Amana Amv6177aab, Amv6177aaq, Amv6177aaw, Amv6177aas Service Manual

Page 1
Microwave Oven Service Manual
AMV6177AAB AMV6177AAQ AMV6177AAS AMV6177AAW
CAUTION
Page 2
CAUTION
SAFETY PRECAUTIONS
PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE EXPOSURE
TO EXCESSIVE MICROWAVE ENERGY
a. Do not operate or allow the oven to be operated with the door open.
b. Make the following safety checks on all ovens to be serviced before activating the
magnetron or other microwave source, and make repairs as necessary; (1) Interlock operation, (2) proper door closing, (3) seal and sealing surfaces (arcing, wear, and other damage), (4) damage to or loosening of hinges and latches, (5) evidence of dropping or abuse.
c. Before turning on microwave power for any service test or inspection within the
microwave generating compartments, check the magnetron, wave guide or transmission line, and cavity for proper alignment, integrity, and connections.
d. Any defective or misadjusted components in the interlock, monitor, door seal, and
microwave generation and transmission systems shall be repaired, replaced, or adjusted by procedures described in this manual before the oven is released to the owner.
e. A Microwave leakage check to verify compliance with the Federal performance standard should
be performed on each oven prior to release to the owner.
• Proper operation of the microwave ovens requires that the magnetron be assembled to the 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.
Page 3
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.
MODEL AMV6177AAB
AMV6177AAQ AMV6177AAS AMV6177AAW
TABLE OF CONTENTS
(Page)
SAFETY PRECAUTIONS
SPECIFICATIONS
CAUTIONS
INSTALLATIONS
OPERATING INSTRUCTIONS
CONTROL PANEL
CONTROL PANEL INSTRUCTIONS
OVERALL CIRCUIT DIAGRAM
SCHEMATIC DIAGRAM (I)
SCHEMATIC DIAGRAM (II)
MATRIX CIRCUIT FOR TOUCH KEY BOARD
GENERAL INFORMATION FOR SERVICE
GENERAL PRECAUTIONS IN USE
TRIAL OPERATION
FEATURES AND SPECIFICATIONS FEATURES
SERVICE INFORMATION
PRECAUTIONS AND REPAIR SERVICE TIPS
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Inside front page
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5-3
6-1
6-1
6-1
6-1
7-1
7-1
MICROWAVE LEAKAGE TEST
POWER OUTPUT MEASUREMENT
DISASSEMBLY INSTRUCTIONS
INTERLOCK SYSTEM
INTERLOCK CONTINUITY TEST
TEST AND CHECKOUT PROCEDURES AND TROUBLE SHOOTING
A. TEST PROCEDURES
B. CHECKOUT PROCEDURES
C. TROUBLE SHOOTING
EXPLODED VIEW
REPLACEMENT PARTS LIST
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7-3
7-4
7-12
7-14
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7-15
7-15
7-19
7-22
8-1
9-1
Page 4
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
Effective Capacity of Oven Cavity Accessories
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1500W maximum (Microwave oven only) 950W (IEC60705) Adjustable 95W through 950W, 10 steps 2450 MHz ± 50 MHz 120 VAC, 60 Hz
13.5 Amp. (Microwave oven+Cook top lamps+Ventilation fan) Forced Air Cooling Rectification Voltage Double Half-Wave Choke System Magnetron Thermal Fuse:
Open at 150°C ± 6°C
Oven Cavity Thermostat:
Open at 145°C ± 6°C Fuse(20A) Primary Interlock Switch Secondary Interlock Switch Interlock Monitor 2M246-21CT Capacitor: 1.0µF, 2.1 KV AC Diode; 350mA, 9.0 KV 125 V, 20 W 125 V, 20 W Digital, up to 99 mim. 99 sec. (in each cooking stage) Tempered Safety Glass 2915/16"(W)x167/16"(D)x153/8"(H)
1.7 Cu.ft. Owner’s Manual & Cooking Guide, Installation Manual, Exhaust Adapter, Exhaust Damper, Mounting Kit and Two Filters, Rotating Ring Assembly, Metal Rack, Drip Pan.
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Page 5
CAUTIONS
Unlike other appliances, the microwave oven is 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 a 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.
MICROWAVE RADIATION
Personnel 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.
• 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.
ANTENNA
Gasket
COOLING FIN
FILAMENT TERMINALS
MAGNETRON CHASSIS GROUND
MAGNETRON
THE OVEN IS TO BE SERVICED ONLY BY PROPERLY QUALIFIED SERVICE PERSONNEL.
2-1
Page 6
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 the 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. If the 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.
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Page 7
CONTROL PANEL
OPERATING INSTRUCTIONS
For Model: AMV6177AAB
AMV6177AAQ AMV6177AAS AMV6177AAW
4-1
Page 8
CONTROL PANEL INSTRUCTIONS
1. DISPLAY: The Display includes a clock and
indicators to tell you time of day, cooking time settings and cooking functions selected.
2. MICRO: Touch this pad when setting Microwave
cooking.
3. CONV: Touch this pad when setting Convection
cooking.
4. BROIL: Touch this pad when setting broil cooking.
5. COMBI: Touch this pad when setting combination
cooking or preheat.
6. SENSOR POPCORN: Touch this pad when popping
popcorn in your microwave oven. The oven’s sensor will tell the oven how long to cook depending on the amount of humidity it detects from the popcorn.
7. SENSOR COOK: Touch this pad to cook baked
potato, frozen vegetable, fresh vegetable, canned vegetable, frozen entrée and rice. The oven’s sensor will tell the oven how long to cook depending on the amount of humidity coming from the food.
8. SENSOR REHEAT: Touch this pad to reheat
casserole, dinner plate, pizza slice and soup/sauce. The oven’s sensor will tell the oven how long to cook depending on the amount of humidity coming from the food.
9. CUSTOM PROGRAM: Touch this pad to recall one
cooking instruction previously programmed into memory.
10. AUTO COOK: Touch this pad to cook Bacon,
Fresh Roll & Muffin, Frozen Roll & Muffin, Beverage, Chicken Pieces, Hot Cereal.
11. AUTO DEFROST: Touch this pad to select food
type and defrost food by weight.
12. AUTO COMBI: Touch this pad when setting weight
combination cooking.
13. AUTO BROIL: Touch this pad when setting weight
broil cooking.
14. SOFTEN: Touch this pad to soften Butter, Ice
Cream, Cream Cheese or Frozen Juice.
15. MELT: Touch this pad to melt Butter, Chocolate, Cheese, Marshmallow.
16. Add 30 SEC.: Touch this pad to set and start quickly at 100% power level.
17. NUMBER: Touch number pads to enter cooking time, power level, quantities, weights, or cooking temperature.
18. KITCHEN TIMER: Touch this pad to set the kitchen timer.
19. CLOCK: Touch this pad to enter the time of day.
20. CONTROL SETUP: Touch this pad to change the oven’s default settings for sound, clock, display speed and defrost weight.
21. MORE: Touch this pad to add ten seconds of cooking time each time you press it.
22. LESS: Touch this pad to subtract ten seconds of cooking time each time you press it.
23. POWER: Touch this pad to select a cooking power level.
24. STOP/CLEAR: Touch this pad to stop the oven or to clear all entries.
25. ENTER/START: Touch this pad to start a function or enter all entries. If you open the door after oven begins to cook, touch ENTER/START again.
26. TURNTABLE ON/OFF: Touch this pad to turn off the turntable. OFF will appear in the display.
27. LIGHT HI/LO/OFF: Touch this pad to turn on the cooktop/countertop light.
28. LIGHT TIMER: Touch this pad to set the light timer.
29. VENT ON/OFF: Touch this pad to turn the fan on/off.
30. VENT 5-SPEED: Touch this pad to choose one of 5 fan speeds.
31. AUTO TIME SET: Touch this pad when setting ventilation time.(1, 3, 5, 10, 30 minutes.)
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Page 9
OVERALL CIRCUIT DIAGRAM
SCHEMATIC DIAGRAM (I) *Check the Model No.
For Model: AMV6177AAB
AMV6177AAQ AMV6177AAS AMV6177AAW
5-1
Page 10
SCHEMATIC DIAGRAM (II) *Check the Model No. (ADD Noise filter)
DISPLAY ERROR MODE
F1 THERMISTOR OPEN
F2 THERMISTOR SHORT FOR COOKING
F3 THERMISTOR SHORT AFTER COOKING
F4 SENSOR OPEN
F5 DAMPER SWITCH SENSING ERROR
For Model: AMV6177AAB
AMV6177AAQ AMV6177AAS AMV6177AAW
5-2
Page 11
MATRIX CIRCUIT FOR TOUCH KEY BOARD
For Model: AMV6177AAB
AMV617AAQ AMV6177AAS AMV6177AAW
5-3
Page 12
GENERAL INFORMATION FOR SERVICE
GENERAL PRECAUTIONS IN USE
A. 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, etc.) 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.
B. 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. Put a container filled with water (about 1 liter) into
the oven, and close the door tightly.
B. Set cooking time for 10 minutes by touching “1”
and then “0” three times. “1, 0, 0, 0” appears in the display window.
C. 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.
D. 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.
E. Continue operating the unit. Four long beep sound
signal is heard when the time is up. The unit will
shut off automatically. F. Confirm the water is hot. G. Finally, measure the output power according to
“POWER OUTPUT MEASUREMENT” on page 7-3.
FEATURES 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 95W to
950W can be selected by the touch control and electronic computer system.
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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.
B. 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 is applied:
(a) Make sure the interlock switch mechanism
is operating properly by opening and closing the door.
(b) Check microwave energy leakage must
be below the limit of 5 mW/cm2. (All service adjustments should be made for minimum microwave energy leakage readings).
(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. (c) 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.
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Page 14
MICROWAVE LEAKAGE TEST
CAUTIONS
• Be sure to check microwave leakage 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/cm2and 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/cm2. Always start measuring of an unknown field to assure safety for operating personnel from radiation leakage.
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 turntable.
• 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)
EQUIPMENT
TESTER (VOLTS-DC, AC, Ohmmeter)
• Microwave survey meter
- Holaday HI-1500 HI-1501
- Narda 8100 8200
• 600 cc non conductive material beaker (glass or plastic), inside diameter: approx. 8.5 cm (31/2in.)
• Glass thermometer: 100°C or 212°F (1 deg scale)
7-2
Page 15
MEASUREMENT WITH THE OUTER CASE
WATER LOAD
TURNTABLE
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/cm2. 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/cm2.
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. 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/cm2after 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.
POWER OUTPUT MEASUREMENT
(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 prior to the start of the test.
(4) The initial temperature (T1) of the water is (10±2)°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
a 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.
(6) The microwave power output P in watts is
calculated from the following formula :
4,187 X (T) + 0.55 X (T2- T0) X M
P =
T
• T2: Temperature after heating
0
: Temperature after bown
• T
• M : Weight of bowl
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.
7-3
Page 16
DISASSEMBLY INSTRUCTIONS
Figure 1
Control Panel
Screw
Power Transformer
(Relay 8)
(CN1)
(Relay 10)
(Relay 11)
(CN4)
(CN5)
(CN2)
Circuit Board
Figure 2
FPC Connector(S1)
Control Bracket
Circuit Board
Figure 3
IMPORTANT NOTES:
UNIT MUST BE DISCONNECTED FROM ELEC­TRICAL OUTLET WHEN MAKING REPAIRS, RE­PLACEMENTS, ADJUSTMENTS AND CONTIN­UITY 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 CONNE­CTIONS AND LEAD COLORS ARE CORRECTLY MATCHED ACCORDING TO THE OVERALL CIR­CUIT 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 three connectors (CN1, CN2, CN4,
CN5) and wire leads (Relay8, Relay10, Relay11)
from the circuit board.
(4) Remove 3 screws securing the circuit board.
(5) Remove the FPC connector from the terminal
socket following “HOW TO REMOVE THE FPC CONNECTOR” on the next page.
(6) Remove the circuit board from the control bracket
carefully.
7-4
Page 17
HOW TO REMOVE THE F.P.C. CONNECTOR
HOW TO INSERT 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.
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)
Figure 4
Figure 5
Figure 6
Figure 7
7-5
Page 18
B. REMOVING THE OUT CASE(Figure 8)
Vent Grille
Controller
(3 screws)
Door
Mounting Plate
(1 or 2 screws)
Out Case
Mount,All
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 air duct. (3) Remove the mounting plate by turning the screws
(1 or 2 screws) securing it to the out case. (4) Remove two screws on the left central edge and
one screws on the right central edge of Base
plate. Remove the Mount, All from the out case by
removing one screw securing it to the out case. (5) Remove the outcase with disconnecting power
cord connector.
7-6
Page 19
C. REMOVING THE DOOR INTERLOCK
Latch Board
Primary Interlock Switch
Interlock Monitor Switch
Secondary Interlock Switch
Latch Board
BK(CN1) RD(Oven TCO) RD(H.V.Transformer)
WH(from Convection Heater)
Primary Interlock Switch
Monitor Interlock Switch
Secondary Interlock Switch
PK(from P.C.B) GN
(
from P.C.B)
WH
(from H.V.Transformer)
RD/BK
(from H.V.Transformer/
fmn H.V.Transformer/Grill Heater)
Figure 9
Figure 10
WIRE COLOR
SYMBOL COLOR
WH BK BR RD BL PK GY GN N.P.
WHITE BLACK BROWN RED BLUE PINK GREY GREEN Not Provided
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.
7-7
Page 20
D. REMOVING MAGNETRON
Figure 11
Figure 13-a Figure 13-b
Figure 12
Vent Grille
Controller
(3 screws)
Door
Mounting Plate
(1 or 2 screws)
Out Case
Mount,All
(Figures 11 Through 13b)
(1) Remove the vent grille by loosening two screws.
(Figure 11) (2) Remove the outcase. See page 7-6. (3) Remove three tap tite screws securing the
magnetron to the wave guide. (4) Remove the magnetron VERY CAREFULLY.
NOTES:
• When removing the magnetron, make sure that its dome does not hit any adjacent parts, or it may be damaged.
• When replacing the magnetron, be sure to install the magnetron gasket in the correct position and be sure that the gasket is in good condition.
• 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/cm2. (All service adjustments should be made for minimum microwave energy leakage readings.)
7-8
Page 21
E. REMOVING STIRRER FAN
Figure 16
Figure 15
Figure 14
Door Screen
Figure 17
(Figures 14 and 15)
(1) Remove two screws securing it to the oven
upper plate by using drive screw. (2) Rotate slightly and pull out the stirrer fan cover. (3) Remove the stirrer fan.
F. REMOVING DOOR (Figure 16)
(1) Remove the vent grille by two screws securing it to
the outcase loosening.
(2) Lift up and draw the door.
NOTES:
• After replacing the door, be sure to check that the primary interlock switch, the secondary interlock switch and the interlock monitor switch is in good operating normally.
• After replacing the door, check for microwave energy leakage with a survey meter. Microwave energy leakage must be below the limit of 5mW/cm2. (With a 275 ml water load)
G. DISASSEMBLING DOOR (Figure 17)
(1) Remove the dielectric choke by using knife
blade or small screw driver, etc.
(2) Remove two screws securing it to the door handle.
CAUTION: Be careful not to damage door seal
plate with the screwdriver.
7-9
Page 22
H. ASSEMBLING DOOR
Space
(1 or 2 screws)
MOUNT, ALL
Figure 18
Figure 19-a
Figure 19-b
Figure 20
Figure 19-c
(1) When mounting the door assembly to the oven
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.
I. REMOVING THE VENTILATION MOTOR
(1) Remove the mounting plate by loosening
mounting plate screws (1 or 2 screws) securing it to the back plate. (See Figure 18)
(2) Remove MOUNT ALL loosening one screw
loosening one screw securing the ventilation Motor and back plate. (See Figure 19-a)
(3) Carefully pull the ventilation motor ASS'Y out of
the microwave oven. (See Figure 19-b)
J. REPLACING THE HUMIDITY SENSOR
(For sensor model only)
(1) Remove the sensor by removing two screws
securing it to the air duct. (See Figure 19-c)
(2) Mount the new humidity sensor to the air duct.
K. REMOVING GRILL HEATER (Figure 20)
(1) Remove the out case. (2) Remove the air duct by removing six screws
securing it to the oven front plate, guide air and
glasswool-L cover. (3) Disconnect the wire leads of air duct. (4) Remove the upper insulator by removing one
screw. (5) Remove four screws securing the heater terminal
and two net screws securing the heater barrier. (6) Remove the heater holding bracket and remove the
grill heater from the cavity.
7-10
Page 23
L. REMOVING THE TURNTABLE MOTOR
Wire Leads
Turntable Motor
Figure 22-b
Figure 20
Figure 23
Figure 21-a
(1) Remove the turntable. (2) Remove the turntable shaft VERY CAREFULLY
with a slotted screwdriver. (Figure 21)
(3) Remove the base plate by removing 7 screws
securing it to the oven cavity. (Figure 22-a)
(4) Disconnect the leadwire from the turntable motor
terminals.
(5) Remove the 2 screws securing the turntable motor
to the oven cavity ASS'Y. (Figure 22-b)
M. REMOVING CONVECTION HEATER
AND THERMISTOR (Figure 23)
(1) Remove the out case. (2) Remove the air duct by removing six screws
securing it to the oven front plate, guide air and
glasswool-L cover. (3) Disconnect the wire leads of air duct. (4) Remove the magnetron. (5) Remove the latch board assembly. (6) Remove the bottom plate by removing four screws. (7) Remove the four net screws securing chamber
assembly. (8) Lift the chamber assembly from the oven cavity. (9) Remove three screws securing the heater of the
chamber assembly. (10) Lift the convection heater from the chamber
assembly.
NOTES:
• Remove the leadwire from the turntable motor VERY CAREFULLY.
• Be sure to grasp the connector not the wires when removing.
7-11
Page 24
INTERLOCK SYSTEM
LATCH
LATCH BOARD
0-1/64"
0-1/64"
Latch Board
Primary Interlock Switch
Monitor Switch Interlock
Secondary Interlock Switch
Figure 24-a
Figure 24-b
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 Secondary Interlock Switch act as the final safety switch protecting the user from microwave energy. The terminals between “COM” 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.
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 24-a.
(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 24-b 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 the 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.
7-12
Page 25
TEST THE LATCH AND SWITCH SEQUENCE
(5) Open the oven door slowly. Watch the door latch,
the Secondary Switch. Release Rod and Lever on the switches to make sure they are zero to the body of the switches in the following sequence:
- Primary Interlock Switch
- Secondary Interlock Switch
- Interlock Monitor Switch
Adjust the latch board until the switches operate in 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
- Secondary Interlock Switch
- Primary 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.
(7) When you achieve the proper sequence of
switches in Steps 5 and 6, tighten the latch board screws at that point.
TEST THE MICROWAVE ENERGY LEAKAGE
Make sure the microwave energy leakage is below the limit of 1mW/cm2(with a 275 ml water load) and 5mW/cm2(with a 275 ml water load without the cabinet) when measured with a survey meter.
7-13
Page 26
INTERLOCK CONTINUITY 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.
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.
C. 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 meter 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.
COMPONENTS TEST PROCEDURE RESULTS
SWITCHES Check for continuity of the Door Door (Wire leads removed) switch with an Ohm-meter open closed
Primary Switch
Monitor Switch
Secondary Switch
COM
COM
NO
NC
COM
NO
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 FOR PRIMARY SWITCH TYPE NO. SZM-V16-FA-62 OR VP-532A-OF FOR MONITOR SWITCH TYPE NO. SZM-V16-FA-63 OR VP-533A-OF FOR SECONDARY SWITCH
7-14
Page 27
TEST AND CHECKOUT PRECEDURES AND TROUBLESHOOTING
Primary Winding
Secondary Winding
Filament Winding
Figure 24
- CAUTIONS -
- DISCONNECT THE POWER SUPPLY CORD FROM THE WALL OUTLET WHENEVER REMOVINGING THE CABINET FROM THE UNIT. PROCEED WITH THE TESTS ONLY AFTER DISCHARGING THE HIGH VOLTAGE CAPACITOR AND REMOVING THE WIRE LEADS FROM THE PRIMARY WINDING OF THE HIGH VOLTAGE TRANSFORMER. (SEE FIGURE 24)
- ALL OPERATIONAL CHECKS WITH MICROWAVE ENERGY MUST BE DONE WITH A LOAD (1 LITER OF WATER IN CONTAINER) IN THE OVEN.
A. TEST PROCEDURES
COMPONENTS TEST PROCEDURES RESULTS
MAGNETRON
(Wire leads are
removed)
HIGH-VOLTAGE
TRANSFORMER
(Wire leads are
removed)
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
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
Normal reading:
Less than 1 ohm.
Normal reading:
Infinite ohms.
NOTE: Replace the magnetron, if the magnetron checks and all of the high voltage component tests are good, but the unit still does not heat a load.
Normal readings:
Approx. 0.3 to 0.5 ohm. Less than 0.1 ohm. Approx. 65 to 120 ohms.
Normal readings:
Infinite ohms. Infinite ohms.
NOTE: A MICROWAVE ENERGY LEAKAGE TEST MUST ALWAYS BE PERFORMED WHEN THE UNIT IS
SERVICED FOR ANY REASON.
7-15
Page 28
COMPONENTS TEST PROCEDURES RESULTS
Figure 25-a
Figure 25-b
Figure 26-a
Figure 26-b
HIGH-VOLTAGE
CAPACITOR
HIGH-VOLTAGE
DIODE
1. Remove wire leads.
2. Measure resistance. (ohm meter scale: Rx1000)
(1) Terminal to terminal
Ohm-meter
(2) Terminal to case
Ohm-meter
1. Measure continuity. Forward. (ohm meter scale: Rx1000)
Normal: Momentarily indicates several ohm, and then gradually returns to infinite
Normal: Infinite.
Normal:Continuity. Abnormal: Infinite.
HEATER ELEMENT
Ohm-meter
1. Measure continuity. Reverse. (ohm meter scale: Rx1000)
Ohm-meter
1. Remove wire leads.
2. Measure resistance. (ohm meter scale:Rx1)
Normal: Infinite. Abnormal: Continuity.
Normal: Approximately
Conv. HTR
15-25
Abnormal: Infinite or several.
Grill HTR
25-30
7-16
Page 29
COMPONENTS TEST PROCEDURES RESULTS
For Model AMV6177AAB AMV6177AAQ AMV6177AAS AMV6177AAW
Figure 27
1 2
3
Figure 29
1 2 3 4 5 6 7 8 9 10 11 12 13
Figure 28
TOUCH KEY
BOARD
Measure the resistance between terminal pins of connector KEY CONNECTOR.
NOTE:
When reconnecting the FPC connector, make sure that the holes on the FPC connector are properly engaged with hooks on the plastic fastener.
MATRIX CIRCUIT FOR
TOUCH KEY BOARD
CONNECTOR(KEY CON)
Resistance
value
FPC CONNECTOR
When touched
Less than 400 ohms
Top
When not touched
More than 1 mega ohm
SENSOR
(For sensor model only)
1. Remove the 3 pin connector from PCB.
2. Measure resistance across pins 1 & 2.
3. Across pins 2 & 3. (ohm meter scale:Rx1)
7-17
Normal: Approximately
1 & 2
3.1 Kohm
at 68 ± 35°F Abnormal: Infinite or several.
2 & 3
Page 30
COMPONENTS TEST PROCEDURES RESULTS
FAN MOTOR
DAMPER MOTOR
CIRCULATION
MOTOR
VENTILATION MOTOR
SYNCHRONOUS
MOTOR
1. Remove wire leads.
2. Measure resistance. (ohm meter scale: Rx1)
1. Remove wire leads.
2. Measure resistance. (ohm meter scale: Rx1)
1. Remove wire leads.
2. Measure resistance. (ohm meter scale: Rx1000)
Normal: Approximately
Fan
35-55
ohm
Abnormal: Infinite or several.
Normal: Approximately 25 to 45 ohm
Normal: Approximately 3 to 4 Kohm
Damper
2.5-3.5 Kohm
Cir
25-40
ohm
THERMISTOR
1. Remove the connector from PCB.
2. Measure resistance across pins 1 & 3. (ohm meter scale: Rx1)
Abnormal: Infinite or several.
Normal: Approximately 250 to 350 Kohm at 68 ± 35°F
Abnormal: Infinite or several.
7-18
Page 31
COMPONENTS TEST PROCEDURES RESULTS
RELAY 8
1. Measure continuity. (ohm meter scale: Rx1)
2. Remove the lead wires and operate oven at power level 1 through power level 10.
POWER
LEVEL
1 2 3 4 5 6 7 8 9
10
4 sec 6 sec
8 sec 10 sec 12 sec 14 sec 16 sec 18 sec 20 sec 22 sec
18 sec 16 sec 14 sec 12 sec 10 sec
8 sec 6 sec 4 sec 2 sec
0
RELAY 10,11
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, NOT THE WIRES.
1. Measure continuity. (ohm meter scale: Rx1)
2. Remove the lead wires and operate oven at Convection Cooking.
Convection
Cooking Start
OFF
B. 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.
Fuse blows immediately after the door is opened.
Fuse blows when the door is closed and START key is touched.
Improper operation of the primary interlock, secondary interlock switches and/or the interlock monitor switch.
Malfunction of the high voltage transformer; the high 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 the all Interlock switches, PCB Ass’y and the fuse at the same time. After replacing the the all Interlock switches, PCB Ass’y, Fuse with new ones, make sure that they are correctly connected.
• Check for microwave energy leakage according to INTERLOCK ADJUSTMENT PROCEDURES on page 7­12 when the primary interlock, secondary interlock switches and/or the interlock monitor switches are adjusted or replaced.
7-19
Page 32
(2) CHECKOUT PROCEDURES FOR RELAY.
- PROBLEM (A) -
FAN motor and oven lamp turn on without touching
START key when the door is closed.
NO
GOOD
YES
Remove the mate connector of I/O CON from the circuit board. Does the unit still operate?
NO
Replace the circuit board
Defective
RELAY1
Replace RELAY1
YES
- PROBLEM (B) -
FAN motor and oven lamp turn on When the door is
closed and START key is touched.
7-20
YES
GOOD
NO
Measure the voltage at pin NO. 35 of U01 Voltage reading: 0 Vdc 10 of U03 Voltage reading: about 15V
NO
Defective Replace the circuit board
RELAY1 or poor
connection of
RELAY1
Replace
RELAY1 or correct
the connection.
YES
Page 33
(3) CHECKOUT PROCEDURES FOR CIRCUIT
BOARD 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.
2) The unit with a normal relay continuously operates.
3) Proper temperature measurement is not obtained.
4) The buzzer does not sound or continues to sound.
5) Some segments of one or more digits do not light up, or they continue to light up, or segments light when they should not.
NOTE: A MICROWAVE ENERGY LEAKAGE TEST MUST ALWAYS BE PERFORMED WHEN THE UNIT IS
SERVICED FOR ANY REASON.
6) Wrong figures appear.
7) The figures of all digits.
8) Some of the indicators do no flicker light up.
9) The clock does not keep time properly.
7-21
Page 34
plugged into wall outlet.
2. FUSE (See CHECKOUT PROCEDURES FOR FUSE BLOWING: on page 7- 18)
3. OVEN CAVITY THERMOSTAT
Check: 1. POWER SUPPLY
PROBLEM - A: PLEASE SET TIME OF DAY does not appear in display window when power supply cord is
C. TROUBLE SHOOTING
Before following this troubleshooting read TRIAL OPERATION on page 6- 1.
• DISPLAY Problems, A thru C
• HELP UP Problems, D thru E • BUZZER Problems, F
1
7-22
correct indications when programmed.
PROBLEM - B: Display does not show correct numbers and/ or
1
Page 35
no heating is produced in oven load.
Check: 1. TOUCH KEY BOARD (START KEY FUNCTION)
PROBLEM - C: Display does not start countdown when START key is touched.
1
Check: 1. AIR VENTS
PROBLEM - D: Unit operation seems to be normal but
1
7-23
Page 36
START key is touched for HIGH POWER cooking.
2. THERMOSTAT
Check: 1. PRIMARY AND SECONDARY INTERLOCK SWITCHES
PROBLEM - E: Unit does not heat up even if display counts down when
1
2
7-24
Page 37
stages or at end of cooking
PROBLEM - F: No buzzing when touching the key, between
1
7-25
Page 38
2. FUSE
Check: 1. POWER SUPPLY
PROBLEM - G: Ventilation fan does not operate when FAN HIGH/ LOW key is touched.
1
7-26
Page 39

#EV#

EXPLODED VIEW
DOOR PARTS
FOR MODEL: AMV6177AAB
AMV6177AAQ AMV6177AAW
1005
1003
1009
1011
1000
W105
1008
W109
Serial Number ldentification
(Figure Check First & Second) ex) 1 0
W150
1004
1006
1007
FOR MODEL: AMV6177AAS
1005
1008
1381
1000
1009
1011
1004
W106
1006
1007
W105
8-1
Page 40

#EV#

* 07
* 07
2004
2004
2000
2002
2381
2381
2006
2006
2008
2018
W130
W105
W138
2008
2018
* Check the Serial No.
* Check the Serial No.
CONTROLLER PARTS
FOR MODEL: AMV6177AAB
AMV6177AAQ AMV6177AAW
10
Serial No.
Check the rating label of Model and order SVC parts according to the Serial No.
FOR MODEL: AMV6177AAS
8-2
Page 41

#EV#

* 07
* 07
2004
2004
2000
2002
2381
2381
2006
2006
2008
W130
W105
W138
2008
* Check the Serial No.
* Check the Serial No.
CONTROLLER PARTS
FOR MODEL: AMV6177AAB
AMV6177AAQ AMV6177AAW
11
Serial No.
Check the rating label of Model and order SVC parts according to the Serial No.
FOR MODEL: AMV6177AAS
8-3
Page 42

#EV#

W108
W108
3031
3001
3103
3029
3005
W178
W202
3024
3010
W138
W138
W142
For Model
AMV6177AAB AMV6177AAS
For Model
AMV6177AAW AMV6177AAQ
W142
3026
3011
3025
W121
3006
3032
W105
3009
3045
3037
6000
OVEN CAVITY PARTS
8-4
Page 43

#EV#

4001
4000
4002
W111
4003
4002
4004
LATCH BOARD PARTS
8-5
Page 44

#EV#

INTERIOR PARTS (I)
3048
3002
5411
3012
3008
3034
W125
W124
W109
W141
5403
W121
5024
5062
3206
W109
3207
W121
5021
W101
W105
5023
5029
5049
5003
5007
5008
W109
5002
5012
5009
W110
5052
5000
5018
W101
W109
5035
5407
W124
W121
W141
3208
5402
5401
W108
9002
9001
5028
W105
W105
5039
W150
8-6
4009
5409
W123
5068
W105
W123
5705
W121
W101
5019
5404
Page 45

#EV#

*01
*04
3045
5045
W117
W117
5056
3021
W109
5011
3033
5037
3027
5410
W150
5016
3051
5006
5010
5001
5017
W105
5014
W101
W109
W150
W109
W109
* Check the Serial No.
* Check the Serial No.
INTERIOR PARTS (II - I)
10
Serial No.
Check the rating label of Model and order SVC parts according to the Serial No.
8-7
Page 46

#EV#

*01
*04
3045
5045
W117
W117
5056
3021
W109
5011
3033
5037
3027
5410
W150
5016
3051
5006
5010
5001
5041
W144
5014
W101
2018
W109
W150
W109
W109
* Check the Serial No.
* Check the Serial No.
* Check the Serial No.
INTERIOR PARTS (II - II)
11
Serial No.
Check the rating label of Model and order SVC parts according to the Serial No.
8-8
Page 47

#EV#

VINYL
BAG
6011
6009
6010
6008
INSTALLATION PARTS
8-9
Page 48
P/NO : 3828W5S4606
Printed in Korea
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