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PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE EXPO-
SURE TO EXCESSIVE MICROWAVE ENERGY

BEFORE SERVICING

CHAPTER 1. WARNING TO SERVICE PERSONNEL

CHAPTER 2. MICROWAVE MEASUREMENT PRO-
CEDURE

CHAPTER 3. FOREWORD AND WARNING

CHAPTER 4. PRODUCT DESCRIPTION

CHAPTER 5. GENERAL INFORMATION

CHAPTER 6. OPERATION

CHAPTER 7. TROUBLESHOOTING GUIDE

CHAPTER 8. TEST PROCEDURES

CHAPTER 9. TOUCH CONTROL PANEL ASSEMBLY

CHAPTER 10. PRECAUTIONS FOR USING LEAD-
FREE SOLDER

CHAPTER 11. COMPONENT REPLACEMENT AND
ADJUSTMENT PROCEDURE

CHAPTER 12. CIRCUIT DIAGRAMS

SY612R408LPSTF

SERVICE MANUAL

R408LS

CONTENTS

This document has been published to be used for
after sales service only.
The contents are subject to change without notice.

TopPage

MICROWAVE OVEN

R-408LS

MODEL

In the interest of user-safety the oven should be restored to its origi-
nal condition and only parts identical to those specified should be
used.

WARNING TO SERVICE PERSONNEL: Microwave ovens con-
tain circuitry capable of producing very high voltage and cur-
rent, contact with following parts may result in a severe,
possibly fatal, electrical shock. (High Voltage Capacitor, High
Voltage Power Transformer, Magnetron, High Voltage Rectifier
Assembly, High Voltage Harness etc..)

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Summary of Contents for R-408LS

Page 1: ...PROCEDURE CHAPTER 12 CIRCUIT DIAGRAMS Parts List SY612R408LPSTF SERVICE MANUAL R408LS CONTENTS This document has been published to be used for after sales service only The contents are subject to change without notice TopPage MICROWAVE OVEN R 408LS MODEL In the interest of user safety the oven should be restored to its origi nal condition and only parts identical to those specified should be used ...

Page 2: ... 9 H BLOWN MONITOR FUSE TEST 8 4 10 I NOISE FILTER TEST 8 4 11 J TOUCH CONTROL PANEL ASSEM BLY TEST 8 4 12 K KEY UNIT TEST 8 5 13 L RELAY TEST 8 5 14 M DEFROST TEST 8 6 15 N FOIL PATTERN ON THE PRINTED WIRING BOARD TEST 8 6 CHAPTER 9 TOUCH CONTROL PANEL ASSEM BLY 1 OUTLINE OF TOUCH CONTROL PAN EL 9 1 2 SERVICING FOR TOUCH CONTROL PANEL 9 1 CHAPTER 10 PRECAUTIONS FOR USING LEAD FREE SOLDER 1 Employ...

Page 3: ...components in the interlock monitor door seal and microwave generation and transmission systems shall be repaired replaced or adjusted by procedures described in this manual before the oven is released to the owner e A microwave leakage check to verify compliance with the Federal Performance Standard should be performed on each oven prior to release to the owner BEFORE SERVICING Before servicing a...

Page 4: ...gh voltage capacitor 4 Disconnect the leads to the primary of the power transformer 5 Ensure that the leads remain isolated from other components and oven chassis by using insulation tape 6 After that procedure reconnect the power supply cord 2 When the testing is completed 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capa...

Page 5: ...he oven cavity The water container shall be a low form of 600 ml 20 oz beaker with an inside diameter of approx 8 5 cm 3 1 2 in and made of an electrically nonconductive material such as glass or plastic The placing of this standard load in the oven is important not only to protect the oven but also to insure that any leakage is measured accurately 4 Set the cooking control on Full Power Cooking M...

Page 6: ...ets and hinges are not defective C The door packing is not damaged D The door is not deformed or warped E There is no other visible damage with the oven Servicing and repair work must be carried out only by trained service personnel 3 DANGER Certain initial parts are intentionally not grounded and present a risk of electrical shock only during servicing Service personnel Do not contact the followi...

Page 7: ...s less Control Complement Touch Control System Clock 1 00 12 59 Timer 0 99 minutes 99 seconds Microwave Power for Variable Cooking Repetition Rate P HI Full power throughout the cooking time P 90 approx 90 of FULL Power P 80 approx 80 of FULL Power P 70 approx 70 of FULL Power P 60 approx 60 of FULL Power P 50 approx 50 of FULL Power P 40 approx 30 of FULL Power P 30 approx 40 of FULL Power P 20 a...

Page 8: ...ptacle is encountered it is the personal responsibility and obligation of the customer to contact a qualified electrician and have it replaced with a properly grounded three pronged wall receptacle or have a grounding adapter properly grounded and polarized If the extension cord must be used it should be a 3 wire 15 amp or higher rated cord Do not drape over a countertop or table where it can be p...

Page 9: ...NEL NOTE Some one touch cooking features such as MINUTE PLUS are disabled after three minutes when the oven is not in use These fea tures are automatically enabled when the door is opened and closed or the STOP CLEAR pad is pressed ...

Page 10: ...e high voltage components are de energized the oven lamp remains on and the digital read out displays the time still remaining in the cook cycle when the door was opened 7 The monitor switch electrically monitors the operation of the pri mary interlock switch and secondary interlock relay and is mechan ically associated with the door so that it will function in the following sequence a When the do...

Page 11: ...MAGNETRON HIGH VOLTAGE CAPACITOR 0 94uF AC2200V SECONDARY INTERLOCK RELAY GND RY1 OVEN LAMP RELAY COM N O COM N C HIGH VOLTAGE RECTIFIER H N C3 C2 C1 C1 LINE CROSS CAPACITOR 0 22uF AC250V C2 C3 LINE BYPASS CAPACITOR 0 033uF AC250V BLK NOISE FILTER MONITOR FUSE 20A TO LOAD TO LOAD TO SOURCE TO SOURCE OVEN THERMAL CUT OUT 120VAC 60Hz WHT GRN B2 B1 CONTROL UNIT MAGNETRON TEMPERATURE FUSE RY2 DOOR SEN...

Page 12: ...SING SWITCH SECONDARY INTER LOCK RELAY RY2 RE LAY RY1 PRIMARY INTER LOCK SWITCH AND MONITOR SWITCH FOR PROPER OPERATION REFER TO CHAPTER TEST PROCE DURE NOTE MONITOR FUSE AND MONITOR SWITCH ARE REPLACED AS AN ASSEMBLY 4 TURNTABLE MOTOR The turntable motor rotates the turntable located on the bottom of the oven cavity so that the foods on the turntable cook evenly during cooking The turntable may t...

Page 13: ...led 7 Run the oven and check all functions 1 TROUBLESHOOTING CHART Never touch any part in the circuit with your hand or an uninsulated tool while the power supply is connected RE CK A B C D E F F G H RE RE RE J CK CK CK K L N I POSSIBLE CASE AND DEFECTIVE PARTS SHORT IN POWER CORD SHORT OR OPENED WIRING MAGNETRON POWER TRANSFORMER H V RECTIFIER ASSEMBLY HIGH VOLTAGE CAPACITOR MAGNETRON TEMPERATUR...

Page 14: ... the temperature making sure to stir the thermometer or thermocouple through the water until the maximum temperature is recorded 4 Subtract the cold water temperature from the hot water temperature The normal result should be 34 8 to 64 6 F 19 3 to 35 9 C rise in tempera ture If the water temperatures are accurately measured and tested for the required time period the test results will indicate if...

Page 15: ...the magnetron Check for restricted air flow to the magnetron especially the cool ing fan and air guide An open thermal cut out Oven indicates overheating of the oven exchange the thermal cut out and check inside of oven cavity and for improper setting of cooking time or operation of control unit Check for restricted air flow through the vent holes of the oven cavity especially the cooling fan and ...

Page 16: ... 5 Reconnect all leads removed from components during testing 6 Reinstall the outer case cabinet 7 Reconnect the power supply cord after the outer case is installed 8 Run the oven and check all functions 8 G MONITOR SWITCH TEST 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Before performing this test make sure t...

Page 17: ...uter case cabinet 7 Reconnect the power supply cord after the outer case is installed 8 Run the oven and check all functions 11 J TOUCH CONTROL PANEL ASSEMBLY TEST The touch control panel consists of circuits including semiconductors such as LSI ICs etc Therefore unlike conventional microwave ovens proper maintenance cannot be performed with only a voltmeter and ohmmeter In this service manual the...

Page 18: ...ds removed from components during testing 5 Reinstall the outer case cabinet 6 Reconnect the power supply cord after the outer case is installed 7 Run the oven and check all functions 12 K KEY UNIT TEST If the display fails to clear when the STOP CLEAR pad is depressed first verify the flat ribbon cable is making good contact verify that the door sens ing switch stop switch operates properly that ...

Page 19: ...the oven and check all functions 14 M DEFROST TEST WARNING The oven should be fully assembled before following procedure 1 Open the door 2 Place one cup of water in the center of the turntable tray in the oven cavity 3 Close the door touch the DEFROST pad once 4 Press 2 then press 5 5 Touch the START pad 6 The oven is in Defrost cooking condition 7 The oven will operate as follows 8 If improper op...

Page 20: ...primary of the power transformer 5 Ensure that these leads remain isolated from other components and oven chassis by using insulation tape 6 After that procedure reconnect the power supply cord 7 Follow the troubleshooting guide given below for repair 8 Disconnect the power supply cord and then remove outer case 9 Open the door and block it open 10 Discharge high voltage capacitor 11 Reconnect all...

Page 21: ...ircuit In order to protect CMOS LSI 1 When storing and transporting thoroughly wrap them in aluminium foil Also wrap 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 Servicing of Touch Control Panel We describe the procedures to permit servicing of the touch control panel of the microwave oven...

Page 22: ...ing Tools Tools required to service the touch control panel assembly 1 Soldering iron 60W It is recommended to use a soldering iron with a grounding termi nal 2 Oscilloscope Single beam frequency range DC 10MHz type or more advanced model 3 Others Hand tools 4 Other Precautions 1 Before turning on the power source of the control unit remove the aluminium foil applied for preventing static electric...

Page 23: ...s adjusted accordingly 3 Soldering As the melting point of lead free solder Sn Ag Cu is higher and has poorer wettability flow to prevent damage to the land of the PWB extreme care should be taken not to leave the bit in contact with the PWB for an extended period of time Remove the bit as soon as a good flow is achieved The high content of tin in lead free solder will cause premature corrosion of...

Page 24: ... close firmly 2 Door hinge support or latch hook is damaged 3 The door gasket or seal is damaged 4 The door is bent or warped 5 There are defective parts in the door interlock system 6 There are defective parts in the microwave generating and transmission assembly 7 There is visible damage to the oven Do not operate the oven 1 Without the RF gasket Magnetron 2 If the wave guide or oven cavity are ...

Page 25: ... HIGH VOLTAGE CAPACITOR REMOVAL To remove the components proceed as follows 1 Disconnect the power supply cord and remove outer case 2 Open the oven door and block it open 3 Discharge high voltage capacitor 4 Disconnect the high voltage wire of the power transformer from the high voltage capacitor 5 Disconnect the high voltage wire of high voltage rectifier assembly from the magnetron 6 Disconnect...

Page 26: ...40P10000 to fit the turntable motor cover 9 COOLING FAN MOTOR REMOVAL 1 REMOVAL 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Disconnect the wire leads from the fan motor 5 Remove the two 2 screws holding the fan motor to the oven cavity back plate 6 Remove the fan blade from the fan motor shaft according to the...

Page 27: ...ining adhesive on the control panel frame surfaces with a soft cloth soaked in alcohol 2 Tear the backing paper from the new membrane switch 3 Insert the ribbon cable of the membrane switch into the slit of the control panel frame 4 Adjust the upper edge and right edge of the membrane switch to the small depression on the surface of the control panel frame 5 Attach the membrane switch to the contr...

Page 28: ...justed so that the plunger of the monitor switch is pressed with the door closed 6 Secure the screws with washers firmly 7 Check the operation of all switches If each switch has not activated with the door closed loosen screw and adjust the latch hook posi tion 2 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 po...

Page 29: ...t door sensing switch and primary interlock switch are operating properly Refer to chapter Test Proce dures 2 An approved microwave survey meter should be used to assure compliance with proper microwave radiation emission limitation standards 3 After any service make sure of the following 1 Door latch heads smoothly catch latch hook through latch holes and that latch head goes through center of la...

Page 30: ...BRN ORG THERMAL CUT OUT OVEN MAGNETRON TEMP FUSE FAN MOTOR RED RED WHT WHT RED RED POWER SUPPLY CORD 120V 60Hz NOTE The neutral WHT wire must be connected to the terminal with N mark on the power supply cord RED WHT WHT H N NOTE The grounding conductor of the power supply cord has been grounded by power supply cord fixing screw The screw must always be kept tight COM N O DOOR SENSING SWITCH GRY GR...

Page 31: ...71 P70 5V GND INT BZ DOOR M T1 PA151DR D1 D4 1N4002x4 AN4 AN5 AN6 Q4 DTA143EKA D30 SP1 RY1 RY2 DU12D1 1P M R AC N AC H 0 1uF 50 d a b c V POWER UNIT R110 15K AN7 R13 10K R14 10K R15 10K IC1 AN7 AN6 AN5 AN4 AN3 AN2 AN1 VL1 VL2 AN0 P57 P56 P55 CNTR0 P53 P52 P51 P50 P47 P46 P45 P44 P43 INT0 SEG10 SEG11 SEG12 SEG13 SEG14 SEG15 SEG16 SEG9 SEG8 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 BL F F...

Page 32: ...R408LS 12 3 3 Printed Wiring Board Figure S 3 Figure S 3 Printed Wiring Board ...

Page 33: ...O 4 DESCRIPTION Parts marked may cause undue microwave exposure Parts marked are used in voltage more than 250V PartsGuide 1 OVEN PARTS 2 DOOR AND CONTROL PANEL PARTS INDEX CONTENTS DOOR PROTECTION SHEET SPADPA204WRE0 TOP PAD ASSEMBLY FPADBA624WRKZ PLASTIC BAG SSAKHA032WRE0 Not replaceable items PACKING CASE FPAK A572WRKZ BOTTOM PAD ASSEMBLY FPADBA625WRKZ 6 2 TURNTABLE TRAY 6 7 OPERATION MANUAL 6 ...

Page 34: ...3 4 11 6 4 1 10 4 3 4 5 4 7 6 2 6 1 2 2 7 1 1 12 4 10 7 3 7 3 4 1 1 13 7 9 7 5 7 11 7 6 7 8 7 8 4 4 7 10 1 5 4 8 7 7 1 4 1 4 4 6 7 8 4 2 1 9 1 8 2 3 2 3 2 3 2 3 7 10 7 4 4 9 7 10 7 1 4 12 1 7 7 10 7 10 7 2 7 2 1 2 1 11 7 10 4 14 7 1 1 2 1 3 1 1 ...

Page 35: ... Interchangeable 1 12 RMOTDA264WRZZ AT Turntable motor 1 12 RMOTDA186WRE0 AW Turntable motor Interchangeable 1 13 RTRN A746WRZZ BM Power transformer 1 13 RTRN A745WRZZ Power transformer for production use Interchangeable CABINET PARTS 2 1 GCABUB010WRPZ BH Outer case cabinet 2 2 GDAI A403WRWZ BA Base plate 2 3 GLEGPA104WREZ AF Leg OVEN PARTS 4 1 PHOK A130WRFZ AK Latch hook 4 2 LBNDKA172WRPZ AM H V ...

Page 36: ...DOOR AND CONTROL PANEL PARTS Actual wire harness may be different from illustration 6 6 6 5 5 6 5 7 5 3 3 3 6 7 3 2 5 3 1 5 3 2 5 2 5 5 5 9 5 9 5 9 5 4 5 8 3 1 3 1 4 3 1 5 3 1 2 3 1 3 3 1 1 3 1 1 1 3 1 1 2 3 3 5 1 ...

Page 37: ...KA077DRZZ AQ FPC 3 2 DPWBFC563WRKZ BK Control unit 3 3 XEPS730P08XS0 AB Screw 3mm x 8mm DOOR PARTS 5 1 FDORFA412WRTZ BF Door panel 5 2 PSHEPA336WRP0 AF Sealer film 5 3 FWAKPA462WRKZ BE Door frame assembly 5 3 1 GWAKPB081WRFZ AX Door frame 5 3 2 HDECQA334WRRZ BB Door decoration 5 4 HPNL A890WRRZ AP Door screen 5 5 GCOVHA382WRF0 AM Choke cover 5 6 LSTPPA139WRF0 AE Latch head 5 7 MSPRTA084WRE0 AB Lat...

Page 38: ...7WREZ 2 3 1 3 AF MSPRTA084WRE0 2 5 7 AB N NFANJA053WRFZ 1 4 3 AG NTNT A108WREZ 1 6 2 AW P PCOVPA311WRE0 1 4 7 AG PCUSGA532WRP0 1 4 8 AF PCUSUA191WRP0 1 4 9 AC PCUSUA410WRP0 1 4 11 AB PCUSUA455WRP0 1 4 12 AD PDUC A610WRF0 1 4 13 AR PDUC A936WRFZ 1 4 14 AV PHOK A130WRFZ 1 4 1 AK PPACGA084WRF0 1 4 10 AE PPACGA272WREZ 1 4 15 AG PSHEPA336WRP0 2 5 2 AF PSHEPB238WREZ 2 3 1 4 AM Q QFS TA013WRE0 1 1 3 AG Q...

Page 39: ......

Page 40: ...ALL RIGHTS RESERVED No part of this publication may be reproduced stored in retrieval systems or transmitted in anyform or by any means electronic mechanical photocopying re cording or other wise without prior written permission of the publisher ...

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