SHARP

” -.- _~__

_ _

SERVICE MANUAL

S8304 R3A55PJ/

R-3A55

MICROWAVE OVEN

Momx R-3A55

In interests of user-safety the oven should be restored to its original condi-

TABLE OF CONTENTS

GENERAL IMPORTANT INFORMATiON.. ...................................................................................................

WARNING ......................................................................................................................................................

RODUCT SPECIFICATIONS .........................................................................................................................

APPEARANCE VIEW ....................................................................................................................................

OPERATING SEQUENCE .............................................................................................................................

FUNCTION OF IMPORTANT COMPONENTS’ ............................................................................................

TRABLESHOOTING CHART .........................................................................................................................

TEST PROCEDURE ......................................................................................................................................

TOUCH CONTROL PANEL .........................................................................................................................

COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE ........................................................

MICROWAVE MEASUREMENT ..................................................................................................................

WIRING DIAGRAM ......................................................................................................................................

PICTORIAL DIAGRAM .............................................................................................................................

CONTROL PANEL CIRCUIT .......................................................................................................................

PRINTED WIRING BOAD ...........................................................................................................................

PARTS LIST ................................................................................................................................................. page

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1

2

3

21

26

27

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7

9

16

29

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31

SHARP CORPORATION

SERVICE MANUAL

MICROWAVE OVEN

R-3A55

GENERAL IMPORTANT INFORMATION

This Manual has been prepared to provide Sharp Corp. Service engineers with Operation and Service Information.

It is recommended that service engineers carefully study the en- tire text of this manual. so that they will be qualified to render sat- isfactory customer service.

7

CAUTION

MICROWAVE RADIATION

Service engineers should not be exposed to the microwave en- ergy which may radiate from the magnetron or other microwave generating devices if it is improperly used or connected. All in- put and output microwave connections, waveguides, flanges andgaskets must be secured. Never operate the device without a microwave energy absorbing load attached. Never look into an open waveguide.

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WARNING

Never operate the oven until the following points are ensured.

(A) The door is tightly closed.

(B) The door brackets and hinges are not defective.

(C) The door packing is not damaged.

(D) The door is not deformed or warped.

(E) There is not any other visible damage with the oven.

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

All the parts marked “*” on parts list are used at voltages more than 25OV.

Removal of the outer wrap gives access to potentials above

25ov.

PRODUCT SPECIFICATION

OPEARTING SEQUENCE

TOUCH CONTROL PANEL

AND ADJUSTMENT PROCEDURE A

--- --

MICROWAVE MESUREMENT

-P

WIRING DIAGRAMS

PARTS LIST

SHARP CORPORATION

OSAKA, JAPAN

Fb3A55

ITEM

Power Requirements

Power Consumption

Power Output

Case Dimensions

Cooking Cavity Dimensions

Turntable diameter

Control Complement

PRODUCT SPECIFICATIONS

DESCRIPTION

240 Volts

50 Hertz

Single phase, 3 wire earthed

1.35 kW Approx. 6.1 A

750 watts nominal of RF microwave energy (AS 2895 1986)

850 watts (IEC-705-1988 )

Operating frequency of 2450MHz

Width 520mm

Height 305mm

Depth 385mm

Width 348mm

Height 197mm

Depth 368mm

325mm

Touch Control System

Clock ( 1:00 - 12:59)

Timer (0 - 99 minutes 99 secinds)

Microwave Power for Variable Cooking

Repetition Rate;

HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full power throughout the cooking time

MEDIUM HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 70% of Full Power

MEDIUM . . . . . . . . . . . . ..*..................*.*........................* approx. 50% of Full Power

MEDIUM LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*..................... approx. 30% of Full Power

LOW . . . . . . . . . . . . . . . ..*.......................*......*...*............... approx. 10% of Full Power

INSTANT ACTION (8 menu)

AUTO COOK pad

EASY DEFROST

NUMBER pads

POWER LEVEL pad

MORE. LESS pads

STOP/CLEAR pad

AUTO START/CLOCK pad

INSTANT COOK/START pad

A ---a.* 4P I.-

13

KCI

GENERAL INFORMATION

WARNING

THIS APPLIANCE BE EARTHED

IMPORTANT

THE WIRES IN THIS MAINS LEAD ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:

GREEN-AND-YELLOW

BLUE

BROWN

: EARTH

: NEUTRAL

: LIVE

NOTE: Numbers and letters shown after sentences such as “RD44101 IJ” are for factory use only.

2

APPEARANCE VIEW

.fi (Top)

/‘-

1. Ventilation openings

2. Oven lamp

3. Door hinges

4. Door safety latches

5. See through door

6. Coupling

7, Door open button

8. Touch control panel

9. Digital readout

10. Wave guide cover

11. Access cover for oven lamp replacement

12. Power supply cord

13. Rating label

DISPLAY

I REtiEAT 3E=ROST MED LOW rflGc; j

1 Km .

/x/ \I/ /x/ /\I /QiJ

AUTO Kg COOK t

TOUCH CONTROL PANEL

INSTANTACTiONPADS pCpdiTMU.

AUTOCOOKMENUS ww.

3Jacket potato

4RoastLamb

5cornedMeat

AUTO

COOK

, z3,or4 SERVE OuANTTlY PAD

Toaxktw,three,orfourse~es, press~padprior~pressing

- ltlf2InslarltAdionpad.

-N-PADS

Presstoentercooldhgtines,dod< tine,weigMofquantih/offood,or

AUTOSTART/CLOCKPAD

Prtzsstoset~ofAutostalttime.

3

R-3A55

OPERATION SEQUENCE

OFF CONDITION

Closing the door activates all door interlock switches

(1 st. latch switch, 2nd. latch switch and stop switch)

IMPORTANT

When the oven door is closed, the monitor switch contacts

(COM-NC) must be open.

When the microwave oven is plugged in a wall outlet, rated voltage is supplied to the point A3+A5 in the control unit.

Figure O-l on page 27

1. The display flashes “88:88”.

2. To set any programmes or set the clock, you must first touch the STOP/CLEAR pad.

3. “88:88” appears in the display and the time counts up every minute.

NOTE:When the oven door is opened, comes on at this time.

MICROWAVE COOKING CONDITION

the oven lamp

HIGH COOKING

Enter a desired cooking time with the touching NUMBER

Pad and start the oven with touching START pad.

Function sequence

Figure O-2 on page 27

CONNECTED COMPONENTS

Oven lamp. Fan motor, Turntable motor

Power transformer

RELAY

RYl

RY2

1. Rated voltage. is supplied to the primary winding of the power transformer. The voltage is converted to about

3.3 volts A.C. output on the filament winding and high

2 voltage of approximately 2000 volts A.C. on the secon- dary winding.

The filament winding voltage (3.3 volts) heats the mag-

3. netron filament and the high voltage (2000 volts) is sent to the voltage doubling circuit, where it is doubled to negative voltage of approximately 4000 volts D.C..

The 2450 MHz microwave energy produced in the magnetron generates a wave length of 12.24 cm. This energy is channeled through the waveguide (transport channel) into the oven cavity, where the food is placed to be cooked.

4.

5.

When the cooking time is up, a signal tone is heard and the relays RYl+RY2 go back to their home position.

The circuits to the oven lamp, power transformer, fan motor and turntable motor are cut off.

When the door is opened during a cook cycle, the switches come to the following condition

SWITCH

1st. latch switches

2nd. latch switch

Monitor switch

Stop switch

CONTACT

COM-NO

COM-NO

COM-NC

COM-NO

CONDITION

DURING DOOR OPEN

CCXMNG (NO COOKING)

Closed Open

Closed Open

Open Closed

Closed

Open

4

6-3

The circuits to the power transformer, fan motor and turntable motor are cut off when the 1st. latch switch,

2nd. latch switch, and stop switch are made open. The oven lamp remains on even if the oven door is opened after the cooking cycle has been interrupted, because the relay RYl stays closed. Shown in the display is the remaining time.

6. MONITOR SWITCH CIRCUIT

The monitor switch is mechanically controlled by oven

6-1 door, and monitors the operation of the 1st and 2nd. latch switches.

When the oven door is opened during or after the cycle of a cooking program, the 1st. latch switch, 2nd. latch switch and stop switch must open their contacts first.

After that the contacts (COM-NC) of the monitor switch can be closed.

6-2. When the oven door is closed, the contacts (COM-

NC) of the monitor switch must be opened. After that the contacts of the 1st. latch switch, 2nd. latch switch and stop switch are closed.

When the oven door is opened and the contacts of thelst. latch switch, 2nd. latch switch remain closed.

The fuse M8A will blow, because the monitor switch is closed and a short circuit is caused.

MEDIUM HIGH, MEDIUM, MEDIUM LOW, LOW

COOKING

When the microwave oven is preset for variable cooking power 240 volts AC. power is supplied to the power trans- former intermittently within a 32-second time base through the relay contact which is coupled with the current-limiting relay. The following levels of microwave power are given.

SETTING:

32 sec. ON

HIGH

24 sec. ON

MEDIUM HIGH

MEDIUM

18 sec. ON

N-1

12 sec. ON

MEDIUM LOW I]

LOW

6 sec. ON m-1

8 sec. OFF

14 sec. OFF

Approx. 50% = 450 Watts

20 sec. OFF

Approx. 30% = 270 Watts

26 sec. OFF

Approx. 10% = 90 Watts

NOTE:The ON/OFF time ratio does not exactly corre- spond to the percentage of microwave power, be- cause approx. 2 seconds are needed for heating up the magnetron filament.

FUNCTION OF IMPORTANT COMPONENTS

DOOR OPEN MECHANISM

The door is opened by pushing the open button on the control panel, refer to the Figure D-l.

When the open button is pushed, the open button pushes up the switch lever, and then the switch lever pushes up the the latch head. The latch heads are moved upward and released from latch hook. Now the door will open.

ASYMMETRIC RECTIFIER

The asymmetric rectifier is a solid state device that pre- vents current flow in both directions. And it prevents the temperature rise of the power transformer by blowing the fuse M8A when the high voltage rectifier is shorted.

LATCH dOOK

SWITCH

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Figure D-l. Door Open Mechanism

--. MONITCR

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HIGH VOLTAGE RECTIFIER

The rated peak reverse voltage of DI of the asymmetric rectifier is 6 KV The rated peak reverse voltage of D2 of the asymmetric rectifier is 1.7 KV. Dl and D2 of the asymmet- ric rectifier or high voltage rectifier are shorted when the each peak reverse voltage goes beyond the each rated peak reverse voltage. (The process of blowing the fuse

MSA.)

1. The high voitage rectifier is shorted by any causes when microwave cooking.

2. The peak reverse voltage oi Df of the rectifier goes beyond the rated peak reverse voltage i .7 KV in the voltage doubler cir- cuit.

3. D2 of the rectifier is shorted.

4. The large electric currents flow through the high voltage winding of the power transformer

5. The large electric currents beyond 8A flow through the primary winding of the power transformer.

6. The fuse M8A blows by the large electric currents.

7. The power supply to the all electrical parts are cut off.

1ST. LATCH SWITCH, 2ND. LATCH SWITCH

AND STOP SWITCH

1. When the oven door is closed, the contacts COM-NO) must be closed.

2. When the oven door is opened, the contacts .(COM-

NO) must be opened.

MONITOR SWITCH

1. When the oven door is closed, the contacts (COM-NC) must be opened.

2. When the oven door is opened, the contacts (COM-NC) must be closed.

3. If the oven door is opened and the contacts (COM-NO) of the 1st. latch switch and 2nd. latch switch fail to open, the fuse M8A blows simultaneously with closing the contacts (COM-NC) of the monitor switch.

CAUTION: BEFORE REPLACING A BLOWN FUSE M8A

TEST THE 1ST. LATCH SWITCH, 2ND.

LATCH SWITCH MONITOR SWITCH AND

MONITOR RESISTOR FOR PROPER OP-

ERATION.

MONITOR RESISTOR R 0.8R 20W

The monitor resistor prevents the fuse M8A bursting when the fuse M8A blows due to the operation of the monitor switch.

5

FUSE M8A

1. The fuse M8A blows when the contacts (COM-NO) of the 1st. latch switch and 2nd. latch switch remain closed with the oven door open and when the monitor switch closes.

2. The fuse M8A also blows when asymmetric rectifier,

H.V. rectifier, H.V. wire harness, H.V.capacitor, magne- tron or secondary winding of power transformer is shorted.

3. If the wire harness or electrical components are short- circuited, this fuse M8A blows to prevent an electric shock or fire hazard.

THERMAL CUT-OUT TC 145°C (MG)

This thermal cut-out protects the magnetron against over- heating. If the temperature goes up higher than 145°C because the fan motor is interrupted, the ventilation open- ings are blocked, the thermal cut-out will open and the line voltages to the power transformer will be cut off and the operation of the magnetron will be stopped.

The defective thermal cut-out must be replaced with new one.

R-3A55

THERMAL CUT-OUT TC 145”@(OVEN)

The thermal cut-out located on the top of the oven cavity is designed to prevent damage to the oven if the foods in the oven catch fire due to over heating produced by improper setting of cook time or failure of control unit. Under normal operation, the oven thermal cut-out remains closed. How- ever, when abnormally high temperatures are reached within the oven cavity, the oven thermal cut-out will open at

145”C, causing the oven to shut down. The defective ther- mal cut-out must be replace with new one.

THERMAL CUT-OUT 95°C (FAN MOTOR)

The thermal cut-out protect the fan motor against over- heating. If its temperature goes up higher than 95’C be- cause the fan motor is locked or the ventilation operating are blocked, the contacts of the thermal cut-out will open and switch off the oven. When the oven cools itself down to

7523, the contacts of the thermal cut-out will close again.

TURNTABLE MOTOR

The turntable motor drives the turntable roller assembly to rotate the turntable.

FAN MOTOR

The 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 chan- neled 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

R-3A55

TROUBLESHOOTING CHART

WARNING TO SERVICE PERSONNEL

Microwave ovens contain circuitry capable of producing very high voltage and current, contact with any part of the high voltage circuit will result in electrocution.

REMEMBER TO CHECK 30

REMEMBER TO CHECK4FJ

1) Disconnect the supply.

2) Door opened, and wedged open.

3) Discharge high voltage capacitor.

1) Reconnect all leads removed from components testing.

2) Replace the outer case (cabinet). during

WARNING AGAINST THE CHARGE OF THE

The high-voltage capacitor remains charged 1 about 60 seconds after the oven has been I

/ switched off. Wait for 60 seconds and then short- circuit the connection of the high-voltage capaci- 1 tor (that is, of the connecting lead of the high-volt- / i age rectifier) against the chassis with the use of /

/ an insulated screwdriver.

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Sharp recommend that wherever possible fault-find- ing is carried out with the supply disconnected. It may in, some cases, be necessary to connect the supply after the outer case has been removed, in this event carry out 30 checks and then disconnect the leads to the primary of the power transformer.

Ensure that these leads remain isolated from other components and the.oven chassis, (Use insulation tape if necessary.) When the testing is completed carry out 3tJ checks and reconnect the leads to the primary of the power transformer.

4) Run the oven. Check all functions.

3, Reconnect the supply-

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 microwave timer for two (2) minutes. Set the power level to HIGH and push the START button. When the two minutes has elapsed (timer at zero) carefully check that the water is now hot. If the water remains cold carry out 30 checks and re-examine 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 reakage test carried out

TROUBLESHOOTING GUIDE

When troubleshooting the microwave oven, it is helpful to follow the Sequence of Operation in performing the checks. Many of the possible causes of trouble will re- quire 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 fuse M8A in the 1st. latch switch - 2nd. latch switch - monitor switch - monitor resistor circuit, check the 1st. latch switch, 2nd. latch switch, monitor switch and monitor resistor before replacing the fuse M8A.

R-3A55

CONDITION

TEST PROCEDURE

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POSSIBLE CASE

AND DEFECTIVE

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:ONDITION

Display does not ooeratt properly when STOPICLEAF

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1 Oven iamp does not irah? a ooor ooeped. iDlsp!aG ap

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Over or any erectncai parts aoes no: stop when cookrng time 1s 0 c- STOP/CLEAR pat is touched.

Oven seem to be operatmg but little or no heat is produced

;n oven load. iMIcrowave power level IS se: at HIGH)

Oven Uoes not seems to be operating properly when ME-

DIUM HIGH, MEDIUM, ME-

DIUM LOW or LOW is set.

(Oven operates properly at

HIGH and then the STOP/

CLEAR pad is touched the oven stops.)

Oven goes into cook cycie but shuts down before end of cooking cycle.

Oven stops as soon as when the START pad is touched.

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8

TEST PROCEDURES

PROCEDURE

LElTER

A

COMPONENT TEST

MAGNETRON TEST

1 NEVER TOUCH ANY PART IN THE CIRCUIT WITH YOUR HAND OR AN INSULATED TOOL /

I

WHILE THE OVEN IS IN OPERATION.

CARRY OUT 3D CHECKS

Isolate the magnetron from the high voltage circuit by removing all leads connected to the filament terminal.

To test for an open circuit filament use an ohmmeter to make a continuity test between the magnetron filament terminals, the meter should show a reading of less than 1 ohm.

To test for a short circuit filament to anode condition, connect ohmmeter between one of the filament terminals and the case of the magnetron (ground). This test should be indicated an infinite resistance.

If a low or zero resistance reading is obtained then the magnetron should be replaced.

MICROWAVE OUTPUT POWER (1 Liter water load)

The foliowing test procedure should be carried out with the microwaveoven in a fully assembled condi- tion (outer case fitted).Microwave output power from the magnetron can be measured by way oflEC

705, i.e. it can be measured by using water load how much it can be absorbed by the water load. To measure the microwave output power in the microwave oven, the relation of calorie and watt is used.When P(W) heating works for t(second), approximately P x t/4.1 87calorie is generated. On the other hand. if the temperature of the water with V(ml) rises AT (“C) during this microwave heating period, the calorie of thewater is V x IT

/ The formula is as follows:

I Pxti4.187=Vx_l-T P(W)=4.l87xVxAT/t

1 Our condition for the water load is as follows:

1 Water load . . . . . 1000 g

/

Room temperature . . . . . . . . . . . . . . . . . . . . . . . . . . around 20°C Power supply Voltage

P =‘85 x IT

Initial temperature . . . . . . . . . . . 10+2”C

. . . . . . . . . . . . . . . Rated voltage

Heating time . . . . . . . . . . . . . . . . . . . . . 49 sec. j

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Measuring condition:

1. Container

The water container must be a cylindrical borosilicate glass vessel having a maximum material thickness of 3 mm and an outside diameter of approximately 190 mm.

2. Temperature of the oven and vessel

The oven and the empty vessel are at ambient temperature prior to the start of the test.

3. Temperature of the water

The initial temperature of the water is (10 12)“C.

4. Select the initial and final water temperature so that the maximum difference between the final water temperature and the ambient temperature is 5°C.

5. Select stirring devices and measuring instruments in order to minimize addition or removal of heat.

6. The graduation of the thermometer must be scaled by 0.1 “C at minimum and an accurate ther- mometer.

7. The water load must be (1000 f 5) g.

8. “t” is measured while the microwave generator is operating at full power. Magnetron filament heat- up time is not included.

NOTE: The operation time of the microwave oven is “t + 2” sec. 2 sec. is magnetron filament heat-up time.

Measuring method:

1. Measure the initial temperature of the water before the water is added to the vessel.

(Example: The initial temperature Tl = 11 “C)

2. Add the 1 litre water to the vessel.

3 Place the load on the centre of the shelf.

9

TEST PROCEDURES

PROCEDURE

LElTER COMPONENT TEST

4. Operate the microwave oven at HIGH for the temperature of the water rises by a value A T of

(10 ?I 2)“C.

5. Stir the water to equalize temperature throughout the vessel.

6. Measure the final water temperature.

(Example: The final temperature T2 = 21 “C)

7. Calculate the microwave power output P in watts from above formula.

Initial temperature ............................................................................................

Temperature after (49+2)= 51 sec. .................................................................

Temperature difference Cold-Warm .............................................................

Measured output power

The equation is “P= 85 x

AT” ................................................

Tl = 11°C

T2=21C

AT1 =

10°C

P= 85 x 10°C = 850 Watts

JUDGMENT: The measured output power should be at least f 15 % of the rated output power.

CAUTION: 1 C CORRESPONDS TO 85 WA-l-l-S. REPEAT MEASUREMENT IF THE POWER IS

INSUFFICIENT.

.

T2.C

Heat up for 51 sec.

MICROWAVE OUTPUT POWER (2 Liter water load)

The following test procedure should be carried out with the microwave oven in a fully assembled condition (with outer case fitted).

Microwave output power from the magnetron can be measured by way of substitution, i.e. it can be measured by using a water load how much it can be absorbed by the water load. To measure the microwave output power in the microwave oven the relation of calorie and watt is used.

On the other hand, if the temperature of the water with V(ml) rises

AT

(“C) during this microwave heating period, the calorie of the water is V x AT.

The formulae is as follows;

P =8330xAT/t

Our condition for the water load is as follows:

Room temperature . . . . . . . . . . . . . . . . . 23* 2°C

Water load

. . . . . . . 2000 ml

Power supply Voltage

Initial temperature . . . . . . . 23 2 1 “C

. . . . . . . . . . . . . . . . . . Rated voltage.

Heating time . . . . 1 min. 51 sec.

P = 75 x AT

Measuring method:

A) The two water containers must be prepared.

The water container must be one (1) litre beaker made of Pyrex glass and its diameter approxi- mately 12cm.

B) Put the one (1) litre water into each beaker (Each beaker has one litre water). The initial tempera- ture of the water should be 23+2X.

C) Mark Tl on the one beaker and mark T2 on the other one. And stir the water and measure the temperature of water the thermometer and note them. The graduation of the thermometer must be scaled by 0.1% at minimum and an accurate mercury thermometer is recommended.

D) Place the two (2) beakers as touching each other in the centre of the oven cavity.

E) Set the timer to 1 minute and 51 seconds start the oven at HIGH.

10

TEST PROCEDURES

PROCEDURE

LETTER COMPONENT TEST

F) The time must be measured with stopwatch or wristwatch.

G) After 1 minute and 51 seconds, stop the oven by opening the door.

H) Put the two (2) beakers out of the oven cavity and measure the temperature of the water by stirring the water with thermometer and note them.

Example

Initial temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tl = 23°C T2 = 24°C

Temperature after 1 min. 51 sec. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tl = 33°C T2 = 34°C

Temperature difference Cold-Warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 = 10°C

AT2 =

10°C

Mean temperature rise IT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT = (AT1 !I AT2) ; 2 = (1 OcC+lO”C) / 2 = 10°C

Measured output power

The equation is P= 75 x AT . . . . . . . . . . . . . . . . . . . . ..I....................................... P= 75 x 10°C = 750 Watts

NOTE: The measured output power should be at least z 15 % of the rated output power.

CAUTION: 1°C CORRESPONDS TO 75 WATTS.

REPEAT MEASUREMENT IF THE POWER IS INSUFFICIENT.

1 I

~

:

-

- -

-- iT1 OC)

1, 1

I

1

-

(-EOC) (Tl OC;

(T2OC)

B

C

POWER TRANSFORMER TEST

WARNING: High voltages and large currents are present at the secondary winding and fila- 1 ment winding of the power transformer. It is very dangerous to work near this 1 part when the oven is on. NEVER make any voltage measurements at the high- voltage circuits, including the magnetron filament.

CARRY OUT 3D CHECKS.

Disconnect the leads to the primary winding of the power transformer. Disconnect the filament and secondary winding connections from the rest of the HV circuitry. Using an ohmmeter, set on a low range, it is possible to check the continuity of all three windings. The following readings should be obtained : a. Primary winding ......................... approximately 1.73 ohms. b. Secondary winding ................... approximately 104.7ohms. c. Filament winding ...................................... less than 1 ohm.

If the reading obtained are not as stated above, then the power transformer is probably faulty and should be replaced.

CARRY OUT 4R CHECKS

HIGH VOLTAGE RECTIFIER ASSEMBLY TEST

HIGH VOLTAGE RECTIFIER TEST

CARRY OUT 3D CHECKS.

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.

11

TEST PROCEDURES

PROCEDURE

LEl-l-ER COMPONENT TEST

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 mor than 100 kL2 in the other direction.

A D2 Dl B

CARRY OUT 4R CHECKS

ASYMMETRIC RECTIFIER TEST

ASYMMETRIC

RECTIFIER

CARRY OUT 3D CHECKS. c HIGH VOLTAGE RECTIFIER

+T@

Isolate the high voltage rectifier assembly from the HV circuit. The asymmetric rectifier can be tested using an ohmmeter set to its highest range. Connect the ohmmeter 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 an asymmetric rectifier is shorted in either direction, then the the asymmetric rectifier is probably faultly and must be replaced with the high voltage rectifier. When the asymmetric rectifier is defective, check whether magnetron, high voltage rectifier, high voltage wire or filament winding of the power trans- former is shorted.

CARRY OUT @ CHECKS

NOTE: For measurement of the resistance of the rectifier, the batteries of the measuring instrument must have a voltage at least 6 volts, because otherwise an infinite resistance might be shown in both directions.

D

E

HIGH VOLTAGE CAPACITOR TEST

CARRY OUT m CHECKS.

A Isolate the high voltage capacitor from the circuit.

3. Continuity check must be carried out with measuring instrument which is set to the highest resis- tance range.

C. A normal capacitor shows continuity for a short time (kick) and then a resistance of about 10 MR after it has been charged.

D. A short-circuited capacitor shows continuity all the time.

E. An open capacitor constantly shows a resistance of about 10 MS1 because of its internal 10 ML2 resistance.

F. When the internal wire is opened in the high voltage capacitor, the capacitor shows an infinite resistance.

G. The resistance across all the terminals and the chassis must be inifinte when the capacitor is nor- mal.

If incorrect readings are obtained, the high voltage capacitor must be replaced.

CARRY OUT 4R CHECKS

SWITCH TEST

CARRY OUT 3D CHECKS.

Isolate the switch to be tested and using an ohmmeter check between the terminals as described in the following table.

Table: Terminal Connection of Switch

Plunger Operation

Released

Depressed

COM to NO

O.C.

S.C.

COM to NC

SC.

O.C.

COM; Common terminal

NO; Normally open terminal

NC; Normally closed terminal

SC.; Short circuit

O.C.; Open circuit

If incorrect readings are obtained, make the necessary switch adjustment or replace the switch.

CARRY OUT $J CHECKS.

12

R-3A55

TEST PROCEDURES

PROCEDURE

LElTER

F

COMPONENT TEST

THERMAL CUT-OUT TEST

CARRY OUT 3fJ CHECKS

Disconnect the leads from the terminals of the thermal cut-out. Then using an ohmmeter. make a continuity test across the two terminals as described in the table below.

CARRY OUT 4J CHECKS

Table: Thermal cut-out Test

Parts Name

Thermal cut-out 145°C

Thermal cut-out 95°C

Temperature of “ON” condition

(closed crrcuit) (‘Cl

Temperature of “OFF” condition

(open circuit) (‘C;

Below -20-C

Below 75°C

Above 14.5 C

Above 95 C

< lndicatron ofohmmeter

I i

(When room temperature f is approx. 20-C‘,

Ciosea e~rcu~: i

I

J

Closed c!rczif.

If incorrect readings are obtained, replace the thermal cut-out.

An open circuit thermal cut-out 145’C (MG) indicates that the magnetron has overheated, This mad ke due to resistricted ventilation, cooling fan failure or a fault condition within the magnetrcn or HV 3:1rzziT

An open circuit thermal cut-out 145°C (OVEN) indicates that the foods in the oven may catcn fire. ths may be due to over heating produced by improper setting of the cooking time or faiiure of the contrc: panel.

An open circuit thermal cut-out 95°C (FAN) indicates that the fan motor !Jvinding has overheated. this may be due to blocked ventilation or locked cooling fan.

G

H

MONITOR RESISTOR TEST

CARRY OUT =CHECKS.

Disconnect the leads from the monitor resist. Using an ohmmeter and set on a low range. Check between the terminals of the monitor resistor.

The resistance of monitor resistor is approx. 0.8 ohms.

If incorrect readings are obtained, replace the monitor resistor.

CARRY OUT 4R CHECKS.

MOTOR WINDING TEST

CARRY OUT 3DCHECKS

Disconnect the leads from the motor.

Using an ohmmeter, check the resistance between the two terminals as described in the table below.

Motors

Fan motor

1 Turntable motor

Table: Resistance of Motor

Resistance

Aonroximatelv 370 12

1 Approximately 16.08 kQ

If incorrect readings are obtained, replace the motor.

CARRY OUT fi CHECKS

13

TEST PROCEDURES

PROCEDURE

LETTER COMPONENT TEST

BLOWN FUSE F M8A

CARRY OUT 3D CHECKS

1. If the fuse M8A is blown, there could be shorts or ground in electrical parts or wire harness.

Check them and replace the defective parts or repair the wire harness.

2. If the fuse M8A is blown when the door is opened, check the 2nd. latch switch, monitor switch and monitor resistor.

If the fuse M8A is blown by incorrect door switching replace the defective switch(s) and the fuse

M8A.

3. If the fuse M8A is blown, there could be a short in the asymmetric rectifier or there could be a ground in wire harness. A short in the asymmetric rectifier may have occured due to short or ground in H.V. rectifier, magnetron, power transformer or H.V. wire. Check them and re- place the defective parts or repair the wire harness.

CARRY OUT 4R CHECKS

CAUTION: Only replace fuse M8A with the correct value replacement

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 troubleshooting by replacement is described according to the symp- toms indicated.

1 Key Unit aj When touching the pads. a certain pad produces no signal at all. b) When touching a number pad, two figures or more are displayed. c) When touching the pads, sometimes a pad produces no signal.

2. Control Panel

The following symptoms indicate a defective control unit. Replacing the control unit.

2-1 In connection with pads. a> When touching the pads, a certain group of pads do not produce a signal. b) When touching the pads, no pads produce a signal.

2-2 In connection with indicators a) At a certain digit, all or some segments do not light up. b) At a certain digit, brightness is low. c) Only one indicator does not light. dj 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.

2-3 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.

14

K

L

R-3A55

RELAY TEST

CARRY OUTm CHECKS

Remove the outer case and check voltage between Pin Nos. 3 and 5 of the 3 pin connector (A) on the control unit with an A.C. voltmeter.

The meter should indicat 240 volts, if not check oven circuit.

RYl and RY2 Relay Test

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

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

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

/ OPERATIONAL

RELAY SYMBOL j

VOLTAGE

I

I

RYI

RY2

1 Approx. 26.0 V.C.C.

I

/ Approx. 25.0 V.D.C.

1

/

Power

CONNECTED transformer

COMPONENTS

I

CARRY OUT @ CHECKS

PROCEDURES TO BE TAKEN WHEN THE FOIL PATTERN ON THE PRINTED WIRING

BOARD(PWB) IS OPEN.

To protect the electronic circuits, this model is provided with a fine foil pattern added to the primary on the PWB, this foil pattern acts as a fuse. If the foil pattern is open, follow the troubleshooting guide given below for repair.

Problem: POWER ON, indicator does not light up.

CARRY OUT 30 CHECKS

STEPS j

1

OCCURANCE

The rated AC voltage is not present at

POWER terminal of CPU connector (CN-A)

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

Only pattern at “a” is broken.

Pattern at “a” and “b” are broken.

CAUSE OR CORRECTION

Check supply voltage and oven power cord.

Low voltage transformer or secondary circuit defective.

Check and repair.

*Insert jumper wire Jl and solder. (CARRY OUT 30

CHECKS BEFORE REPAIR)

*Insert the coil RCILF2003YAZZ between “c” and “d”.

(CARRY OUTS CHECKS BEFORE REPAIR)

NOTE: At the time of these repairs, make a visual inspection of the varistor for burning damage and examine the transformer with tester for the pres- ence of layer short-circuit (check primary coil resis- tance). If any abnormal condition is detected, re- place the defective parts.

CARRY OUT =CHECKS

15

9-3A55

TOUCH CONTROL PANEL ASSEMBLY

(1) Key Unit

(2) Control Unit

OUTRINE OF TOUCH CONTROL PANEL

The touch control section consists of the following units as shown in the touch control panel circuit.

3) Synchronizing Signal Circuit

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

The principal functions of these units and the signals communicated among them are explained below.

4) ACL Circuit

A circuit to generate a signals which resets the LSI to the initial state when power is supplied.

Key Unit

The key unit is composed of a matrix, signals gener- ated in the LSI are sent to the key unit through RIO-

R13, R20 and R22. When a key pad is touched, a signal is completed through the key unit and passed back to the LSI through ROO-R03 to perform the func- tion that was requested.

5) Buzzer Circuit

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

6) Door Sensing Switch (Stop Switch)

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

Control Unit

Control unit consists of LSI, power source circuit, synchronizing signal circuit, ACL circuit, buzzer circuit and indicator circuit.

7) Relay Circuit

To drive the magnetron, fan motor, turntable motor and light the oven lamp.

1) LSI

This LSI controls the key strobe signal, relay driving signal for oven function and indicator signal.

2) Power Source Circuit

This circuit generates voltages necessary in the control unit.

Symbol Voltage

VC -5v

VP

VFl

VF2

-30v

2.2Vac

Application

LSI(IC1)

Fluorescent display tube : Grid and anode voltage

Filament of fluorescent display tube

(VFl to VF2 voltage)

8) Indicator Circuit

Indicator element is a Fluorescent Display.

Basically, a Fluorescent Display is triode having a cathode, a grid and an anode. Usually. the cathode of a

Fluorescent Display is directly heated and the filament serves as cathode.

The Fluorescent Display has 6-digits, 13-segments are used for displaying figures.

16

DESCRIPTION OF LSI

LSI(IZA496DR)

The I/O signal of the LSl(lZA496DR) is detailed in the following table.

pi” No. ~ ;z;; ~ ; Description

I

Anode (seqment) of Fluorescent Displav illumination

Vp voltage of power source circuit input. voltaqe: -30V

Siqnal cominq from touch kev.

When either one of G12 line keys on key matrix is touched, a corresponding signal will be input into ROo.

/

5

4

6

1 R02 i IN

Siqnal cominq from touch kev.

When either one of

Gl

1 line keys on key matrix is touched, a corresponding signal will be input into ROI.

Siqnal cominq from touch key.

When either one of GlO line keys on key matrix is touched. a corresponding signal will be input into Ron.

Siqnal cominq from touch key.

When either one of G9 line keys on key matrix is toucned. a corresponding signal out of R2o-R23, Rl c-R: s wiil be input into ROs. When no ke :’ is touched. the signal is held at “L” level.

Connected to VC.

7

8

9

/

/

, I

/ TEST ~ IN

/ j RESET i IN

I

I

I

/

/ OSCl osc2

/ IN

\ OUT

Auto clear terminal.

Signal is input to reset the LSI to the initial state when power is supplied. Temporarily set to “L” level the moment power is supplied. at this time the LSI is set. Thereafter set at “H” level.

Internal ciock oscillation frequencv input settinq.

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

Internal clock oscillation frequencv control output.

Output to control oscillation input of OSC2.

10/l 1 / GND/Avss/

12 j AN0

13

15

17

1 AN1

1 AN3

AN5

IN/IN

/ OUT

1

]

OUT

OUT

OUT

IN

Connected to VC.

Oven lampturntable motor and coolinq fan motor drivinq siqnal. (Square Wave- j form : 50Hz) I

To turn on and off the control relay. The pulse signal (50Hz) is delivered to the control 1 relay driving circuit and cook relay control circuit.

I

Terminal not used.

Maqnetron hiqh-voltaqe circuit drivinq siqnal. according to the power level.

I

To turn on and off the cook relay. In low operation, the signals holds “L” level during 1 microwave cooking and “H” level while not cooking. In other cooking modes (MED 1

HIGH, MED,MED LOW,LOW) the signal turns to “H” level and “L” level in repetition 1

I

Terminal not used.

Input siqnal which communicates

Door closed; “H” level signal.

Door opened; “L” level signal. the door open/close information to LSI.

I

I

I

Terminal to change cooking constant.

18-19 AN6-AN7 IN Connected to VC. t

20/2 1 IAVCCNCCI IN/IN Connected to GND.

A Siqnal svnchronized with commercial source freqencv(5OHz).

This is basic timing for time processing of LSI.

Terminal not used.

17

I

I

) Pin No. ( Signal

I

1

! iD2

!

24 i 25

/ 27 i

1

I

28

/

/

I

29

/

30

32

33

’ 34

I/O j OUT

Description t

I

Diqit selection sianai.

Refer to the touch control panel circuit about the relation between signals and digits.

Normally, one pulse is output in every synchronized signal period, and input to the grid of the fluorescent display.

I

I

I

1 BUZZ

I

/ j 05 j D6

! D7

ID8 j R82

I

R8c

R8;

I R83

1 OUT Siqnal to sound buzzer.

A: key touch sound(0.12sec.).

B: Completion sound(2.4sec.).

Diqit selection signal.

Refer to the touch control panel circuit about the relation between signals and digits.

Normally, one pulse is output in every synchronized signal period, and input to the grid of the fluorescent display.

I

I

OUT

I

/

I j

/

: OUT

1 OUT

;

OUT

OUT

OUT

Diqit selection siqnal.

Refer to the touch control panel circuit about the relation between signals and digits.

Normally, one pulse is output in every synchronized signal period, and input to the grid of the fluorescent display. t

Diqit selection siqnal.

Refer to the touch control panel circuit about the relation between signals and digits.

Normally, one pulse is output in every synchronized signal period and input to the grid of the fluorescent display.

-I-

Seqment data siqnal.

Refer to the touch control panel circuit for the relationship between signals and indica- tors. Normally, one pulse is output in every synchronized signal period, and input to the anode of the fluorescent display. i

Seqment data siqnal.

: Refer to the touch control panel circuit for the relationship between signals and indica- tors. Normally. one pulse is output in every synchronized signal period, and input to the anode of the fluorescent display.

-

Seqment data siqnal.

Refer to the touch control panel circuit for the relationship between signals and indica- tors. Normally, one pulse is output in every synchronized signal period, and input to the anode of the fluorescent display.

, OUT

1

I

Diqit selection siqnal.

Refer to the touch control panel circuit about the relation between signals and digits.

Normally, one pulse is output in every synchronized signal period, and input to the grid of the fluorescent display.

/ OUT

Seqment data sianal.

Refer to the touch control panel circuit for the relationship between signals and indica- tors. Normally, one pulse is output in every synchronized signal period, and input to the anode of the fluorescent display.

Seqment data siqnal.

Refer to the touch control panel circuit for the relationship between signals and indica- tors. Normally, one pulse is output in every synchronized signal period, and input to the anode of the fluorescent display.

I

/

I

/

/ 36

/

OUT

Seqment data siqnal.

Signal similar to 08.

Key strobe siqnal.

Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal while one of G8 line keys on key matrix is touched.

Secament data siqnal.

Signal similar to D8.

Kev strobe siqnal.

Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal while one of G7 line keys on key matrix is touched.

18

37

40

41

42

I

R12

R21

R22

I

R23

I/O Description

OUT Seqment data siqnal.

Signal similar to D8.

Kev strobe siqnal.

Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal while one of G6 line keys on key matrix is touched.

OUT Seqment data sianal.

Signal similar to 08.

Kev strobe siqnal.

Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal while one of G5 line keys on key matrix is touched.

OUT Seament data siqnal.

Signal similar to D8.

Key strobe siqnal.

Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal whiie one of G4 line keys on key matrix is touched.

OUT Seqment data siqnal.

OUT

Signal similar to 08.

Kev strobe siqnal.

Signal applied to touch-key section. A pulse signa I is input to ROo-ROs terminai whiie one of G3 line keys on key matrix is touched.

-

Seament data siqnal.

Signal similar to 08.

Kev strobe siqnal.

Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal while one of G2 line keys on key matrix is touched.

.

OUT Seqment data siqnal.

Signal similar to D8.

Key strobe siqnal.

Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal while I one of GI line keys on key matrix is touched. 1

19

+3A55

1 .Precautions for Handling Electronic Components

This unit uses CMOS LSI in the integral part of the circuits. When handling these parts, the following pre- cautions should be strictly followed. CMOS LSI have ex- tremely high impedance at its input and output terminals.

For this reason, it is easily influenced by the surrounding high voltage power source, static electricity charge in clothes, etc, and sometimes it is not fully protected by the built-in protection circuit.

In order to protect CMOS LSI.

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

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

2.Shapes of Electronic Components d&2 /

1 M ohm

3.Servicing of Touch Control Panel

SERVICING

touch control panel and the oven itself is so short that the two can’t be separated. For those models, check and re- pair all the controls (sensor-related ones included) of the touch control panel while keeping it connected to the oven.

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

(2)Servicing the touch control panel with power sup- ply from an external power source:

Disconnect the touch control panel completely from the oven properand short both ends of the door sensing switch (on PWB) of the touch control panel,which brings about an operational state that isequivalent 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-re- lated controls of the touch control panel by using the dummy resistor(s).

Transistor

D-I-Al 14ES

DTBl43ES

DTDi 43ES

2SA933S

4.Servicing Tools

Tools required to service the touch control panel assem- biv.

I j’ Soldering iron: 30W ilt is recommended to use a soidering iron with a grounding terminai.)

2) Oscilloscope: Single beam. frequency range: DC-

1 OMHz type or more advanced model.

3; Others: Hand tools

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 avail- able either from the power line of the oven itself or from an external power source.

(1)Servicing the touch control panel with power sup- ply of the oven:

CAUTION:

THE HIGH VOLTAGE TRANSFORMER OF THE MI-

CROWAVE OVEN IS STILL LIVE DURING SERVIC-

ING PRESENTS A HAZARD.

Therefore, when checking the performance of the touch control panel, put the outer cabinet on the oven to avoid touching the high voltage transformer, or unplug the pri- mary terminal (connector) of the high voltage trans- former to turn it off; the end of such connector must be insulated with an insulating tape. After servicing, be sure to replace the leads to their original locations.

A. On some models, the power supply cord between the

5.0ther Precautions

1) i3efore 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 abnor- mal 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 pre- cision is required.

20

COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE

WARNING: AVOID POSSIBLE EXPOSURE TO MICROWAVE ENERGY. PLEASE FOLLOW THE INSTRUC-

TIONS BELOW .BRBEFORE OPERATING THE OVEN.

1.

2.

CARRY OUT 3D CHECKS.

Make sure that a definite “click” can be heard when the 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 heads to rise, it is then pos-

3. sible to hear a “click” as the door switches operate.)

Visually check the door and cavity face plate for dam- age (dents, cracks. signs of arcing etc.).

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:

Carry out any remedial work that is necessary before oper- ating the oven.

3. If the door is not closed.

Do not operate the oven if any of the following conditions

4. If the outer case (cabinet) is not fitted. exist

1. Door does not close firmly.

Please refer to ‘OVEN PARTS, CABINET PARTS, DOOR PARTS’, when carrying out any of the following removal proce- dures:

1. Without the RF gasket (Magnetron).

2. If the wave guide or oven cavity are not intact.

OUTER CASE REMOVAL

To remove the outer case, proceed as follows.

1. Disconnect oven from power supply.

2.

3.

Open the oven door and wedge it open.

Remove the screws from rear and along the side edge

4.

5. of case.

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

Lift the entire case from the oven.

6. Discharge the H.V. capacitor before carring out any further work.

7. Do not operate the oven with the outer case removed.

N.B.; Step 1,2 and 6 from the basis of the 3fJ checks.

CAUTION: DISCHARGE HIGH VOLTAGE CAPACI-

TOR BEFORE TOUCHING ANY OVEN

COMPONENTS OR WIRING.

\

POWER TRANSFORMER

1.

2.

CARRY OUT =CHECKS

Disconnect wire leads from power transformer, magne-

3.

4. tron and capacitor terminals.

Remove four (4) screws holding transformer to base plate (right).

Remove transformer.

Re-install

1. Rest transformer on the base cabinet with its primary

REMOVAL

terminals toward the oven face plate.

2. Transformer with four screws to base plate (right).

3. Reconnect wire leads (primary and high voltage) to power transformer and filament leads of transformer to magnetron and high voltage capacitor. Refer to “PIC-

TORIAL DIAGRAM”.

4. Re-install outer case and check that oven is operating properly.

MAGNETRON REMOVAL

1.

2.

3.

CARRY OUT aCHECKS

Disconnect wire leads from magnetron.

Carefully loosen four(4) screws holding magnetron to waveguide flange.

CAUTION: WHEN REPLACING MAGNETRON, BE

SURE THE R.F. GASKET IS IN PLACE, AND

MOUNTING SCREWS ARE TIGHTENED

SECURELY.

HIGH VOLTAGE RECTIFIER AND HIGH VOLTAGE CAPACITOR REMOVAL

1.

2.

CARRY OUT 3lJCHECKS

Remove one(l) screw holding capacitor holder to oven

3.

4. cavity rear plate.

Disconnect rectifier terminal from capacitor.

Rectifier and high voltage assembly is now free.

Remove one (1) screw holding high voltage rectifier assembly to capacitor holder.

5. Disconnect wire leads from capacitor and remove ca- pacitor holder. Capacitor is now free.

CAUTION: WHEN REPLACING HIGH VOLTAGE REC-

TIFIER AND HIGH VOLTAGE CAPACITOR,

GROUND SIDE TERMINAL OF THE HIGH

VOLTAGE RECTIFIER MUST BE SECURED

FIRMLY WITH A GROUNDING SCREW.

21

OVEN LAMP AND LAMP SOCKET REMOVAL

1. CARRY OUT aCHECKS

2. Disconnect the wire leads from the lamp socket.

3. Remove the lamp holder from partition angle.

4. Remove the oven lamp from the lamp socket.

TURNTABLE MOTOR REMOVAL

1. Disconnect oven from power supply.

2. Remove turntable and turntable support from oven cavity.

3. Remove two(2) screws holding turntable motor cover to base plates oven cavity and remove turntable motor cover from bottom plate (right).

4. Disconnect wire leads from turntable motor.

(See “Positive lock connector removal”)

5. Remove two (2) screws holding turntable motor to oven cavity.

6. Now the turntable motor is free.

FAN MOTOR REPLACEMENT

EMOVAL

1. CARRY OUT 3D CHECKS

2. Disconnect the wire leads from the fan motor and ther- mal cut-out.

3. Remove the three (3) screws holding the fan motor assembly to the oven cavity.

4. Release the fan duct assembly from the oven cavity.

5 Remove one (1) screw from the thermal cut-out angle.

6. Remove the fan motor assembly from the oven cavity.

6. Remove the fan blade from the fan motor shaft accord- ing the following procedure.

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

CAUTION:

* Make sure that any pieces do not enter the gap be- tween the rotor and the stator of the fan motor.

Because the rotor is easy to be 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 transform the bracket by touching with the pliers,

2) Remove the fan blade assembly from the shaft of the fan motor by pulling fan retainer clip and rotating the fan blade with your hand.

3) Now, the fan blade will be free.

CAUTION:

* Do not use this removed fan blade

again.Because

the hole(for shaft) of it may become bigger than a standard one.

7. Remove the two (2) screws holding the fan motor to the fan motor angle.

8. Now, the fan motor is free.

INSTALLATION

1. Install the fan motor to the fan motor angle with the two

(2) screws.

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

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

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

3) Install the fan blade to the shaft of fan motor by pushing the fan blade with a small, light weight. ball peen ham- mer or rubber mallet.

CAUTION: l

Do not hit the fan blade strongly when installed because the bracket may be transformed.

* Make sure that the fan blade rotates smooth after installed.

*

3.

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

Install the thermal cut-out angle to the fan motor with

4. the one (I) screw.

Install the the fan motor angle to the oven cavity with

5. two (2) screws.

Connect the wire leads to the fan motor and the thermal cut-out, referring to the pictorial diagram. move jomt pliers

Rear view

Side view

22 hese are the posltlon here should be nched with pliers

1

POSITIVE LOCK3 CONNECTOR (NO-CASE TYPE) REMOVA

Push the lever of positive lock% connector. Pull down on the positive lock% connector.

CAUTION: WHEN YOU CONNECTING THE POSITIVE

LOCKQ CONNECTORS TO THETERMI-

NALS, INSTALL THE POSITIVE LOCK” SO

THAT THE LEVER FACES YOU

Figure C-l. Positive lock” connector

CONTROL PANEL ASSEMBLY REMOVAL

1, CARRY OUT aCHECKS

2. Disconnect wire leads from panel components.

3. Remove one (1) screw from upper side.

4. Remove control panel assembly and slide upward.

5. Now, individual components can be removed.

1ST. LATCH SWITCH, 2ND. LATCH SWITCH, STQP SWITCH AND MONITOR SWITCH REMOVAL

1. CARRY OUT QCHECKS

2. Disconnect wire leads from the switches.

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

4. Remove latch hook assembly from oven flange.

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

6. Switch is now free.

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

Re-install

1. Re-install each s;Nitc h lever and !atch switch in its place. The stop/monitor swrrches are in rhe iower posi- tion and the 2nd. latch s&itch LS in the upper positicr.

The 1st latch switch 1s rn the iower postion at the barn side of the iatch hook.

2. Re-connect wire leads to each switch.

Refer to pictoriai diagram.

3. Secure latch hook (with two (2: mounting screws! 12 oven flange.

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

1ST. LATCH SWITCH, 2ND. LATCH SWITCH AND MONITOR SWITCH ADJUSTMEPIT

If the 1st. latch switch, 2nd. latch switch, stop switch and monitor switch do not operate properly due to a misadjust- ment, the following adjustment should be made.

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

2. 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 1st. latch switch and 2nd. latch switch and the stop switch are activated with the door closed.

3. Secure the screws with washers firmly.

4. Check the 2nd. latch switch operation. If the 2nd. latch switch has not activated with the door closed, loosen screw and adjust the latch hook position.

2. The 2nd. latch switch, 1 st latch switch, and stop 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 me- ter. (Refer to Microwave Measurement Procedure.)

L4TCH HOOK

2ND LATCH

/ SWITCH

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. i

/i

-. MOixiTCIR

SWIT:I

STOP SbVi’C?

Figure C-2. Latch Switch Adjustments

23

DOOR REPLACEMENT AND ADJUSTMENT

REMOVAL

1. Disconnect oven from power supply and remove turn- table tray and turntable ring from oven cavity.

2. Remove the outer case cabinet, refer to “OUTER

CASE CABINET REMOVAL”.

3. Remove two (2) screws from upper oven hinge.

4. Remove three (3) screws holding lower oven hinge and base plate (Left) to the bottom side of the oven.

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

6. Release the upper oven hinge from upper door hinge pin by pulling down the door.

Note: When the individual parts are replaced, refer to

“Door Disassembly”.;

RE-INSTALL

1. On re-installing door, insert the lower oven hinge to

2. lower door hinge pin.

Insert the lower oven hinge to square opening in the lower right side of the oven cavity face plate. (from front)

Insert the upper oven hinge to square opening in the upper right side of the oven cavity face plate. (from rear)

4. t5.

Shut the door (close the contacts of interlock switches).

Make sure upper and lower oven hinges are inserted into the upper an lower door hinge pins.

6. Make sure the door is parallel with oven face lines (left and upper side lines) and door latch heads pass through latch holes correctly.

Secure three (3) screws holding the lower oven hinge and the base plate (Left) to the bottom side of oven cavity.

8. Secure two (2) screws holding the upper oven hinge to the top of the oven cavity.

Note: After any service to the door;

(A) Make sure that door sensing switch and secon- dary interlock switch are operating properly. (Re- fer to chapter “Test Procedures”.).

(B) An approved microwave survey meter should be used to assure compliance with proper micro- wave radiation emission limitation standards.

After adjustment, 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 cav- ity face plate is to be less than 1 .Omm.

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

4. Re-install outer case and check for microwave leakage around door with an approved microwave survey me- ter. (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 func- tion does not require that door be air-tight, moisture

(condensation)-tight or light-tight. Therefore, occa- sional apperance 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 micro- wave energy from oven cavity.

\ RE-INSTALL

/

RE-INSTALL

‘. LOWER

DOOR :

HINGE I

PIN ,

SCREWS

*

SCREWS

Figure C-3. Door Replacement

SE PLATE (LEFT) and adjustment

DOOR ADJUSTMENT

The door can be adjusted by keeping screws of each hinge loose. Lower oven hinge can be loosened with screw driver.

24

DOOR DISASSEMBLY

Remove door assembly, refer to “Door Replacement”.

Replacement of door components are as follows:

1. Place door assembly on a soft cloth with latches facing

UP.

Note: As the engaging part of choke cover and door panel are provided at 18 places, do not force any particular part.

2. Insert an putty knife (thickness of about 0.5mm) into the gap between the choke cover and corner portion of door panel as shown Figure C-4 to free engaging parts.

3. Lift up choke cover.

4. Now choke cover is free from door panel.

5. Remove four (4) screws holding the door flame to the gutter for choke cover.

6. Remove the door flame with pulling the upper door hinge pin.

25

-3A55

MICROWAVE MEASUREMENT

After adjustment of door latch switches, monitor switch and doorare completed individually or collectively, the fol- lowing leakage test must be performed with a survey in- strument and it must be confirmed that the result meets the requirements of the performance standard for microwave oven.

REQUIREMENT

The safety switch must prevent microwave radiation emis- sion in excess of 5mW/cm2 at any point 5cm or more from external surface ofthe oven.

PREPARATION FOR TESTING:

Before beginning the actual test for leakage, proceed as follows;

1. Make sure that the test instrument is operating normally as specified in its instruction booklet.

Important:

Survey instruments that comply with the requirement for instrumentations as prescribed by the performance standard for microwave ovens must be used for testing.

Recommended instruments are:

NARDA 8100

NARDA 8200

HOLADAY HI 1500

SIMPSON 380M

2. Place the oven tray into the oven cavity.

3. Place the load of 275 +15ml of water initially at 20 +5”C in the center of the oven tray. The water container should be a low form of 600 ml beaker with inside di- ameter of approx. 8.5cm and made of an electrically non-conductive material such as glass or plastic.

The placing of this standard load in the oven is impor- tant not only to protect the oven, but also to insure that any leakage is measured accurately.

4. Close the door and turn the oven ON with the timer set for several minutes. If the water begins to boil before the survey is completed, replace it with 275ml of cool water.

5. Move the probe slowly (not faster that 2.5cm/sec.) along the gap.

6. The microwave radiation emission should be measured at any point of 5cm or more from the external surface of the oven.

.

SHARP

Microwave leakage measurement at 5 cm distance

26

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PARTS LIST

Note: The voltage supllied to the part ‘I*” are greater than 25OV.

REF. NO. PART NO. DESCRIPTION l- 1 i- 2 l- 3 l- 4 l- 5 l- 6 i- 7

_1

-- 8 i- 9 i-10 l-11 l-12 i-13

1 i-15 l-l.6

ELECTRICAL PARTS

QSW-mllOWRE0

QSW-MAlliWREO

1st.

RV-MZA197WREO

'*Iagze'-, ron

RTHfVI-AO80WREO

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RTPJT-A3

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R31

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VCm31CW47 6M Zz?acitor 4T-F

VCKYDllCYiO3N Capacitor 0.01 LF 151;

VCTY"3THF103Z

VCKYDllCY103N

RCRS-A012DREO

Zasacitor

VCEA&3l:H%.04M CaDacicor

VCEm31~/W4?5M Capacitor

Capacitor

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16V

Ceramic resonator (CST4.00MGW)

CR50

Dl

D20-21

RMPTEAOllDREO CR array

RSRCDA013DREO Diode b&dge(SlNBlO)

VHDlSS27OA/-1 Diode (lSS270A)

D23 VHDlSS270A/-1

D30 VHDlSS27OA/-1

D50-57 VHDlSS27OA/-1

RH-IZA496DREO

Diode (lSS270A)

Diode (lSS270A)

Diode (lSS270A)

LSI ICl

Ql

Q20

Q21

VS2SA933S//-3

VSDTA114ES/-3

VSDTD143ES/-3

Transistor (2SA933S)

Transistor (DTA114ES)

Transistor (DTD143ES)

Q22 VSDTB143ES/-3

VRD-B12HF202J

VRD-B12HF681J

VRS-B13AA102J

1

Transistor (DTB143ES)

Resistor 2k ohm

1/2w

Resistor 680 ohm 1/2w

Resistor lk ohm lw

Resistor

Resistor

2esistor lk ohm 1/4w

15k ohm 1/4w

330 ohm 1/4w

1 VRD-B12EF56;i

VRD-Bl2EF471;

47k ohm 1/4w

56k ohm 1/4w

470 ohm 1/4w

330 ohm 1/4w

VRD-B12EF33lJ

VRD-B12EF472J

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VRD-B12EF332J 1

4.7k ohm 1/4w

3.3k ohn 1/4w lk ohm i/4W

1M ohm :i4w

I tesiscor

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3.3K obm~ 1/4w

3.9K ol-xn 1/4w

RRLY-A080DREO Relay (OJ-SH-124LL11)

31

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1 REF. NO. 1

PART NO.

I

DESCRIPTION

RY2

SP40

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231

232

2- 2

3- 3

?- 4

2- 5

AO8lDREG Re;ay (VX324)

?&,I%-A0;43REO Buzzer (PKM22EPT-CA)

?&-VCAA0323RE0

-J-#~:&3 ’ -

“IhTC BO l?WmKO

Varistor (lOG47l.K)

Zener diode (HZ4C-3)

Control panel frame with key unit

5 0 Open button spring

XEPS230P10xSO Screw; Control unit mto. n _

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4- 3 a- 5

4- 6

4- 7 i" 8

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PHOK-A0859dRFO Latch hook

Fuse angle

H-V. capacitor band LBNDKAO95WRPO

LANGQA343WRPO

NFANJAO29WREO

PDUC-A534WRPO

Thermal cut-out (Fan) mounting angle

Fan blade

Fan duct

FOVN-A285WRTO

FDA:-A171WRYO

GDAI-A235WRPO

Oven cavity

Bottom piate R assembly

Bottom plate L

GLEGPA019~&?EO Foot

Partition angle yyc,-3-q: j iQ!jj,FG

?JTcp~--~~~c 4 5krnF’O

3ver hinge (Lower)

Switch lever

2oupl kg

1 - motor cox.er

Lu-cie cover

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200: screen

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spring

“ROL”,m 5 3hPXO Roller stay

\TK-AO46WREG Turntable tray

TCADCA493WRRO cook book

TINS-k378WRRO Operation manual

-FW-i'ZB122WO Switch harness

FW-~-ZB23OWREO Main wire harness

QW-QZA187WREO High voltage wire A

LHLDWA034WXEO Cabie clip

QTANP0020YBEO Connector CE-230

TSPCIU386iWXRO Name plate

LHLDWAOllWREO Purse lock "M"

32

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REF. NO. PART NO. DESCRIPTION

7- 1

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7- 7

?- 8

7 9

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7-1;

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7-13

SCREWS, NUTS AND WASHERS

XOTSD40P12000 Screw; 4mm x 12n-1

Screw; 4mm x 8mm

XFPSD30P08000 Screw: 3pm x 81x-1

LX-CZAO38WREO Special

LX-CZ0052wREG Special screw screw

XFPSD30P06000

LX-CZA029WREO Special screw

XFPSD40P08000

Screw; 41-1-m

XOTSD40P12RI,70

Screw; 4-m x 12rm

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

17 AA

5 AA

1

AA

1 AA

1 AA

1 AA

2 AA

2 AA

4 AA.

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3 AA

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33

R-3A55

1 2 3 4 I 5 I 6

1

1 I

2

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34

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5

6

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CONTROL PANEL PARTS

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I

I

1

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R-3A55

1 r

A

1

2 3

4 I 5 6

B

C

Actual wire harness may be different than illustration.

PACKiNG AND ACCESSORIES

Dl

7

I

I

I

I f

F1

I

7

I

/

I

1

El

I

Gl

‘e

@;

TURNTABLE TRAY

0 DOOR PROTECTION SHEET

OPERATION MANUAL

SPADPA204WREO

COOK BOOK 3

/’

/ t

, cx TURNTABLE SUPPORT

MICROWAVE OV

0 TRAY PACK

SPADFA257WREO

DOOR PAD

SPADFAO61 WREO

Not Replaceable Items.

H

~

I-

1 ! 2 I

3

!

36

4

‘?

0 PACKING PAD KIT

CPADBAICZWRKO e POLYETHYLENG

SSAKHA034WREO

BAG

5 6

I

SHARP

38

‘93 SHARP CORP. (07K0.75E) Printed tn Austraha