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R408LS
SERVICE MANUAL
SY612R408LPSTF
MICROWAVE OVEN
MODEL
R-408LS
In the interest of user-safety the oven should be restored to its original condition and only parts identical to those specified should be
used.
WARNING TO SERVICE PERSONNEL: Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts may result in a severe,
possibly fatal, electrical shock. (High Voltage Capacitor, High
Voltage Power Transformer, Magnetron, High Voltage Rectifier
Assembly, High Voltage Harness etc..)
CONTENTS
PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY
CHAPTER 7. TROUBLESHOOTING GUIDE
BEFORE SERVICING
CHAPTER 9. TOUCH CONTROL PANEL ASSEMBLY
CHAPTER 1. WARNING TO SERVICE PERSONNEL
CHAPTER 10. PRECAUTIONS FOR USING LEADFREE SOLDER
CHAPTER 2. MICROWAVE MEASUREMENT PROCEDURE
CHAPTER 8. TEST PROCEDURES
CHAPTER 11. COMPONENT REPLACEMENT AND
ADJUSTMENT PROCEDURE
CHAPTER 3. FOREWORD AND WARNING
CHAPTER 12. CIRCUIT DIAGRAMS
CHAPTER 4. PRODUCT DESCRIPTION
Parts List
CHAPTER 5. GENERAL INFORMATION
CHAPTER 6. OPERATION
This document has been published to be used for
after sales service only.
The contents are subject to change without notice.
CONTENTS
PRECAUTIONS TO BE OBSERVED BEFORE
AND DURING SERVICING TO AVOID POSSIBLE
EXPOSURE TO EXCESSIVE MICROWAVE ENERGY
[13] L: RELAY TEST .......................................... 8-5
[14] M: DEFROST TEST.................................... 8-6
[15] N: FOIL PATTERN ON THE PRINTED
WIRING BOARD TEST............................... 8-6
BEFORE SERVICING
CHAPTER 9. TOUCH CONTROL PANEL ASSEMBLY
[1] OUTLINE OF TOUCH CONTROL PANEL ............................................................... 9-1
[2] SERVICING FOR TOUCH CONTROL
PANEL ........................................................ 9-1
CHAPTER 1. WARNING TO SERVICE PERSONNEL
[1] Before Servicing.......................................... 1-1
[2] When the testing is completed,................... 1-1
[3] After repairing.............................................. 1-1
CHAPTER 2. MICROWAVE MEASUREMENT
PROCEDURE
[1] Requirements:............................................. 2-1
[2] Preparation for testing:................................ 2-1
[3] Leakage test: .............................................. 2-1
CHAPTER 3. FOREWORD AND WARNING
[1] FOREWORD............................................... 3-1
[2] WARNING................................................... 3-1
[3] DANGER..................................................... 3-1
CHAPTER 4. PRODUCT DESCRIPTION
[1] SPECIFICATIONS ...................................... 4-1
CHAPTER 5. GENERAL INFORMATION
[1] GROUNDING INSTRUCTIONS.................. 5-1
[2] OVEN DIAGRAM ........................................ 5-1
CHAPTER 6. OPERATION
[1] DESCRIPTION OF OPERATING SEQUENCE .................................................... 6-1
[2] OVEN SCHEMATIC .................................... 6-2
[3] DESCRIPTION AND FUNCTION OF
COMPONENTS .......................................... 6-3
CHAPTER 7. TROUBLESHOOTING GUIDE
[1] TROUBLESHOOTING CHART ................. 7-1
CHAPTER 8. TEST PROCEDURES
[1] A: MAGNETRON ASSEMBLY TEST .......... 8-1
[2] B: POWER TRANSFORMER TEST ........... 8-1
[3] C: HIGH VOLTAGE RECTIFIER TEST....... 8-1
[4] D: HIGH VOLTAGE CAPACITOR TEST..... 8-2
[5] E: TEMPERATURE FUSE OR THERMAL CUT-OUT TEST ................................. 8-2
[6] F: PRIMARY INTERLOCK SWITCH
TEST........................................................... 8-2
[7] F: SECONDARY INTERLOCK SYSTEM
TEST........................................................... 8-3
[8] G: MONITOR SWITCH TEST ..................... 8-3
[9] H: BLOWN MONITOR FUSE TEST ........... 8-4
[10] I: NOISE FILTER TEST .............................. 8-4
[11] J: TOUCH CONTROL PANEL ASSEMBLY TEST ................................................... 8-4
[12] K: KEY UNIT TEST..................................... 8-5
CHAPTER 10. PRECAUTIONS FOR USING LEADFREE SOLDER
[1] Employing lead-free solder ....................... 10-1
[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
[3] POWER TRANSFORMER REMOVAL ......11-2
[4] HIGH VOLTAGE RECTIFIER AND HIGH
VOLTAGE CAPACITOR REMOVAL...........11-2
[5] MAGNETRON REMOVAL .........................11-2
[6] OVEN LAMP REMOVAL............................11-3
[7] POSITIVE LOCK CONNECTOR (NOCASE TYPE) REMOVAL ...........................11-3
[8] TURNTABLE MOTOR REMOVAL .............11-3
[9] COOLING FAN MOTOR REMOVAL..........11-3
[10] CONTROL PANEL ASSEMBLY REMOVAL.......................................................11-4
[11] GRAPHIC SHEET AND MEMBRANE
SWITCH REPLACEMENT .........................11-4
[12] DOOR SENSING SWITCH/PRIMARY
INTERLOCK SWITCH AND MONITOR
SWITCH REMOVAL...................................11-5
[13] DOOR SENSING SWITCH/PRIMARY
INTERLOCK SWITCH AND MONITOR
SWITCH ADJUSTMENT............................11-5
[14] DOOR REPLACEMENT ............................11-5
CHAPTER 12. CIRCUIT DIAGRAMS
[1] Pictorial Diagram (Figure S-1) .................. 12-1
[2] Control Panel Circuit (Figure S-2)............. 12-2
[3] Printed Wiring Board (Figure S-3)............. 12-3
Parts List
R408LS
R408LS
Service
PRECAUTIONS TO BE OBSERVED BEFORE
AND Manual
DURING SERVICING TO AVOID
POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY
PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE
EXPOSURE TO EXCESSIVE MICROWAVE
ENERGY
(a) Do not operate or allow the oven to be operated with the door open.
(b) Make the following safety checks on all ovens to be serviced before activating the magnetron or other
microwave source, and make repairs as necessary: (1) interlock operation, (2) proper door closing, (3)
seal and sealing surfaces (arcing, wear, and other damage), (4) damage to or loosening of hinges and
latches, (5) evidence of dropping or abuse.
(c) Before turning on microwave power for any service test or inspection within the microwave generating
compartments, check the magnetron, wave guide or transmission line, and cavity for proper alignment,
integrity, and connections.
(d) Any defective or misadjusted components in the interlock, monitor, door seal, and microwave
generation and transmission systems shall be repaired, replaced, or adjusted by procedures described
in this manual before the oven is released to the owner
.
(e) A microwave leakage check to verify compliance with the Federal Performance Standard should be
performed on each oven prior to release to the owner.
BEFORE SERVICING
BEFORE SERVICING
Before servicing an operative unit, perform a microwave emission check as per the Microwave
Measurement Procedure outlined in this service manual.
If microwave emissions level is in excess of the specified limit, contact SHARP ELECTRONICS
CORPORATION immediately @1-800-237-4277.
If the unit operates with the door open, service person should 1) tell the user not to operate the oven
and 2) contact SHARP ELECTRONICS CORPORATION and Food and Drug Administration's
Center for Devices and Radiological Health immediately.
Service personnel should inform SHARP ELECTRONICS CORPORATION of any certified unit found
with emissions in excess of 4mW/cm2. The owner of the unit should be instructed not to use the unit
until the oven has been brought into compliance.
i
R408LS
Service Manual
CHAPTER 1. WARNING TO SERVICE PERSONNEL
R408LS
Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts may result in a severe, possibly
fatal, electrical shock.
(Example)
High Voltage Capacitor, High Voltage Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..
Read the Service Manual carefully and follow all instructions.
Don't Touch !
Danger High Voltage
[2] When the testing is completed,
[1] Before Servicing
1. Disconnect the power supply cord, and then remove outer case.
1. Disconnect the power supply cord
case.
, and then remove outer
2. Open the door and block it open.
3. Discharge high voltage capacitor.
2. Open the door and block it open.
4. Reconnect the leads to the primary of the power transformer.
3. Discharge high voltage capacitor.
5. Reinstall the outer case (cabinet).
WARNING: RISK OF ELECTRIC SHOCK. DISCHARGE THE HIGHVOLTAGE CAPACITOR BEFORE SERVICING.
6. Reconnect the power supply cord after the outer case is installed.
The high-voltage capacitor remains charged about 60 seconds
after the oven has been switched off. Wait for 60 seconds and
then short-circuit the connection of the high-voltage capacitor
(that is the connecting lead of the high-voltage rectifier) against
the chassis with the use of an insulated screwdriver.
7. Run the oven and check all functions.
Whenever troubleshooting is performed the power supply must be disconnected. It may, in some cases, be necessary to connect the power
supply after the outer case has been removed, in this event,
2. Reinstall the outer case (cabinet).
[3] After repairing
1. Reconnect all leads removed from components during testing.
3. Reconnect the power supply cord after the outer case is installed.
4. Run the oven and check all functions.
1) Disconnect the power supply cord, and then remove outer case.
Microwave ovens should not be run empty. To test for the presence of
microwave energy within a cavity, place a cup of cold water on the
oven turntable, close the door and set the power to HIGH and set the
microwave timer for two (2) minutes. When the two minutes has
elapsed (timer at zero) carefully check that the water is now hot. If the
water remains cold carry out Before Servicing procedure and reexamine the connections to the component being tested.
2) Open the door and block it open.
3) Discharge high voltage capacitor.
4) Disconnect the leads to the primary of the power transformer.
5) Ensure that the leads remain isolated from other components and
oven chassis by using insulation tape.
When all service work is completed and the oven is fully assembled,
the microwave power output should be checked and microwave leakage test should be carried out.
6) After that procedure, reconnect the power supply cord.
1–1
R408LS
Service
Manual
CHAPTER 2. MICROWAVE MEASUREMENT
PROCEDURE
R408LS
[1] Requirements:
1. Microwave leakage limit (Power density limit): The power density of microwave radiation emitted by a microwave oven should not exceed 1mW/
cm2 at any point 5cm or more from the external surface of the oven, measured prior to acquisition by a purchaser, and thereafter (through the useful life of the oven), 5 mW/cm2 at any point 5cm or more from the external surface of the oven.
2. Safety interlock switches:
Primary interlock 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/cm2 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/cm2, 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
R408LS
CHAPTER 3. FOREWORD AND WARNINGService
R408LS
Manual
[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-408LS.
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
R408LS
CHAPTER 4. PRODUCT DESCRIPTION
R408LS
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 17-1/2"
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-80 -------------------- approx. 80% of FULL Power
P-70 -------------------- approx. 70% of FULL Power
P-60 -------------------- approx. 60% of FULL Power
P-50 -------------------- approx. 50% of FULL Power
P-40 -------------------- approx. 30% of FULL Power
P-30 -------------------- approx. 40% of FULL Power
P-20 -------------------- approx. 20% of FULL Power
P-10 -------------------- approx. 10% of FULL Power
P-0 ---------------------- No power throughout the cooking time
POPCORN 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
4–1
R408LS
CHAPTER 5. GENERAL INFORMATION
R408LS
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
Grounded
Receptacle Box
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.
3-Pronged
Plug
Grounding Pin
3-Pronged Receptacle
CAUTION: DO NOT UNDER ANY CIRCUMSTANCES CUT OR REMOVE THE ROUND
GROUNDING PRONG FROM THIS PLUG.
[2] OVEN DIAGRAM
1. OVEN
1. One touch door open button.
5
6
Push to open door.
7
2. Door latches.
9
The oven will not operate unless
the door is securely closed.
3. Removable turntable support
8
2
10
4. Removable turntable.
1
The turntable will rotate clockwise
or counterclockwise.
5. Oven lamp.
4
3
It will light when oven is operating
or door is opened.
6. Oven door with see-through window
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.
5–1
11
R408LS
2. TOUCH CONTROL PANEL
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
R408LS
CHAPTER 6. OPERATION
R408LS
Service Manual
[1] DESCRIPTION OF OPERATING SEQUENCE
The following is a description of component functions during oven operation.
1. OFF CONDITION
3. POWER LEVEL P-0 TO P-90 COOKING
Closing the door activates the door sensing switch and primary interlock switch. (In this condition, the monitor switch contacts are opened.)
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:
When oven is plugged in, 120 volts A.C. is supplied to the control unit.
(Figure O-1).
VARI-MODE
P-HI (100% power)
P-90 (approx. 90% power)
P-80 (approx. 80% power)
P-70 (approx. 70% power)
P-60 (approx. 60% power)
P-50 (approx. 50% power)
P-40 (approx. 40% power)
P-30 (approx. 30% power)
P-20 (approx. 20% power)
P-10 (approx. 10% power)
P-0 (0% power)
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)
RELAY
RY-1
RY-2
ON TIME
32 sec.
30 sec.
26 sec.
24 sec.
22 sec.
18 sec.
16 sec.
12 sec.
8 sec.
6 sec.
0 sec.
OFF TIME
0 sec.
2 sec.
6 sec.
8 sec.
10 sec.
14 sec.
16 sec.
20 sec.
24 sec.
26 sec.
32 sec.
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.
CONNECTED COMPONENTS
oven lamp/turntable motor/fan motor
power transformer
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 switch,
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
R408LS
[2] OVEN SCHEMATIC
1. Off Condition
SCHEMATIC
NOTE: CONDITION OF OVEN
1. DOOR CLOSED
2. CLOCK APPEARS ON DISPLAY
"TO LOAD"
B2
DOOR
SENSING
SWITCH
POWER TRANSFORMER
B1
GRN
GND
" indicates components with potentials above 250V
(RY2)
SECONDARY
INTERLOCK
RELAY
C2
C1
MAGNETRON
H
120VAC
60Hz
NOTE: "
MAGNETRON
TEMPERATURE
FUSE
MONITOR
FUSE (20A)
BLK
"TO SOURCE"
OVEN
THERMAL CUT-OUT
C3
N
CONTROL UNIT
(RY1)
HIGH
VOLTAGE
CAPACITOR
0.94uF/ AC2200V
NOISE
FILTER
"TO LOAD"
"TO SOURCE"
WHT
OVEN
LAMP
RELAY
MONITOR
SWITCH N.C.
OL
TURN
FAN
TTM TABLE FM
MOTOR
MOTOR
OVEN
LAMP
HIGH
VOLTAGE
RECTIFIER
COM.
COM.
C1:
LINE CROSS CAPACITOR ------- 0.22uF/ AC250V
C2, C3: LINE BYPASS CAPACITOR ------ 0.033uF/ AC250V
N.O.
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.
"TO LOAD"
B2
DOOR
SENSING
SWITCH
B1
GRN
GND
POWER TRANSFORMER
(RY2)
SECONDARY
INTERLOCK
RELAY
C2
C1
MAGNETRON
H
C3
N
CONTROL UNIT
(RY1)
HIGH
VOLTAGE
CAPACITOR
0.94uF/ AC2200V
OVEN
LAMP
RELAY
NOISE
FILTER
"TO LOAD"
"TO SOURCE"
WHT
120VAC
60Hz
MAGNETRON
TEMPERATURE
FUSE
MONITOR
FUSE (20A)
BLK
"TO SOURCE"
OVEN
THERMAL CUT-OUT
MONITOR
SWITCH N.C.
OL
TURN
FAN
TTM TABLE FM
MOTOR
MOTOR
OVEN
LAMP
COM.
COM.
C1:
LINE CROSS CAPACITOR ------- 0.22uF/ AC250V
C2, C3: LINE BYPASS CAPACITOR ------ 0.033uF/ AC250V
N.O.
PRIMARY INTERLOCK
SWITCH
Figure O-2. Oven Schematic-Cooking Condition
6–2
HIGH
VOLTAGE
RECTIFIER
R408LS
[3] DESCRIPTION AND FUNCTION OF COMPONENTS
1. DOOR OPEN MECHANISM
4. TURNTABLE MOTOR
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.
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.
Latch Heads
6. OVEN THERMAL CUT-OUT
Door Sensing
Switch
Door
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.
Monitor Switch
Switch Lever
Primary Interlock
Switch
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.
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.
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.
3. MONITOR SWITCH
2) If the wire harness or electrical components are short-circuited, this
monitor fuse blows to prevent an electric shock or fire hazard.
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.
9. NOISE FILER
The noise filter prevents the radio frequency interference that might
flow back in the power circuit.
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 INTERLOCK RELAY (RY2), RE-LAY (RY1), PRIMARY INTERLOCK SWITCH AND MONITOR SWITCH FOR PROPER
OPERATION. (REFER TO CHAPTER “TEST PROCEDURE”).
NOTE: MONITOR FUSE AND MONITOR SWITCH ARE REPLACED
AS AN ASSEMBLY.
6–3
R408LS
CHAPTER 7. TROUBLESHOOTING GUIDEService
R408LS
Manual
Never touch any part in the circuit with your hand or an uninsulated tool while the power supply is connected.
When troubleshooting the microwave oven, it is helpful to follow the Sequence of Operation in performing the checks. Many of the possible causes of
trouble will require that a specific test be performed. These tests are given a procedure letter which will be found in the "Test Procedure "section.
IMPORTANT:
3) Discharge high voltage capacitor.
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.
4) Disconnect the leads to the primary of the power transformer.
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,
2) Open the door and block it open.
1) Disconnect the power supply cord, and then remove outer case.
5) Reinstall the outer case (cabinet).
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,
3) Discharge high voltage capacitor.
4) Reconnect the leads to the primary of the power transformer.
6) Reconnect the power supply cord after the outer case is installed.
2) Open the door and block it open.
7) Run the oven and check all functions.
[1] TROUBLESHOOTING CHART
L M N
KEY UNIT (MEMBRAINE SWITCH)
RELAY (RY1)
DEFROST
FOIL PATTERN ON PWB
DIRTY OVEN CAVITY
LOW VOLTAGE
WRONG OPERATION
J CK CK CK K
TOUCH CONTROL PANEL
I
TURNTABLE MOTOR
NOISE FILTER
COOLING FAN MOTOR
OVEN LAMP
H RE RE RE
MONITOR FUSE
MAGNETRON TEMPERATURE FUSE
SECONDARY INTERLOCK SYSTEM
7–1
F G
MONITOR SWITCH
HIGH VOLTAGE CAPACITOR
Home fuse or circuit breaker blows when
power cord is plugged into wall receptacle
Monitor fuse blows when power cord is plugged into wall receptacle.
OFF
All letters and indicators do not appear in disCONDITION play when power cord is first plugged into
wall outlet.
Display does not operate properly when
STOP/CLEAR pad is touched. (Buzzer
should sound and " : " or time of day
should appear in display.)
Oven lamp does not light when door is
opened.
Oven lamp does not go out when door is
closed.
Oven lamp lights but fan motor and turntable
motor do not operate.
Oven does not go into cook cycle when
START pad is touched
COOKING Oven seems to be operating but little or no
heat is produced in oven load. (Food incomCONDITION pletely 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.
F
PRIMARY INTERLOCK SWITCH
E
OVEN THERMAL CUT-OUT
D E
H.V. RECTIFIER ASSEMBLY
PROBLEM
C
POWER TRANSFORMER
CONDITION
B
SHORT IN POWER CORD
POSSIBLE CASE
AND DEFECTIVE PARTS
RE CK A
SHORT OR OPENED WIRING
MAGNETRON
RE: Replace / CK: Check
TTEST PROCEDURE
R408LS
CHAPTER 8. TEST PROCEDURES
R408LS
Service Manual
[1] A: MAGNETRON ASSEMBLY TEST
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. To test for an open filament, isolate the magnetron from the high voltage circuit. A continuity check across the magnetron filament leads should
indicate less than 1 ohm.
5. To test for a shorted magnetron, connect the ohmmeter leads between the magnetron filament leads and chassis ground. This test should indicate
an infinite resistance. If there is little or no resistance the magnetron is grounded and must be replaced.
6. Reconnect all leads removed from components during testing.
7. Reinstall the outer case (cabinet).
8. Reconnect the power supply cord after the outer case is installed.
9. Run the oven and check all functions.
1. MICROWAVE OUTPUT POWER
The following test procedure should be carried out with the microwave oven in a fully assembled condition (outer case fitted).
HIGH VOLTAGES ARE PRESENT DURING THE COOK CYCLE, SO EXTREME CAUTION SHOULD BE OBSERVED.
Power output of the magnetron can be measured by performing a water temperature rise test. This test should only be used if above tests do not indicate a faulty magnetron and there is no defect in the following components or wiring: silicon rectifier, high voltage capacitor and power transformer.
This test will require a 16 ounce (453cc) measuring cup and an accurate mercury thermometer or thermocouple type temperature tester. For accurate
results, the following procedure must be followed carefully:
1. Fill the measuring cup with 16 oz. (453cc) of tap water and measure the temperature of the water with a thermometer or thermocouple temperature tester. Stir the thermometer or thermocouple through the water until the temperature stabilizes. Record the temperature of the water.
2. Place the cup of water in the oven. Operate oven at 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] B: POWER TRANSFORMER TEST
1. Disconnect the power supply cord, and then remove outer case.
2. Open the door and block it open.
3. Discharge high voltage capacitor.
4. Disconnect the 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.
5. Reconnect all leads removed from components during testing.
6. Reinstall the outer case (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
(HIGH VOLTAGES ARE PRESENT AT THE HIGH VOLTAGE TERMINAL, SO DO NOT ATTEMPT TO MEASURE THE FILAMENT AND HIGH
VOLTAGE.)
[3] C: HIGH VOLTAGE RECTIFIER TEST
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. 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.
8–1
R408LS
5. Reconnect all leads removed from components during testing.
6. Reinstall the outer case (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
NOTE: Be sure to use an ohmmeter that will supply a forward bias voltage of more than 6.3 volts.
[4] D: HIGH VOLTAGE CAPACITOR TEST
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. If the capacitor is open, no high voltage will be available to the magnetron. Disconnect input leads and check for short or open between the terminals using an ohmmeter.
Checking with a high ohm scale, if the high voltage capacitor is normal, the meter will indicate continuity for a short time and should indicate an
open circuit once the capacitor is charged. If the above is not the case, check the capacitor with an ohmmeter to see if it is shorted between either
of the terminals and case. If it is shorted, replace the capacitor.
5. Reconnect all leads removed from components during testing.
6. Reinstall the outer case (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
[5] E: TEMPERATURE FUSE OR THERMAL CUT-OUT TEST
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. 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
Temperature of “OFF” condition
(closed circuit).
(open circuit).
This is not resetable type.
Above 150°C (302°F)
This is not resetable type.
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.
6. Reconnect all leads removed from components during testing.
7. Reinstall the outer case (Cabinet).
8. Reconnect the power supply cord after the outer case is installed.
9. Run the oven and check all functions.
CAUTION: IF THE TEMPERATURE FUSE OR THERMAL CUT-OUT INDICATES AN OPEN CIRCUIT AT ROOM TEMPERATURE, REPLACE IT.
[6] F: PRIMARY INTERLOCK SWITCH TEST
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. 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.
5. Reconnect all leads removed from components during testing.
6. Reinstall the outer case (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
8–2
R408LS
[7] F: SECONDARY INTERLOCK SYSTEM TEST
1. DOOR SENSING SWITCH
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. Isolate the switch and connect the ohmmeter to the common (COM.) and normally open (NO) terminal of the switch. The meter should indicate an
open circuit with the door open and a closed circuit with the door closed. If improper operation is indicated, replace the door sensing switch.
5. Reconnect all leads removed from components during testing.
6. Reinstall the outer case (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
NOTE: If the door sensing switch contacts fail in the open position and the door is closed, the cooling fan, turntable and oven light will be activated by
RY1.
2. SECONDARY INTERLOCK RELAY (RY2)
1. Disconnect the power supply cord, and then remove outer case.
2. Open the door and block it open.
3. Discharge high voltage capacitor.
4. Disconnect 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.
5. Reconnect all leads removed from components during testing.
6. Reinstall the outer case (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
[8] G: MONITOR SWITCH TEST
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. 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.
5. Reconnect all leads removed from components during testing.
6. Reinstall the outer case (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
Red
White/ White
Screw Driver
Ohmmeter
Primary
Interlock Switch
Monitor Switch
8–3
R408LS
[9] H: BLOWN MONITOR FUSE TEST
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. 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.
5. Reconnect all leads removed from components during testing.
6. Reinstall the outer case (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
[10] I: NOISE FILTER TEST
1. Disconnect the power supply cord, and then remove outer case.
2. Open the door and block it open.
NOISE FILTER
3. Discharge high voltage capacitor.
N
L
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.
LINE CROSS CAPACITOR
0.22μF / AC 250V
5. Reconnect all leads removed from components during testing.
NOISE SUPPRESSION COIL
FUSE 20A
6. Reinstall the outer case (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
MEASURING POINT
Between N and L
Between terminal N and WHITE
Between terminal L and RED
LINE BYPASS
CAPACITOR
0.0033μF / AC 250V
INDICATION OF OHMMETER
Open circuit.
Short circuit.
Short circuit.
WHITE
LINE BYPASS
CAPACITOR
0.0033μF / AC 250V
RED
[11] 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.
2) Open the door and block it open.
3) Discharge high voltage capacitor.
4) Disconnect the leads to the primary of the power transformer.
5) Ensure that these leads remain isolated from other components and oven chassis by using insulation tape.
1. Key Unit
1) Reinstall the outer case (cabinet).
2) Reconnect the power supply cord after the outer case is installed.
3) Run the oven and check all functions.
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.
2. Control Unit.
The following symptoms indicate a defective control unit.
8–4
R408LS
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.
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) Replace the Control unit assembly.
5) Reconnect all leads removed from components during testing.
6) Reinstall the outer case (cabinet).
7) Reconnect the power supply cord after the outer case is installed.
8) Run the oven and check all functions.
4. When testing is completed,
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) Reconnect all leads removed from components during testing.
5) Reinstall the outer case (cabinet).
6) Reconnect the power supply cord after the outer case is installed.
7) Run the oven and check all functions.
[12] 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
G6
G9
G10
G11
DEFROST
G12
SOFTEN
G13
NC
MELT
COOK
G5
G4
REHEAT
2
1
5
4
8
7
0
[13] L: RELAY TEST
1. Disconnect the power supply cord, and then remove outer case.
2. Open the door and block it open.
8–5
G3
G2
START
WARM
TIMER
CLOCK
STOP
CLEAR
POWER
LEVEL
9
G1
3
MINUTE
PLUS
6
POPCORN
R408LS
3. Discharge high voltage capacitor.
4. Disconnect the leads to the primary of the power transformer.
5. Ensure that these leads remain isolated from other components and oven chassis by using insulation tape.
6. After that procedure, re-connect the power supply cord.
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.
9. Open the door and block it open.
10.Discharge high voltage capacitor.
11.Reconnect all leads removed from components during testing.
12.Reinstall 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] 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
Steaks/Chops
0.5lb
1ST STAGE
LEVEL
TIME
60%
20sec.
2ND STAGE
LEVEL
TIME
40%
20sec.
3RD STAGE
LEVEL
TIME
30%
45sec.
8. If improper operation is indicated, the control unit is probably defective and should be checked.
[15] 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.
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) Follow the troubleshooting guide given below for repair.
STEPS
1
2
OCCURRENCE
Only pattern at “a” is broken.
Pattern at “a” and “b” are broken.
CAUSE OR CORRECTION
*Insert jumper wire J1 and solder.
Replace the control unit.
8–6
R408LS
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 563Ω±10%). If any abnormal
condition is detected, replace the control unit.
a
6) Reconnect all leads removed from components during testing.
7) Reinstall the outer case (cabinet).
c
8) Reconnect the power supply cord after the outer case is installed.
b
d
9) Run the oven and check all functions.
2. Follow the troubleshooting guide given below, if indicator does not light up after
above check and repairs are finished.
1) Disconnect the power supply cord and then remove outer case.
2) Open the door and block it open.
3) Discharge high voltage capacitor.
4) Disconnect the leads to the primary of the power transformer.
5) Ensure that these leads remain isolated from other components and oven chassis by using insulation tape.
6) After that procedure, reconnect 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.
8) Disconnect the power supply cord and then remove outer case.
9) Open the door and block it open.
10)Discharge high voltage capacitor.
11)Reconnect all leads removed from components during testing.
12)Reinstall the outer case (cabinet).
13)Reconnect the power supply cord after the outer case is installed.
14)Run the oven and check all functions.
8–7
CAUSE OR CORRECTION
Check supply voltage and oven power cord.
Low voltage transformer or secondary circuit defective.
Check and replace control unit.
R408LS
Service Manual
CHAPTER 9. TOUCH CONTROL PANEL ASSEMBLY
R408LS
[1] OUTLINE OF TOUCH CONTROL PANEL
3) Power Source Circuit
This circuit generates voltage necessary in the control unit from the
AC line voltage.
The touch control section consists of the following units.
(1) Key Unit
In addition, the synchronizing signal is available in order to compose a basic standard time in the clock circuit.
(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.
Symbol
VSS
1. Key Unit
Voltage
-5V
Application
LSI(IC1)
4) Relay Circuit
The key unit is composed of a matrix, signals generated in the LSI are
sent to the key unit through P20-P27.
A circuit to drive the magnetron, fan motor, turntable motor and light
the oven lamp.
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.
5) Buzzer Circuit
2. Control Unit
6) Synchronizing Signal Circuit
The buzzer is responsive to signals from the LSI to emit audible
sounds (key touch sound and completion sound).
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.
Control unit consists of LSI, reset circuit, indicator circuit, power
source circuit, relay circuit, buzzer circuit, synchronizing signal circuit
and back light circuit.
7) Door Sensing Switch
1) Reset Circuit
A switch to “tell” the LSI if the door is open or closed.
This circuit generates a signal which resets the LSI to the initial
state when power is supplied.
8) Back Light Circuit
2) Indicator Circuit
A circuit to drive the back light (Light emitting diodes LD1- LD4).
This circuit consists of 17 segments and 4 common electrodes
using a Liquid Crystal Display.
[2] SERVICING FOR TOUCH CONTROL PANEL
1. Precautions for Handling Electronic Components
2) Open the door and block it open.
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.
3) Discharge high voltage capacitor.
In order to protect CMOS LSI.
After checking the performance of the touch control panel,
1) When storing and transporting, thoroughly wrap them in aluminium
foil. Also wrap PW boards containing them in aluminium foil.
1) Disconnect the power supply cord.
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.
2) Open the door and block it open.
2) When soldering, ground the technician as shown in the figure and
use grounded soldering iron and work table.
3) Re-connect the leads to the primary of the power transformer.
4) Re-install the outer case (cabinet).
5) Re-connect the power supply cord after the outer case is
installed.
approx. 1M ohm
6) Run the oven and check all functions.
a) On some models, the power supply cord between the touch
control panel and the oven itself is so short that the two can't
be separated. For those models, check and repair all the
controls (sensor-related ones included) of the touch control
panel while keeping it connected to the oven.
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.
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.
1. Servicing the touch control panel with power supply of the oven:
CAUTION: THE HIGH VOLTAGE TRANSFORMER OF THE MICROWAVE OVEN IS STILL LIVE DURING SERVICING AND
PRESENTS A HAZARD.
Therefore, before checking the performance of the touch control
panel,
1) Disconnect the power supply cord and then remove outer case.
9–1
R408LS
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.
9–2
R408LS
Service
Manual SOLDER
CHAPTER 10. PRECAUTIONS FOR USING
LEAD-FREE
R408LS
[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
R408LS
Service AND
Manual ADJUSTMENT PROCECHAPTER 11. COMPONENT REPLACEMENT
R408LS
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
R408LS
[2] OUTER CASE REMOVAL
To remove the outer case, procedure as follows.
1. Disconnect the power supply cord.
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.
Special screw
CAUTION: DISCONNECT OVEN FROM POWER SUPPLY BEFORE
REMOVING OUTER CASE.
DISCHARGE THE HIGH VOLTAGE CAPACITOR
BEFORE TOUCHING ANY OVEN COMPONENTS OR
WIRING.
Screw Driver
(Type: TORX T20 H or
GTXH20-100)
NOTE: When replacing the outer case, the 2 special Torx screws
must be reinstalled in the same locations.
[3] POWER TRANSFORMER REMOVAL
1. REMOVAL
7. Remove transformer from bottom plate.
1. Disconnect the power supply cord and remove outer case.
2. REINSTALLATION
2. Open the oven door and block it open.
3. Discharge high voltage capacitor.
1. Rest transformer on the bottom plate with its primary terminals
toward the oven face plate.
4. Disconnect wire leads (primary) from power transformer and the filament leads from the magnetron and capacitor terminals.
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”.
5. Disconnect high voltage lead of the power transformer from the
high voltage capacitor.
6. Remove two (2) screws holding transformer to bottom plate.
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.
7. Remove the one (1) screw holding capacitor holder with the high
voltage rectifier to the base plate.
1. Disconnect the power supply cord and remove outer case.
8. Disconnect rectifier terminal from capacitor. High voltage rectifier
assembly is now free.
2. Open the oven door and block it open.
3. Discharge high voltage capacitor.
9. Remove capacitor holder. Capacitor is now free.
4. Disconnect the high voltage wire of the power transformer from the
high voltage capacitor.
CAUTION: WHEN REPLACING HIGH VOLTAGE RECTIFIER AND
HIGH VOLTAGE CAPACITOR, GROUND SIDE TERMINAL OF THE HIGH VOLTAGE RECTIFIER MUST BE
SECURED FIRMLY WITH A GROUNDING SCREW.
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.
[5] MAGNETRON REMOVAL
1. REMOVAL
8. Remove magnetron with care so that magnetron antenna is not hit
by any metal object around the antenna.
1. Disconnect the power supply cord and then remove outer case.
9. Now, the magnetron is free.
2. Open the oven door and block it open.
3. Discharge high voltage capacitor.
2. REINSTALLATION
4. Disconnect all wire leads from magnetron.
1. Reinstall the magnetron to waveguide flange with car to prevent
damage to the magnetron antenna.
5. Remove the two (2) screws holding the chassis support to the magnetron and the oven cavity front flange.
2. Secure the magnetron with the four (4) screws.
6. Slide the magnetron duct slightly so that the two (2)screws at left
hand side of the magnetron appear.
3. Hold the chassis support to the oven cavity front plate and the magnetron with the two (2) screws.
7. Carefully remove the four (4) screws holding magnetron to
waveguide flange.
4. Reconnect the wire leads to the magnetron. Refer to “PICTORIAL
DIAGRAM”.
11 – 2
R408LS
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.
[6] OVEN LAMP REMOVAL
1. Disconnect the power supply cord and then remove outer case.
7. Now, the oven lamp is free.
2. Open the oven door and block it open.
3. Discharge high voltage capacitor.
Terminal
4. Disconnect the wire leads from the oven lamp.
Oven lamp
5. Remove the one (1) screw holding the oven lamp to the magnetron
duct.
Figure C-1. Oven lamp
6. Remove the oven lamp from the magnetron duct.
[7] POSITIVE LOCK CONNECTOR (NO-CASE TYPE) REMOVAL
1. Disconnect the power supply cord, and remove outer case.
Terminal
2. Open the door and block it open.
3. Discharge high voltage capacitor.
Positive lock¨
connector
4. Push the lever of positive lock® connector.
1
Push
5. Pull down on the positive lock® connector.
CAUTION: WHEN CONNECTING THE POSITIVE LOCK® CONNECTORS TO THE TERMINALS, CONNECT THE POSITIVE
LOCK® SO THAT THE LEVER FACES YOU.
Lever
2
Pull down
Figure C-2. Positive lock® connector
[8] TURNTABLE MOTOR REMOVAL
5. Disconnect wire leads from turntable motor.
1. Disconnect the power supply cord.
(See “Positive lock® connector removal”)
2. Remove turntable and turntable support from oven cavity.
6. Remove one (1) screw holding turntable motor to oven cavity.
3. Lay the oven on it's backside. Remove the turntable motor cover by
snipping off the material in four corners.
7. Now, the turntable motor is free.
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.
8. After replacement use the one (1) screw XOTS740P10000 to fit the
turntable motor cover.
[9] COOLING FAN MOTOR REMOVAL
1. REMOVAL
8. Remove the fan blade assembly from the shaft of the fan motor by
pulling and rotating the fan blade with your hand.
1. Disconnect the power supply cord and then remove outer case.
9. Now, the fan blade will be free.
2. Open the door and block it open.
CAUTION: Do not reuse the removed fan blade because the hole
(for shaft) may be larger than normal.
3. Discharge high voltage capacitor.
4. Disconnect the wire leads from the fan motor.
2. REINSTALLATION
5. Remove the two (2) screws holding the fan motor to the oven cavity
back plate.
1. Install the fan blade to the fan motor shaft according to the following
procedure.
6. Remove the fan blade from 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.
7. Hold the edge of the rotor of the fan motor by using a pair of groove
joint pliers.
3. Apply the screw lock tight into the hole (for shaft) of the fan blade.
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.
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.
Do not touch the pliers to the coil of the fan motor
because the coil may be cut or injured.
Make sure that the fan blade rotates smooth after
installation.
Do not disfigure the bracket by touching with the pliers.
Make sure that the axis of the shaft is not slanted.
11 – 3
R408LS
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.
Coil
Shaft
Groove joint pliers
Shaft
Axis
Stator
Gap
Bracket
These are the positions
that should be pinched
with pliers.
Stator
Rotor
Rear View
Table
Center of
bracket
Rotor
Side View
[10] CONTROL PANEL ASSEMBLY REMOVAL
1. Disconnect the power supply cord and then remove outer case.
5. Remove the one (1) screw holding the control panel to the oven
cavity front plate.
2. Open the door and block it open.
6. Straighten the nail holding the control panel assembly to the oven
cavity front plate.
3. Discharge high voltage capacitor.
4. Disconnect the wire leads from panel components.
7. Slide the control panel assembly upward and remove it.
8. Now, individual components can be removed.
[11] GRAPHIC SHEET AND MEMBRANE SWITCH REPLACEMENT
1. REMOVAL
11. Insert and connect the edge of the membrane switch’s ribbon cable
into the connector CN-G.
1. Disconnect the power supply cord and then remove outer case.
12.Insert the back light PWB into the square hole.
2. Open the door and block it open.
13.Reinstall the display window to the control panel frame.
3. Discharge high voltage capacitor.
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.
4. Remove the control panel assembly, referring to chapter of CONTROL PANEL ASSEMBLY REMOVAL.
5. Disconnect the ribbon cable of the membrane switch from the control unit.
Control panel frame
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.
Small
depression
9. Tear away the graphic sheet from the control panel frame.
10.Tear away the membrane switch from the control panel frame.
Slit
Ribbon
cable
2. REINSTALLATION
1. Remove remaining adhesive on the control panel frame surfaces
with a soft cloth soaked in alcohol.
Large
depression
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.
Membrame switch (FPC)
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.
Graphic sheet (Key sheet)
6. Tear the backing paper from the new graphic sheet.
Graphic Sheet and Membrane Switch Replacement
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 – 4
R408LS
[12] DOOR SENSING SWITCH/PRIMARY INTERLOCK SWITCH AND MONITOR SWITCH
REMOVAL
1. REMOVAL
At this time switch lever will be free, do not lose it.
1. Disconnect the power supply cord and remove outer case.
2. REINSTALLATION
2. Open the door and block it open.
4. Disconnect wire leads from the switches.
1. Reinstall 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.
5. Remove two (2) screws holding latch hook to oven flange.
2. Reconnect wire leads to each switch. Refer to pictorial diagram.
6. Remove latch hook assembly from oven flange.
3. Secure latch hook (with two (2) mounting screws) to oven flange.
7. Push outward on the two (2) retaining tabs holding switch in place.
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.
3. Discharge high voltage capacitor.
8. Switch is now free.
[13] DOOR SENSING SWITCH/PRIMARY INTERLOCK SWITCH AND MONITOR SWITCH
ADJUSTMENT
1. Adjustment
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.
1. Disconnect the power supply cord, and then remove outer case.
2. Open the door and block it open.
2. The door sensing switch and primary interlock switch interrupt the
circuit before the door can be opened.
3. Discharge high voltage capacitor.
3. Monitor switch contacts close when door is opened.
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. Reinstall outer case and check for microwave leakage around door
with an approved microwave survey meter. (Refer to Microwave
Measurement Procedure.)
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.
Latch Heads
Door Sensing
Switch
Door
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.
Monitor Switch
Switch Lever
2. After adjustment, check the following.
Primary Interlock
Switch
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.
Figure C-3. Latch Switch Adjustments
[14] DOOR REPLACEMENT
1. REMOVAL
9. Pry the choke cover by inserting a putty knife as shown Figure C-4.
1. Disconnect oven from power supply.
10.Release choke cover from door panel.
2. Push the open button and open the door slightly.
11. Now choke cover is free.
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.
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.
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.
11 – 5
R408LS
4. Check for microwave leakage around door with an approved microwave survey meter. (Refer to Microwave Measurement Procedure.)
Door stopper
1
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.
2
13
3
12
11
4
5
10
6
9
7
Door Frame
8
Putty Knife
Pin
Choke Cover
Upper oven hinge
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.
Door
assembly
13.Now, latch head and latch spring are free.
Door
stopper
14.Remove the three (3) screws holding the door panel to the door
frame.
15.Release door panel from nine (9) tabs of door frame by sliding door
panel downward.
Lower
oven hinge
16.Now, door panel with sealer film is free.
Choke
cover
17.Tear sealer film from door panel.
18.Now, door panel is free.
Pin
19.Remove door screen from door frame.
Lower
oven
hinge
20.Now, door screen is free.
21.Remove the door decoration from the door frame by straightening
the tabs of the door decoration.
Figure C-5. Door Replacement
22.Now, the door frame is free.
4. SEALER FILM
2. REINSTALLATION
1. Put the adhesive tape on the backing film of the sealer film as
shown in Fig. C-6.
1. Reinstall the door decoration to the door frame by bending the tabs
of the door decoration.
2. Tear the backing film by pulling the adhesive tape.
2. Reinstall door screen to door frame.
3. Put the pasted side of the sealer film on the door panel.
3. Put sealer film on door panel. Refer to “Sealer Film” about how to
handle new one.
Sealer film
4. Reinstall door panel to door frame by fitting nine (9) tabs of door
frame to nine (9) holes of door panel.
Backing film
Adhesive tape
5. Hold the door panel to the door frame with the three (3) screws.
6. Reinstall the latch spring to the latch head. Reinstall the latch
spring to the door frame. Reinstall latch head to door frame.
7. Reinstall choke cover to door panel by pushing
Figure C-6. Sealer film
8. Catch two (2) pins of door panel on two (2) hole of upper and lower
oven hinges as shown Figure C-5.
9. Reinstall the door stopper to the door assembly.
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.
11 – 6
Figure S-1. Pictorial Diagram
12 – 1
ORG
WHT
GRY
RY1
T1
COM.
PRIMARY
NO
INTERLOCK
SWITCH
N.C.
RED
GRY
GRY
WHT
WHT
COM.
WHT
WHT
GRY
GRN
WHT
GRY
TURNTABLE
MOTOR
BRN
ORG
OVEN LAMP
RED
THERMAL CUT-OUT
(OVEN)
RED
RED
RED
WHT
WHT
MAGNETRON TEMP FUSE
ORG
ORG
N
POWER SUPPLY
CORD 120V 60Hz
NOTE:
The grounding conductor of
the power supply cord has
been grounded by power
supply cord fixing screw.
The screw must always be
kept tight.
WHT
N
RED
L
ORG
ORG
WHT
RED
RED
MAGNETRON
POWER
TRANSFORMER
H.V. RECTIFIER
HIGH
VOLTAGE
CAPACITOR
HIGH VOLTAGE COMPONENTS
FAN MOTOR
WHT
WHT
NOTE:
The neutral (WHT) wire must be connected to the
terminal with "N" mark on the power supply cord.
H
CHAPTER 12. CIRCUIT DIAGRAMS
BRN
RY2
SP1
13
CN-B
1 GRY
2 GRN
GRN
GRN
N.O.
RED
R408LS
RED
RED
2
SECOND
INTERLOCK
RELAY
1
CN-B
1
CN-G
CONTROL UNIT
to Chassis support
COM.
DOOR
SENSING
SWITCH
MONITOR
SWITCH
WHT
R408LS
Service Manual
[1] Pictorial Diagram (Figure S-1)
AC(N)
DOOR
SENSING
SWITCH
MICRO
AC(H)
OVEN LAMP,
TURNTABLE
MOTOR,
FAN MOTOR
B-2
B-1
d
a
D1~D4
RY1
NOTE:
D31 1SS270A
D30 1SS270A
DU12D1-1P(M)-R
RY2
D6
R3
KTA1267Y
Q2
4.7K 1/4W
R5
510
1/2W
POWER UNIT
Q4 DTA123JS
10u/35V
C5
Q3 DTD143ES
SP1
LTST-C190KGKT x 4
LD4 LD3 LD2 LD1
27 1/4W
R4
1SS270A x2
D5
R2
JUMPER
WIER
: IF NOT SPECIFIED 1/10W 5%
0.1uF
50V
C1
DU12D1-1P(M)-R
c
b
PA151DR
T1
DOOR
M
COM
BZ
BL
-5V
INT
GND
CPU UNIT
Q20
DTA143EKA
(F)
(G)
P45
P41
P71
P70
0.1uF
50V
C20
R41
15K
15K
R72
R71
15K
R70
15K
R69
15K
R68
15K
AN5
12KF
AN6
C60㨪C63:330pF/50Vx4
AN4
R74㨪R78:270Kx5
Q10
2SA1037AK
Q30
DTA143EKA
Q11
DTA143EKA
AN7
GND
G9
CN-G
5597-13CPB7F
SOFTEN
G8
G7
(G)
10K
R14
MELT
15K
R110
10K
R13
DEFROST
G10
G11
12 – 2
G12
Figure S-2. Control Panel Circuit
G13
1N4002x4
COOK
G6
10K
R15
80
8
0
4
7
KEY UNIT
2
5
REHEAT
1
G4
25
IC1
G5
24
P53
P52
P51
P50
P47
P46
P45
P44
P43
INT0
CNTR0
VL2
VL1
AN7
AN6
AN5
AN4
AN3
AN2
AN1
AN0
P57
P56
P55
1
40
41
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16
P17
SEG16
SEG15
SEG14
SEG13
SEG12
SEG11
SEG10
WARM
9
3
6
TIMER
CLOCK
STOP
CLEAR
POWER
LEVEL
G2
G1
(F)
POPCORN
MINUTE
PLUS
SEG8
SEG7
SEG6
SEG5
SEG4
SEG3
SEG2
SEG1
SEG0
START
G3
CSTLS4M00G56P18-A0
CF1
64
SEG8
SEG9
65
LCD (RLCDSA155DR ZZ)
R408LS
[2] Control Panel Circuit (Figure S-2)
R408LS
[3] Printed Wiring Board (Figure S-3)
Figure S-3. Printed Wiring Board
12 – 3
R408LS
PARTS LIST
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
MICROWAVE OVEN
MODEL
R-408LS
Parts marked "*" may cause undue microwave exposure.
Parts marked " " are used in voltage more than 250V.
CONTENTS
PartsGuide
[1]
[2]
DOOR AND CONTROL PANEL
PARTS
„
INDEX
OVEN PARTS
TOP PAD ASSEMBLY
FPADBA624WRKZ
DOOR PROTECTION SHEET
SPADPA204WRE0
CABINET COVER
SPAKHA010WRE0
PLASTIC BAG
SSAKHA032WRE0
FOAM SHEET
SPAKHA013WREZ
6- 7
OPERATION MANUAL
BOTTOM PAD ASSEMBLY
FPADBA625WRKZ
6-2
TURNTABLE TRAY
6-1 TURNTABLE SUPPORT
TRAY PAD ASSEMBLY
INTO THE
OVEN CAVITY
CPADBA386WRKZ
Not replaceable items.
PACKING CASE
FPAK-A572WRKZ
This document has been published to be used
for after sales service only.
The contents are subject to change without notice.
R408LS
[1] OVEN PARTS
7-10
7-2
7-10
2-1
4-13
7-2
6-3
6-4
1-6
4-11
1-10
7-1
1-2
7-9
4-15
7-6
1-7
4-3
1-1
1-3
7-5
7-8
4-5
7-11
7-8
4-4
7-10
4-8
1-5
4-7
4-12
7-3
7-10
7-3
6-2
7-7
4-10
4-1
1-12
1-11
1-4
4-14
1-13
7-1
6-1
1-2
2-2
1-4
7-8
4-6
4-2
1-9
1-8
7-1
7-10
7-10
2-3
2-3
7-4
2-3
2-3
2
4-9
R408LS
NO.
PARTS CODE
PRICE NEW PART
RANK MARK RANK
DESCRIPTION
[1] OVEN PARTS
ELECTRIC PARTS
1-1 FPWBFA417WRKZ
1-1 FPWBFA389WRKZ
1-2 FFS-BA033WRKZ
1-2 FFS-BA037WRKZ
1-3 QFS-TA013WRE0
1-4 QSW-MA085WRE0
1-4 QSW-MA147WRZZ
!
*
!
!
!
!
*
*
AY
AW
-AN
AG
AF
AG
Noise filter assembly
Noise filter assembly (Interchangeable)
Monitor fuse 20A and monitor switch(V-5220Q)
Monitor fuse 20A and monitor switch(D3V-1G-2C25) (Interchangeable)
Temp. fuse 150C (Magnetron)
Primary interlock switch/ door sensing switch
Primary interlock switch/ door sensing switch (Interchangeable)
RV-MZA346WRZZ
BK
Magnetron
1-6 RTHM-A119WRE0
1-6 RTHM-A075WRE0
1-6 RTHM-A134WRZZ
1-7 FACCDA083WRE0
1-7 FACCDA085WREZ
1-7 FACCDA103WREZ
1-8 FH-DZA118WRKZ
1-8 FH-DZA131WRKZ
1-9 RC-QZA211WRE0
1-9 RC-QZA331WRZZ
1-10 RMOTEA433WRZZ
1-11 RLMPTA087WRZZ
1-11 RLMPTA082WRZZ
1-11 RLMPTA085WRZZ
1-12 RMOTDA264WRZZ
1-12 RMOTDA186WRE0
1-13 RTRN-A746WRZZ
1-13 RTRN-A745WRZZ
CABINET PARTS
2-1 GCABUB010WRPZ
2-2 GDAI-A403WRWZ
2-3 GLEGPA104WREZ
OVEN PARTS
4-1 PHOK-A130WRFZ
4-2 LBNDKA172WRPZ
4-3 NFANJA053WRFZ
4-4 LANGTA419WRPZ
4-5 *************
4-6 MLEVPA244WRFZ
4-7 PCOVPA311WRE0
4-8 PCUSGA532WRP0
4-9 PCUSUA191WRP0
4-10 PPACGA084WRF0
4-11 PCUSUA410WRP0
4-12 PCUSUA455WRP0
4-13 PDUC-A610WRF0
4-14 PDUC-A936WRFZ
4-15 PPACGA272WREZ
MISCELLANEOUS
6-1 FROLPA097WRKZ
6-2 NTNT-A108WREZ
6-3 TCAUAA292WRRZ
6-4 TCAUAA296WRRZ
SCREWS, NUTS AND WASHERS
7-1 XHPS740P08K00
7-2 LX-CZA070WRE0
7-3 LX-CZ0052WRE0
7-4 LX-EZA042WRE0
7-5 LX-EZA050WRE0
7-6 XHPS730P06000
7-7 XHPS740P08000
7-8 XHTS740P08RV0
7-9 XHTS740P12RV0
7-10 XOTS740P10000
7-11 XETS740P10000
AK
AN
AK
AQ
AQ
AQ
AN
-AV
-AX
AL
AL
AL
AT
AW
BM
--
Thermal cut-out 145C (Oven)
Thermal cut-out 145C (Oven)
Thermal cut-out 145C (Oven)
Power supply cord
Power supply cord (Interchangeable)
Power supply cord (Interchangeable)
H.V. rectifier assembly
H.V. rectifier assembly for production use (Interchangeable)
High voltage capacitor
High voltage capacitor for production use (Interchangeable)
Fan motor
Oven lamp
Oven lamp (Interchangeable)
Oven lamp (Interchangeable)
Turntable motor
Turntable motor (Interchangeable)
Power transformer
Power transformer for production use (Interchangeable)
BH
BA
AF
Outer case cabinet
Base plate
Leg
AK
AM
AG
AT
-AG
AG
AF
AC
AE
AB
AD
AR
AV
AG
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
AN
AW
AE
AH
Roller assy
Turntable
Monitor caution
DHHS caution label
AB
AC
AA
AB
AB
AB
AB
AG
AC
AB
AA
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
Screw : 4mm x 10mm
1-5
3
R408LS
[2] DOOR AND CONTROL PANEL PARTS
5-8
5-9
5-2
5-5
5-9
5-3
5-1
5-3-1
5-9
5-7
5-3-2
5-6
3-1
3-3
5-4
3-3
3-1-2
3-2
3-1-4
3-1-1
3-1-1-1
3-1-3
6-5
3-1-1-2
Actual wire harness may be different from illustration.
3-1-5
6-7
4
6-6
R408LS
NO.
PARTS CODE
PRICE NEW PART
RANK MARK RANK
DESCRIPTION
[2] DOOR AND CONTROL PANEL PARTS
*
*
*
*
*
CONTROL PANEL PARTS
3-1 DPNLCC019WRKZ
3-1-1 FBTN-A164WRKZ
3-1-1-1 JBTN-B391WRFZ
3-1-1-2 HDECQA328WRPZ
3-1-2 HDECQA329WRPZ
3-1-3 MSPRCA157WREZ
3-1-4 PSHEPB238WREZ
3-1-5 QSW-KA077DRZZ
3-2 DPWBFC563WRKZ
3-3 XEPS730P08XS0
DOOR PARTS
5-1 FDORFA412WRTZ
5-2 PSHEPA336WRP0
5-3 FWAKPA462WRKZ
5-3-1 GWAKPB081WRFZ
5-3-2 HDECQA334WRRZ
5-4 HPNL-A890WRRZ
5-5 GCOVHA382WRF0
5-6 LSTPPA139WRF0
5-7 MSPRTA084WRE0
5-8 LSTPPA167WRF0
5-9 XEPS740P08000
MISCELLANEOUS
6-5 FW-VZC094WREZ
6-6 FW-VZC093WREZ
6-7 TINSEB137WRRZ
BF
AP
AH
AM
AU
AF
AM
AQ
BK
AB
Panel med assembly
Open button assembly
Open button
Button decoration
Panel decoration
Open button spring
Key sheet
FPC
Control unit
Screw; 3mm x 8mm
BF
AF
BE
AX
BB
AP
AM
AE
AB
AG
AB
Door panel
Sealer film
Door frame assembly
Door frame
Door decoration
Door screen
Choke cover
Latch head
Latch spring
Door stopper
Screw: 4mm x 8mm
AS
AN
AL
Main wire harness
Filter harness
Instruction book
5
R408LS
„INDEX
PARTS CODE
[ D ]
DPNLCC019WRKZ
DPWBFC563WRKZ
[ F ]
FACCDA083WRE0
FACCDA085WREZ
FACCDA103WREZ
FBTN-A164WRKZ
FDORFA412WRTZ
FFS-BA033WRKZ
FFS-BA037WRKZ
FH-DZA118WRKZ
FH-DZA131WRKZ
FPWBFA389WRKZ
FPWBFA417WRKZ
FROLPA097WRKZ
FWAKPA462WRKZ
FW-VZC093WREZ
FW-VZC094WREZ
[ G ]
GCABUB010WRPZ
GCOVHA382WRF0
GDAI-A403WRWZ
GLEGPA104WREZ
GWAKPB081WRFZ
[ H ]
HDECQA328WRPZ
HDECQA329WRPZ
HDECQA334WRRZ
HPNL-A890WRRZ
[ J ]
JBTN-B391WRFZ
[ L ]
LANGTA419WRPZ
LBNDKA172WRPZ
LSTPPA139WRF0
LSTPPA167WRF0
LX-CZ0052WRE0
LX-CZA070WRE0
LX-EZA042WRE0
LX-EZA050WRE0
[ M ]
MLEVPA244WRFZ
MSPRCA157WREZ
MSPRTA084WRE0
[ N ]
NFANJA053WRFZ
NTNT-A108WREZ
[ P ]
PCOVPA311WRE0
PCUSGA532WRP0
PCUSUA191WRP0
PCUSUA410WRP0
PCUSUA455WRP0
PDUC-A610WRF0
PDUC-A936WRFZ
PHOK-A130WRFZ
PPACGA084WRF0
PPACGA272WREZ
PSHEPA336WRP0
PSHEPB238WREZ
[ Q ]
QFS-TA013WRE0
QSW-KA077DRZZ
QSW-MA085WRE0
QSW-MA147WRZZ
[ R ]
RC-QZA211WRE0
RC-QZA331WRZZ
RLMPTA082WRZZ
RLMPTA085WRZZ
RLMPTA087WRZZ
RMOTDA186WRE0
RMOTDA264WRZZ
RMOTEA433WRZZ
RTHM-A075WRE0
RTHM-A119WRE0
RTHM-A134WRZZ
RTRN-A745WRZZ
No.
PRICE NEW PART
RANK MARK RANK
2-3-1
2-3-2
BF
BK
1-1-7
1-1-7
1-1-7
2-3-1-1
2-5-1
1-1-2
1-1-2
1-1-8
1-1-8
1-1-1
1-1-1
1-6-1
2-5-3
2-6-6
2-6-5
AQ
AQ
AQ
AP
BF
-AN
AN
-AW
AY
AN
BE
AN
AS
1-2-1
2-5-5
1-2-2
1-2-3
2-5-3-1
BH
AM
BA
AF
AX
2-3-1-1-2
2-3-1-2
2-5-3-2
2-5-4
AM
AU
BB
AP
2-3-1-1-1
AH
1-4-4
1-4-2
2-5-6
2-5-8
1-7-3
1-7-2
1-7-4
1-7-5
AT
AM
AE
AG
AA
AC
AB
AB
1-4-6
2-3-1-3
2-5-7
AG
AF
AB
1-4-3
1-6-2
AG
AW
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
2-3-1-4
AG
AF
AC
AB
AD
AR
AV
AK
AE
AG
AF
AM
1-1-3
2-3-1-5
1-1-4
1-1-4
AG
AQ
AF
AG
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
AV
-AL
AL
AL
AW
AT
AX
AN
AK
AK
--
PARTS CODE
RTRN-A746WRZZ
RV-MZA346WRZZ
[ T ]
TCAUAA292WRRZ
TCAUAA296WRRZ
TINSEB137WRRZ
[ X ]
XEPS730P08XS0
XEPS740P08000
XETS740P10000
XHPS730P06000
XHPS740P08000
XHPS740P08K00
XHTS740P08RV0
XHTS740P12RV0
XOTS740P10000
6
No.
PRICE NEW PART
RANK MARK RANK
1-1-13
1-1-5
BM
BK
1-6-3
1-6-4
2-6-7
AE
AH
AL
2-3-3
2-5-9
1-7-11
1-7-6
1-7-7
1-7-1
1-7-8
1-7-9
1-7-10
AB
AB
AA
AB
AB
AB
AG
AC
AB
EndPage
COPYRIGHT © 2006 BY SHARP CORPORATION
ALL RIGHTS RESERVED.
No part of this publication may be reproduced, stored
in retrieval systems, or transmitted in anyform or by
any means, electronic, mechanical, photocopying, recording, or other wise, without prior written permission
of the publisher.
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