLEAR

COOK

DEFROST

REHEAT

SOFTEN

MELT WARM

3

6

9

TIMER

CLOCK

START

NOTE: Some one-touch cooking features such as “MINUTE PLUS” are disabled after three minutes when the oven is not in use. These features are automatically enabled when the door is opened and closed or the STOP/ CLEAR pad is pressed.

5 – 2

R405KST


Service Manual

[1] DESCRIPTION OF OPERATING SEQUENCE

The following is a description of component functions during oven operation.

1. OFF CONDITION

Closing the door activates the door sensing switch and primary interlock switch. (In this condition, the monitor switch contacts are opened.)

When oven is plugged in, 120 volts A.C. is supplied to the control unit.

(Figure O-1).

1) The display will show flashing “88:88”.

To set any program or set the clock, you must first touch the STOP/

CLEAR pad. The display will clear, and " : " will appear.

2. COOKING CONDITION

Program desired cooking time by touching the NUMBER pads. Program the power level by touching the POWERLEVEL pad and then a

Number pad. When the START pad is touched, the following operations occur:

1) The contacts of relays are closed and components connected to the relays are turned on as follows.

(For details, refer to Figure O-2)

RY-1 oven lamp/turntable motor/fan motor

3. POWER LEVEL P-0 TO P-90 COOKING

When Variable Cooking Power is programmed, the 120 volts A.C. is supplied to the power transformer intermittently through the contacts of relay (RY-2) which is operated by the control unit within a 32 second time base. Microwave power operation is as follows:

VARI-MODE ON TIME

P-HI (100% power)

P-90 (approx. 90% power)

32 sec.

30 sec.

0 sec.

2 sec.





26 sec.

24 sec.

22 sec.

18 sec.

6 sec.

8 sec.

10 sec.

14 sec.





P-0 (0% power)

16 sec.

12 sec.

8 sec.

6 sec.

0 sec.

16 sec.

20 sec.

24 sec.

26 sec.

32 sec.

NOTE: The ON/OFF time ratio does not correspond with the percentage of microwave power, because approx. 3 seconds are needed for heating of the magnetron filament.

2) 120 volts A.C. is supplied to the primary winding of the power transformer and is converted to about 3.3 volts A.C. output on the filament winding, and approximately 2370 volts A.C. on the high voltage winding.

3) The filament winding voltage heats the magnetron filament and the

H.V. winding voltage is sent to a voltage doubler circuit.

4) 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.

5) Upon completion of the cooking time, the power transformer, oven lamp, etc. are turned off, and the generation of microwave energy is stopped. The oven will revert to the OFF condition.

6) When the door is opened during a cook cycle, the monitor witch, door sensing switch, primary interlock switch, relay (RY1) and secondary interlock relay are activated with the following results. The circuits to the turntable motor, the cooling fan motor, and the high voltage components are de-energized, the oven lamp remains on, and the digital read-out displays the time still remaining in the cook cycle when the door was opened.

7) The monitor switch electrically monitors the operation of the primary interlock switch and secondary interlock relay and is mechanically associated with the door so that it will function in the following sequence.

a) When the door opens from the closed position, the secondary interlock relay (RY2) and primary interlock switch open their contacts. And contacts of the relay (RY1) remains closed. Then the monitor switch contacts close. b) When the door is closed from the open position, the monitor switch contacts open first. Then the contacts of the primary interlock switch and door sensing switch close. And contacts of the relay (RY1) open.

If the primary interlock switch and secondary interlock relay (RY2) fail with the contacts closed when the door is opened, the closing of the monitor switch contacts will form a short circuit through the monitor fuse, primary interlock switch, relay (RY1) and secondary interlock relay (RY2), causing the monitor fuse to blow.

6 – 1

R405KST

[2] OVEN SCHEMATIC

1. Off Condition

SCHEMATIC

NOTE: CONDITION OF OVEN

1. DOOR CLOSED

2. CLOCK APPEARS ON DISPLAY

OVEN

THERMAL CUT-OUT

MAGNETRON

TEMPERATURE

FUSE

NOTE: " " indicates components with potentials above 250V

B2

DOOR

SENSING

SWITCH

H

GRN

120VAC

60Hz

N

GND

C1

C2

C3

(RY2)

SECONDARY

INTERLOCK

RELAY

CONTROL UNIT

B1

(RY1)

OVEN

LAMP

RELAY

NOISE

FILTER

C1: LINE CROSS CAPACITOR ------- 0.22uF/ AC250V

C2, C3: LINE BYPASS CAPACITOR ------ 0.033uF/ AC250V

OL

OVEN

LAMP

N.O.

TTM

TURN

TABLE

MOTOR

FM

FAN

MOTOR

MONITOR

SWITCH

N.C.

COM.

COM.

PRIMARY INTERLOCK

SWITCH

Figure O-1. Oven Schematic-Off Condition

2. Cooking Condition

SCHEMATIC

NOTE: CONDITION OF OVEN

1. DOOR CLOSED.

2. COOKING TIME PROGRAMMED.

3. VARIABLE COOKING CONTROL "P-HI".

4. START PAD TOUCHED.

OVEN

THERMAL CUT-OUT

MAGNETRON

TEMPERATURE

FUSE

POWER TRANSFORMER

HIGH

VOLTAGE

CAPACITOR

0.94uF/ AC2200V

HIGH

VOLTAGE

RECTIFIER

B2

DOOR

SENSING

SWITCH

H

GRN

120VAC

60Hz

N

GND

C1

C2

C3

(RY2)

SECONDARY

INTERLOCK

RELAY

B1

(RY1)

OVEN

LAMP

RELAY

CONTROL UNIT

NOISE

FILTER

C1: LINE CROSS CAPACITOR ------- 0.22uF/ AC250V

C2, C3: LINE BYPASS CAPACITOR ------ 0.033uF/ AC250V

OL

OVEN

LAMP

COM.

N.O.

TTM

TURN

TABLE

MOTOR

FM

FAN

MOTOR

MONITOR

SWITCH

N.C.

COM.

PRIMARY INTERLOCK

SWITCH

Figure O-2. Oven Schematic-Cooking Condition

POWER TRANSFORMER

HIGH

VOLTAGE

CAPACITOR

0.94uF/ AC2200V

HIGH

VOLTAGE

RECTIFIER

6 – 2

R405KST

[3] DESCRIPTION AND FUNCTION OF COMPONENTS

1. DOOR OPEN MECHANISM

The door is opened by pushing the open button on the control panel, refer to the Figure D-1. When the open button is pushed, the open button pushes up the switch lever, and then the switch lever pushes up the latch head. The latch heads are moved upward and released from latch hook. Now the door will open.

Door

Switch Lever

Latch Heads

Door Sensing

Switch

Monitor Switch

Primary Interlock

Switch

Figure D-1. Door Open Mechanism.

2. DOOR SENSING AND PRIMARY INTERLOCK

SWITCHES

The primary interlock switch is mounted in the lower position of the latch hook and the door sensing switch in the secondary interlock system is mounted in the upper position of the latch hook. They are activated by the latch heads on the door. When the door is opened, the switches interrupt the power to all high voltage components. A cook cycle cannot take place until the door is firmly closed there by activating both interlock switches. The secondary interlock system consists of the door sensing switch and secondary interlock relay located on the control circuit board.

3. MONITOR SWITCH

The monitor switch is activated (the contacts opened) by the latch head on the door while the door is closed. The switch is intended to render the oven inoperative, by means of blowing the monitor fuse, when the contacts of the secondary interlock relay (RY2) and primary interlock switch fail to open when the door is opened.

Functions:

1) When the door is opened, the monitor switch contact close (to the

ON condition) due to their being normally closed. At this time the secondary interlock relay (RY2) and primary interlock switch are in the OFF condition (contacts open) due to their being normally open contact switches.

2) As the door goes to a closed position, the monitor switch contacts are first opened and then the door sensing switch and the primary interlock switch contacts close. (On opening the door, each of these switches operate inversely.)

3) If the door is opened, and the secondary interlock relay (RY2) and primary interlock switch contacts fail to open, the monitor fuse blows simultaneously with closing of the monitor switch contacts.

CAUTION: BEFORE REPLACING A BLOWN MONITORFUSE TEST

THE DOOR SENSING SWITCH, SECONDARY INTER-

LOCK RELAY (RY2), RE-LAY (RY1), PRIMARY INTER-

LOCK SWITCH AND MONITOR SWITCH FOR PROPER

OPERATION. (REFER TO CHAPTER “TEST PROCE-

DURE”).

NOTE: MONITOR FUSE AND MONITOR SWITCH ARE REPLACED

AS AN ASSEMBLY.

4. TURNTABLE MOTOR

The turntable motor rotates the turntable located on the bottom of the oven cavity, so that the foods on the turntable cook evenly during cooking. The turntable may turn in either direction.

5. COOLING FAN MOTOR

The cooling fan motor drives a blade which draws external cool air.

This cool air is directed through the air vanes surrounding the magnetron and cools the magnetron. This air is channeled through the oven cavity to remove steam and vapors given off from the heating foods. It is then exhausted through the exhausting air vents at the oven cavity.

6. OVEN THERMAL CUT-OUT

The thermal cut-out, located on the top of the oven cavity, 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 thermal cutout will open. Under normal operation, the oven thermal cut-out remains closed. However, when abnormally high temperatures are reached within the oven cavity, the oven thermal cut-out will open at

293 ° F(145 ° C), causing the oven to shut down.

7. MAGNETRON TEMPERATURE FUSE

The magnetron temperature fuse located near the magnetron is designed to prevent damage to the magnetron if an over heated condition develops in the tube due to cooling fan failure, obstructed air guide, dirty or blocked air intake, etc. Under normal operation, the magnetron temperature fuse remains closed. However, when abnormally high temperatures are reached within the magnetron, the magnetron temperature fuse will open at 302 ° F(150 ° C) causing the oven to shut down.

NOTE: This is a fuse. It does not reset.

8. MONITOR FUSE

1) The monitor fuse blows when the contacts (COM-NO) of the primary interlock relay (RY2) and secondary interlock switch remain closed with the oven door open and when the monitor switch closes.

2) If the wire harness or electrical components are short-circuited, this monitor fuse blows to prevent an electric shock or fire hazard.

9. NOISE FILER

The noise filter prevents the radio frequency interference that might flow back in the power circuit.

6 – 3

R405KST


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

: 3) Discharge high voltage capacitor.

4) Disconnect the leads to the primary of the power transformer.

If the oven becomes inoperative because of a blown monitor fuse, check the monitor switch, relay (RY1) secondary interlock relay (RY2), door sensing switch and primary interlock switch before replacing the monitor fuse. If the monitor fuse is replaced, the monitor switch must also be replaced. Use part FFS-BA033WRKZ or FFS-BA037WRKZ as an assembly.

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,

IMPORTANT

: 1) Disconnect the power supply cord, and then remove outer case.


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,


4) Reconnect the leads to the primary of the power transformer.


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.

[1] TROUBLESHOOTING CHART

TTEST PROCEDURE RE CK A B C D E E F F G H RE RE CK I J CK CK CK K L M N

POSSIBLE CASE

AND DEFECTIVE PARTS

CONDITION PROBLEM

Home fuse or circuit breaker blows when power cord is plugged into wall receptacle

OFF

CONDITION

Monitor fuse blows when power cord is plugged into wall receptacle.

All letters and indicators do not appear in display when power cord is first plugged into wall outlet.

Display does not operate properly when

STOP/CLEAR pad is touched. (Buzzer s h o u l d s o u n d a n d " : " o r t i m e o f d a y should appear in display.)

O v e n l a m p d o e s n o t l i g h t w h e n d o o r i s opened.

Oven lamp does not go out when door is closed.

Oven lamp lights but fan motor and turntable motor do not operate.

COOKING

CONDITION

Oven does not go into cook cycle when

START pad is touched

Oven seems to be operating but little or no heat is produced in oven load. (Food incompletely cooked or not cooked at all at end of cook cycle.)

Oven goes into a cook cycle but extremely uneven heating is produced in oven load

(food).

Oven does not cook properly when programmed for Cooking Power P-50 mode. (Operates properly on Cooking Power P-HI (HIGH) mode.)

Oven goes into DEFROST but food is not defrosted well.

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Service Manual

[1] Procedure A: MAGNETRON ASSEMBLY TEST




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.





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 POWER 10 (HIGH) 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 34.8 to 64.6

° F(19.3 to 35.9

° C) rise in temperature. 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 120 volts and the oven cavity is clean.

[2] Procedure B: POWER TRANSFORMER TEST




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 159 ohms (RTRN-A746WRZZ) or approximately 150 ohms (RTRN-A745WRZZ); the resistance of the filament coil should be less than 1 ohm.





(HIGH VOLTAGES ARE PRESENT AT THE HIGH VOLTAGE TERMINAL, SO DO NOT ATTEMPT TO MEASURE THE FILAMENT AND HIGH

VOLTAGE.)

[3] Procedure C: HIGH VOLTAGE RECTIFIER TEST




4. Isolate the rectifier from the circuit. Using the highest ohm scale of the meter, read the resistance across the terminals and observe, reverse the leads to the rectifier terminals and observe meter reading. If a short is indicated in both directions, or if an infinite resistance is read in both directions, the rectifier is probably defective and should be replaced.

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R405KST





NOTE: Be sure to use an ohmmeter that will supply a forward bias voltage of more than 6.3 volts.

[4] Procedure D: HIGH VOLTAGE CAPACITOR TEST




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] Procedure E: TEMPERATURE FUSE OR THERMAL CUT-OUT TEST




4. Check a continuity across the temperature fuse or thermal cut-out terminals in the table below.

Parts Name

Temperature fuse 150 ° C

Thermal cut-out 145 ° C

Table: Temperature Fuse and Thermal Cut-out Test

Temperature of “ON” condition

(closed circuit).

This is not resetable type.

This is not resetable type.

Temperature of “OFF” condition

(open circuit).

Above 150 ° C (302 ° F)

Above 145 ° C (293 ° F)

Indication of ohmmeter (When room temperature is approx. 20 ° C.)

Closed circuit

Closed circuit

5. An open temperature fuse (Magnetron) indicates overheating of the magnetron. Check for restricted air flow to the magnetron, especially the cooling fan and air guide.

An open thermal cut-out (Oven) indicates overheating of the oven, exchange the thermal cut-out and check inside of oven cavity and for improper setting of cooking time or operation of control unit. Check for restricted air flow through the vent holes of the oven cavity, especially the cooling fan and air guide.


7. Reinstall the outer case (Cabinet).



CAUTION: IF THE TEMPERATURE FUSE OR THERMAL CUT-OUT INDICATES AN OPEN CIRCUIT AT ROOM TEMPERATURE, REPLACE IT.

[6] Procedure F: PRIMARY INTERLOCK SWITCH TEST




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 primary interlock switch.





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[7] Procedure F: SECONDARY INTERLOCK SYSTEM TEST

1. DOOR SENSING SWITCH




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.





NOTE: If the door sensing switch contacts fail in the open position and the door is closed, the cooling fan, turntable and oven light will be activated by

RY1.

2. SECONDARY INTERLOCK RELAY (RY2)




4. Disconnect two (2) wire leads from the male tab terminals of the Secondary Interlock Relay. 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.





[8] Procedure G: MONITOR SWITCH TEST




4. Before performing this test, make sure that the primary interlock switch and the secondary interlock relay are operating properly, according to the above Switch Test Procedure. Disconnect the wire lead from the monitor switch (COM) terminal. Check the monitor switch 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 lower 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 switch, reconnect the wire lead to the monitor switch (COM) terminal and check the continuity of the monitor circuit.





Red

White/ White

Screw Driver

Primary

Interlock Switch

Monitor Switch

Ohmmeter

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[9] Procedure H: BLOWN MONITOR FUSE TEST




4. If the monitor fuse is blown when the door is opened, check the primary interlock switch, secondary interlock relay (RY2), relay (RY1) and monitor switch according to the “TEST PROCEDURE” for those switches before replacing the blown monitor fuse.

CAUTION: BEFORE REPLACING A BLOWN MONITOR FUSE, TEST THE PRIMARY INTERLOCK SWITCH, SECONDARY INTERLOCK RELAY,

DOOR SENSING SWITCH AND MONITOR SWITCH 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 or FFS-BA037WRKZ, even if the monitor switch operates normally. The monitor fuse and monitor switch assembly is comprised of a 20 ampere fuse and switch.





[10] Procedure I: NOISE FILTER TEST




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 readings are obtained, replace the noise filter.





MEASURING POINT

Between N and L

INDICATION OF OHMMETER

Open circuit.

Between terminal N and WHITE Short circuit.

Between terminal L and RED Short circuit.

N

NOISE FILTER

FUSE 20A

LINE CROSS CAPACITOR

0.22μF / AC 250V

L

LINE BYPASS

CAPACITOR

0.0033μF / AC 250V

LINE BYPASS

CAPACITOR

0.0033μF / AC 250V

WHITE

NOISE SUPPRESSION COIL

RED

[11] Procedure J: TOUCH CONTROL PANEL ASSEMBLY TEST

The touch control panel consists of circuits including semiconductors such as LSI, ICs, etc. Therefore, unlike conventional microwave ovens, proper maintenance cannot be performed with only a voltmeter and ohmmeter.

In this service manual, the touch control panel assembly is divided into two units, Control Unit and Key Unit, and also the Control Unit is divided into two units, CPU Unit and Power Unit, and troubleshooting by unit replacement is described according to the symptoms indicated.

Before testing,

1) Disconnect the power supply cord and then remove outer case.




5) Ensure that these leads remain isolated from other components and oven chassis by using insulation tape.

1. Key Unit

NOTE:

1) Re-install the outer case (cabinet).



The following symptoms indicate a defective key unit.

a) When touching the pads, a certain pad produces no signal at all.

b) When touching a number pad, two figures or more are displayed.

c) When touching the pads, sometimes a pad produces no signal.

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2. Control Unit.

The following symptoms indicate a defective control unit.

1) In connection with pads.

a) When touching the pads, a certain group of pads do not produce a signal.

b) When touching the pads, no pads produce a signal.

2) In connection with indicators a) At a certain digit, all or some segments do not light up.

b) At a certain digit, brightness is low.

c) Only one indicator does not light. d) The corresponding segments of all digits do not light up; or they continue to light up.

e) Wrong figure appears.

f) A certain group of indicators do not light up.

g) The figure of all digits flicker.

3) Other possible problems caused by defective control unit.

a) Buzzer does not sound or continues to sound.

b) Clock does not operate properly.

c) Cooking is not possible.

3. If the Key unit or the Control unit is defective.




4) Replace the Control unit assembly.

5) Reconnect all leads removed from components during testing.




4. When testing is completed,








[12] Procedure K: KEY UNIT TEST

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 keypad is at fault.

G8 G7

G9

G10

G11

G12

G13

NIGHT

LIGHT

DEFROST

SOFTEN MELT

NC

G6 G5

COOK

REHEAT

1

4

7

G4

2

5

8

0

G3 G2 G1

START

TIMER

CLOCK

STOP

CLEAR

POWER

LEVEL

WARM

9

3

6

MINUTE

PLUS

POPCORN

[13] Procedure L: RELAY TEST


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4. Disconnect the leads to the primary of the power transformer.

5. Ensure that these leads remain isolated from other components and oven chassis by using insulation tape.

6. After that procedure, re-connect the power supply cord.

7. Remove the outer case and check voltage between the cabinet side terminal of the relay RY1 and the lower side terminal of the relay RY2 on the control unit with an A.C. voltmeter.

The meter should indicate 120 volts, if not check oven circuit.

RY1 and RY2 Relay Test

These relays are operated by D.C. voltage

Check voltage at the relay coil with a D.C. voltmeter during the microwave cooking operation.

DC. voltage indicated ................. Defective relay.

DC. voltage not indicated ........... Check diode which is connected to the relay coil. If diode is good, control unit is defective.

RELAY SYMBOL

RY1

RY2

OPERATIONAL VOLTAGE

Approx. 12.0V D.C.

Approx. 12.0V D.C.

CONNECTED COMPONENTS

Oven lamp / Turntable motor / Cooling fan motor

Power transformer

8. Disconnect the power supply cord and then remove outer case.


10.Discharge high voltage capacitor.

11.Reconnect all leads removed from components during testing.

12.Re-install the outer case (cabinet).

13.Reconnect the power supply cord after the outer case is installed.

14.Run the oven and check all functions.

[14] Procedure M: DEFROST TEST

WARNING: The oven should be fully assembled before following procedure.

1. Open the door.

2. Place one cup of water in the center of the turntable tray in the oven cavity.

3. Close the door, touch the “DEFROST“ pad once.

4. Press “2”, then press “5”.

5. Touch the “START “ pad.

6. The oven is in Defrost cooking condition.

7. The oven will operate as follows.

MENU 1ST STAGE

Steaks/Chops LEVEL

0.5lb

60%

TIME

20sec.

2ND STAGE

LEVEL

40%

TIME

20sec.

3RD STAGE

LEVEL

30%

TIME

45sec.

8. If improper operation is indicated, the control unit is probably defective and should be checked.

[15] Procedure N: FOIL PATTERN ON THE PRINTED WIRING BOARD TEST

To protect the electronic circuits, this model is provided with a fine foil pattern added to the primary on the PWB, this foil pattern acts as a fuse.

1. Foil pattern check and repairs.




4) Follow the troubleshooting guide given below for repair.

STEPS

1

2

OCCURRENCE CAUSE OR CORRECTION

Only pattern at “a” is broken.

*Insert jumper wire J1 and solder.

Pattern at “a” and “b” are broken. *Insert the coil RCILF2003YAZZ between “c” and “d”.

8 – 6

R405KST

5) Make a visual inspection of the varistor. Check for burned damage and examine the transformer with a tester for the presence of layer short-circuit (check the primary coil resistance which is approximately 563 Ω± 10%). If any abnormal condition is detected, replace the control unit.





2. Follow the troubleshooting guide given below, if indicator does not light up after above check and repairs are finished.

c






6) After that procedure, re-connect the power supply cord.

7) Follow the troubleshooting guide given below for repair.

STEPS

1

2

OCCURRENCE

The rated AC voltage is not present between the cabinet side terminal of the relay RY1 and the lower side terminal of the relay RY2.

The rated AC voltage is present at primary side of low voltage transformer.



10)Discharge high voltage capacitor.

11)Reconnect all leads removed from components during testing.

12)Re-install the outer case (cabinet).

13)Reconnect the power supply cord after the outer case is installed.

14)Run the oven and check all functions.

a b d

CAUSE OR CORRECTION

Check supply voltage and oven power cord.

Low voltage transformer or secondary circuit defective.

Check and replace control unit.

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R405KST

CHAPTER 9. TOUCH CONTROL PANEL ASSEMBLY

[1] OUTLINE OF TOUCH CONTROL PANEL

The touch control section consists of the following units.

(1) Key Unit

(2) Control Unit (The Control Unit consists of Power Unit and LSI Unit).

The principal functions of these units and their related signals are explained below.

1. Key Unit

The key unit is composed of a matrix, signals generated in the LSI are sent to the key unit through P20-P27.

When a key pad is touched, a signal is completed through the key unit and passed back to the LSI through P70, P71, P41 and P45 to perform the function that was requested.

2. Control Unit

Control unit consists of LSI, reset circuit, indicator circuit, power source circuit, relay circuit, buzzer circuit, synchronizing signal circuit and back light circuit.

1) Reset Circuit

This circuit generates a signal which resets the LSI to the initial state when power is supplied.

2) Indicator Circuit

This circuit consists of 17 segments and 4 common electrodes using a Liquid Crystal Display.

3) Power Source Circuit

This circuit generates voltage necessary in the control unit from the

AC line voltage.

In addition, the synchronizing signal is available in order to compose a basic standard time in the clock circuit.

Symbol

VSS

Voltage

-5V

Application

LSI(IC1)

4) Relay Circuit

A circuit to drive the magnetron, fan motor, turntable motor and light the oven lamp.

5) Buzzer Circuit

The buzzer is responsive to signals from the LSI to emit audible sounds (key touch sound and completion sound).

6) Synchronizing Signal Circuit

The power source synchronizing signal is available in order to compose a basic standard time in the clock circuit. It accompanies a very small error because it works on commercial frequency.

7) Door Sensing Switch

A switch to “tell” the LSI if the door is open or closed.

8) Back Light Circuit

A circuit to drive the back light (Light emitting diodes LD1- LD4).

9) Night Light Circuit

A circuit to drive the light emitting diode (LD10).

[2] DESCRIPTION OF LSI

The I/O signal of the LSI are detailed in the following table.

Pin No.

1-2

3-6

7

8

9

10

11-13

14

Signal

VL2-VL1

AN7-AN4

AN3

AN2

AN1

AN0

P57-P55

CNTR0

I/O Description

IN

IN

Power source voltage input terminal.

Standard voltage for LCD.

Terminal to change cooking input according to the Model.

By using the A/D converter contained in the LSI, DC voltage in accordance with the Model in operation is applied to set up its cooking constant.

IN Terminal not used.

IN

To input signal which communicates the door open/close information to LSI.

Door close “H” level signal (0V). Door open “L” level signal (-5V)



OUT Terminal not used.

Signal to sound buzzer (2.0 kHz).

A: key touch sound.

B: Completion sound.

0.1 sec.

H : GND

OUT A

L : -5V

2.0 sec.

H : GND

B

L : -5V

15

16

P53

P52


OUT

Oven lamp, fan motor and turntable motor driving signal

To turn on and off shut off relay (RY1). The square waveform voltage is delivered to the RY1 driving circuit and

RY2 control circuit.

16.7 msec.

H : GND

L : -5V

During cooking

17 P51 OUT Terminal not used.

9 – 1

28

29

30

25

26

27

31

32

33

R405KST

Pin No.

Signal

18

19

20

21

22-23

24

34

35

36

37

38

39

40

41

42-55

P41

P40

RESET

P71

P70

XIN

XOUT

VSS

P27

P50

P47

P46

P45

P44-P43

INTP0

P26

P25

P24

P23

P22

P21

P20

P17

P16-P3

I/O

OUT

Description

Magnetron high-voltage circuit driving signal.

To turn on and off the cook relay (RY2). The signals holds “L” level during microwave cooking and “H” level while not cooking. In other cooking modes (variable cooking) the signal turns to “H” level and “L” level in repetition according to the power level.

Maximum output

OFF

ON

H : GND

L : -5V

OFF OFF

H : GND

70% of maximum output

24 sec.

ON

8 sec.

L : -5V

IN Connected to GND.

OUT Night light circuit (light emitting diode) driving signal.

IN

Signal coming from touch key.

When either G12 line on key matrix is touched, a corresponding signal out of P20 - P27 will be input into P45.

When no key is touched, the signal is held at “H” level.


Signal synchronized with commercial power source frequency.

This is the basic timing for time processing of LSI.

H : GND

IN

L : -5V

16.7 msec.

IN

Signal similar to P45.

When either G11 line on key matrix is touched, a corresponding signal will be input into P41.

IN Connected to GND through the pull-down resistor.

IN

IN

Auto clear terminal.

Signal is input to reset the LSI to the initial state when power is applied.



IN

IN

OUT



Internal clock oscillation frequency input setting.

The internal clock frequency is set by inserting the ceramic filter oscillation circuit with respect to XOUT terminal.

Internal clock oscillation frequency control output.

Output to control oscillation input of XIN.

IN

OUT

OUT

OUT

Power source voltage: -5.0V.

The power source voltage to the drive LSI is input to VSS terminal.

Key strobe signal.

Signal applied to touch-key section. A pulse signal is input to P70, P71, P41 and P45 terminal while one of G8 line keys on key matrix is touched.





OUT

OUT

OUT

OUT

OUT











OUT Back light signal (light emitting diode) driving signal.


9 – 2

Pin No.

56-72

73

74

75

76

77

78

79

80

Signal

SEG16-SEG0

VCC

VREF

I/O

OUT

Description

Segment data signal.

Connected to LCD. The relation between signals are as follows:

LSI signal (Pin No.) LCD (segment) LSI signal (Pin No.) LCD (segment)

SEG 0 (72) ----------------- SEG 0 SEG 9 (63) ----------------- SEG 9

SEG 1 (71) ----------------- SEG 1 SEG 10(62) ----------------- SEG 10

SEG 2 (70) ----------------- SEG 2 SEG 11(61) ----------------- SEG 11

SEG 3 (69) ----------------- SEG 3 SEG 12 (60) ----------------- SEG 12

SEG 4 (68) ----------------- SEG 4 SEG 13 (59) ----------------- SEG 13

SEG 6 (66) ----------------- SEG 6 SEG 14 (58) ----------------- SEG 14

SEG 7 (65) ----------------- SEG 7 SEG 15 (57) ----------------- SEG 15

SEG 8 (64) ----------------- SEG 8 SEG 16 (56) ----------------- SEG 16

IN Power source voltage: GND (0V).

IN

A/D converter power source voltage: GND (0V).

The power source voltage to drive the A/D converter. Connected to GND.

AVSS

COM3

COM2

COM1

COM0

VL3

IN

OUT

OUT

OUT

OUT

IN

A/D converter power source voltage: -5.0V.

The power source voltage to drive the A/D converter.

Common data signal.

Connected to LCD signal COM3.







Power source voltage input terminal.

Standard voltage for LCD. Connected to GND.

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[3] SERVICING FOR TOUCH CONTROL PANEL

1. Precautions for Handling Electronic Components

This unit uses CMOS LSI in the integral part of the circuits. When handling these parts, the following precautions should be strictly followed.

CMOS LSI have extremely high impedance at its input and output terminals. For this reason, it is easily influenced by the surrounding high voltage power source, static electricity charge in clothes, etc., and sometimes it is not fully protected by the built-in protection circuit.

In order to protect CMOS LSI.

1) When storing and transporting, thoroughly wrap them in aluminium foil. Also wrap PW boards containing them in aluminium foil.

2) When soldering, ground the technician as shown in the figure and use grounded soldering iron and work table.

approx. 1M ohm

2. Servicing of Touch Control Panel

We describe the procedures to permit servicing of the touch control panel of the microwave oven and the precautions you must take when doing so. To perform the servicing, power to the touch control panel is available either from the power line of the oven itself or from an external power source.

1. Servicing the touch control panel with power supply of the oven:

CAUTION: THE HIGH VOLTAGE TRANSFORMER OF THE MICRO-

WAVE OVEN IS STILL LIVE DURING SERVICING AND

PRESENTS A HAZARD.

Therefore, before checking the performance of the touch control panel,






6) After that procedure, re-connect the power supply cord.

After checking the performance of the touch control panel,

1) Disconnect the power supply cord.


3) Re-connect the leads to the primary of the power transformer.


5) Re-connect the power supply cord after the outer case is installed.


a) On some models, the power supply cord between the touch control panel and the oven itself is so short that the two can't be separated. For those models, check and repair all the controls (sensor-related ones included) of the touch control panel while keeping it connected to the oven.

b) On some models, the power supply cord between the touch control panel and the oven proper is so long enough that they may be separated from each other. For those models, therefore, it is possible to check and repair the controls of the touch control panel while keeping it apart from the oven proper; in this case you must short both ends of the door sensing switch (on PWB) of the touch control panel with a jumper, which brings about an operational state that is equivalent to the oven door being closed. As for the sensorrelated controls of the touch control panel, checking them is possible if the dummy resistor(s) with resistance equal to that of the controls are used.

2. Servicing the touch control panel with power supply from an external power source:

Disconnect the touch control panel completely from the oven proper, and short both ends of the door sensing switch (on PWB) of the touch control panel, which brings about an operational state that is equivalent to the oven door being closed. Connect an external power source to the power input terminal of the touch control panel, then it is possible to check and repair the controls of the touch control panel; it is also possible to check the sensor-related controls of the touch control panel by using the dummy resistor(s).

3. Servicing Tools

Tools required to service the touch control panel assembly.

1) Soldering iron: 60W

(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.

3) Others: Hand tools

4. Other Precautions

1) Before turning on the power source of the control unit, remove the aluminium foil applied for preventing static electricity.

2) Connect the connector of the key unit to the control unit being sure that the lead wires are not twisted.

3) After aluminium foil is removed, be careful that abnormal voltage due to static electricity etc. is not applied to the input or output terminals.

4) Attach connectors, electrolytic capacitors, etc. to PWB, making sure that all connections are tight.

5) Be sure to use specified components where high precision is required.

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CHAPTER 10. PRECAUTIONS FOR USING LEAD-FREE SOLDER

[1] 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

[2] 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.

[3] Soldering

As the melting point of lead-free solder (Sn-Ag-Cu) is higher and has poorer wettability, (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.

10 – 1

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CHAPTER 11. COMPONENT REPLACEMENT AND ADJUSTMENT PROCE-

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 push the door open button 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) Wait for 60 seconds, then discharge the high voltage capacitor.

2. Do not let the wire leads touch to the following parts;

1) High voltage parts:

Magnetron, High voltage transformer, High voltage capacitor and High voltage rectifier assembly.

2) Hot parts:

Oven lamp, Magnetron, Power 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)

Fan blade, Fan motor, Switch, Switch lever, Open button.

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:

11 – 1

[2] OUTER CASE REMOVAL

To remove the outer case, procedure as follows.


2. Open the oven door and block it open.

3. Remove the two (2) screws from the lower portion of the rear cabinet using a T20H Torx type or GTXH20-100 screw driver.

4. Remove the remaining two (2) screws from rear.

5. Slide the entire outer case back out about 1 inch (3 cm) to free it from retaining clips on the cavity face plate.

6. Lift entire outer case from the unit.

CAUTION: DISCONNECT OVEN FROM POWER SUPPLY BEFORE

REMOVING OUTER CASE.

DISCHARGE THE HIGH VOLTAGE CAPACITOR

BEFORE TOUCHING ANY OVEN COMPONENTS OR

WIRING.

R405KST

NOTE: When replacing the outer case, the 2 special Torx screws must be reinstalled in the same locations.

Special screw

Screw Driver

(Type: TORX T20 H or

GTXH20-100)

[3] POWER TRANSFORMER REMOVAL

1. REMOVAL

1. Disconnect the power supply cord and remove outer case.



4. Disconnect wire leads (primary) from power transformer and the filament leads from the magnetron and capacitor terminals.

5. Disconnect high voltage lead of the power transformer from the high voltage capacitor.

6. Remove two (2) screws holding transformer to bottom plate.

7. Remove transformer from bottom plate.

2. REINSTALLATION

1. Rest transformer on the bottom plate with its primary terminals toward the oven face plate.

2. Secure transformer with two (2) screws to bottom plate.

3. Reconnect the wire leads (primary) to power transformer and filament leads of transformer to magnetron and high voltage capacitor.

Reconnect the high voltage lead of the power transformer to the high voltage capacitor. Refer to “PICTORIAL DIAGRAM”.

4. Reinstall outer case and check that oven is operating properly.

[4] HIGH VOLTAGE RECTIFIER AND HIGH VOLTAGE CAPACITOR REMOVAL

To remove the components, proceed as follows.




4. Disconnect the high voltage wire of the power transformer from the high voltage capacitor.

5. Disconnect the high voltage wire of high voltage rectifier assembly from the magnetron.

6. Disconnect the filament lead (short one) of the power transformer from the high voltage capacitor.

7. Remove the one (1) screw holding capacitor holder with the high voltage rectifier to the base plate.

8. Disconnect rectifier terminal from capacitor. High voltage rectifier assembly is now free.

9. Remove capacitor holder. Capacitor is now free.

CAUTION: WHEN REPLACING HIGH VOLTAGE RECTIFIER AND

HIGH VOLTAGE CAPACITOR, GROUND SIDE TERMI-

NAL OF THE HIGH VOLTAGE RECTIFIER MUST BE

SECURED FIRMLY WITH A GROUNDING SCREW.

[5] MAGNETRON REMOVAL

1. REMOVAL




4. Disconnect all wire leads from magnetron.

5. Remove the two (2) screws holding the chassis support to the magnetron and the oven cavity front flange.

6. Slide the magnetron duct slightly so that the two (2)screws at left hand side of the magnetron appear.

7. Carefully remove the four (4) screws holding magnetron to waveguide flange.

8. Remove magnetron with care so that magnetron antenna is not hit by any metal object around the antenna.

9. Now, the magnetron is free.


1. Re-install the magnetron to waveguide flange with car to prevent damage to the magnetron antenna.

2. Secure the magnetron with the four (4) screws.

11 – 2

R405KST

3. Hold the chassis support to the oven cavity front plate and the magnetron with the two (2) screws.

4. Reconnect the wire leads to the magnetron. Refer to “PICTORIAL

DIAGRAM”.

[6] OVEN LAMP REMOVAL




4. Disconnect the wire leads from the oven lamp.

5. Remove the one (1) screw holding the oven lamp to the magnetron duct.

6. Remove the oven lamp from the magnetron duct.

5. Reinstall outer case and check that the oven is operating properly.

CAUTION: WHEN REPLACING MAGNETRON, BE SURE THE R.F.

GASKET IS IN PLACE AND MOUNTING SCREWS ARE

TIGHTENED SECURELY.

7. Now, the oven lamp is free.

Terminal

Figure C-1. Oven lamp

[7] POSITIVE LOCK CONNECTOR (NO-CASE TYPE) REMOVAL

1. Disconnect the power supply cord, and remove outer case.



4. Push the lever of positive lock ® connector.

5. Pull down on the positive lock ® connector.

CAUTION: WHEN CONNECTING THE POSITIVE LOCK ® CONNEC-

TORS TO THE TERMINALS, CONNECT THE POSITIVE

LOCK ® SO THAT THE LEVER FACES YOU.

Positive lock¨ connector

Lever

Oven lamp

Terminal

1

Push

2

Pull down

Figure C-2. Positive lock ® connector

[8] CONTROL PANEL ASSEMBLY REMOVAL




4. Disconnect the wire leads from panel components.

5. Straighten the nail holding the control panel assembly to the oven cavity front plate.

6. Slide the control panel assembly upward and remove it.

7. Now, individual components can be removed.

[9] GRAPHIC SHEET AND MEMBRANE SWITCH REPLACEMENT

1. REMOVAL




4. Remove the control panel assembly, referring to chapter of CON-

TROL PANEL ASSEMBLY REMOVAL.

5. Disconnect the ribbon cable of the membrane switch from the control unit.

6. Remove the back light PWB from the control panel frame.

7. Remove the four (4) screws holding the control unit to the control panel frame. And remove the control unit.

8. Remove the display window from the control panel frame.

9. Tear away the graphic sheet from the control panel frame.

10.Tear away the membrane switch from the control panel frame.


1. Remove remaining adhesive on the control panel frame surfaces with a soft cloth soaked in alcohol.

2. Tear the backing paper from the new membrane switch.

3. Insert the ribbon cable of the membrane switch into the slit of the control panel frame.

4. Adjust the upper edge and right edge of the membrane switch to the small depression on the surface of the control panel frame.

5. Attach the membrane switch to the control panel frame by rubbing with a soft cloth not to scratch.

6. Tear the backing paper from the new graphic sheet.

7. Adjust the upper edge and left edge of the graphic sheet to the large depression on the surface of the control panel frame.

8. Attach the graphic sheet to the control panel frame by rubbing with a soft cloth not to scratch.

9. Insert the ribbon cable into the slit of the control unit.

10.Reinstall the control unit to the control panel frame and hold with the four (4) screws.

11.Insert and connect the edge of the membrane switch’s ribbon cable into the connector CN-G.

12.Insert the back light PWB into the square hole.

13.Reinstall the display window to the control panel frame.

11 – 3

R405KST

Left tab

Square hole of control panel frame

Cut off portion

Right tab

Wire lead

Back light PWB

(LD10)

Back light PWB installation

CAUTION: When the back light PWB is installed into the square hole of the control panel frame, the wire leads should be routed through the cut off portion, not to be pinched.

Control panel frame

Display window

Small depression

Ribbon cable

Large depression

Slit

Graphic sheet (Key sheet)

Membrame switch

Graphic Sheet and Membrane Switch Replacement

[10] TURNTABLE MOTOR REMOVAL


2. Remove turntable and turntable support from oven cavity.

3. Lay the oven on it's backside. Remove the turntable motor cover by snipping off the material in four corners.

4. Where the corners have been snipped off bend corner areas flat.

No sharp edges must be evident after removal of the turntable motor cover.

[11] COOLING FAN MOTOR REMOVAL

1. REMOVAL




4. Disconnect the wire leads from the fan motor.

5. Remove the two (2) screws holding the fan motor to the oven cavity back plate.

6. Remove the fan blade from the fan motor shaft according to the following procedure.

7. Hold the edge of the rotor of the fan motor by using a pair of groove joint pliers.

CAUTION: Make sure that no metal pieces enter the gap between the rotor and the stator of the fan motor because the rotor is easily shaven by pliers and metal pieces may be produced.

Do not touch the pliers to the coil of the fan motor because the coil may be cut or injured.

Do not disfigure the bracket by touching with the pliers.

8. Remove the fan blade assembly from the shaft of the fan motor by pulling and rotating the fan blade with your hand.

9. Now, the fan blade will be free.

CAUTION: Do not reuse the removed fan blade because the hole

(for shaft) may be larger than normal.

5. Disconnect wire leads from turntable motor.

(See “Positive lock ® connector removal”)

6. Remove one (1) screw holding turntable motor to oven cavity.

7. Now, the turntable motor is free.

8. After replacement use the one (1) screw XOTS740P10000 to fit the turntable motor cover.


1. Install the fan blade to the fan motor shaft according to the following procedure.

2. Hold the center of the bracket which supports the shaft of the fan motor on the flat table.

3. Apply the screw lock tight into the hole (for shaft) of the fan blade.

4. Install the fan blade to the shaft of fan motor by pushing the fan blade with a small, light weight, ball peen hammer or rubber mallet.

CAUTION: Do not hit the fan blade strongly when installed because the bracket may be disfigured.

Make sure that the fan blade rotates smooth after installation.

Make sure that the axis of the shaft is not slanted.

5. Install the fan motor assembly to the oven cavity back plate with two (2) screws.

6. Connect the wire leads to the magnetron and fan motor, referring to the pictorial diagram.

11 – 4

R405KST

Coil

Groove joint pliers Shaft

Stator

Gap

Bracket Rotor

Rear View

Shaft

Axis

Stator

Rotor

Side View

These are the positions that should be pinched with pliers.

Table

Center of bracket

[12] DOOR SENSING SWITCH/PRIMARY INTERLOCK SWITCH AND MONITOR SWITCH

REMOVAL

1. REMOVAL




4. Disconnect wire leads from the switches.

5. Remove two (2) screws holding latch hook to oven flange.

6. Remove latch hook assembly from oven flange.

7. Push outward on the two (2) retaining tabs holding switch in place.

8. Switch is now free.

At this time switch lever will be free, do not lose it.


1. Re-install each switch in its place. The primary interlock/ monitor switches are in the lower position and the door sensing switch is in the upper position.

2. Reconnect wire leads to each switch. Refer to pictorial diagram.

3. Secure latch hook (with two (2) mounting screws) to oven flange.

4. Make sure that the monitor switch is operating properly and check continuity of the monitor circuit. Refer to chapter “Test Procedure” and Adjustment procedure.

[13] DOOR SENSING SWITCH/PRIMARY INTERLOCK SWITCH AND MONITOR SWITCH

ADJUSTMENT

1. Adjustment




If the door sensing switch, primary interlock switch and monitor switch do not operate properly due to a misadjustment, the following adjustment should be made.

4. Loosen the two (2) screws holding latch hook to the oven cavity front flange.

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 primary interlock switch are activated with the door closed. The horizontal position of the latch hook should be adjusted so that the plunger of the monitor switch is pressed with the door closed.

6. Secure the screws with washers firmly.

7. Check the operation of all switches. If each switch has not activated with the door closed, loosen screw and adjust the latch hook position.

2. After adjustment, check the following.

1. In and out play of door remains less than 0.5mm when in the latched position. First check upper position of latch hook, pushing and pulling upper portion of door toward the oven face.

Then check lower portion of the latch hook, pushing and pulling lower portion of the door toward the oven face. Both results (play in the door) should be less than 0.5mm.

2. The door sensing switch and primary interlock switch interrupt the circuit before the door can be opened.

3. Monitor switch contacts close when door is opened.

4. Re-install outer case and check for microwave leakage around door with an approved microwave survey meter. (Refer to Microwave Measurement Procedure.)

Door

Switch Lever

Latch Heads

Door Sensing

Switch

Monitor Switch

Primary Interlock

Switch

Figure C-3. Latch Switch Adjustments

[14] DOOR REPLACEMENT

1. REMOVAL

1. Disconnect oven from power supply.

2. Push the open button and open the door slightly.

11 – 5

3. Insert a putty knife (thickness of about 0.5mm) into the gap between the door stopper and the choke cover to free engaging parts as shown in Figure C-4.

4. Try the principles of the lever and lift up the door stopper.

5. Now, the door stopper is free from the door assembly.

6. Release two (2) pins of door panel from two (2) holes of upper and lower oven hinges by lifting up.

7. Now, door panel is free from oven cavity.

8. Insert a putty knife (thickness of about 0.5mm) into the gap between the choke cover and door frame as shown in Figure C-4 to free engaging parts.

9. Pry the choke cover by inserting a putty knife as shown Figure C-4.

10.Release choke cover from door panel.

11.Now choke cover 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.

R405KST

NOTE: After any service to the door;

1) Make sure that door sensing switch and primary interlock switch 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.

3. After any service, make sure of the following:

1. Door latch heads smoothly catch latch hook through latch holes and that latch head goes through center of latch hole.

2. Deviation of door alignment from horizontal line of cavity face plate is to be less than 1.0mm.

3. Door is positioned with its face pressed toward cavity face plate.

4. Check for microwave leakage around door with an approved microwave survey meter. (Refer to Microwave Measurement Procedure.)

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. 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.

10

11

12

13

9

8

7

1

6

2

Door stopper

3

4

5

Door Frame

Putty Knife

Pin

Upper oven hinge

Choke Cover

Figure C-4. Door Disassembly

12.Slide latch head upward and remove it from door frame with releasing latch spring from door frame and latch head.

13.Now, latch head and latch spring are free.

14.Release door panel from nine (9) tabs of door frame by sliding door panel downward.

15.Now, door panel with sealer film is free.

16.Tear sealer film from door panel.

17.Now, door panel is free.

18.Remove door screen from door frame.

19.Now, door screen is free.

20.Remove the door decoration from the door frame by straightening the tabs of the door decoration.

21.Now, the door frame is free.


1. Reinstall the door decoration to the door frame by bending the tabs of the door decoration.

2. Reinstall door screen to door frame.

3. Put sealer film on door panel. Refer to “Sealer Film” about how to handle new one.

4. Reinstall door panel to door frame by fitting nine (9) tabs of door frame to nine (9) holes of door panel.

5. Reinstall the latch spring to the latch head. Reinstall the latch spring to the door frame. Reinstall latch head to door frame.

6. Reinstall choke cover to door panel by pushing

7. Catch two (2) pins of door panel on two (2) hole of upper and lower oven hinges as shown Figure C-5.

8. Re-install the door stopper to the door assembly.

11 – 6

Door assembly

Sealer film

Choke cover

Door stopper

Lower oven hinge

Pin

Lower oven hinge

Figure C-5. Door Replacement

4. SEALER FILM

1. Put the adhesive tape on the backing film of the sealer film as shown in Fig. C-6.

2. Tear the backing film by pulling the adhesive tape.

3. Put the pasted side of the sealer film on the door panel.

Backing film

Adhesive tape

Figure C-6. Sealer film

R405KST


[1] Pictorial Diagram (Figure S-1)

Service Manual

Figure S-1. Pictorial Diagram

12 – 1

SWITCH

MONITOR

[2] Control Panel Circuit (Figure S-2)

G9 G10 G11 G12 G13

R405KST

Figure S-2. Control Panel Circuit

12 – 2

R405KST

[3] Printed Wiring Board (Figure S-3)

Figure S-3. Printed Wiring Board

12 – 3

R405KST

PARTS LIST

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

MODEL R-405KS-T

Parts marked "*" may cause undue microwave exposure.

Parts marked " " are used in voltage more than 250V.

CONTENTS

[1] OVEN PARTS PANEL PARTS

[2] DOOR AND CONTROL

INDEX

DOOR PROTECTION SHEET

SPADPA204WRE0

TOP PAD ASSEMBLY

FPADBA624WRKZ

CABINET COVER

SPAKHA010WRE0

PLASTIC BAG

SSAKHA032WRE0

INTO THE

OVEN CAVITY

6- 7 OPERATION MANUAL

6-2 TURNTABLE TRAY

6-1 TURNTABLE SUPPORT

TRAY PACK

SPADFA389WRE0

Not replaceable items.

BOTTOM PAD ASSEMBLY

FPADBA625WRKZ

PACKING CASE

FPAK-A563WRKZ

SHARP CORPORATION

This document has been published to be used for after sales service only.

The contents are subject to change without notice.

R405KST

[1] OVEN PARTS

7-10

7-2

7-10

2-1

4-13

1-6

6-3

4-11

6-4

1-10

4-5

4-15

4-3

7-5

7-8

1-7

7-9

7-6

1-3

7-8

7-1

4-4

1-1

1-2

4-7

7-10

6-1

6-2

2-3

2-2

7-1

2-3

2-3

4-10

1-12

1-13

7-3

7-3

4-8

4-12

4-1

1-4

7-7

7-8

4-2

4-6

1-4

1-2

1-9

1-8

7-1

7-10

2-3

7-4

4-9

1-5

7-10

7-10

1-11

4-14

2

7-2

*

!

*

*

!

!

!

!

!

NO.

PARTS CODE

[1] OVEN PARTS

ELECTRIC PARTS

1-1

1-1

1-2

1-2

1-3

1-4

1-4

FPWBFA417WRKZ

FPWBFA389WRKZ

FFS-BA033WRKZ

FFS-BA037WRKZ

QFS-TA013WRE0

QSW-MA085WRE0

QSW-MA147WRZZ

1-5 RV-MZA346WRZZ

1-10

1-11

1-11

1-11

1-12

1-12

1-13

1-13

1-6

1-6

1-6

1-7

1-7

1-8

1-9

1-9

4-1

4-2

4-3

4-4

4-5

4-6

4-7

4-8

RTHM-A119WRE0

RTHM-A075WRE0

RTHM-A134WRZZ

FACCDA083WRE0

FACCDA085WREZ

FH-DZA118WRKZ

RC-QZA211WRE0

RC-QZA331WRZZ

RMOTEA433WRZZ

RLMPTA087WRZZ

RLMPTA082WRZZ

RLMPTA085WRZZ

RMOTDA264WRZZ

RMOTDA186WRE0

RTRN-A746WRZZ

RTRN-A745WRZZ

OVEN PARTS

2-1

2-2

2-3

OVEN PARTS

GCABUB010WRPZ

GDAI-A390WRWZ

GLEGPA104WREZ

PHOK-A130WRFZ

LBNDKA163WRPZ

NFANJA053WRFZ

LANGTA419WRPZ

*************

MLEVPA244WRFZ

PCOVPA311WRE0

PCUSGA532WRP0

4-9

4-10

4-11

4-12

PCUSUA191WRP0

PPACGA084WRF0

PCUSUA410WRP0

PCUSUA455WRP0

4-13

4-14

PDUC-A610WRF0

PDUC-A936WRFZ

4-15 PPACGA272WREZ

MISCELLANEOUS

6-1

6-2

6-3

6-4

FROLPA097WRKZ

NTNT-A108WREZ

TCAUAA292WRRZ

TCAUAA296WRRZ

SCREWS, NUTS AND WASHERS

7-1 XHPS740P08K00

LX-CZA070WRE0 7-2

7-3

7-4

7-5

7-6

7-7

7-8

7-9

7-10

LX-CZ0052WRE0

LX-EZA042WRE0

LX-EZA050WRE0

XHPS730P06000

XHPS740P08000

XHTS740P08RV0

XHTS740P12RV0

XOTS740P10000

PRICE

RANK

NEW

MARK

PART

RANK

BH

BA

AF

AC

AE

AB

AD

AR

AV

AG

--

AG

AG

AF

AK

AK

AG

AT

AY

AW

--

AN

AG

AF

AG

BK

AT

AW

BM

--

AX

AL

AL

AL

AQ

AN

AV

--

AK

AN

AK

AQ

AB

AB

AB

AG

AB

AC

AA

AB

AC

AB

AN

AW

AE

AH

DESCRIPTION

Noise filter assembly

Noise filter assembly (Interchangeable)

Monitor fuse 20A and monitor switch

Monitor fuse 20A and monitor switch (Interchangeable)

Temp. fuse 150C (Magnetron)

Primary interlock switch/ door sensing switch

Primary interlock switch/ door sensing switch (Interchangeable)

Magnetron

Thermal cut-out 145C (Oven)



Power supply cord

Power supply cord (Interchangeable)

H.V. rectifier assy

High voltage capacitor

High voltage capacitor (Interchangeable)

Fan motor

Oven lamp

Oven lamp (Interchangeable)

Oven lamp (Interchangeable)

Turntable motor

Turntable motor (Interchangeable)

Power transformer

Power transformer (Interchangeable)

Outer case cabinet

Base plate

Leg

Latch hook

H.V. capacitor band

Fan blade

Chassis support

Oven cavity (Not a replacement part)

Switch lever

Waveguide cover

Cushion

Cushion

TTM packing

Cushion

Cushion

Fan duct

MG duct

Cushion

Roller assy

Turntable

Monitor caution

DHHS caution label

Screw : 4mm x 8mm

Special screw (Torx tamper proof screw

Special screw

Special screw

Special screw

Screw : 3mm x 6mm

Screw : 4mm x 8mm

Screw : 4mm x 8mm

Screw : 4mm x 12mm

Screw : 4mm x 10mm

R405KST

3

R405KST

[2] DOOR AND CONTROL PANEL PARTS

5-3

5-4

5-1

5-2

5-3-1

5-8

5-5

5-3-2

5-7

5-6

3-1

3-3

3-3

3-1-5

3-1-4

3-1-2

3-1-6

3-2

3-1-1

3-1-1-1

3-1-3

6-5

3-1-1-2

6-7

Actual wire harness may be different from illustration.

6-6

4

*

*

*

*

*

NO.

PARTS CODE

PRICE

RANK

NEW

MARK

[2] DOOR AND CONTROL PANEL PARTS

CONTROL PANEL PARTS

3-1

3-1-1

3-1-1-1

3-1-1-2

3-1-2

3-1-3

3-1-4

3-1-5

3-1-6

3-2

3-3

DOOR PARTS

5-1

DPNLCB972WRKZ

FBTN-A158WRKZ

JBTN-B358WRFZ

HDECQA299WRPZ

HDECQA300WRPZ

MSPRCA157WREZ

GMADIA158WRRZ

PSHEPB178WREZ

QSW-KA065DRZZ

DPWBFC531WRKZ

XEPS730P08XS0

FDORFA412WRTZ

5-4

5-5

5-6

5-7

5-2

5-3

5-3-1

5-3-2

PSHEPA336WRP0

FWAKPA445WRKZ

GWAKPB033WRFZ

HDECQA303WRPZ

HPNL-A866WRRZ

GCOVHA382WRF0

LSTPPA139WRF0

MSPRTA084WRE0

5-8 LSTPPA167WRF0

MISCELLANEOUS

6-5

6-6

6-7

FW-VZC094WREZ

FW-VZC093WREZ

TINSEB118WRRZ

BF

AF

BF

AX

BA

AR

AM

AE

AB

AG

BD

AX

AK

AL

AT

AF

AH

AT

AQ

BK

AB

AS

AN

AM

PART

RANK

Panel med assembly

Open button assembly

Open button

Button decoration

Panel decoration

Open button spring

Display window

Key sheet

FPC

Control unit

Screw; 3mm x 8mm

Door panel

Sealer film

Door frame assembly

Door frame

Door decoration

Door screen

Choke cover

Latch head

Latch spring

Door stopper

Main wire harness

Filter harness

Instruction book

DESCRIPTION

R405KST

5

R405KST

INDEX

PARTS CODE

[ D ]

DPNLCB972WRKZ

DPWBFC531WRKZ

[ F ]

FACCDA083WRE0

FACCDA085WREZ

FBTN-A158WRKZ

FDORFA412WRTZ

FFS-BA033WRKZ

FFS-BA037WRKZ

FH-DZA118WRKZ

FPWBFA389WRKZ

FPWBFA417WRKZ

FROLPA097WRKZ

FWAKPA445WRKZ

FW-VZC093WREZ

FW-VZC094WREZ

[ G ]

GCABUB010WRPZ

GCOVHA382WRF0

GDAI-A390WRWZ

GLEGPA104WREZ

GMADIA158WRRZ

GWAKPB033WRFZ

[ H ]

HDECQA299WRPZ

HDECQA300WRPZ

HDECQA303WRPZ

HPNL-A866WRRZ

[ J ]

JBTN-B358WRFZ

[ L ]

LANGTA419WRPZ

LBNDKA163WRPZ

LSTPPA139WRF0

LSTPPA167WRF0

LX-CZ0052WRE0

LX-CZA070WRE0

LX-EZA042WRE0

LX-EZA050WRE0

[ M ]

MLEVPA244WRFZ

MSPRCA157WREZ

MSPRTA084WRE0

[ N ]

NFANJA053WRFZ

NTNT-A108WREZ

No.

1-4-4

1-4-2

2-5-6

2-5-8

1-7-3

1-7-2

1-7-4

1-7-5

1-4-6

2-3-1-3

2-5-7

1-4-3

1-6-2

2-3-1

2-3-2

1-1-1

1-1-1

1-6-1

2-5-3

2-6-6

2-6-5

1-1-7

1-1-7

2-3-1-1

2-5-1

1-1-2

1-1-2

1-1-8

1-2-1

2-5-5

1-2-2

1-2-3

2-3-1-4

2-5-3-1

2-3-1-1-2

2-3-1-2

2-5-3-2

2-5-4

2-3-1-1-1

PRICE

RANK

NEW

MARK

PART

RANK

AT

AK

AE

AG

AA

AC

AB

AB

AG

AF

AB

AG

AW

BD

BK

AW

AY

AN

BF

AN

AS

AQ

AQ

AX

BF

--

AN

AN

BH

AM

BA

AF

AH

AX

AL

AT

BA

AR

AK

PARTS CODE

[ P ]

PCOVPA311WRE0

PCUSGA532WRP0

PCUSUA191WRP0

PCUSUA410WRP0

PCUSUA455WRP0

PDUC-A610WRF0

PDUC-A936WRFZ

PHOK-A130WRFZ

PPACGA084WRF0

PPACGA272WREZ

PSHEPA336WRP0

PSHEPB178WREZ

[ Q ]

QFS-TA013WRE0

QSW-KA065DRZZ

QSW-MA085WRE0

QSW-MA147WRZZ

[ R ]

RC-QZA211WRE0

RC-QZA331WRZZ

RLMPTA082WRZZ

RLMPTA085WRZZ

RLMPTA087WRZZ

RMOTDA186WRE0

RMOTDA264WRZZ

RMOTEA433WRZZ

RTHM-A075WRE0

RTHM-A119WRE0

RTHM-A134WRZZ

RTRN-A745WRZZ

RTRN-A746WRZZ

RV-MZA346WRZZ

[ T ]

TCAUAA292WRRZ

TCAUAA296WRRZ

TINSEB118WRRZ

[ X ]

XEPS730P08XS0

XHPS730P06000

XHPS740P08000

XHPS740P08K00

XHTS740P08RV0

XHTS740P12RV0

XOTS740P10000

1-4-7

1-4-8

1-4-9

1-4-11

1-4-12

1-4-13

1-4-14

1-4-1

1-4-10

1-4-15

2-5-2

2-3-1-5

1-1-3

2-3-1-6

1-1-4

1-1-4

1-1-9

1-1-9

1-1-11

1-1-11

1-1-11

1-1-12

1-1-12

1-1-10

1-1-6

1-1-6

1-1-6

1-1-13

1-1-13

1-1-5

1-6-3

1-6-4

2-6-7

2-3-3

1-7-6

1-7-7

1-7-1

1-7-8

1-7-9

1-7-10

No.

PRICE

RANK

NEW

MARK

PART

RANK

AD

AR

AV

AK

AE

AG

AF

AC

AB

AG

AF

AT

AG

AQ

AF

AG

AL

AW

AT

AX

AN

AK

AV

--

AL

AL

AK

--

BM

BK

AE

AH

AM

AB

AB

AB

AB

AG

AC

AB

6

COPYRIGHT © 2006 BY SHARP CORPORATION

ALL RIGHTS RESERVED.

COPYRIGHT

©

XXXX BYSHARP CORPORATION

No part of this publication may be reproduced, stored any means, electronic, mechanical, photocopying, recording, or other wise, without prior written permission

stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher.

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