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Microwave Oven: Service Manual
Microwave Oven: Service Manual
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MICROWAVE OVEN
SERVICE MANUAL
MODEL: MS-7042MK
CAUTION
BEFORE SERVICING THE UNIT, READ THE
SAFETY PRECAUTIONS IN THIS MANUAL.
July, 2002
P/NO : 3828W5S2395 Printed in Korea
SAFETY PRECAUTIONS
This device is to be serviced only by properly qualified service personnel.
Consult the service manual for proper service procedures to assure continued safety operation and for precautions to be
taken to avoid possible exposure to excessive microwave energy.
SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
CAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
INSTALLATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
FEATURES- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Magnetron 2M213
Nameplate Location
Back Side
1-1
CAUTIONS
ANTENNA
Gasket
COOLING FIN
FILAMENT
TERMINALS
MAGNETRON
CHASSIS GROUND
2-1
INSTALLATIONS
BEFORE YOU BEGIN, READ THE FOLLOWING INSTRUCTIONS COMPLETELY AND CAREFULLY.
10cm
INSURE PROPER GROUND AND
FIRM CONNECTION BEFORE USE
3-1
OPERATING INSTRUCTIONS
FEATURES
Oven Front Plate
Window Door Screen
Door Seal
Display Window
Control Panel
Rotating Ring
CONTROL PANEL
1. INDICATORS
2. ONE TOUCH CONTROL: Used to cook the foods
listed by one touch.
1 3. +30: Allows you to cook for 30 seconds at 100%
power by simply touching this pad. You can also
extend cooking time in multiples of 30 seconds by
2 repeatedly touching this pad during cooking.
4. CLOCK: Used to set the time of day.
5. TIMER
3 6. AUTO DEFROST: Used to select the desired auto
4 5 weight defrost programmed with weight pad.
6 7. Q-DEFROST
7
8. NUMBER: Used to set for time of day, cooking time,
power level or defrost weight.
9. TIME: Used to cook food for a desired time.
8 10. POWER: Used to select the desired power level for
cooking.
11. STOP/CLEAR: Used to stop oven and clear all
9 10 entries except time of day.
12. START: One tap allows oven to begin functioning.
11 12
4-1
OPERATING SEQUENCE
The following is a description of component functions 6. MULTI-STAGE COOKING
during oven operation.
1ST STAGE
1. SETTING THE CLOCK
STOP/CLEAR TIME NUMBER POWER
STOP/CLEAR CLOCK NUMBER CLOCK
NUMBER
ex.) To set 4:30, touch number key [4],[3], and [0].
2. CANCEL FUNCTION
NUMBER START
Touch the STOP/CLEAR pad whenever you need to
cancel an entry or a function currently in use.
The display will either return to the last item entered
or to the clock. 7. AUTO DEFROST COOKING
8. CHILD LOCK
4. ONE TOUCH COOKING This oven has a CHILD LOCK feature
TO SET CHILD LOCK
STOP/CLEAR POPCORN
• Touch the 0 pad
• Touch and hold 0 pad L appear on
NOTE: Heat only 1 package at a time
the display.
NUMBER START
4-2
4-3
SCHEMATIC DIAGRAM
IMPORTANT SAFETY NOTE: THE SHADED AREAS ON THIS SCHEMATIC DIAGRAM INCORPORATE SPECIAL FEATURES
IMPORTANT FOR PROTECTION FROM MICROWAVE RADIATION, FIRE, ELECTRICAL SHOCK, AND
HAZARDS. WHEN SERVICING IT IS ESSENTIAL THAT ONLY MANUFACTURER’S SPECIFIED PARTS
BE USED FOR THE CRITICAL COMPONENTS IN THE SHADED AREAS OF THE SCHEMATIC DIAGRAM.
NOTICE: SINCE THIS IS BASIC SCHEMATIC DIAGRAM, THE VALUES OF COMPONENTS AND
SOME PARTIAL CONNECTIONS ARE SUBJECT TO CHANGE FOR IMPROVEMENT.
CIRCUIT DESCRIPTION
WHEN TOUCHING THE START PAD WHEN THE DOOR IS OPENED DURING
• The coil of the relay is energized by the micom COOKING
controller.
• Both the primary switch and relay 2 cut off the primary
• Power input is supplied to the high voltage transformer
winding voltage of the high voltage transformer.
through the fuse to the primary switch and relay 2.
• ON-OFF of relay 2 is coupled electrically with opening
• Turntable rotates.
and closing of the secondary switch.
• When the door is opened, the secondary switch is
opened and when the door is closed, the secondary
switch is closed.
• The cooking time stops counting down.
N • Relay stops functioning.
• As the door is opened, if the contact of primary switch
MONITOR H.V. and relay2 and/or secondary switch fail to open, the
SWITCH TRANS-
L FORMER fuse opens due to the large current surge caused by
the monitor switch activation, which in turn stops
FUSE
magnetron oscillation.
PRIMARY SECONDARY
SWITCH RELAY 2 SWITCH
N
MICOM CONTROLLER H.V.
MONITOR
SWITCH TRANS-
L FORMER
• The fan motor rotates and cools the magnetron by
blowing the air (coming from the intake on the FUSE
baseplate).
• The air is also directed into the oven to exhaust the PRIMARY SECONDARY
vapor in the oven through the upper plate. SWITCH RELAY 2 SWITCH
• Cooking time starts counting down.
• 3.2 volts AC is generated from the filament winding of
the high voltage transformer. This 3.2 volts is applied to
MICOM CONTROLLER
the magnetron to heat the magnetron filament through
two noise-preventing choke coils.
4-4
SERVICE INFORMATION
TOOLS AND MEASURING INSTRUMENTS
NECESSARY TOOLS NECESSARY MEASURING INSTRUMENTS
Tools normally used for TV servicing are sufficient. • TESTER (VOLTS-DC, AC, Ohmmeter)
Standard tools are listed below. • Microwave survey meter
• Diagonal pliers - Holaday HI-1500
• Long nose pliers HI-1501
• Phillips screwdriver - Narda 8100
• Flat blade screwdriver 8200
• Wrench (size 5mm) • Inch scale
• Nutdriver (size 5mm) • 600 cc non conductive material beaker (glass or plastic),
• Adjustable wrench inside diameter: approx. 8.5 cm (31/2 in.)
• Soldering iron • Cylindrical and made of borosilicate glass vessel.
• Solder max. thickness: 3 mm
• Vinyl insulation tape outside diameter: approx. 190mm
• Polishing cloth height: approx. 90mm
• Glass thermometer: 100°C or 212°F (1 deg scale)
5-1
MEASUREMENT WITH OUTER CASE NOTES WHEN MEASURING
REMOVED • Do not exceed meter full scale deflection.
• When you replace the magnetron, measure for • The test probe must be removed no faster than
microwave energy leakage before the outer case is 1 inch/sec (2.5 cm/sec) along the shaded area,
installed and after all necessary components are otherwise a false reading may result.
replaced or adjusted. • The test probe must be held with the grip portion of the
Special care should be taken in measuring the handle.
following parts. (Circled area of Fig. below) A false reading may result if the operator's hand is
- Around the magnetron between the handle and the probe.
- The waveguide • 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
WARNING : AVOID CONTACTING ANY cause probe damage.
HIGH VOLTAGE PARTS
RECORD KEEPING AND NOTIFICATION
AFTER MEASUREMENT
• 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.
• The microwave energy leakage should not be more
than 4 mW/cm.sq. after determining that all parts are in
good condition, functioning properly and genuine
replacement parts which are listed in this manual have
been used.
• At least once a year, have the electromagnetic energy
leakage monitor checked for calibration by its
manufacturer.
5-2
MEASUREMENT OF MICROWAVE POWER OUTPUT
• Microwave power output measurement is made with • The microwave power output P in watts is calculated
the microwave oven supplied at its rated voltage and from the following formula :
operated at its maximum microwave power setting with
4187 x (∆T)
a load of (1000±5) g of potable water. P=
• The water is contained in a cylindrical borosilicate glass T
vessel having a maximum material thickness of 3 mm is measured while the microwave generator is
and an outside diameter of approximately 190mm. operating at full power. Magnetron filament heat-up
• The oven and the empty vessel are at ambient time is not included. (about 3 sec)
temperature prior to the start of the test. • The water is stirred to equalize temperature throughout
• The initial temperature (T1) of the water is (10±2)°C It the vessel, prior to measuring the final water
is measured immediately before the water is added to temperature.
the vessel. After addition of the water to the vessel, • Stirring devices and measuring instruments are
the load is immediately placed on the center of the selected in order to minimize addition or removal of
turntable which is in the lowest position and the heat.
microwave power switched on.
• The time T for the temperature of the water to rise by a WATER LOAD
value ∆ T of (10±2)°K is measured, where T is the time
in seconds and ∆T 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.
TURNTABLE
1) Disconnect the power supply cord from the outlet. securing screw
2) Remove the screws from the rear of the case.
The outer case must be moved backward to be lifted
off.
5-3
D. DOOR GROSS ASSEMBLY REMOVAL E. HIGH VOLTAGE TRANSFORMER
1) Open the door. REMOVAL
2) Remove the choke cover very carefully with a
1) Discharge the high voltage capacitor.
flat-blade screwdriver.
2) Disconnect the leadwire from magnetron, high voltage
CAUTION : Be careful not to damage door seal plate
transformer, and capacitor.
by screwdriver.
3) Remove the screw holding the high voltage
3) Lift up and push the door.
transformer to the baseplate.
NOTE:
1. After replacing the door, be sure to check that the F. FAN MOTOR ASSEMBLY REMOVAL
primary switch, monitor switch, and secondary switch 1) Discharge the high voltage capacitor.
operate normally. 2) Disconnect the leadwire from fan motor, and high
2. After replacing the door, check for microwave energy voltage capacitor.
leakage with a survey meter. Microwave energy must 3) Remove the two screws holding the the suction guide
be below the limit of 5 mW/cm. (with a 275 ml water ASS’Y to the oven cavity and remove the high voltage
load) diode earth screw.
3. When mounting the door assembly to the oven 4) Remove the two screws holding the fan motor ASS’Y
assembly, be sure to adjust the door assembly parallel to the suction guide ASS’Y.
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
G. HIGH VOLTAGE CAPACITOR AND
properly, microwaves may leak from the clearance DIODE REMOVAL
between the door and the oven. 1) Discharge the high voltage capacitor.
2) Disconnect the leadwire from fan motor, and high
Remove choke cover voltage capacitor.
3) Remove the screw holding the suction guide ASS’Y to
the oven cavity and remove the high voltage diode
earth screw.
4) Remove the screw holding the high voltage capacitor
bracket.
Suction
Guide
H.V.
Remove door Transformer
H.V.
Capacitor
H.V.
Diode
5-4
H. AIR DUCT ASSEMBLY REMOVAL J. REMOVING THE TURNTABLE MOTOR
1) Disconnect the leadwire from lamp. 1) Remove the turntable.
2) Remove the mounting screw to Latch Board. 2) Remove the turntable shaft VERY CAREFULLY
with a slotted screwdriver.
3) Lay the unit down on its back.
I. MAGNETRON REMOVAL 4) Remove the turntable motor cover.
1) Disconnect the leadwire from the high voltage The turntable base cover is easily removed by
transformer. pinching the six parts with a wire cutting.
2) Carefully remove the mounting screws holding the 5) Disconnect the leadwire from the turntable motor
magnetron to the waveguide. terminals.
3) Remove the magnetron ASS’Y until the tube is 6) Remove the screw securing the turntable motor to
clear from the waveguide. the oven cavity ASS’Y
7) After repairing the motor, rotate the removed
NOTE: turntable motor cover.
1. When removing the magnetron, make sure its 8) Fit the turntable motor cover’s projecting part to the
dome does not hit any adjacent parts, or it may be base plate slit.
damaged.
2. When replacing the magnetron, be sure to install NOTE:
the magnetron gasket in the correct position and 1. Remove the wire lead from the turntable motor
be sure that the gasket is in good condition. VERY CAREFULLY.
3. After replacing the magnetron, check for microwave 2. Be sure to grasp the connector, not the wires, when
leakage with a survey meter around the removing.
magnetron. Microwave energy must be below the
limit of 5 mW/cm2. (With a 275 ml. water load).
Make sure that gasket is rigidly attached to the
magnetron. To prevent microwave leakage,
tighten the mounting screws properly, making sure
there is no gap between the waveguide and the
magnetron.
Magnetron
Magnetron
Waveguide
5-5
K. PCB ASSEMBLY REMOVAL L. INTERLOCK SYSTEM
1) Remove the control panel assembly from the 1) INTERLOCK MECHANISM
cavity. (Refer to control panel assembly removal The door lock mechanism is a device which has
on previous page.) been specially designed to eliminate completely
2) Remove screws which hold the PCB SUB ASS’Y to microwave activity when the door is opened during
the control panel. cooking and thus to prevent the danger resulting
3) Disconnect the flat cable from the PCB SUB from the microwave leakage.
ASS’Y and take off the PCB SUB ASS’Y.
2) MOUNTING OF THE PRIMARY/MONITOR/
SECONDARY SWITCHES TO THE LATCH
BOARD
PCB Sub Asm
Control Panel ADJUSTMENT
DIRECTION
Key Membrane
PRIMARY
SWITCH
MONITOR
SWITCH
SECONDARY
SWITCH
5-6
INTERLOCK CONTINUITY TEST
WARNING : FOR CONTINUED PROTECTION AGAINST EXCESSIVE RADIATION
EMISSION, REPLACE ONLY WITH IDENTICAL REPLACEMENT PARTS.
TYPE NO. SZM-V 16-FA-63 OR VP-533A-OF OR V-5230Q FOR PRIMARY SWITCH
TYPE NO. SZM-V 16-FA-62 OR VP-532A-OF OR V-5220Q FOR MONITOR SWITCH
TYPE NO. SZM-V 16-FA-63 OR VP-533A-OF OR V-5230Q FOR SECONDARY SWITCH
Primary COM
NO
NT
Switch
Monitor NC
NT ADJUSTM
Switch COM
DIRECTIO
Secondary
Switch COM
NO
NT
NOTE : After checking for the continuity of switches, make sure that they are
connected correctly.
5-7
COMPONENT TEST PROCEDURE
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 WIRE LEADS FROM THE PRIMARY WINDING OF THE
HIGH VOLTAGE TRANSFORMER. (SEE PAGE 2-1)
2. ALL OPERATIONAL CHECKS WITH MICROWAVE ENERGY MUST BE DONE WITH A LOAD (1 LITER
OF WATER IN CONTAINER) IN THE OVEN.
SECONDARY
TERMINAL
PRIMARY
TERMINAL
5-8
COMPONENTS TEST PROCEDURE RESULTS
Antenna
Gasket
Chassis
Filament
NOTE: When testing the magnetron, be sure to install the magnetron gasket
in the correct position and be sure that the gasket is in good condition.
NOTE :
Some inexpensive meters
may indicate infinite
resistance in both direction. Normal: Infinite.
Measure the continuity (Reverse).
(Ohm-meter scale: Rx10000) Abnormal: Continuity.
5-9
COMPONENTS TEST PROCEDURE RESULTS
RELAY 2 Check for continuity of relay 2 with an POWER
ohm-meter. LEVEL
(Remove wire leads from relay 2 and
operate the unit.) 1 4 sec 18 sec
2 6 sec 16 sec
3 8 sec 14 sec
Relay 1 4 10 sec 12 sec
5 12 sec 10 sec
6 14 sec 8 sec
7 16 sec 6 sec
8 18 sec 4 sec
9 20 sec 2 sec
10 22 sec 0 sec
Relay 2
NOTE : • A MICROWAVE LEAKAGE 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, NOT THE WIRES.
5-10
TROUBLE SHOOTING
WHEN YOU GET A COMPLAINT FROM YOUR CUSTOMER, EVALUATE THE COMPLAINT CAREFULLY. IF
THE FOLLOWING SYMPTOMS APPLY, PLEASE INSTRUCT THE CUSTOMER IN THE PROPER USE OF THE
MICROWAVE OVEN. THIS CAN ELIMINATE AN UNNECESSARY SERVICE CALL.
CAUTIONS
1. Check grounding before checking for trouble.
2. Be careful of the high voltage circuit.
3. Discharge the high voltage capacitor. (See page 2-1)
4. When checking the continuity of the switches or of the high voltage transformer, disconnect one lead wire
from these parts and then check continuity with the AC plug removed. To do otherwise may result in a
false reading or damage to your meter.
5. Do not touch any part of the circuit on the PCB since static electric discharge may damage this control
panel.
Always touch yourself to ground while working on this panel to discharge any static charge built up in your
body. (Micom model only)
Microwave oven Inserting many plugs into one Avoid using other electrical
does not work. outlet and using appliances when you use the
them at the same time microwave oven.
(blown fuse or breaker)
Output power is too low. Low AC input voltage. Use the microwave oven at
adequate line voltage.
Sparks occur. Using metallic ware and Do not use metallic ware for
allowing it to touch the oven cooking except where noted
wall. in the cooking guide.
5-11
(TROUBLE 1) The following visual conditions indicate a probable defective control circuit.
1. Incomplete segments.
• Segment missing.
• Partial segment missing.
• Digit flickering (NOTE: Slight flickering is normal.)
2. Colon does not turn on or blink.
3. A distinct change in the brightness of one or more numbers in display.
4. One or more digits in the display are not lighting.
5. Display does not count down with time blinking or up with clock operation.
6. Display obviously jumps in time while counting down.
7. Display counts down too fast while cooking.
8. Each indicator light does not turn on after setting cooking cycle.
9. Display time of day does not reappear when cooking is finished.
10. Beep sound is not heard when correct key is touched.
2. Some inputs Replace key Everything works Defective key Replace key
cannot be membrane as specified. membrane membrane
programmed. assembly and assembly. assembly.
check operation.
4. Random
programming
when touching
other pads.
5. Display is fixed
at some figure
and can not
accept any
input.
5-12
(TROUBLE 2) Oven does not operate at all, Display window does not display any figures,
and no input is accepted.
NOTE : All these switches must be replaced at the same time. Refer to page 5-7, 5-8
Continuity.
5-13
(TROUBLE 3) Display shows all figures set, but oven does not start cooking while desired
program times are set and START pad is touched.
2. Fan motor or Check fan motor. Abnormal Defective fan motor. Replace fan motor.
oven lamp do
not turn on. Check oven lamp. Abnormal Defective oven lamp. Replace oven lamp.
Normal
(TROUBLE 4) Oven seems to be operating but little heat is produced in oven load.
NOTE : Simple test of power output-conducted by heating one liter water for one min. if available.
Minimum 8.5°C temperature rise is normal condition.
5-14
(TROUBLE 5) No microwave oscillation even though oven lamp and fan motor run.
(Display operates properly)
Normal
Normal
5-15
#EV#
EXPLODED VIEW
INTRODUCTION
6-1
#EV#
DOOR PARTS
13581A 13552A
13213A
13536A
13352A
14026A
14970A
13720D
6-2
#EV#
CONTROLLER PARTS
24781M
268711
23572A
WTP028
23506A
6-3
#EV#
WTT021
948503
33112U
WTT021
WTT010
33052A 33390G
35889A
36549S
WTP013
6-4
#EV#
466001
466003
43500A 466001
WSZ085 44510A
6-5
#EV#
INTERIOR PARTS
56411A
55006F
WSZ002
WSZ002
50FZZA
948501
56930V 56324A
WSZ002
WTT037
56549F
55900A
54974S
56912B
568771
55262A
6-6
#EV#
WTT028
56170D
54810C
63303A
50CZZH
56851D
948502
65006B
WTT021
WSZ002
6-7
SCHEMATIC DIAGRAM OF P.C.B.
8-1
PRINTED CIRCUIT BOARD
8-2