Service Manual - Appliance Factory Parts
Contents
1. 5 TEST RESULTS Measure the resistance between terminal TOUCH KET BOARD pins of connector KEY CONNECTOR When When not NOTE Resistance touched touched When reconnecting the FPC connector value Less than More than make sure that the holes on the FPC 400 ohms 1 mega ohm connector are properly engaged with hooks on the plastic fastener FPC CONNECTOR MATRIX CIRCUIT FOR Top TOUCH KEY BOARD CONNECTOR KEY CON len 2 gt 3 gt 4 5 7 2 3 4 5 6 gt gt 6 me di BA AA Tie WARM Y ONOFF SLEVEL STOP START SOFTEN MET 7 Z gt 12 70 L 42 42 42 13 POPCORN 14997 No AUTO AUTO A AR MSI A OA TURNTABLE AUTO KITCHEN cLocK A ON OFF GEN TIMER A TIMER A A A N C ee FROZEN eGerasue PIZZA POTATO MINUTE 4 AGD d A A NOTES A MICROWAVE ENERGY TEST MUST ALWAYS BE PERFORMED WHEN THE UNIT IS SERVICED FOR ANY REASON MAKE SURE THE WIRE LEADS ARE IN THE CORRECT POSITION WHEN REMOVING THE WIRE LEADS FROM THE PARTS BE SURE TO GRASP THE CONNECTOR THE WIRES 5 RESULTS 1 Measure continuity Relay ohm meter scale Rx1 R Opan 2 Remove the lead wires and operate 1 4 Sec 18 Sec oven at power level 1 through power level 10 2 6 Sec 16 Sec2. 199102 LNH leuuloN LACH 518 N MO 1281009 LS 30 joejuo9 2949 joeJuoy 81 19E UOI 1010802 ay 2 2 JEWJON 1994109 3021000 1004 NS gt LE pueog EULION preoq 1 15 1 Z SAHOLIMS HMOOTHILNI AUVANOISS ANY AUVINIHd 49949 L 6upjooo 10 si Aey LHWLS umop sjunoo y dn jeay 2 7 23 uolyesado jewuou 2 45 jo pua Jo safes usemjeq ay Buizznq ON NITAOHd 7 24 55 1010 A SSV uone nuan sun ON suny MO 1281009 p Z ass LS 101090009 Jo 9E UOI 49949 9109 121002 1004 LE joejuo9 MO JOE UOO joejuoo JE SOULAY USANO jo yORJUOD
3. 98 100 JO pue 4991109 saop 8 NITAOHd T 1 I QIUE SISAI 1091109 LNO J0P9UU0O9 pue I abeyon 0 preoq BUON 1VISONHIHL ALIAVO NINO 81 2 uo DNIMOT8 ISNA HOS 995 SSNs 2 Niddns 1 rem 51 p409 Ajddns semod ueym ul jou JO INIL 145 ASVIT V NATAOHd dy YIZZNG 3 MY O MU Y AVTASIO 1 9 eed uo NOLLWHAdO IVIUL Peas sty ONLLOOHS 18NOHL 2 7 22 suny CNH i m O A H 91 295 AH 40 Aynuguoo 0940 aouejsisal x 91 ass aoue sisal 10 Aynunuos ay 4994 jeuuoN S Z ass 2 JO 5
4. is the initial temperature of the water in T2 is the final temperature of the water in C tis the heating time in seconds excluding the magnetron filament heat up time WATER LOAD TURNTABLE DISASSEMBLY INSTRUCTIONS IMPORTANT NOTES UNIT MUST BE DISCONNECTED FROM ELEC TRICAL OUTLET WHEN MAKING REPAIRS RE PLACEMENTS ADJUSTMENTS AND CONTIN UITY CHECKS WAIT AT LEAST ONE MINUTE UNTIL THE HIGH VOLTAGE CAPACITOR IN THE HIGH VOLTAGE POWER SUPPLY HAS FULLY DISCHARGED THE CAPACITOR SHOULD BE DISCHARGED BY USING INSULATED WIRE I E TEST PROBE CONNECTED TO 10K OHM RESISTOR IN SERIES TO GROUND WHEN RECONNECTING THE WIRE LEADS TO ANY PART MAKE SURE THE WIRING CONNE CTIONS AND LEAD COLORS ARE CORRECTLY MATCHED ACCORDING TO THE OVERALL CIR CUIT DIAGRAM ESPECIALLY SWITCHES AND HIGH VOLTAGE CIRCUIT A REMOVING POWER AND CONTROL CIRCUIT BOARD Figures 1 2 and 3 1 Remove a screw securing the control panel assembly to the oven cavity 2 Remove the control panel with pushing it upward 3 Remove the connectors CN1 and wire leads Relay8 from the circuit board Control Panel Circuit Board Power Transformer N rva Figure 1 7 4 4 Remove 3 screws securing the circuit board Circuit Board Figure 2 5 Remove the FPC connector from the terminal socket following
5. SEARS DIVISION 22 BASIC FIELD MANUAL FOR MICROWAVE OVEN MODEL 721 80042700 721 80049700 721 80044700 721 80043700 721 81043700 June 2007 CAUTION SAFETY PRECAUTIONS PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY Do not operate or allow the oven to be operated with the door open 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 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 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 Proper operation of the microwave ovens requires that the magnetron be assembled to the
6. A false reading may result if the operator s hand is between the handle and the probe 4 When testing near a corner of the door keep the probe perpendicular to the surface making sure the probe horizontally along the oven surface this may possibly cause probe damage RECORD KEEPING AND NOTIFICATION AFTER MEASUREMENT 1 After adjustment and repair of any microwave energy interruption or microwave energy blocking device record the measured values for future reference Also enter the information on the service invoice 2 Should the microwave energy leakage not be more than 2 mW cm after determining that all parts are in good condition functioning properly and genuine replacement parts which are listed in this manual have been used 3 At least once a year have the electromagnetic energy leakage monitor checked for calibration by its manufacturer 4187 Mw T2 T1 0 55Mc T2 0 T is measured while the microwave generator is operating at full power Magnetron filament heat up time is not included about 3 sec 7 The water is stirred to equalize temperature throughout the vessel prior to measuring the final water temperature 8 Stirring devices and measuring instruments are selected in order to minimize addition or removal of heat Where P is the microwave power output in watts Mw is the mass of the water in grams Mc is the mass of the container in grams TO is the ambient temperature
7. A TEST PROCEDURES COMPONENTS H V Transformer TEST FILAMENT SECONDARY WINDING 0 WINDING PRIMARY WINDING 1 Remove wire leads 2 Measure resistance ohm meter scale Rx1 Primary winding Secondary winding Filament winding 3 Measure resistance ohm meter scale Rx1000 Primary winding to ground Filament winding to ground RESULTS Approx 0 3 to 0 5 ohms Approx 65 to 120 ohms 0 ohm Normal Infinite Normal Infinite MAGNETRON Antenna Gasket Chassis 1 Remove wire leads Install the magnetron seal in the correct position Check that the seal is in good condition 2 Measure resistance ohm meter scale Rx1 Filament terminal 3 Measure resistance ohm meter scale Rx1000 Filament to chassis Normal Less than 1 ohm Abnormal Infinite Normal Infinite 7 15 5 TEST RESULTS 1 Check DC 9V battery before performing tests PIN Gapeclor 2 Select the DCV scale on the meter 3 Using the meter battery and jump wire connect the items as illustrated in figures Terminal to terminal Normal Approximately 9V Abnormal Approximately OV Normal Approximately or a value displayed in mV Will be seen H V Diode RECTIFIER STEP 1 Test the diode to see if it is shorted Procedure 1 Select the ohm scale on the meter 2 Place the
8. V 30 W or 40 W Digital up to 99 mim 99 sec in each cooking stage Tempered Safety Glass 291 16 W X 167 16 H X15 16 D 2196 W x9 a 14 0 1 6 Cu ft Owner s Manual amp Cooking Guide Installation Manual Exhaust Adapter Exhaust Damper Mounting Kit and Two Filters Rotating Ring Assembly 1 1 CAUTIONS Unlike other appliances the microwave oven 15 high voltage and high current equipment Though it is free from danger in ordinary use extreme care should be taken during repair DO NOT operate on 2 wire extension cord during repair and use NEVER TOUCH any oven components or wiring during operation BEFORE TOUCHING any parts of the oven always remove the power plug from the outlet For about 30 seconds after the oven stops an electric charge remains in the high voltage capacitor When replacing or checking you must discharge the high voltage capacitor by shorting across the two terminals with an insulated screwdriver Remove your watches whenever working close to or replacing the Magnetron DO NOT touch any parts of the control panel circuit A resulting static electric discharge may damage this P C B NEVER operate the oven with no load NEVER injure the door seal and front plate of the oven cavity NEVER put iron tools on the magnetron NEVER put anything into the latch hole and the interlock switches area MICROWAVE RADIATION Personnel
9. wave guide and cavity Never operate the magnetron unless it is properly installed Be sure that the magnetron gasket is properly installed around the dome of the tube whenever installing the magnetron Routine service safety procedures should be exercised at all times Untrained personnel should not attempt service without a thorough review of the test procedures and safety information contained in this manual FOREWORD Read this Manual carefully Failure to adhere to or observe the information in this Manual may result in exposing yourself to the Microwave Energy normally contained within the oven cavity TABLE OF CONTENTS Page SAFETY PRECAUTIONS 0000 000 eee Inside front page SPECIFICATIONS iii ii i iii iii 1 1 CAUTIONS 2 1 INSTALLATIONS 3 1 OPERATING INSTRUCTIONS 4 1 CONTROL PANEL 4 1 CONTROL PANEL INSTRUCTIONS 4 2 OVERALL CIRCUIT DIAGRAM 5 1 SCHEMATIC DIAGRAM 5 1 MATRIX CIRCUIT FOR TOUCH KEY BOARD 5 2 GENERAL INFORMATION FOR SERVICE 6 1 GENERAL PRECAUTIONS IN USE iii 6 1 TRIAL OPERATION 6 1 FEATURES AND SPECIFICATIONS FEATURES 0 6 1 SERVICE INFORMATION 7 1 P
10. 3 8 Sec 14 Sec 4 10 Sec 12 Sec 5 12 Sec 10 Sec 6 14 Sec 8 Sec 7 16 Sec 6 Sec 8 18 4 9 20 Sec 2 Sec 10 22Sec Sec Noise Filter 1 Unplug microwave oven or disconnect power Nmornal 2 Remove wires 3 Measure resistance ohm meter scale Rx1000 L 1 L 2 coil Less than 1 ohm N 1 N 2 coil Less than 1 ohm Abnormal infinite Normal L 1 or L 2 N 1 or N 2 resistor 1 5M ohms Abnormal 0 ohms Ventilation Motor Remove wire leads 2 Measure resistance ohm meter scale Rx1 Normal Approximately 20 to 40 ohm Abnormal Infinite Turntable Motor Remove wire leads 2 Measure resistance ohm meter scale Rx1000 Normal Approximately 2 5 to 3 5 Kohms Abnormal Infinite or several Absolute Humidity Sensor For sensor model Disconnect sensor connector from micom computer board 2 Measure resistance terminal to terminal ohm meter scale Rx1000 Normal Approximately BK RD 6 0 Kohms RD WH 3 0 Kohms BK WH 3 0 Kohms Abnormal Infinite or approx 0 ohm CHECKOUT PROCEDURES 1 CHECKOUT PROCEDURES FOR FUSE BLOWING CAUTION REPLACE BLOWN FUSE WITH 20 AMPERE FUSE PROBLEMS CAUSES Fuse blows immediately after the door is closed Improper operation of the primary interlock secondary Fuse blows immediately after interlock switches and or the interlock monito
11. ARD The following symptoms indicate a defective circuit board 1 The start function fails to operate but the high voltage Systems the interlock switches the door sensing and the relay check good The unit with a normal relay continuously operates Proper temperature measurement is not obtained The buzzer does not sound or continues to sound Some segments of one or more digits do nat light up or they continue to light up or segments light when they should not 2 3 4 5 Wrong figures appear The figures of all digits Some of the indicators do no flicker light up 6 7 8 9 The clock does not keep time properly NOTE A MICROWAVE ENERGY LEAKAGE TEST MUST ALWAYS BE PERFORMED WHEN THE UNIT IS SERVICED FOR ANY REASON 7 21 suny yano jELUION yono 89UE SISAY 21 2 pue p 2 LS 40 99UUOI I Jaye jo 5 i joejuoo I 1991109 100d 1 1 LS 1 jo aouejsisal joe uo9 49949 ELON 1 1 p eoq xo peuo 1 1 1 1 I L
12. HOW TO REMOVE THE FPC CONNECTOR on the next 6 Remove the circuit board from the control bracket carefully Control Bracket FPC Connector S1 Circuit Board Figure 3 HOW REMOVE THE F P C CONNECTOR Follow the steps below as illustrated in Figures 4 and 5 to remove the F P C connector 1 Hold the edges of the plastic fastener with thumb and forefinger Figure 4 2 Lift up the lever of the plastic fastener from the terminal socket by lightly pressing the lever end with forefinger Figure 5 3 Remove the F P C connector from the terminal socket Plastic fastener Connector Terminal socket Figure 4 Plastic fastener Connector Terminal socket Figure 5 HOW TO INSERT THE F P C CONNECTOR Follow the steps below as illustrated in Figures 6 and 7 to insert the F P C connector 1 Insert the F P C connector into the terminal socket securely with the fingers 2 Hold the plastic fastener with thumb and forefinger of the other hand and push it slowly into the terminal socket Figure 6 NOTE When reconnecting the F P C connector make sure that the holes on the F P C connector are properly engaged with the hooks on the plastic fastener 3 Lock the level of the plastic fastener into the hook of the terminal socket securely by releasing the fingers Figure 7 Plastic fastener Connector Terminal socket Figure 6 Plastic fas
13. R OPENED amp COOK OFF MODE ONLY FUSE 204 NOISE u FILTER AS M A i GND D MICRO COMPUTER BOARD 3 3 LV TRANSF ORMER OVEN 90 0 C OVEN LAMP HoH HoH BR CONDENSER COOK LAMP BK SECONDARY 9 TURNTABLE SWITCH MOTOR GY YL TOR NO BK ABSOLUTE C HUMIDITY MONITOR SWITCH MIDDLE H V TRANSFORMER RECTIFIER PRIMARY lt GND BOTTOM H V CAPACITOR OPTIONAL FUNCTION FOR SENSOR MODEL ONLY WIRE COLORS CONTROL MODULE SYMBOL COLOR WH WHITE WH RD BLBRGY GN YL WH RD BK BK _ BLACK ro RED 123 4567 8 vELLOW PNK BL BLUE BR BROWN 8 PIN CONNECTOR CN1 3 PIN GN GREEN CONNECTOR CN5 CONNECTOR ONB FOR SENSOR L ey GREY 5 1 THERMOSTAT MATRIX CIRCUIT FOR TOUCH KEY BOARD KEY MATRIX COOK HOLD EXPRESS TIME WARM DEFROST 9 VENT VENT LIGHT ON OFF 5LEVEL HIGHNIGHTIOFFL STOP START SOFTEN MELT 10 AUTO AUTO AUTO TURNTABLE OFF KITCHEN FRESH ADD 13 5 2 GENERAL INFORMATION FOR SERVICE GENERAL PRECAUTIONS IN USE Never operate the unit when it is empty Operating the oven with no load may shorten the life of the magnetron Whenever cooking dry foods dried fish bread et
14. RECAUTIONS AND REPAIR SERVICE TIPS iii 7 1 MICROWAVE LEAKAGE TEST 2000 7 2 POWER OUTPUT MEASUREMENT iii 7 3 DISASSEMBLY INSTRUCTIONS 4 7 4 INTERLOCK 5 5 4 7 12 INTERLOCK CONTINUITY 8 7 14 TEST CHECKOUT PROCEDURES AND TROUBLE SHOOTING 7 15 A TEST PROCEDURES iii 7 15 CHECKOUT PROCEDURES 7 18 TROUBLE SHOOTING 7 21 EXPLODED VIEW 8 1 PART REFERENCE LIST 9 1 SPECIFICATIONS Rated Power Consumption Microwave Output Frequency Power Supply Rated Current Magnetron Cooling Rectification Door Sealing Safety Devices Magnetron High Voltage Capacitor High Voltage Diode Cook top Lamp Cavity Lamp Timer Tray Overall Dimensions Oven Cavity Size Effective Capacity of Oven Cavity Accessories 1500W maximum Microwave oven Cook top lamps Ventilation fan 1000W IEC60705 Adjustable 100W through 1000W 10 steps 2450 MHz 50 MHz 120 VAC 60 Hz 14 Amp Microwave oven Cook top lamp Ventilation fan Forced Air Cooling Rectification Voltage Double Half Wave Choke System Magnetron Thermal Fuse Open at 90 C 5 C Fuse 20A Primary Interlock Switch Secondary Interlock Switch Interlock Monitor Switch 2M214 161GP Capacitor 1 04F 2 1 KV AC Diode 350mA 9 0 KV 125
15. RES AND SPECIFICATIONS FEATURES A The safety systems incorporated in this model are 1 Primary interlock switch 2 Secondary interlock switch 3 Interlock monitor switch 4 Choke system 5 Magnetron thermostat 6 Oven cavity thermostat Note This thermostat located on the oven cavity will open and stop the unit from operation only if a high temperature is reached such as a fire created by overcooking food B Any one of 10 power output levels ranging 100W to 1000W can be selected by the touch control and electronic computer system SERVICE INFORMATION PRECAUTIONS AND REPAIR SERVICE TIPS PRELIMINARY A SINCE NEARLY 2 100 VOLTS EXISTS IN SOME CIRCUITS OF THIS UNIT REPAIRS SHOULD BE CARRIED OUT WITH GREAT CARE The filament leads of magnetron carry High Voltage with respect to ground Extreme caution must be exercised Never plug the unit into a power source to determine which component is defective in high voltage section TO AVOID POSSIBLE EXPOSURE TO MICROWAVE ENERGY LEAKAGE THE FOLLOWING PRECAUTIONS MUST BE TAKEN BEFORE SERVICING 1 Before the power is applied a Make sure the primary interlock switch the secondary interlock switch and the interlock monitor switch operate properly by opening and closing the door several by opening and closing the door several times b Make sure the perforated screen and the dielectric choke of the door are correctly and firmly mounted 2 After power
16. TINUITY TEST A PRIMARY INTERLOCK SWITCH TEST When the door is opened slowly an audible click should be heard at the same time or successively at intervals and the latches should activate the switches with an audible click If the latches do not activate the switches when the door is closed the switches should be a adjusted in accordance with the adjustment procedure Disconnect the wire lead from the primary switch Connect the ohmmeter leads to the common COM and normally open NO terminal of the switch The meter should indicate an open circuit in the door open condition When the door is closed the meter should indicate a closed circuit When the primary switch operation is abnormal make the necessary adjustment or replace the switch only with the same type of switch COMPONENTS TEST PROCEDURE B SECONDARY INTERLOCK SWITCH TEST Disconnect the wire lead from the secondary switch Connect the ohmmeter leads to the common COM and normally open NO terminals of the switch The meter should indicate a open circuit in the door open condition When the door is closed meter should indicate an closed circuit When the secondary switch operation is abnormal make the necessary adjustment or replace the switch only with the same type of switch MONITOR SWITCH TEST Disconnect the wire lead from the monitor switch Connect the ohmmeter leads to the common COM and normally closed NC terminals of the switch The me
17. UREMENT 1 Microwave power output measurement is made with the microwave oven supplied at its rated voltage and operated at its maximum microwave power setting with a load of 1000 5 g of potable water 2 The water is contained in a cylindrical borosilicate glass vessel having a maximum material thickness of 1 8 3 mm and an outside diameter of approximately 7 6 190mm 3 The oven and the empty vessel are at ambient Temperature TO prior to the start of the test 4 The initial temperature T1 of the water 15 10 1 C 50 F It is measured immediately before the water is added to the vessel After addition of the water to the vessel the load is immediately placed on the center of the turntable which is in the lowest position and the microwave power switched on 5 The time T for the temperature of the water to rise by avalue AT of 10 1 K is measured where T is the time in seconds and AT is the temperature rise The initial and final water temperatures are selected so that the maximum difference between the final water temperature and the ambient temperature is 5 K 6 The microwave power output P in watts is calculated from the following formula NOTE WHEN MEASURING 1 Do not exceed meter full scale deflection 2 The test probe must be removed no faster than 1 inch sec 2 5cm sec along the shaded area otherwise a false reading may result 3 The test probe must be held with the grip portion of the handle
18. ay 2940 GS 3505 5 1 SI NV aje edo Jou ug 3 NITAOHd 7 25 EV EXPLODED VIEW DOOR PARTS For Model 721 80049700 721 80042700 721 80044700 For Model 721 80043700 721 81043700 e CONTROLLER PARTS For Model 721 80049700 721 80042700 721 80044700 For Model 721 80043700 721 81043700 EV OVEN CAVITY PARTS LATCH BOARD PARTS EV INTERIOR PARTS I 8 5 EV INTERIOR PARTS II EV INSTALLATION PARTS owners 01 gt 04 gt COOKING UPPER WALL MANUAL MANUAL PEA TEMPLATE TEMPLATE 8 7
19. ble Set the energy leakage monitor to 2 450 MHz and use it following the manufacturer s recommended test procedure to assure correct result When measuring the leakage always use the 2 inch 5cm spacer supplied with the probe Operate the oven at its maximum output Measure the microwave radiation using and electromagnetic radiation monitor by holding the probe perpendicular to the surface being measured Move probe along shaded area Probe scanning speed Less than 2 5 cm sec 1 in sec MEASUREMENT WITH THE OUTER CASE REMOVED 1 When you replace the magnetron measure for microwave energy leakage before the outer case is installed and after all necessary components are replaced or adjusted Special care should be taken in measuring the following parts Around the magnetron The waveguide WARNING AVOID CONTACTING ANY HIGH VOLTAGE PARTS MEASUREMENT WITH A FULLY ASSEMBLED OVEN 1 After all components including the outer panels are fully assembled measure for microwave energy leakage around the door viewing window the exhaust opening and air inlet openings 2 Microwave energy leakage must not exceed the values prescribed below NOTES Leakage with the outer panels removed less than 5 mW cm Leakage for a fully assembled oven Before the latch switch primary is interrupted with the door in a slightly opened position less than 2 mW cm POWER OUTPUT MEAS
20. c or a small amount of food be sure to put a glass of water into the cooking compartment The glass turntable may become hot after operating be careful when touching it Aluminum foil should be avoided because it will disrupt cooking and may cause arcing However small pieces may be used to cover some parts of food to slow the cooking Any aluminum foil used should never be closer than 2 5 cm to any side wall of the oven TRIAL OPERATION After installation the following sequences and results should be checked carefully A B Put a container filled with water about 1 liter into the oven and close the door tightly Set cooking time for 10 minutes by touching 1 and then 0 three times 1 0 0 0 appears in the display window Touch the START key Make sure the cavity light comes on The unit will begin cooking and the display window will show the time counting down by seconds After about 5 minutes make sure the primary interlock switch the secondary interlock switch and the interlock monitor switch operate properly by opening and closing the door several times Touch the START key each time the door is closed Continue operating the unit Two short and a long beep sound signal is heard when the time is up The unit will shut off automatically Confirm the water is hot Finally measure the output power according to POWER OUTPUT MEASUREMENT on page 7 3 6 1 FEATU
21. e event of an electrical short circuit grounding reduces the risk of electrical shock The plug must be plugged into an outlet that is properly installed and grounded CAUTION This unit is equipped with a 3 prong plug for your safety Ifthe wall outlet is a grounded 3 hole type the unit will be grounded automatically Plug with Ground Prong Properly Polarized and Grounded Outlet WARNING Improper use of the grounding plug can result in a risk of electric shock Do not under any circumstances cut or remove the third ground prong from the power cord plug 3 1 OPERATING INSTRUCTIONS CONTROL PANEL O SMART TOUCH SENSOR Popcorn Pizza Potato Dinner Frozen Frozen Express Plate Entree Vegetable Defrost AD Auto Auto Hold Auto 42 Cook Reheat Warm Defrost tt Add Kitchen 46 Minute Soften Melt Timer 49 209 1 2 3 Turntable 4 5 6 9 7 8 9 START ok 0 Power Dr i Auto Off o 8 8 AN High Night Off On Off 5 Speed 4 1 10 11 12 13 ONTROL PANEL INSTRUCTIONS Display The display includes a clock and indicators to tell you time of day cooking time settings cook powers quantities weights and cooking functions selected Popcorn Touch this pad to pop popcorn with the sensor feature The oven s sensor will tell the oven how long to cook depending on the amount of humidity it detects from t
22. e the mounting plate by removing two screws securing it to the back plate See Figure 16 2 Remove the two screws securing the MOUNT ALL and one screw securing the ventilation fan ASS Y See Figure 17 Mount All Figure 17 7 10 H REMOVING THE TURNTABLE MOTOR 1 Remove the turntable 2 Remove the turntable shaft VERY CAREFULLY with a slotted screwdriver Figure 19 3 Remove the base plate by removing eight screws securing it to the oven cavity Figure 20 4 Disconnect the leadwire from the turntable motor terminals 5 Remove a screw securing the turntable motor to the oven cavity ASS Y Figure 21 NOTES Remove the leadwire from the turntable motor VERY CAREFULLY Be sure to grasp the connector not the wires when removing Figure 19 Figure 20 2 8 CD Wire Leads e Turntable Motor Figure 21 INTERLOCK SYSTEM INTERLOCK MECHANISM The door lock mechanism is a device which has been specially designed to eliminate completely microwave activity when the door is opened during cooking and thus to prevent the danger resulting from the microwave leakage ADJUSTMENT PROCEDURES To avoid possible exposure to microwave energy leakage adjust the door latches and interlock switches using the following procedure The Interlock Monitor and Primary Interlock Switch act as the final safety switch protecting the user from microwave energy The ter
23. he oven and or away from the door latch until the gaps are less than 1 64 0 5 mm Hold the latch board tightly in this position until you check the sequence of the switches in steps 5 and 6 TEST THE LATCH AND SWITCH SEQUENCE 5 Open the oven door slowly Watch the door latch 7 When you achieve the proper sequence of the Secondary Switch Release Rod and Lever switches in Steps 5 and 6 tighten the latch board on the switches to make sure they are zero to the screws at that point body of the switches in the following sequence TEST THE MICROWAVE ENERGY LEAKAGE Primary Interlock Switch Secondary Interlock Switch Interlock Monitor Switch Make sure the microwave energy leakage is below the limit of 1mW crr with a 275 ml water load and 5mW cm with a 275 ml water load without the Adjust the latch board until the switches operate in cabinet when measured with a survey meter this sequence See Steps 3 and 4 6 Close the oven door slowly and be sure it is tightly closed Watch the three switches to make sure they are zero to the body of the switches in the following sequence Interlock Monitor Switch Primary Interlock Switch Secondary Interlock Switch NOTE The Interlock Monitor Switch is an added safety check on the Primary and Secondary Interlock Switches If the Primary and Secondary Interlock Switches allow the oven to operate with the door open the Monitor Switch will blow the fuse INTERLOCK CON
24. he popcorn Pizza Touch this pad to reheat one or several slices of pizza without entering a cook time or power Potato Touch this pad to cook potatoes without entering a cook time or power Dinner Plate Touch this pad to cook without entering a cook time or power Frozen Entree Touch this pad to cook a 10 to 20 ounce 284 to 567 g frozen entree without entering a cook time or power Frozen Vegetable Touch this pad to cook without entering a cook time or power Express Defrost Touch this pad to express defrost GROUND BEEF 1 0 LBS TOUCH START will appear in the display Auto Cook Touch this pad to cook microwavable foods without entering a cook time or power Auto Reheat Touch this pad to reheat microwavable foods without entering a cook time or power Hold Warm Touch this pad to keep hot cooked foods safely warm in your oven for up to 99 minutes 99 seconds Hold Warm can be used by itself or it can automatically follow a cooking cycle Auto Defrost Touch this pad followed by Number Pads to thaw frozen meat by weight Add Minute Touch this pad to cook for 1 minute at 100 cook power or to add extra minutes at the set cook power to your cooking cycle 4 2 14 Soften Touch this pad to soften utter ice cream cream cheese or frozen juice 15 Melt Touch this pad to melt butter or margarine chocolate cheese or marshmallows 16 Kitchen Timer Touch t
25. his pad to set the kitchen timer 17 Number Pads Touch number pads to enter cooking times cook powers quantities weights or food categories 18 Clock Touch this pad to enter the correct time of day 19 Turntable On Off Touch this pad to turn off the turntable T TABLE OFF will appear in the display 20 START Touch this pad to start a function If you open the door after the oven begins to cook retouch START 21 Cook Time Touch this pad followed by Number Pads to set a cooking time 22 Power Touch this pad after the cook time has been set followed by a Number Pad to set the amount of microwave energy released to cook the food The higher the number the higher the microwave power or cooking speed 23 STOP Touch this pad to erase an incorrect command cancel a program during cooking or to clear the Display 24 Light Touch this pad to turn the light on high night low or off 25 Fan amp On Off Touch this pad to turn the fan on or off 26 Fan 5 Speed Touch this pad to choose one of 5 fan speeds 27 Auto Off Fan timer Touch this pad followed by Number pad to set a time for the fan stopping automatically NOTE If you try to enter incorrect instructions you will not hear any tones Touch STOP Clear and re enter the instructions OVERALL CIRCUIT DIAGRAM SCHEMATIC DIAGRAM Note 120 VAC 60Hz_ rl SINGLE PHASE 1 DOO
26. is applied a Make sure the interlock switch mechanism is operating properly by opening and closing the door b Check microwave energy leakage must bebelow the limit of 5 mW cm All service adjustments should be made for minimum microwave energy leakage readings 7 1 3 Do not operate the unit until it is completely repaired if any of the following conditions exist The unit must not be operated a The door does not close firmly b The hinge is broken The door seal is damaged d The door is bent or warped or there is any other visible damage on the unit that may cause microwave energy leakage NOTE Always keep the seal clean e Make sure that there are no defective parts in the interlock mechanism f Make sure that there are no detective parts in the microwave generating and transmission assembly especially waveguide 4 The following items should be checked after the unit is repaired a The interlock monitor switch is connected correctly and firmly b The magnetron gasket is properly positioned and mounted c The waveguide and the oven cavity are intact no microwave energy leakage d The door can be properly closed and the safety switches work properly e The unit must stop when the door is opened or the time is up The unit must not be operated with any of the above components removed or by passed MICROWAVE LEAKAGE TEST CAUTIONS Be sure to check microwave lea
27. kage prior to servicing the oven if the oven is operative prior to servicing The service personnel should inform the manufacture importer or assembler of any certified oven unit found to have a microwave emission level in excess of 5 mW cm and should repair any unit found to have excessive emission levels at no cost to the owner and should ascertain the cause of the excessive leakage The service personnel should instruct the owner not to use the unit until the oven has been brought into compliance If the oven operates with the door open the service personnel should Tell the user not to operate the oven The service personnel should check all surface and vent openings for microwave leakage Check for microwave leakage after every servicing The power density of the microwave radiation leakage emitted by the microwave oven should not exceed 4 mW crr Always start measuring of an unknown field to assure safety for operating personnel from radiation leakage EQUIPMENT TESTER VOLTS DC AC Ohmmeter Microwave survey meter Holaday HI 1500 HI 1501 8100 8200 600 cc non conductive material beaker glass or plastic inside diameter approx 8 5 cm 3 in Glass thermometer 100 C or 212 F 1 deg scale MEASURING MICROWAVE ENERGY LEAKAGE Pour 275 15cc of 20 5 C 68 9 F water in a beaker which is graduated to 600 cc and place the beaker on the center of the turnta
28. meter leads across the diode as pictured in Figure 1 The reading should be 40M OL or a reading of infinity 3 Reverse the meter leads The reading should again indicate a reading of infinity If the diode shows infinity in BOTH directions it is NOT shorted 4 If the diode is not shorted proceed to step 2 STEP 2 Test the diode for forward biasing Procedure 1 Select the DCV scale on the meter 2 Using the meter battery and jumper wire connect the items as illustrated in Figure 2 This has the positive side of the battery connected to the cathode of the diode 3 The diode should be forward biased therefore a voltage reading of approximately 4 7 VDC to 6 4 VDC will be read depending on meter battery strength etc Note If the meter leads were reversed a negative voltage of the same amount would be seen STEP 3 Test the diode for reverse biasing Procedure 1 Using the same scale on the meter connect the positive side of the battery to the anode of the diode as illustrated in Figure 3 2 The diode should be reverse biased therefore a reading of 0 volt or a value displayed in mV will be seen The display will be erratic changing values rapidly in the mV scale Normal Approximately 4 7 6 4V Normal Approximately 7 16
29. minals between and NC of the Interlock Monitor must close when the door is opened After adjusting the Interlock Monitor Switch make sure that it is correctly connected Mounting of the primary monitor secondary switches to the latch board 1 Latch Board NH Secondary Interlock Switch Interlock Monitor Switch Primary Interlock Switch Figure 22 LATCH 0 1 64 Figure 23 LATCH BOARD 0 1 64 7 12 CHECK THE DOOR LATCH AND SWITCH CLOSING NOTE The outer cover of the microwave oven is removed 1 Set the microwave oven on its side so that you can see the latch board and the switches as shown in Figure 22 2 Close the door tightly and check gaps A and B to be sure they are no more than 1 64 0 5 mm See Figure 23 for close up view of gaps A and B door latches If all gaps are less than 1 64 0 5 mm adjustment of the latch board may not be necessary Go to Steps 5 and 6 to check the sequence of the switches NOTE To correct sequence of the Primary Interlock Switch Secondary Interlock Switch and the Interlock Monitor Switch is very important If any gap is larger than 1 64 0 5 mm you will need to adjust the latch board Go to step 3 and follow all steps in order ADJUST THE LATCH AND SWITCH CLOSING 3 Loosen the two screws holding the plastic latch board as shown 4 With the oven door closed tightly move the latch board upward toward the top of t
30. ount all damaged 3 Remove outcase A When replacing the magnetron be sure to install 5 the magnetron gasket in the correct position and be sure that the gasket is in good condition Disconnect the wireleads Remove the three screws and Magnetron very carefully After replacing the magnetron check for microwave energy leakage with a survey meter Check microwave energy leakage must be below the limit of 5 mW cm All service adjustments should be made for minimum microwave energy leakage readings mount all vertgrille Figure 12 Figure 13 7 8 E DOOR ASSEMBLY REMOVAL 1 Open the door 2 Remove the choke cover very carefully with a flat blade screwdriver CAUTION Be careful not to damage door seal plate by screwdriver 3 Lift up and push the door Remove door assembly 7 9 F ASSEMBLING DOOR 3 Carefully pull the ventilation motor ASS Y out of 1 When mounting the door assembly to the oven the microwave oven See Figure 18 assembly be sure to adjust the door assembly parallel to the chassis Also adjust so the door has no play between the inner door surface and oven frame assembly If the door assembly is not mounted properly microwaves may leak from the clearance between the door and the oven Space ree t Figure 18 G REMOVING THE VENTILATION FAN ASS Y 1 Remov
31. r switch the door is opened Fuse blows when the door is closed and START Malfunction of the high voltage transformer the high key is touched voltage capacitor including the diode the magnetron the blower motor or the circuit board NOTES If the fuse is blown by an improper switch operation replace all switches and the fuse at the same time After replacing the defective switches with new ones make sure that they are correctly connected Check for microwave energy leakage according to INTERLOCK ADJUSTMENT PROCEDURES on page 7 12 when the primary interlock secondary interlock switches and or the interlock monitor switches are adjusted or replaced 2 CHECKOUT PROCEDURES FOR RELAY PROBLEM A Oven lamp turn on without touching START key when the door is closed 5 Remove the mate connector of I O D 209 CON from the circuit board Does the unit still operate IS Replace the circuit board Defective RELAY1 Replace RELAY1 PROBLEM B Oven lamp turn on When the door is closed and START key 15 touched ie GOOD 7 20 Measure the voltage at pin NO 35 of 001 Voltage reading 5 Vdc Defective Replace the RELAY1 or poor circuit board connection of RELAY1 Replace RELAY1 or correct the connection 3 CHECKOUT PROCEDURES FOR CIRCUIT BO
32. should not be exposed to the microwave energy which may radiate from the magnetron or other microwave generating device if it is improperly used or connection All input and output microwave connections waveguide flange and gasket must be secure never operate the device without a microwave energy absorbing load attached Never look into an open waveguide or antenna while the device is energized Proper operation of the microwave oven requires that the magnetron be assembled to the waveguide and cavity Never operate the magnetron unless it is properly installed Be sure that the magnetron gasket is properly installed around the dome of the tube whenever installing the magnetron ANTENNA Gasket COOLING FIN FILAMENT TERMINALS MAGNETRON CHASSIS GROUND MAGNETRON THE OVEN IS TO BE SERVICED ONLY BY PROPERLY QUALIFIED SERVICE PERSONNEL INSTALLATIONS BEFORE YOU BEGIN READ THE FOLLOWING INSTRUCTIONS COMPLETELY AND CAREFULLY PRECAUTIONS ON INSTALLATION A Plug the power supply cord into a 120V AC 60Hz single phase power source with a capacity of 15A or 20A B Avoid placing the unit in a location where there is direct heat or splashing water C Install the unit on the mounting plate firmly D Place the unit as far away as possible from TV radio etc to prevent interference GROUNDING INSTRUCTIONS For personal safety this appliance must be fully grounded at all times In th
33. tener Connector Terminal socket Figure 7 B REMOVING THE OUT CASE Figure 8 1 Remove the vent grille by removing two screws securing it to the out case 2 Remove two screws securing it to the front bracket 3 Remove two screws securing it to the air duct 4 Remove the mounting plate by turning the two screws securing it to the out case 5 Remove the base plate by removing four screws securing it to the out case Remove the Mount All from the out case by removing two screws securing it to the out case 6 Remove four screws from the rear section 7 Remove the outcase with pushing it back Mount All Power code Mounting Plate Out Case Vent Grille N Controller Figure 8 7 6 REMOVING THE DOOR INTERLOCK SWITCHES Figures 9 10 1 Disconnect the wire leads from the interlock switches 2 Remove two screws securing the Latch Board 3 Make necessary replacements and check microwave energy leakage according to ADJUSTMENT PROCEDURE on page 7 12 Latch Board Monitor Interlock Switch Figure 9 Latch Board Secondary Interlock Switch Interlock Monitor Switch Primary Interlock Switch Figure 10 7 7 D REMOVING MAGNETRON NOTES Figures 11 Through 13 When removing the magnetron make sure that 15 1 Remove the vent grille dome does not hit any adjacent parts or it may be 2 Remove m
34. ter should indicate closed circuit in the door open condition When the door is closed meter should indicate an open circuit When the monitor switch operation is abnormal replace with the same type of switch NOTE After repairing the door or the interlock system it is necessary to do this continuity test before operating the oven RESULTS SWITCHES Wire leads removed Check for continuity of the switch with an Ohm meter Door open Primary Switch Monitor Switch Secondary Switch NOTE After checking for the continuity of switches make sure that they are connected correctly WARNING FOR CONTINUED PROTECTION AGAINST EXCESSIVE RADIATION EMISSION REPLACE ONLY WITH IDENTICAL REPLACEMENT PARTS TYPE NO SZM V16 FA 63 OR VP 533A OF OR 52300 FOR PRIMARY SWITCH TYPE NO SZM V16 FA 62 OR VP 532A OF OR 52200 FOR MONITOR SWITCH TYPE NO SZM V16 FA 63 OR VP 533A OF OR 52300 FOR SECONDARY SWITCH TEST CHECKOUT PRECEDURES AND TROUBLESHOOTING CAUTIONS 1 DISCONNECT THE POWER SUPPLY CORD FROM THE OUTLET WHENEVER REMOVING THE OUTER CASE FROM THE UNIT PROCEED WITH THE TEST ONLY AFTER DISCHARGING THE HIGH VOLTAGE CAPACITOR AND REMOVING THE LEAD WIRES FROM THE PRIMARY WINDING OF THE HIGH VOLTAGE TRANSFORMER 2 ALL OPERATIONAL CHECKS WITH MICROWAVE ENERGY MUST BE DONE WITH A LOAD 1 LITER OF WATER IN CONTAINER IN THE OVEN
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