R-3A55

SHARP

SERVICE MANUAL
S8304 R3A55PJ/

MICROWAVE OVEN
-._~__ _ _

Momx R-3A55
In interests of user-safety the oven should be restored to its original condi-

TABLE OF CONTENTS GENERAL IMPORTANT INFORMATiON.. ................................................................................................... WARNING ...................................................................................................................................................... ......................................................................................................................... RODUCT SPECIFICATIONS APPEARANCE VIEW .................................................................................................................................... OPERATING SEQUENCE ............................................................................................................................. FUNCTION OF IMPORTANT COMPONENTS ............................................................................................ TRABLESHOOTING CHART ......................................................................................................................... TEST PROCEDURE ...................................................................................................................................... TOUCH CONTROL PANEL ......................................................................................................................... COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE ........................................................ MICROWAVE MEASUREMENT .................................................................................................................. WIRING DIAGRAM ...................................................................................................................................... PICTORIAL DIAGRAM ............................................................................................................................. CONTROL PANEL CIRCUIT ....................................................................................................................... PRINTED WIRING BOAD ........................................................................................................................... PARTS LIST ................................................................................................................................................. page .I 1 2 3 .: 7 9 16 21 26 27 ...2 8 29 .30 31

SHARP CORPORATION

SERVICE MANUAL

PRODUCT SPECIFICATION
MICROWAVE R-3A55 GENERAL This Manual engineers IMPORTANT INFORMATION OVEN

has been prepared to provide Sharp Corp. Service and Service Information.

with Operation

OPEARTING
It is recommended that service engineers carefully study the entire text of this manual. so that they will be qualified to render satisfactory customer service.
7

SEQUENCE

CAUTION MICROWAVE RADIATION

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

I / / I / / I I I

-J

TOUCH CONTROL
WARNING Never operate the oven until the following (A) (B) (C) (D) (E) points are ensured.

PANEL

The door is tightly closed. The door brackets and hinges are not defective. The door packing is not damaged. The door is not deformed or warped. There is not any other visible damage with the oven.

AND ADJUSTMENT

PROCEDURE

----MICROWAVE MESUREMENT

-P

Servicing and repair work must be carried out only by trained service engineers. All the parts marked * on parts list are used at voltages than 25OV. Removal 25ov. of the outer wrap gives access to potentials more

WIRING DIAGRAMS

above

PARTS LIST

SHARP CORPORATION OSAKA, JAPAN

Fb3A55

PRODUCT SPECIFICATIONS
ITEM Power Requirements 240 Volts 50 Hertz Single phase, 3 wire earthed Power Consumption Power Output 1.35 kW Approx. 6.1 A energy (AS 2895 1986) ) 750 watts nominal of RF microwave 850 watts (IEC-705-1988 Operating Case Dimensions frequency Width 520mm Height 305mm Depth Cooking Cavity Dimensions 385mm Width 348mm Height 197mm Depth Turntable diameter 325mm Touch Control System Clock ( 1:00 - 12:59) Timer (0 - 99 minutes 99 secinds) Microwave Repetition Power for Variable Cooking Rate; Control Complement 368mm of 2450MHz DESCRIPTION

HIGH . .. .. . . ... .. . .. .. .. . .. .. .. . ... .. . . . .. .. .. . . . ... Full power throughout the cooking time MEDIUM HIGH . .. . . .... . . .. .. .. . . . ... . . .. . .. ... . . .. .. .. . . . .. .. . . approx. 70% of Full Power MEDIUM MEDIUM .. ... . . ... .. ..*..................*.*........................* LOW .. . .. ... . .. .. .. . . .. ... .. . . ....*..................... approx. 50% of Full Power approx. 30% of Full Power approx. 10% of Full Power

LOW . .. . . . .. .. .. . ....*.......................*......*...*............... INSTANT ACTION (8 menu)

AUTO COOK pad EASY DEFROST NUMBER pads POWER LEVEL pad MORE. LESS pads STOP/CLEAR pad pad pad AUTO START/CLOCK INSTANT COOK/START I.A---a.* 4P nuurux. 13 KCI

GENERAL

INFORMATION

WARNING THIS APPLIANCE BE EARTHED

IMPORTANT THE WIRES IN THIS MAINS LEAD ARE COLOURED IN ACCORDANCE GREEN-AND-YELLOW BLUE BROWN NOTE: : EARTH : NEUTRAL : LIVE WITH THE FOLLOWING CODE:

Numbers and letters shown after sentences such as RD44101 IJ are for factory use only. 2

R-3A55

APPEARANCE
.fi (Top) /-

VIEW

1. 2. 3. 4. 5. 6.
7,

Ventilation openings Oven lamp Door hinges Door safety latches See through door Coupling Door open button

8. 9. 10. 11. 12. 13.

Touch control panel Digital readout Wave guide cover Access cover for oven lamp replacement Power supply cord Rating label

DISPLAY

1 Km I\r/l I\///I /TI . /x/ \I/ /x//\I /QiJ?ldrcator VA

AUTO Kg COOK t

REtiEAT

3E=ROST

MED

LOW

rflGc; j

TOUCH CONTROL

PANEL

INSTANTACTiONPADS
pCpdiTMU.

AUTOCOOKMENUS 3Jacket potato 4RoastLamb 5cornedMeat

z3,or4 SERVE OuANTTlY PAD Toaxktw,three,orfourse~es,

AUTO COOK

press~padprior~pressing ltlf2InslarltAdionpad.
-N-PADS Presstoentercooldhgtines,dod< tine,weigMofquantih/offood,or

, ww.

AUTOSTART/CLOCKPAD Prtzsstoset~ofAutostalttime.

OPERATION
OFF CONDITION
Closing the door activates all door interlock switches (1 st. latch switch, 2nd. latch switch and stop switch) IMPORTANT When the oven door is closed, the monitor switch contacts (COM-NC) must be open. When the microwave oven is plugged in a wall outlet, rated voltage is supplied to the point A3+A5 in the control unit. Figure O-l on page 27 1. The display flashes 88:88. 2. To set any programmes or set the clock, you must first touch the STOP/CLEAR pad. 3. 88:88 appears in the display and the time counts up every minute. NOTE:When the oven door is opened, the oven lamp comes on at this time.

SEQUENCE
The circuits to the power transformer, fan motor and turntable motor are cut off when the 1st. latch switch, 2nd. latch switch, and stop switch are made open. The oven lamp remains on even if the oven door is opened after the cooking cycle has been interrupted, because the relay RYl stays closed. Shown in the display is the remaining time.

MICROWAVE

COOKING

CONDITION
NUMBER

HIGH COOKING Enter a desired cooking time with the touching Pad and start the oven with touching Function START pad.

sequence Figure O-2 on page 27

COMPONENTS

6. MONITOR SWITCH CIRCUIT The monitor switch is mechanically controlled by oven door, and monitors the operation of the 1st and 2nd. latch switches. 6-1 When the oven door is opened during or after the cycle of a cooking program, the 1st. latch switch, 2nd. latch switch and stop switch must open their contacts first. After that the contacts (COM-NC) of the monitor switch can be closed. 6-2. When the oven door is closed, the contacts (COMNC) of the monitor switch must be opened. After that the contacts of the 1st. latch switch, 2nd. latch switch and stop switch are closed. 6-3 When the oven door is opened and the contacts of thelst. latch switch, 2nd. latch switch remain closed. The fuse M8A will blow, because the monitor switch is closed and a short circuit is caused.

CONNECTED

RELAY
RYl RY2

Oven lamp. Fan motor, Turntable motor Power transformer

MEDIUM HIGH, MEDIUM, COOKING

MEDIUM LOW, LOW

1. Rated voltage. is supplied to the primary winding of the power transformer. The voltage is converted to about 3.3 volts A.C. output on the filament winding and high voltage of approximately 2000 volts A.C. on the secondary winding. 2 The filament winding voltage (3.3 volts) heats the magnetron filament and the high voltage (2000 volts) is sent to the voltage doubling circuit, where it is doubled to negative voltage of approximately 4000 volts D.C.. 3. The 2450 MHz microwave energy produced in the magnetron generates a wave length of 12.24 cm. This energy is channeled through the waveguide (transport channel) into the oven cavity, where the food is placed to be cooked. 4. When the cooking time is up, a signal tone is heard and the relays RYl+RY2 go back to their home position. The circuits to the oven lamp, power transformer, fan motor and turntable motor are cut off. 5. When the door is opened during a cook cycle, the switches come to the following condition
CONDITION DURING DOOR OPEN CCXMNG (NO COOKING) Closed Open Closed Open Closed Open Closed Open

When the microwave oven is preset for variable cooking power 240 volts AC. power is supplied to the power transformer intermittently within a 32-second time base through the relay contact which is coupled with the current-limiting relay. The following levels of microwave power are given. SETTING:
32 sec. ON HIGH 24 sec. ON MEDIUM HIGH 18 sec. ON MEDIUM N-1 LOW 12 sec. ON I] 6 sec. ON LOW m-1 14 sec. OFF Approx. 50% = 450 Watts 20 sec. OFF Approx. 30% = 270 Watts 26 sec. OFF Approx. 10% = 90 Watts 8 sec. OFF

MEDIUM

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

SWITCH 1st. latch switches 2nd. latch switch Monitor switch Stop switch

CONTACT COM-NO COM-NO COM-NC COM-NO

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

COMPONENTS
RECTIFIER

ASYMMETRIC

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

LATCH

dOOK

HIGH VOLTAGE

RECTIFIER

\.. * / f\ TV \ &g$& I ,a %\\ 4; _, -lb yp 1 ii? ?

,i iA& Id, 1, /I g-)

2ND LATCH SW!TCH

,_ ~gq~~ \ < :-?J T$ r/t

SWITCH --. MONITCR

Figure D-l. Door Open Mechanism

The rated peak reverse voltage of DI of the asymmetric rectifier is 6 KV The rated peak reverse voltage of D2 of the asymmetric rectifier is 1.7 KV. Dl and D2 of the asymmetric rectifier or high voltage rectifier are shorted when the each peak reverse voltage goes beyond the each rated peak reverse voltage. (The process of blowing the fuse MSA.) 1. The high voitage rectifier is shorted by any causes when microwave cooking. 2. The peak reverse voltage oi Df of the rectifier goes beyond the rated peak reverse voltage i .7 KV in the voltage doubler circuit. 3. D2 of the rectifier is shorted. 4. The large electric currents flow through the high voltage winding of the power transformer 5. The large electric currents beyond 8A flow through the primary winding of the power transformer. 6. The fuse M8A blows by the large electric currents. 7. The power supply to the all electrical parts are cut off.

1ST. LATCH SWITCH, 2ND. LATCH SWITCH AND STOP SWITCH

1. When the oven door is closed, the contacts COM-NO) must be closed. 2. When the oven door is opened, the contacts .(COMNO) must be opened.

FUSE M8A
1. The fuse M8A blows when the contacts (COM-NO) of the 1st. latch switch and 2nd. latch switch remain closed with the oven door open and when the monitor switch closes. 2. The fuse M8A also blows when asymmetric rectifier, H.V. rectifier, H.V. wire harness, H.V.capacitor, magnetron or secondary winding of power transformer is shorted. 3. If the wire harness or electrical components are shortcircuited, this fuse M8A blows to prevent an electric shock or fire hazard.

MONITOR

SWITCH

1. When the oven door is closed, the contacts (COM-NC) must be opened. 2. When the oven door is opened, the contacts (COM-NC) must be closed. 3. If the oven door is opened and the contacts (COM-NO) of the 1st. latch switch and 2nd. latch switch fail to open, the fuse M8A blows simultaneously with closing the contacts (COM-NC) of the monitor switch. CAUTION: BEFORE REPLACING A BLOWN FUSE M8A TEST THE 1ST. LATCH SWITCH, 2ND. LATCH SWITCH MONITOR SWITCH AND MONITOR RESISTOR FOR PROPER OPERATION.

THERMAL

CUT-OUT TC 145C (MG)

MONITOR

RESISTOR

R 0.8R 20W

This thermal cut-out protects the magnetron against overheating. If the temperature goes up higher than 145C because the fan motor is interrupted, the ventilation openings are blocked, the thermal cut-out will open and the line voltages to the power transformer will be cut off and the operation of the magnetron will be stopped. The defective thermal cut-out must be replaced with new one.

The monitor resistor prevents the fuse M8A bursting when the fuse M8A blows due to the operation of the monitor switch. 5

R-3A55

THERMAL

CUT-OUT TC 145@(OVEN)

TURNTABLE

MOTOR
roller assembly to

The thermal cut-out located on the top of the oven cavity is designed to prevent damage to the oven if the foods in the oven catch fire due to over heating produced by improper setting of cook time or failure of control unit. Under normal operation, the oven thermal cut-out remains closed. However, when abnormally high temperatures are reached within the oven cavity, the oven thermal cut-out will open at 145C, causing the oven to shut down. The defective thermal cut-out must be replace with new one.

The turntable motor drives the turntable rotate the turntable.

FAN MOTOR
The fan motor drives a blade which draws external cool air. This cool air is directed through the air vanes surrounding the magnetron and cools the magnetron. This air is 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

THERMAL

CUT-OUT

95C (FAN MOTOR)

The thermal cut-out protect the fan motor against overheating. If its temperature goes up higher than 95C because the fan motor is locked or the ventilation operating are blocked, the contacts of the thermal cut-out will open and switch off the oven. When the oven cools itself down to 7523, the contacts of the thermal cut-out will close again.

R-3A55

TROUBLESHOOTING

CHART

WARNING TO SERVICE PERSONNEL

Microwave ovens contain circuitry capable of producing high voltage circuit will result in electrocution. REMEMBER TO CHECK 30 very high voltage and current, contact with any part of the

REMEMBER

TO CHECK4FJ during

1) Disconnect the supply. 2) Door opened, and wedged open. 3) Discharge high voltage capacitor. WARNING AGAINST THE CHARGE OF THE

1) Reconnect all leads removed from components testing. 2) Replace the outer case (cabinet). 4) Run the oven. Check all functions.

The high-voltage capacitor remains charged about 60 seconds after the oven has been / switched off. Wait for 60 seconds and then shortcircuit the connection of the high-voltage capacitor (that is, of the connecting lead of the high-volti age rectifier) against the chassis with the use of / an insulated screwdriver. I Sharp recommend that wherever possible fault-finding is carried out with the supply disconnected. It may in, some cases, be necessary to connect the supply after the outer case has been removed, in this event carry out 30 checks and then disconnect the leads to the primary of the power transformer. Ensure that these leads remain isolated from other components and the.oven chassis, (Use insulation tape if necessary.) When the testing is completed carry out 3tJ checks and reconnect the leads to the primary of the power transformer.

1 I 1 / / 1

3, Reconnect the supplyMicrowave ovens should not be run empty, To test for the presence of microwave energy within a cavity, place a cup of cold water on the oven turntable, close the door and set the microwave timer for two (2) minutes. Set the power level to HIGH and push the START button. When the two minutes has elapsed (timer at zero) carefully check that the water is now hot. If the water remains cold carry out 30 checks and re-examine the connections to the component being tested.

When all service work is completed, and the oven is fully assembled, checked and microwave reakage test carried out

the microwave

power output should

be

TROUBLESHOOTING
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 Proceduresection.

GUIDE
If the oven becomes inoperative because of a blown fuse M8A in the 1st. latch switch - 2nd. latch switch - monitor switch - monitor resistor circuit, check the 1st. latch switch, 2nd. latch switch, monitor switch and monitor resistor before replacing the fuse M8A.

IMPORTANT:

R-3A55

TEST PROCEDURE POSSIBLE CASE AND DEFECTIVE

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CONDITION

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I
)FF :ONDITION

supply .cord is plugged wall outle?.

intc

88:88 does not appear in drs

i
I 1 Oven iamp does not irah? a ooor ooeped. iDlsp!aG ap I pears.! Display does not ooeratt properly when STOPICLEAF pad IS touched.

1 +

siay a,npeaf-s i Sver 12~5 does noi r!gnr (DISp av 293ears.i Far; mote- aoes not ooeiate 3 s;;la) 223e2rs : ir Yp!25iE more- assem3ly aoes nc : zoerate !Zsp!ah ap. Gears. I Over or any erectncai parts aoes no: stop when cookrng time 1s 0 c- STOP/CLEAR pat is touched.
OOKING ONDITIOP

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Oven seem
but

to be operatmg

-----L-l d

little or no heat is produced ;n oven load. iMIcrowave power level IS se: at HIGH) Oven Uoes not seems to be operating properly when MEDIUM HIGH, MEDIUM, MEDIUM LOW or LOW is set. (Oven operates properly at HIGH and then the STOP/ CLEAR pad is touched the oven stops.) Oven goes into cook cycie but shuts down before end of cooking cycle. Oven stops as soon as when the START pad is touched.

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TEST PROCEDURES PROCEDURE LElTER A MAGNETRON TEST WITH YOUR HAND OR AN INSULATED TOOL / I I ,

COMPONENT

TEST

1 NEVER TOUCH ANY PART IN THE CIRCUIT WHILE THE OVEN IS IN OPERATION. CARRY OUT 3D CHECKS Isolate the magnetron terminal.

from the high voltage circuit by removing

all leads connected

to the filament

To test for an open circuit filament use an ohmmeter to make a continuity test between the magnetron filament terminals, the meter should show a reading of less than 1 ohm. To test for a short circuit filament to anode condition, connect ohmmeter between one of the filament terminals and the case of the magnetron (ground). This test should be indicated an infinite resistance. If a low or zero resistance reading is obtained then the magnetron should be replaced. MICROWAVE OUTPUT POWER (1 Liter water load) The foliowing test procedure should be carried out with the microwaveoven in a fully assembled condition (outer case fitted).Microwave output power from the magnetron can be measured by way oflEC 705, i.e. it can be measured by using water load how much it can be absorbed by the water load. To measure the microwave output power in the microwave oven, the relation of calorie and watt is used.When P(W) heating works for t(second), approximately P x t/4.1 87calorie is generated. On the other hand. if the temperature of the water with V(ml) rises AT (C) during this microwave heating period, the calorie of thewater is V x IT / The formula is as follows: I Pxti4.187=Vx_l-T P(W)=4.l87xVxAT/t 1 Our condition for the water load is as follows: Room temperature .. . . .. .. . .. . ... .. . .. .. .. . . around 20C Power supply Voltage .. . . ... ... . . .. . Rated voltage 1 Water load . .. .. 1000 g Initial temperature .. . . .. . .. .. 10+2C Heating time .. ... . . .. .. .. . . . .. .. . 49 sec. / P =85 x IT Measuring condition: 1. Container The water container must be a cylindrical borosilicate glass vessel having a maximum material thickness of 3 mm and an outside diameter of approximately 190 mm. 2. Temperature of the oven and vessel The oven and the empty vessel are at ambient temperature prior to the start of the test. 3. Temperature of the water The initial temperature of the water is (10 12)C. 4. Select the initial and final water temperature so that the maximum difference between the final water temperature and the ambient temperature is 5C. 5. Select stirring devices and measuring instruments in order to minimize addition or removal of heat. 6. The graduation of the thermometer must be scaled by 0.1 C at minimum and an accurate thermometer. 7. The water load must be (1000 f 5) g. 8. t is measured while the microwave generator is operating at full power. Magnetron filament heatup time is not included. NOTE: The operation time of the microwave oven is t + 2 sec. 2 sec. is magnetron filament heat-up time. Measuring method: 1. Measure the initial temperature of the water before the water is added to the vessel. (Example: The initial temperature Tl = 11 C) 2. Add the 1 litre water to the vessel. 3 Place the load on the centre of the shelf.

I I I j /

TEST PROCEDURES PROCEDURE LElTER

COMPONENT 4. Operate the microwave oven at HIGH (10 ?I 2)C. 5. Stir the water to equalize temperature 6. Measure the final water temperature. (Example: The final temperature T2 = 7. Calculate the microwave power output

TEST of the water rises by a value A T of

for the temperature throughout

the vessel.

21 C) P in watts from above formula.

Tl = 11C Initial temperature ............................................................................................ T2=21C Temperature after (49+2)= 51 sec. ................................................................. AT1 = 10C Temperature difference Cold-Warm ............................................................. Measured output power P= 85 x 10C = 850 Watts The equation is P= 85 x AT ................................................ JUDGMENT: The measured power. output power should be at least f 15 % of the rated output

CAUTION:

1 C CORRESPONDS INSUFFICIENT.

TO 85 WA-l-l-S. REPEAT

MEASUREMENT

IF THE POWER IS

T2.C

Heat up for 51 sec.

MICROWAVE OUTPUT POWER (2 Liter water load) The following test procedure should be carried out with the microwave oven in a fully assembled condition (with outer case fitted). Microwave output power from the magnetron can be measured by way of substitution, i.e. it can be measured by using a water load how much it can be absorbed by the water load. To measure the microwave output power in the microwave oven the relation of calorie and watt is used. On the other hand, if the temperature of the water with V(ml) rises AT (C) during this microwave heating period, the calorie of the water is V x AT. The formulae is as follows; P =8330xAT/t Our condition for the water load is as follows: Room temperature . .. .. .. . .. ... . . .. 23* 2C Power supply Voltage .. .. .. . .. .. . .. . . . . Rated voltage. Water load .. .. .. . 2000 ml Initial temperature . . .. . . . 23 2 1 C Heating time . .. . 1min. 51 sec. P = 75 x AT Measuring method: A) The two water containers must be prepared. The water container must be one (1) litre beaker made of Pyrex glass and its diameter approximately 12cm. B) Put the one (1) litre water into each beaker (Each beaker has one litre water). The initial temperature of the water should be 23+2X. C) Mark Tl on the one beaker and mark T2 on the other one. And stir the water and measure the temperature of water the thermometer and note them. The graduation of the thermometer must be scaled by 0.1% at minimum and an accurate mercury thermometer is recommended. D) Place the two (2) beakers as touching each other in the centre of the oven cavity. E) Set the timer to 1 minute and 51 seconds start the oven at HIGH. 10

TEST PROCEDURES PROCEDURE LETTER

COMPONENT

TEST

F) The time must be measured with stopwatch or wristwatch. G) After 1 minute and 51 seconds, stop the oven by opening the door. H) Put the two (2) beakers out of the oven cavity and measure the temperature the water with thermometer and note them. Example

of the water by stirring

Initial temperature . .. . .. . . . .. .. .. . . ... . .. . . .. .. .. . . ... .. ... .. . .. .. .. . .. . .. .. .. . . . .. .. . .. . . . .. .. . .. . .. Tl = 23C T2 = 24C Temperature after 1 min. 51 sec. . .. ... . .. . .. .. . .. .. .. . ... . . .. . ... . .. . . ... . . . .. . . .. .. . .. . . .. Tl = 33C T2 = 34C Temperature difference Cold-Warm ... . . .. .. .. . .. . ... . . ... . .. . .. .. . .. . . .. . .. .. . . . . ... . 111 = 10C AT2 = 10C Mean temperature rise IT . ... .. . . ... . . .. . ... .. . . .. ... . . IT = (AT1 !I AT2) ; 2 = (1 OcC+lOC) / 2 = 10C Measured output power The equation is P= 75 x AT . . .. .. . . . .. .. .. . . ... ..I....................................... P= 75 x 10C = 750 Watts NOTE: The measured output power should be at least z 15 % of the rated output power.

CAUTION:

1C CORRESPONDS TO 75 WATTS. REPEAT MEASUREMENT IF THE POWER IS INSUFFICIENT.

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(-EOC) (Tl OC; (T2OC)

tieat il3or: nn 5set

POWER TRANSFORMER WARNING:

TEST

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

CARRY OUT 3D CHECKS. Disconnect the leads to the primary winding of the power transformer. Disconnect the filament and secondary winding connections from the rest of the HV circuitry. Using an ohmmeter, set on a low range, it is possible to check the continuity of all three windings. The following readings should be obtained : a. Primary winding ......................... approximately 1.73 ohms. b. Secondary winding ................... approximately 104.7ohms. c. Filament winding ...................................... less than 1 ohm. If the reading obtained should be replaced. are not as stated above, then the power transformer is probably faulty and

CARRY OUT 4R CHECKS C HIGH VOLTAGE HIGH VOLTAGE RECTIFIER RECTIFIER ASSEMBLY TEST TEST

CARRY OUT 3D CHECKS. Isolate the high voltage rectifier assembly from the HV circuit. The high voltage rectifier can be tested using an ohmmeter set to its highest range. 11

TEST PROCEDURES PROCEDURE LEl-l-ER

COMPONENT

TEST

Connect the ohmmeter across the terminal B+C of the high voltage rectifier and note the reading obtained. Reverse the meter leads and note this second reading. The normal resistance is infinite in one direction and mor than 100 kL2 in the other direction. A CARRY OUT 4R CHECKS ASYMMETRIC RECTIFIER TEST +T@
ASYMMETRIC RECTIFIER c HIGH VOLTAGE RECTIFIER D2 Dl

CARRY OUT 3D CHECKS.

Isolate the high voltage rectifier assembly from the HV circuit. The asymmetric rectifier can be tested using an ohmmeter set to its highest range. Connect the ohmmeter across the terminals A+B of the asymmetric rectifier and note the reading obtained. Reverse the meter leads and note this second reading. If an open circuit is indicated in both directions then the asymmetric rectifier is good. If an asymmetric rectifier is shorted in either direction, then the the asymmetric rectifier is probably faultly and must be replaced with the high voltage rectifier. When the asymmetric rectifier is defective, check whether magnetron, high voltage rectifier, high voltage wire or filament winding of the power transformer is shorted. CARRY OUT @ CHECKS NOTE: For measurement of the resistance of the rectifier, the batteries of the measuring instrument must have a voltage at least 6 volts, because otherwise an infinite resistance might be shown in both directions. D HIGH VOLTAGE CARRY OUT m CAPACITOR CHECKS. TEST

A Isolate the high voltage capacitor from the circuit. 3. Continuity check must be carried out with measuring instrument which is set to the highest resistance range. C. A normal capacitor shows continuity for a short time (kick) and then a resistance of about 10 MR after it has been charged. D. A short-circuited capacitor shows continuity all the time. E. An open capacitor constantly shows a resistance of about 10 MS1 because of its internal 10 ML2 resistance. F. When the internal wire is opened in the high voltage capacitor, the capacitor shows an infinite resistance. G. The resistance across all the terminals and the chassis must be inifinte when the capacitor is normal. If incorrect readings are obtained, the high voltage capacitor must be replaced. CARRY OUT 4R CHECKS E SWITCH TEST CARRY OUT 3D CHECKS. Isolate the switch to be tested and using an ohmmeter check between the terminals as described following table.
Table: Terminal Connection Plunger Operation Released Depressed COM to NO O.C. S.C. of Switch COM to NC SC. O.C. COM; NO; NC; SC.; O.C.; Common terminal Normally open terminal Normally closed terminal Short circuit Open circuit

in the

If incorrect readings are obtained, CARRY OUT $J CHECKS.

make the necessary

switch adjustment

or replace the switch.

12

R-3A55

TEST PROCEDURES PROCEDURE LElTER F THERMAL CUT-OUT TEST

COMPONENT

TEST

CARRY OUT 3fJ CHECKS Disconnect the leads from the terminals of the thermal cut-out. Then using an ohmmeter. continuity test across the two terminals as described in the table below. CARRY OUT 4J CHECKS Table: Thermal
Temperature Parts Name Thermal cut-out 145C Thermal cut-out 95C of ON condition

make a

cut-out Test <

Temperature of OFF condition (open circuit) (C; Above 14.5 C Above 95 C lndicatron ofohmmeter (When room temperature is approx. 20-C, Ciosea e~rcu~: Closed c!rczif. I f i I J
i

(closed crrcuit) (Cl Below -20-C Below 75C

If incorrect readings are obtained,

replace the thermal cut-out.

An open circuit thermal cut-out 145C (MG) indicates that the magnetron has overheated, This mad ke due to resistricted ventilation, cooling fan failure or a fault condition within the magnetrcn or HV 3:1rzziT An open circuit thermal cut-out 145C (OVEN) indicates that the foods in the oven may catcn fire. ths may be due to over heating produced by improper setting of the cooking time or faiiure of the contrc: panel. An open circuit thermal cut-out 95C (FAN) indicates that the fan motor !Jvinding has overheated. may be due to blocked ventilation or locked cooling fan. G MONITOR RESISTOR TEST this

CARRY OUT =CHECKS. Disconnect the leads from the monitor resist. Using an ohmmeter between the terminals of the monitor resistor. The resistance of monitor resistor is approx. 0.8 ohms. and set on a low range. Check

If incorrect readings are obtained, CARRY OUT 4R CHECKS. H MOTOR WINDING TEST

replace the monitor resistor.

CARRY OUT 3DCHECKS Disconnect the leads from the motor. Using an ohmmeter, check the resistance

between the two terminals of Motor 370 12 16.08 kQ

as described

in the table below.

Table: Resistance Motors Fan motor 1 Turntable motor If incorrect readings are obtained, CARRY OUT fi CHECKS

Resistance Aonroximatelv 1 Approximately

replace the motor.

13

TEST PROCEDURES PROCEDURE LETTER BLOWN FUSE F M8A CARRY OUT 3D CHECKS 1. If the fuse M8A is blown, there could be shorts or ground in electrical parts or wire harness. Check them and replace the defective parts or repair the wire harness. 2. If the fuse M8A is blown when the door is opened, check the 2nd. latch switch, monitor switch and monitor resistor. If the fuse M8A is blown by incorrect door switching M8A. replace the defective switch(s) and the fuse

COMPONENT

TEST

3. If the fuse M8A is blown, there could be a short in the asymmetric rectifier or there could be a ground in wire harness. A short in the asymmetric rectifier may have occured due to short or ground in H.V. rectifier, magnetron, power transformer or H.V. wire. Check them and replace the defective parts or repair the wire harness. CARRY OUT 4R CHECKS CAUTION: Only replace fuse M8A with the correct value replacement PANEL ASSEMBLY TEST

TOUCH CONTROL

The touch control panel consists of circuits including semiconductors such as LSI, ICs, etc. Therefore, unlike conventional microwave ovens, proper maintenance cannot be performed with only a voltmeter and ohmmeter. In this service manual, the touch control panel assembly is divided into two units, Control Unit and Key Unit, and troubleshooting by replacement is described according to the symptoms indicated. 1 Key Unit The following s ^y m p toms indicate a defective key unit. Replace the key unit. aj When touching the pads. a certain pad produces no signal at all. b) When touching a number pad, two figures or more are displayed. c) When touching the pads, sometimes a pad produces no signal. 2. Control Panel The following symptoms indicate a defective control unit. Replacing the control unit. 2-1 In connection with pads. a> When touching the pads, a certain group of pads do not produce a signal. b) When touching the pads, no pads produce a signal. 2-2 In connection with indicators a) At a certain digit, all or some segments do not light up. b) At a certain digit, brightness is low. c) Only one indicator does not light. dj The corresponding segments of all digits do not light up; or they continue to light up. e) Wrong figure appears. f) A certain group of indicators do not light up. g) The figure of all digits flicker. 2-3 Other possible problems caused by defective control unit. a) Buzzer does not sound or continues to sound. b) Clock does not operate properly. c) Cooking is not possible.

14

R-3A55

RELAY TEST CARRY OUTm CHECKS (A) on the

Remove the outer case and check voltage between Pin Nos. 3 and 5 of the 3 pin connector control unit with an A.C. voltmeter. The meter should indicat 240 volts, if not check oven circuit.

RYl and RY2 Relay Test Check voltage at the relay coil with a D.C. voltmeter during the microwave cooking operation. DC. voltage indicated . . .. .. . .. . . ... Defective relay. DC. voltage not indicated . . .. .. Check diode which is connected to the relay coil. If diode is good, control unit is defective.
t I

RELAY SYMBOL
RYI RY2

/ OPERATIONAL j VOLTAGE I I
1Approx. 26.0 V.C.C. I / Approx. 25.0 V.D.C.

1 /

CONNECTED

COMPONENTS

Oven lamp/Turntablemotor/Coolingfan motor

Power

transformer

CARRY OUT @ CHECKS L PROCEDURES BOARD(PWB) TO BE TAKEN WHEN THE FOIL PATTERN IS OPEN. ON THE PRINTED WIRING

To protect the electronic circuits, this model is provided with a fine foil pattern added to the primary on the PWB, this foil pattern acts as a fuse. If the foil pattern is open, follow the troubleshooting guide given below for repair. Problem: POWER ON, indicator does not light up. CARRY OUT 30 CHECKS

STEPS
1

OCCURANCE
The rated AC voltage is not present at POWER terminal of CPU connector (CN-A)

CAUSE OR CORRECTION
Check supply voltage and oven power cord.

The rated AC voltage is present at primary side of low voltage transformer. Only pattern at a is broken.

Low voltage transformer Check and repair.

or secondary

circuit defective.

*Insert jumper wire Jl and solder. (CARRY OUT 30 CHECKS BEFORE REPAIR) between c and d. REPAIR)

Pattern at a and b are broken.

*Insert the coil RCILF2003YAZZ (CARRY OUTS CHECKS

BEFORE

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

CARRY OUT =CHECKS

15

9-3A55

TOUCH CONTROL PANEL ASSEMBLY

OUTRINE The touch control section consists of the following as shown in the touch control panel circuit. (1) Key Unit (2) Control Unit The principal functions of these units and the signals communicated among them are explained below. Key Unit The key unit is composed of a matrix, signals generated in the LSI are sent to the key unit through RIOR13, R20 and R22. When a key pad is touched, a signal is completed through the key unit and passed back to the LSI through ROO-R03 to perform the function that was requested. Control Unit Control unit consists of LSI, power source circuit, synchronizing signal circuit, ACL circuit, buzzer circuit and indicator circuit. 1) LSI This LSI controls the key strobe signal, relay driving signal for oven function and indicator signal. 2) Power Source Circuit This circuit generates voltages necessary unit. Symbol VC VP VFl VF2 Voltage -5v -30v 2.2Vac 5) Buzzer Circuit The buzzer is responsive to signals from the LSI to emit noticing sounds (key touch sound and completionsound). OF TOUCH CONTROL units PANEL Signal Circuit

3) Synchronizing

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.

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

6) Door Sensing

Switch (Stop Switch)

A switch to tell the LSI if the door is open or closed. 7) Relay Circuit To drive the magnetron, light the oven lamp.

fan motor, turntable

motor and

in the control

Application LSI(IC1) Fluorescent display tube : Grid and anode voltage Filament of fluorescent display tube (VFl to VF2 voltage)

8) Indicator Circuit Indicator element is a Fluorescent Display. Basically, a Fluorescent Display is triode having a cathode, a grid and an anode. Usually. the cathode of a Fluorescent Display is directly heated and the filament serves as cathode. The Fluorescent Display has 6-digits, 13-segments are used for displaying figures.

16

DESCRIPTION LSI(IZA496DR) The I/O signal of the LSl(lZA496DR)

pi No. ~ ;z;; ~ ;

OF LSI

is detailed in the following table.

Description

Anode (seqment) of Fluorescent Displav illumination Vp voltage of power source circuit input.

voltaqe: -30V

Siqnal cominq from touch kev. When either one of G12 line keys on key matrix is touched, a corresponding be input into ROo. Siqnal cominq from touch kev. When either one of Gl 1 line keys on key matrix is touched, a corresponding be input into ROI. 4 1 R02 i IN

/ signal will

signal will

Siqnal cominq from touch key. When either one of GlO line keys on key matrix is touched. a corresponding be input into Ron.

signal

will

Siqnal cominq from touch key. When either one of G9 line keys on key matrix is toucned. a corresponding signal out of R2o-R23, Rl c-R: s wiil be input into ROs. When no ke : is touched. the signal is held at L level. IN IN Connected to VC.

6 7

/ TEST / j
/ /

~ i /
I I I

RESET

Auto clear terminal. Signal is input to reset the LSI to the initial state when power is supplied. Temporarily set to L level the moment power is supplied. at this time the LSI is set. Thereafter set at H level. Internal ciock oscillation frequencv input settinq. The internal clock frequency is set by inserting the ceramic filter oscillation respect to OSCl terminal. Internal clock oscillation frequencv control output. Output to control oscillation input of OSC2. Connected to VC. j I 1 I I 1 1 1 I
I I

/ OSCl

IN

circuit with

osc2

\ OUT IN/IN / OUT

10/l 1 12

/GND/Avss/ j AN0

Oven lampturntable motor and coolinq fan motor drivinq siqnal. (Square Waveform : 50Hz) To turn on and off the control relay. The pulse signal (50Hz) is delivered to the control relay driving circuit and cook relay control circuit. Terminal not used.

13

1 AN1

OUT OUT

Maqnetron hiqh-voltaqe circuit drivinq siqnal. To turn on and off the cook relay. In low operation, the signals holds L level during microwave cooking and H level while not cooking. In other cooking modes (MED HIGH, MED,MED LOW,LOW) the signal turns to H level and L level in repetition according to the power level. Terminal not used. the door open/close information
to LSI.

15

1 AN3

OUT

Input siqnal which communicates Door closed; H level signal. Door opened; L level signal. 17 18-19 20/2 1
AN5

IN IN IN/IN

Terminal Connected Connected

to change cooking constant. to VC. to GND. t

AN6-AN7 IAVCCNCCI

Siqnal svnchronized with commercial source freqencv(5OHz). This is basic timing for time processing of LSI. Terminal not used. 17

) Pin No. I 1

-r /
I/O
I t

( Signal !

Description

24

iD2

OUT

Diqit selection sianai.

Refer to the touch control panel circuit about the relation between signals and digits. Normally, one pulse is output in every synchronized signal period, and input to the grid of the fluorescent display.

i 25

1 BUZZ

OUT

Siqnal to sound buzzer. A: key touch sound(0.12sec.). B: Completion sound(2.4sec.). Diqit selection signal. Refer to the touch control panel circuit about the relation between signals and digits. Normally, one pulse is output in every synchronized signal period, and input to the grid of the fluorescent display.

/ 27

j 05

OUT

Diqit selection siqnal. Refer to the touch control panel circuit about the relation between signals and digits. Normally, one pulse is output in every synchronized signal period, and input to the grid of the fluorescent display. Diqit selection siqnal. Refer to the touch control panel circuit about the relation between signals and digits. Normally, one pulse is output in every synchronized signal period, and input to the grid of the fluorescent display. t Diqit selection siqnal. Refer to the touch control panel circuit about the relation between signals and digits. Normally, one pulse is output in every synchronized signal period and input to the grid of the fluorescent display. Seqment data siqnal. Refer to the touch control panel circuit for the relationship between signals and indicators. Normally, one pulse is output in every synchronized signal period, and input to the anode of the fluorescent display. Seqment data siqnal. : Refer to the touch control panel circuit for the relationship between signals and indicators. Normally. one pulse is output in every synchronized signal period, and input to the anode of the fluorescent display. Seqment data siqnal. Refer to the touch control panel circuit for the relationship between signals and indicators. Normally, one pulse is output in every synchronized signal period, and input to the anode of the fluorescent display. Seqment data sianal. Refer to the touch control panel circuit for the relationship between signals and indicators. Normally, one pulse is output in every synchronized signal period, and input to the anode of the fluorescent display. Seqment data siqnal. Refer to the touch control panel circuit for the relationship between signals and indicators. Normally, one pulse is output in every synchronized signal period, and input to the anode of the fluorescent display. Seqment data siqnal. Signal similar to 08. Key strobe siqnal. Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal while one of G8 line keys on key matrix is touched.

28 1 I

j D6

OUT

I i

29

! D7
I / I / I j
I /

OUT

/ I /

-I-

30

ID8

OUT

R8c

OUT

32

R8;

OUT

33

j R82 I
I

, I 1 I
I I

OUT

34

I R83

OUT

I / I /

/ 36 /

OUT

Secament data siqnal. Signal similar to D8. Kev strobe siqnal. Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal while one of G7 line keys on key matrix is touched. 18

I/O

Description

37

R12

OUT

Seqment data siqnal. Signal similar to D8. Kev strobe siqnal. Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal while one of G6 line keys on key matrix is touched. Seqment data sianal. Signal similar to 08. Kev strobe siqnal. Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal while one of G5 line keys on key matrix is touched. Seament data siqnal. Signal similar to D8. Key strobe siqnal. Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal whiie one of G4 line keys on key matrix is touched.
Seqment data siqnal.

OUT

OUT

40

R21

OUT

41

R22

OUT

Signal similar to 08. Kev strobe siqnal. Signal applied to touch-key section. A pulse signa I is input to ROo-ROs terminai whiie one of G3 line keys on key matrix is touched. Seament data siqnal. Signal similar to 08. Kev strobe siqnal. Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal while one of G2 line keys on key matrix is touched. Seqment data siqnal. Signal similar to D8. Key strobe siqnal. Signal applied to touch-key section. A pulse signal is input to ROo-ROs terminal while one of GI line keys on key matrix is touched.

42

R23

OUT

I 1

19

+3A55

SERVICING
1 .Precautions for Handling Electronic Components This unit uses CMOS LSI in the integral part of the circuits. When handling these parts, the following precautions should be strictly followed. CMOS LSI have extremely high impedance at its input and output terminals. For this reason, it is easily influenced by the surrounding high voltage power source, static electricity charge in clothes, etc, and sometimes it is not fully protected by the built-in protection circuit. In order to protect CMOS LSI. 1) When storing and transporting, thoroughly wrap them in aluminium foil. Also wrap all PW boards containing them in aluminium foil. 2) When soldering, ground the technician as shown in the figure and use grounded soldering iron and work table. 2.Shapes of Electronic Components
approx 1M ohm

d&2 /

3.Servicing

of Touch Control Panel

touch control panel and the oven itself is so short that the two cant be separated. For those models, check and repair all the controls (sensor-related ones included) of the touch control panel while keeping it connected to the oven. B. On some models, the power supply cord between the touch control panel and the oven proper is 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 sensor-related controls of the touch control panel, checking them is possible if dummy resistor(s) with resistance equal to that of the controls are used. (2)Servicing the touch control panel with power supply from an external power source: Disconnect the touch control panel completely from the oven properand short both ends of the door sensing switch (on PWB) of the touch control panel,which brings about an operational state that isequivalent to the oven door being closed. Connect an external power source to the power input terminal of the touch control panel, then it is possible to check and repair the controls of the touch control panel it is also possible to check the sensor-related controls of the touch control panel by using the dummy resistor(s). 4.Servicing Tools the touch control panel assem-

Transistor D-I-Al 14ES DTBl43ES DTDi 43ES 2SA933S

We describe the procedures to permit servicing of the touch control panel of the microwave oven and the precautions you must take when doing so. To perform the servicing, power to the touch control panel is available either from the power line of the oven itself or from an external power source. (1)Servicing the touch control panel with power supply of the oven: CAUTION: THE HIGH VOLTAGE TRANSFORMER OF THE MICROWAVE OVEN IS STILL LIVE DURING SERVICING PRESENTS A HAZARD. Therefore, when checking the performance of the touch control panel, put the outer cabinet on the oven to avoid touching the high voltage transformer, or unplug the primary terminal (connector) of the high voltage transformer to turn it off; the end of such connector must be insulated with an insulating tape. After servicing, be sure to replace the leads to their original locations. A. On some models, the power supply cord between the

Tools required to service biv. I j Soldering iron: 30W ilt is recommended grounding terminai.) 2) Oscilloscope: Single 1OMHz type or more 3; Others: Hand tools 5.0ther Precautions

to use a soidering beam. frequency advanced model.

iron with a range: DC-

1) i3efore turning on the power source of the control unit, remove the aluminium foil applied for preventing static electricity. 2) Connect the connector of the key unit to the control unit being sure that the lead wires are not twisted. 3) After aluminium foil is removed, be careful that 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.

20

COMPONENT
WARNING:

REPLACEMENT

AND ADJUSTMENT

PROCEDURE
FOLLOW THE INSTRUC-

AVOID POSSIBLE EXPOSURE TO MICROWAVE ENERGY. TIONS BELOW .BRBEFORE OPERATING THE OVEN. 2. 3. 4. 5. 6.

PLEASE

1. CARRY OUT 3D CHECKS. 2. Make sure that a definite click can be heard when the door is unlatched. (Hold the door in a closed position with one hand, then push the door open button with the other, this causes the latch heads to rise, it is then 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 ating the oven. before oper-

Door hinge, support or latch hook is damaged. The door gasket or seal is damaged. The door is bent or warped. There are defective parts in the door interlock system. There are defective parts in the microwave generating and transmission assembly. 7. There is visible damage to the oven. Do 1. 2. 3. 4. not operate the oven: Without the RF gasket (Magnetron). If the wave guide or oven cavity are not intact. If the door is not closed. If the outer case (cabinet) is not fitted.

Do not operate the oven if any of the following conditions exist 1. Door does not close firmly. Please refer to OVEN PARTS, CABINET PARTS, DOOR PARTS, when carrying out any of the following dures:

removal proce-

OUTER CASE REMOVAL

To 1. 2. 3. remove the outer case, proceed as follows. Disconnect oven from power supply. Open the oven door and wedge it open. Remove the screws from rear and along the side edge of case. 4. Slide the entire case back about 1 inch(3 cm) to free it from retaining clips on the cavity face plate. 5. Lift the entire case from the oven. \ 6. Discharge the H.V. capacitor before carring out any further work. 7. Do not operate the oven with the outer case removed. N.B.; Step 1,2 and 6 from the basis of the 3fJ checks. CAUTION: DISCHARGE HIGH VOLTAGE CAPACITOR BEFORE TOUCHING ANY OVEN COMPONENTS OR WIRING.

POWER TRANSFORMER

REMOVAL

1. CARRY OUT =CHECKS 2. Disconnect wire leads from power transformer, magnetron and capacitor terminals. 3. Remove four (4) screws holding transformer to base plate (right). 4. Remove transformer. Re-install 1. Rest transformer on the base cabinet with its primary

terminals toward the oven face plate. 2. Transformer with four screws to base plate (right). 3. Reconnect wire leads (primary and high voltage) to power transformer and filament leads of transformer to magnetron and high voltage capacitor. Refer to PICTORIAL DIAGRAM. 4. Re-install outer case and check that oven is operating properly.

MAGNETRON
1. CARRY OUT aCHECKS 2. Disconnect wire leads from magnetron. 3. Carefully loosen four(4) screws holding waveguide flange.

REMOVAL
CAUTION: WHEN REPLACING MAGNETRON, BE SURE THE R.F. GASKET MOUNTING SECURELY. SCREWS IS IN PLACE, AND ARE TIGHTENED

magnetron

to

HIGH VOLTAGE

RECTIFIER

AND HIGH VOLTAGE

CAPACITOR

REMOVAL

1. CARRY OUT 3lJCHECKS 2. Remove one(l) screw holding capacitor holder to oven cavity rear plate. 3. Disconnect rectifier terminal from capacitor. Rectifier and high voltage assembly is now free. 4. Remove one (1) screw holding high voltage rectifier assembly to capacitor holder.

5. Disconnect wire leads from capacitor and remove capacitor holder. Capacitor is now free. 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. 21

OVEN LAMP AND LAMP SOCKET REMOVAL

1. CARRY OUT aCHECKS 2. Disconnect the wire leads from the lamp socket. 3. Remove the lamp holder from partition angle. 4. Remove the oven lamp from the lamp socket.

TURNTABLE

MOTOR REMOVAL
4. Disconnect wire leads from turntable motor. (See Positive lock connector removal) 5. Remove two (2) screws holding turntable motor to oven cavity. 6. Now the turntable motor is free.

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

FAN MOTOR REPLACEMENT

EMOVAL 1. CARRY OUT 3D CHECKS 2. Disconnect the wire leads from the fan motor and thermal cut-out. 3. Remove the three (3) screws holding the fan motor assembly to the oven cavity. 4. Release the fan duct assembly from the oven cavity. 5 Remove one (1) screw from the thermal cut-out angle. 6. Remove the fan motor assembly from the oven cavity. 6. Remove the fan blade from the fan motor shaft according the following procedure. 1) Hold the edge of the rotor of the fan motor by using a pair of groove joint pliers. CAUTION: * Make sure that any pieces do not enter the gap between the rotor and the stator of the fan motor. Because the rotor is easy to be shaven by pliers and metal pieces may be produced. * Do not touch the pliers to the coil of the fan motor because the coil may be cut or injured. * Do not transform the bracket by touching with the pliers, 2) Remove the fan blade assembly from the shaft of the fan motor by pulling fan retainer clip and rotating the fan blade with your hand. 3) Now, the fan blade will be free. CAUTION: * Do not use this removed fan blade again.Because the hole(for shaft) of it may become bigger than a standard one. 7. Remove the two (2) screws holding the fan motor to the fan motor angle. 8. Now, the fan motor is free. INSTALLATION 1. Install the fan motor to the fan motor angle with the two (2) screws. 2. Install the fan blade to the fan motor shaft according the following procedure. 1) Hold the center of the bracket which supports the shaft of the fan motor on the flat table. 2) Apply the screw lock tight into the hole(for shaft) of the fan blade. 3) Install the fan blade to the shaft of fan motor by pushing the fan blade with a small, light weight. ball peen hammer or rubber mallet. CAUTION: Do not hit the fan blade strongly when installed because the bracket may be transformed. Make sure that the fan blade rotates smooth after installed. Make sure that the axis of the shaft is not slanted. 3. Install the thermal cut-out angle to the fan motor with the one (I) screw. 4. Install the the fan motor angle to the oven cavity with two (2) screws. 5. Connect the wire leads to the fan motor and the thermal cut-out, referring to the pictorial diagram.
l * *

move jomt pliers

hese are the posltlon here should be nched with pliers

Rear view

Side view

22

POSITIVE

LOCK3 CONNECTOR
Pull down on

(NO-CASE TYPE) REMOVA

Posmve iock@ connector

Push the lever of positive lock% connector. the positive lock% connector. CAUTION:

WHEN YOU CONNECTING THE POSITIVE LOCKQ CONNECTORS TO THETERMINALS, INSTALL THE POSITIVE LOCK SO THAT THE LEVER FACES YOU

Figure C-l. Positive

lock connector

CONTROL

PANEL ASSEMBLY

REMOVAL

1, CARRY OUT aCHECKS 2. Disconnect wire leads from panel components. 3. Remove one (1) screw from upper side.

4. Remove control panel assembly and slide upward. 5. Now, individual components can be removed.

1ST. LATCH SWITCH, 2ND. LATCH SWITCH, STQP SWITCH AND MONITOR SWITCH REMOVAL
1. CARRY OUT QCHECKS 2. Disconnect wire leads from the switches. 3. Remove two (2) screws holding latch hook to oven flange. 4. Remove latch hook assembly 5. Push outward switch in place. 6. Switch is now free. At this time switch lever will be free, do not lose it. Re-install 1. Re-install each s;Nitc h lever and !atch switch in its place. The stop/monitor swrrches are in rhe iower position and the 2nd. latch s&itch LSin the upper positicr. The 1st latch switch 1s rn the iower postion at the barn side of the iatch hook. 2. Re-connect wire leads to each switch. Refer to pictoriai diagram. 3. Secure latch hook (with two (2: mounting screws! 12 oven flange. 4. Make sure that the monitor switch is operating orooerly Refer lo and check continuity of the monitor circuit. chapter Test Procedure and Adjustment procedure.

from oven flange. tabs holding

on the two (2) retaining

1ST. LATCH SWITCH, 2ND. LATCH SWITCH AND MONITOR SWITCH ADJUSTMEPIT
If the 1st. latch switch, 2nd. latch switch, stop switch and monitor switch do not operate properly due to a misadjustment, the following adjustment should be made. 1. Loosen the two (2) screws holding latch hook to the oven cavity front flange. 2. With door closed, adjust latch hook by moving it back and forth, and up and down. In and out play of the door allowed by the upper and lower position of the latch hook should be less than 0.5mm. The vertical position of the latch hook should be adjusted so that the 1st. latch switch and 2nd. latch switch and the stop switch are activated with the door closed. 3. Secure the screws with washers firmly. 4. Check the 2nd. latch switch operation. If the 2nd. latch switch has not activated with the door closed, loosen screw and adjust the latch hook position. After adjustment, check the following. 1. In and out play of door remains less than 0.5mm when in the latched position. First check upper position of latch hook, pushing and pulling upper portion of door toward the oven face. Then check lower portion of the latch hook, pushing and pulling lower portion of the door toward the oven face. Both results(play in the door) should be less than 0.5mm. 23 2. The 2nd. latch switch, 1 st latch switch, and stop switch interrupt the circuit before the door can be opened. 3. Monitor switch contacts close when door is opened. 4. Re-install outer case and check for microwave leakage around door with an approved microwave survey meter. (Refer to Microwave Measurement Procedure.)
L4TCH HOOK

2ND LATCH / SWITCH

i & /i

-. MOixiTCIR SWIT:I

STOP SbViC?

Figure C-2. Latch Switch Adjustments

DOOR REPLACEMENT
REMOVAL 1. Disconnect oven from power supply and remove turntable tray and turntable ring from oven cavity. 2. Remove the outer case cabinet, refer to OUTER CASE CABINET REMOVAL. 3. Remove two (2) screws from upper oven hinge. 4. Remove three (3) screws holding lower oven hinge and base plate (Left) to the bottom side of the oven. 5. Push the open button and open the door slightly. 6. Release the upper oven hinge from upper door hinge pin by pulling down the door. Note: When the individual parts are replaced, Door Disassembly.; refer to

AND ADJUSTMENT
After adjustment, make sure of the following : 1. Door latch heads smoothly catch latch hook through latch holes and that latch head goes through center of latch hole. 2. Deviation of door alignment from horizontal line of cavity face plate is to be less than 1 .Omm. 3. Door is positioned with its face pressed toward cavity face plate. 4. Re-install outer case and check for microwave leakage around door with an approved microwave survey meter. (Refer to Microwave Measurement Procedure.) Note: The door on a microwave oven is designed to act as an electronic seal preventing the leakage of microwave energy from oven cavity during cook cycle. This function does not require that door be air-tight, moisture (condensation)-tight or light-tight. Therefore, occasional apperance of moisture, light or sensing of gentle warm air movement around oven door is not abnormal and do not of themselves, indicate a leakage of microwave energy from oven cavity.

RE-INSTALL door, insert the lower oven hinge to 1. On re-installing lower door hinge pin. 2. Insert the lower oven hinge to square opening in the lower right side of the oven cavity face plate. (from front) Q d. Insert the upper oven hinge to square opening in the upper right side of the oven cavity face plate. (from rear) 4. Shut the door (close the contacts of interlock switches). t5. Make sure upper and lower oven hinges are inserted into the upper an lower door hinge pins. 6. Make sure the door is parallel with oven face lines (left and upper side lines) and door latch heads pass through latch holes correctly. 7 / Secure three (3) screws holding the lower oven hinge and the base plate (Left) to the bottom side of oven cavity. 8. Secure two (2) screws holding the upper oven hinge to the top of the oven cavity. Note: After any service to the door; (A) Make sure that door sensing switch and secondary interlock switch are operating properly. (Refer to chapter Test Procedures.). (B) An approved microwave survey meter should be used to assure compliance with proper microwave radiation emission limitation standards. DOOR ADJUSTMENT The door can be adjusted by keeping screws of each hinge loose. Lower oven hinge can be loosened with screw driver.

SCREWS

\ RE-INSTALL /

SE PLATE

(LEFT)

*
. RE-INSTALL LOWER DOOR : HINGE I PIN ,

SCREWS

Figure C-3. Door Replacement

and adjustment

24

DOOR DISASSEMBLY
Remove door assembly, refer to Door Replacement. Replacement of door components are as follows: 1. Place door assembly on a soft cloth with latches facing UP. Note: As the engaging part of choke cover and door panel are provided at 18 places, do not force any particular part. 2. Insert an putty knife (thickness of about 0.5mm) into the gap between the choke cover and corner portion of door panel as shown Figure C-4 to free engaging parts. 3. Lift up choke cover. 4. Now choke cover is free from door panel. 5. Remove four (4) screws holding the door flame to the gutter for choke cover. 6. Remove the door flame with pulling the upper door hinge pin.

25

-3A55

MICROWAVE
After adjustment of door latch switches, monitor switch and doorare completed individually or collectively, the following leakage test must be performed with a survey instrument and it must be confirmed that the result meets the requirements of the performance standard for microwave oven. REQUIREMENT The safety switch must prevent microwave radiation emission in excess of 5mW/cm2 at any point 5cm or more from external surface ofthe oven. PREPARATION FOR TESTING: Before beginning the actual test for leakage, proceed as follows; 1. Make sure that the test instrument is operating normally as specified in its instruction booklet. Important: Survey instruments that comply with the requirement for instrumentations as prescribed by the performance standard for microwave ovens must be used for testing.

MEASUREMENT
Recommended instruments are: NARDA 8100 NARDA 8200 HOLADAY HI 1500 SIMPSON 380M Place the oven tray into the oven cavity. Place the load of 275 +15ml of water initially at 20 +5C in the center of the oven tray. The water container should be a low form of 600 ml beaker with inside diameter of approx. 8.5cm and made of an electrically non-conductive material such as glass or plastic. The placing of this standard load in the oven is important not only to protect the oven, but also to insure that any leakage is measured accurately. Close the door and turn the oven ON with the timer set for several minutes. If the water begins to boil before the survey is completed, replace it with 275ml of cool water. Move the probe slowly (not faster that 2.5cm/sec.) along the gap. The microwave radiation emission should be measured at any point of 5cm or more from the external surface of the oven. .

2. 3.

4.

5. 6.

SHARP

Microwave

leakage measurement

at 5 cm distance

26

R-3A55

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O-l. Oven Schematic-OFF

Condition

i 4.

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Figure O-2. Oven Schematic-Cooking

Condition

27

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R-3A55

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-3A55

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Figure S-3. Printed Wiring Boad

1 2 3 4 5 6

30

PARTS LIST
Note: The voltage supllied to the part I* are greater than 25OV. REF. NO. PART NO. DESCRIPTION ELECTRICAL PARTS QTY CODE

l- 1 i- 2 l- 3 l- 4 l- 5 l- 6 i- 7 _1 -- 8 i- 9 i-10 l-11 l-12 i-13 1 I-14 i-15 l-l.6

21

QSW-mllOWRE0 1st. 2-d. a;ld stop switches QSW-MAlliWREO -lczitor switch RV-MZA197WREO '*Iagze'-, ron RTHfVI-AO80WREO -rkelrmal cut -out 145 ec _J FH-DZA046wR~0 A~A,-k voicaqe rectifier assmbiy __ RC-QZAO95~ ~:g:r: voltage caDacitor 1-e-1y- fan motor RMOTXA265WXEO --,-,*1g RTHM-A072bJREO ?erTai c~~:t-o~::', 7 " 7v corZ5 QACCAAO36WREQ 2ower sum A_ IL OFS-C-AOiOWi?E~ 'se (M8Ai QFSHDAO0&??3~? I-se holder QSOCLAO:l-dRZO ?,-.er: iarrpsocket RLMPT,;O29:tpE5 2-.-er: la129 RMOT~X 69mz 2 T-zr,cablemotor 7 r,-.:RR--?1ZAO03X?.ZZ -'-LA-, iOr reslstar 0.3R 2 xv RTPJT-A3 8OXF.Z:c 3wer tram fcrxer
CABINET FFcT,As;,c 2:q&s<G
~sTJpe:-~ 0 5;PjjFz b Ip7-JT- .1-.-....i&+Lb--%,_ #*lAsLfl

3
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^ A.-I 1 ? L

7r,E/J ;y I -?Pii _"JI iA 7-7 L"i'> .-Lz ;: A7772 _-, 1. x IILFd . (1 -._' ?__ 3.: _.- < j .-.L I --. --I
_.-.3: f 1 4

PARTS

2-l-1 2-l-2
2L 2

--A1 vp+ c-ls?Tix Pc','sG;3 06>%..1? LczL,-LLz ;s:-bt __ - -,er &T-Yre=- LLecLLca>izez rlase

2,-er

: aq2

COTbTeY

asserrkly

.-

-1

;I ;A 3- 13
3- 1c
33Cl

c=;.m,;l-zi -

;j,j>*; <1dAA_ -2

Q(;CyL2A; QC:;C;.GA2 Qcxc:G

3 4 3;F.z - 5 3F.z :: 3 0 ZE?E

3 ; 2

--,_To-& 1-.-zd >---A - -;:x _? -- -sin

13 15

gL--ydyL-,^ 5 Gzp.;iz pc;sc-;ij

RC - KZJ.0

-: - xrescer,t
Z.lSr,iOr!

CONTROL PANEL PARTS 11-: Al&L1 1 z 3eplaceble Itemj (-;! CO rxecE3Z car-nertoy 13: cc7icecx3r (G;
5isPZ.z~ t.ae

3; -. --.<:= -7.-z --A. -_ .YS ; -7 ;1z . > .I7L-!!-. 7-rL! L,z ? l/r ITi TCJJ AL

8 lJjji;
3 7 DFiF 3 * -.J

C2 c3 c4-5 P' LL0 C20 c21 c30 CFl CR50 Dl D20-21 D23 D30 D50-57 ICl
Ql Q20

Q21
Q22

'JCm3 L's.3 j 7): VCm31CW47 6M VCKYDllCYiO3N VCTY"3THF103Z VCEA&3l:H%.04M VCEm31~/W4?5M VCKYDllCY103N RCRS-A012DREO RMPTEAOllDREO RSRCDA013DREO VHDlSS27OA/-1 VHDlSS270A/-1 VHDlSS27OA/-1 VHDlSS27OA/-1 RH-IZA496DREO VS2SA933S//-3 VSDTA114ES/-3 VSDTD143ES/-3 VSDTB143ES/-3 VRD-B12HF202J VRD-B12HF681J VRS-B13AA102J

Rll R20 R30 R31 R40

1 VRD-B12EF56;i VRD-Bl2EF471; VRD-B12EF33lJ VRD-B12EF472J I VRD-B12EF332J

RRLY-A080DREO

5 (y,' s._ * -2 ZmaciEor 33G s35-\,, T z3~aclLor .4T-F ^,-Zz?acitor lOi/ Capacitor 151; 0.01 LF Zasacitor 0.01 UF 5ov 0 .i : L~F CaDacicor 5 OV A Capacitor A. 7 UF 3 5'v' Capacitor 0.01 uF 16V Ceramic resonator (CST4.00MGW) CR array Diode b&dge(SlNBlO) Diode (lSS270A) Diode (lSS270A) Diode (lSS270A) Diode (lSS270A) LSI Transistor (2SA933S) Transistor (DTA114ES) Transistor (DTD143ES) Transistor (DTB143ES) Resistor 2k ohm 1/2w Resistor 680 ohm 1/2w Resistor lk ohm lw Resistor lk ohm 1/4w Resistor 15k ohm 1/4w 2esistor 330 ohm 1/4w 1 3esistor 47k ohm 1/4w I ?esistor 56k ohm 1/4w i iesistor 470 ohm 1/4w I iesistor 330 ohm 1/4w I iesistor 4.7k ohm 1/4w 1i ?esistor 3.3k ohn 1/4w T iesistor lk ohm i/4W E iesistor 1M ohm :i4w tesiscor 3.3K obm~ 1/4w I; iesistor 3.9K ol-xn 1/4w Relay (OJ-SH-124LL11)
1

2 1 1 8 1 1 1 1 1 1 1 1 1 1 1 i i 1 i 1 i 1 1 1 1 1

AG AA AA AA AA As AB A3 AC AC A3 AA AA AA AA AA AA AA AA
AA AA _A.?4 AA AA AA Ai A.2

31

R-3A55

Note: The voltage

1 REF. NO. 1

supllied to the part * are greater than 250V. I DESCRIPTION 1 QT-ODE

zil, AG AK AH A.Gi AA BB -xti x3 A&

PART NO.
;, 2 T 1.7 --.LJ^

RY2 SP40 m-1. i,';;iS1 231 232 2- 2 3- 3 ?- 4 2- 5

Re;ay (VX324) ?&,I%-A0;43REO Buzzer (PKM22EPT-CA) RTPJPA0'793Rl30 Transformer ?&-VCAA0323RE0 Varistor (lOG47l.K) :"TJEE-:2:61, 'i-1 -J-#~:&3 / /- 1 Zener diode (HZ4C-3) IhTC BO l?WmKO Control panel frame with key unit JBTN-.?.862WRFO Oper,button MS P,3,CA 050WXE 0 Open button spring XEPS230P10xSO Screw; Control unit mto.
AO8lDREG

n ;-

_ ;

4- 3 La-4 a- 5 4- 6 4- 7 i" 8 ;I g 4-10 / -< z-2; i* Q-12 n *-3 -t--3 I r--4 CA15 * -r 4--_% , A---: I I,=-r 1 r^ i--Y ^.-. Z--i z -2; r^ 2-L^'-,; I , 1-24 h.1-,_' / -7 I-' r\-z I rx-d*

PHOK-A0859dRFO Latch hook Z.NGQA3 68WRPO Fuse angle LBNDKAO95WRPO H-V. capacitor band LANGQA343WRPO Thermal cut-out (Fan) mounting angle NFANJAO29WREO Fan blade PDUC-A534WRPO Fan duct FOVN-A285WRTO Oven cavity FDA:-A171WRYO Bottom piate R assembly GDAI-A235WRPO Bottom plate L GLEGPA019~&?EO Foot LiiZ1TGFX 6liiE?PO Clhassis support LANGDA3 O?WRPO Partition angle !4lissG -A3 18ImT 0 =>ver, hinge (Upper) XrnG-=13 19wTo 3ver hinge (Lower)
yyc,-3-q: j iQ!jj,FG ?JTcp~--~~~c4 5krnFO

1 ; i 1 1

-4Q AL A!f AK AL

i 1 _1 2. 1 4 i 1 I II
.

Switch lever 2oupl kg

T-drnzablemotor cox.er ,";z\T"rr, 1 2 - cover Lu-cie

2LS-FliOI-l

_1

-. .-c 1r* -..aAeA,'** q-.1A,--dLA.AUil -2, ----A g.2:de I,T-o?mr Cd -*(..,L__-CL ._w -_--L.,. Z~,Sr_iJr, T,z.zaLle ~-~otor pzekng I--.-0 .iL r,'ve_v _--7 ----p ?;S:?iCsl

1 -

AQ BE AT L .w A.5 AM A.? A! --7 r--L -f-;A; -__ --Y--l 7-.?-z -7 rL--~ 7r'f--IL -,-1.C -A --LA 7.--: 7chz -w .--_ a--. ~-i.~ 7 T.+A?,
aiA.2-t id xi

E z;K;r;4 KI 5r;~ i 2 3 iz F c 7 8

yJ~:.~

- !-&2<<c

300-

asserrbll,,

complete.

XW.2;5 $ifi"RT: 100; pane; ~s~O-,~zLLA3 Ct ~~~$L3~choke covey '-_q-/)jj\a,O 32P-_-7 5,z.L zoor frame 1-1 F, - - .A3 ,? 6WJtG 200: screen ;ST:'FLZAL2 (J\@$O L,a-,cb* lqead ~~~SZ?i~A~O 2l\jFsz:O Lacer- spring PSHEPA3&2W?EO I Sealer fiim >:~~S~J~O~~~OGO Screw; 3mm x 6mm

AK A-k7 > Vi -7. *A&r! &Al-i 1 A&

i _1 5

E.- cl- 5 6- 3 o- 4 6- 5 6- 6 6- 7

ROL,m

5 3hPXO

6- 8 6- 9 6-10 1;I;,

\TK-AO46WREG TCADCA493WRRO TINS-k378WRRO -FW-i'ZB122WO FW-~-ZB23OWREO QW-QZA187WREO LHLDWA034WXEO QTANP0020YBEO TCAu?+AO 55wRRo TSPCIU386iWXRO LHLDWAOllWREO

Roller stay Turntable tray cook book Operation manual Switch harness Main wire harness High voltage wire A Cabie clip Connector CE-230 K caution label Name plate Purse lock "M"

1 I 1 * I 7 1 1 ; 1 1

AQ -.-XL As AK &I" ry __ -Al4 AG AA AF AG AB

32

Note: The voltage supllied to the part * are greater than 250V.
REF. NO. PART NO. DESCRIPTION SCREWS, NUTS AND WASHERS

7- 1 ?7- 2 3 7-7 Iy7?7 4 5 6 7 8 9

Lo 7-1; 7-12 / 7-13

XOTSD40P12000 Screw; 4mm x 12n-1 XFPSD40P08KOO Screw; 4mm x 8mm XiITSD40P08000 Screw; 4mm x 8mm XHSSE40P08000 Screw; 4r~u1-1 x 8mx-1 XFPSD30P08000 Screw: 3pm x 81x-1 XVPSD40P20000 Special Screw; 4mn-1 x 2Omm LX-CZAO38WREO LX-CZ0052wREG Special screw screw XFPSD30P06000 Screw; 3rru-n x 6rrn XFPSD30PlOOOO Screw; 3rrmx 1Omm LX-CZA029WREO Special screw XFPSD40P08000 Screw; 41-1-m x 8mm. XOTSD40P12RI,70 Screw; 4-m x 12rm HOW TO ORDER REPLACEMENT PARTS To have your order filled promptly and correctly, please furnish the following information. 1. MODEL NUMBER 2. REF. NO. 3. PART NO. 4. DESCRIPTION

17 5 1 1 1 1 2 2 4 , 3 4 i-. ,A.

AA AA AA AA AA AA AA AA AA. ?A AA AA AA

33

R-3A55

34

/ /

CONTROL

PANEL PARTS
IA

I 1

,A0 / \ / / /
\

4@ ,o J /
i i 1

1 ,

1 I

/ I I I I \
/

1 / ! I I I it I / / I

\ VI \ --2 I 3

-35

/
4

iH

I
! 5 6

R-3A55

1 r

? 1

Actual wire harness may be different than illustration.

Dl

PACKiNG

AND ACCESSORIES

I / I 1 I

El &? TURNTABLE TRAY SHEET ?

PACKING

PAD KIT

CPADBAICZWRKO

0 DOOR PROTECTION I I I I f OPERATION COOK BOOK MANUAL

SPADPA204WREO e @;

I F1

cx

TURNTABLE

SUPPORT

3
/ MICROWAVE DOOR PAD SPADFAO61 WREO

e POLYETHYLENG SSAKHA034WREO

BAG

OV

TRAY

PACK

SPADFA257WREO

Gl

Not Replaceable

Items.

I~

I 3

! 4 5 6

36

SHARP

93 SHARP

CORP. (07K0.75E)

Printed tn Austraha

38