Amana Menumaster DFS11E Service Manual

Service

This manual is to be used by qualified appliance technicians only. Maytag does not assume any responsibility for property damage or personal injury for improper service procedures done by an unqualified person.

MENUMASTER

C O M M E R C I A L M I C R O W A V E O V E N

This manual replaces RS5320015 Revision 0.

International Commercial Microwave Ovens

This Base Manual covers general information

Refer to individual Technical Sheet

for information on specific models

This manual includes, but is

not limited to the following:

2002 Models are listed in bold.

RS511 P1325801M

RS511 P1327805M RS511A P1327806M

RCS511 P1325802M

RCS511 P1327809M

RFS511 P1325803M

RFS511 P1327812M

RFS511SW2 P1325804M

RFS511SW2 P1327813M

URS511 P1325805M

URS511 P1327807M

URCS511 P1325806M

URCS511 P1327810M

URFS511 P1325807M

URFS511 P1327814M

DES11E P1325808M

DES11E P1327808M

DCS11E P1325809M

DCS11E P1327811M

DFS11E P1325810M

DFS11E P1327815M

16021518

Revision 0

October 2002

Important Information

Important Notices for Servicers and Consumers

Maytag will not be responsible for personal injury or property damage from improper service procedures. Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service information. IT IS THE TECHNICIANS RESPONSIBLITY TO REVIEW ALL

APPROPRIATE SERVICE INFORMATION BEFORE BEGINNING REPAIRS.

To avoid risk of severe personal injury or death, disconnect power before working/servicing on appliance to avoid electrical shock.

To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact:

Customer Service Support Center

Contact your local product distributor or vist the Web site at www.amanacommercial.com.

Recognize Safety Symbols, Words, and Labels

DANGER

DANGER—Immediate hazards which WILL result in severe personal injury or death.

WARNING

WARNING!

WARNING—Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION!

CAUTION—Hazards or unsafe practices which COULD result in minor personal injury, product or property

damage.

Table of Contents

Important Information ................................................ 2

Important Product Information ....................................4

Important Safety Information ......................................5

General Information

Placement of the Oven ........................................... 9

Radio Interference.................................................. 9

Earthing Instructions ...............................................9

Electrical Power Cord ...........................................10

Component Testing Procedures ............................... 11

Power Test (Traditional 1 Liter Test).......................13

Service Information

Proper Handling of Magnetron Tubes ....................14

Magnetron Failure Modes .....................................14

Equipment ...........................................................15

Procedure For Measuring Radiation Leakage.........15

Measurement With the Outer Panel Removed .......15

Measurement With a Fully Assembled Oven ..........15

Record Keeping and Notification

After Measurement ............................................15

Troubleshooting

Operating Instructions for the

Narda 8110B Radiation Monitor ..........................16

Radiation Monitor .................................................16

Operating Instructions for Holaday HI1501,

HI1510, and HI1710 ..........................................17

Troubleshooting Guide.............................................18

Disassembly Procedures

Outer Case Removal ............................................20

Control Assembly (painted models) .......................20

Control Assembly (stainless steel models).............20

Oven Light Removal .............................................20

Oven Light Socket Removal ..................................20

Splatter Shield Removal .......................................21

Antenna and Cradle..............................................21

Blower Motor or Wheel Removal ........................... 21

Door Disassembly ................................................21

Interlock Switch Assembly Removal ......................22

Removal of Power Transformer, Capacitor and

Diode (Rectifier) ................................................. 23

Magnetron Removal .............................................. 23

Magnetron Tube Thermal Cut-Out Replacement ...... 24

Oven Cavity Thermal Cut-Out ................................. 24

Oven Tray Replacement ........................................ 24

Removal of Line Filter ............................................ 25

Fuse Block .......................................................... 25

Appendix A

Owner's Manual ................................................. A-2

Important Product Information

WARNING

Precautions to be observed before and during servicing to avoid possible exposure to excessive microwave energy, or electrical shock disconnect power to oven.

WARNING

To avoid risk of electrical shock, injury, or death, make sure these earthing instructions are followed.

(A) Do not operate or allow oven to be operated with

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:

• Interlock operation

• Proper door closing

• Seal and sealing surfaces (arcing, wear, and other damage)

• Damage to or loosening of hinges and latches

• Evidence of dropping or abuse

service test or inspection within the microwave generating compartments, check the magnetron, waveguide 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 oven is released to the consumer.

(E) Check microwave leakage to verify compliance

with the federal performance standard should be performed on each oven prior to release to the consumer.

Earthing Instructions

WARNING

Do not remove earthing prong when installing earthed appliance in a home or business that does not have three wire earthing receptacle, under no condition is earthing prong to be cut off or removed. It is the personal responsibility of the consumer to contact a qualified electrician and have properly earthed three prong wall receptacle installed in accordance with appropriate electrical codes

Should a two prong adapter plug be required temporarily, it is the personal responsibility of the consumer to have it replaced with properly earthed three prong receptacle or the two prong adapter properly earthed by a qualified electrician in accordance with appropriate electrical codes.

Servicing of Earthed Products

The standard accepted color coding for earthing wires is GREEN or GREEN WITH YELLOW STRIPE. These earth leads are NOT to be used as current carrying conductors. It is extremely important that the technician replace any and all earths prior to completion of the service call. Under no condition should earth wire be left off causing a potential hazard to technicians and consumer.

Wiring

Good service practice is to never route wiring over terminals and/or sharp edges. This applies to any wiring without regard to the circuit voltage. Wire insulation material and thickness is designed and regulated for electrical spacing purpose only, but cannot always be relied upon because of possible cuts and/or abrasions, which can occur during servicing.

Important Safety Information

CAUTION

Read the following information to avoid possible exposure to microwave radiation:

The basic design of the Amana or Menumaster microwave ovens make it an inherently safe device to both user and servicer. However, there are some precautions which should be followed when servicing the microwave oven to maintain this safety. These are as follows:

1. Always operate the unit from an adequately earthed outlet. Do not operate on a two-wire extension cord.

2. Before servicing the unit (if unit is operable), perform the microwave leakage test.

3. The oven should never be operated if the door does not fit properly against the seal, the hinges or hinge bearings are damaged or broken; the choke is damaged, (pieces missing, etc.); or any other visible damage can be noted. Check the choke area to ensure that this area is clean and free of all foreign matter.

4. If the oven operates with the door open and produces microwave energy , take the following steps.

A. Tell the user not to operate the oven. B. Contact Maytag immediately.

5. Always have the oven disconnected when the outer case is removed except when making the "live" tests called for in this Service Manual. Do not reach into the equipment area while the unit is energized. Make all connections for the test and check them for tightness before plugging the cord into the outlet.

6. Always earth the capacitors on the magnetron filter box and H. V. Capacitor with an insulated-handle screwdriver before working in the high voltage area of the equipment compartment. Some types of failures will leave a charge in these capacitors and the discharge could cause a reflex action which could make you injure yourself.

7. In the area of the transformer, capacitor , diode, and magnetron there is HIGH VOL T AGE. When the unit is operating, keep this area clean and free of anything which could possibly cause an arc or earthing, etc.

8. Do not for any reason defeat the interlock switches. There is no valid reason for this action at any time; nor will it be condoned by Maytag.

9. IMPORTANT: Before returning a microwave to a customer, check for proper switch interlock action. The primary and secondary switches MUST open when the door is actuated. The monitor switch MUST close at a

10.Before returning a microwave to a customer, verify the door spacing is reasonably uniform along the top, bottom, and sides, and that it measures 1/8" or less.

1 1.The microwave oven should never be operated with:

• Any components removed and/or bypassed.

• Any of the safety interlocks found to be

defective.

• Any of the seal surfaces defective, missing,

or damaged.

12.To ensure that the unit does not emit excessive microwave leakage and to meet the Department of Health Human Service guidelines, check the oven for microwave leakage using Narda Model 8100, 8200, Holaday HI1500, HI1501 or Simpson 380M leakage monitor as outlined in the instructions. The maximum leakage level allowed is 4 mW/cm2.

13.If servicer encounters an emission reading over 4 mw/cm2 the servicer is to cease repair and contact the Maytag Service Department immediately for further direction. Maytag will contact the proper Government Agency upon verification of the test results.

/4" when the door is opened.

General Information

Placement of the Oven

Do not install microwave next to or above source of heat, such as a deep fat fryer. This could cause the microwave to operate improperly and could shorten the life of electrical components.

Install microwave on a level countertop surface. Do not block or obstruct oven filter. Allow access for

cleaning. All air vents must be kept clear during cooking. If air

vents are covered during operation the oven may overheat. In this case, a sensitive thermal safety device automatically turns the oven off. The oven will be inoperable until the oven has cooled sufficiently.

Radio Interference

Microwave oven operation may cause interference to radio, television, or similar equipment. Reduce or eliminate interference by doing the following:

• Clean the door and sealing surfaces of microwave oven according to instructions in “Care and Cleaning” section.

• Place radio, television, ect. as far as possible from the microwave oven.

• Use a properly installed antenna on radio, television, etc. to obtain stronger signal reception.

Earthing Instructions

This appliance MUST be earthed. If an electrical short circuit occurs, earthing reduces the risk of electric shock by providing an escape wire for the electric current. The cord for this appliance has a earthing wire with a earthing plug. Place the plug into an outlet that is properly installed and earthed. Do not use a two–prong adapter.

WARNING

To avoid risk of electric shock, personal injury or death, do not alter the plug and use earthing plug properly.

A–Allow at least 17.8 cm (7") of clearance around sides

of unit. B–Allow at least 17.8 cm (7") of clearance on top unit. C–Allow at least 6.5 cm (2-1/2") of clearance between

air discharge on back of unit and back wall. D–Allow at least 8 cm (3") inches from door front to edge

of countertop, to avoid accidental tipping of the unit. E–Place oven on a level surface a minimum of

85 cm (33-1/2") above the floor.

Consult a qualified electrician if you do not understand the earthing instructions or if you wonder whether the appliance is properly earthed.

Keep the electrical power cord dry and do not pinch or crush it in any way.

The wires in the power cord are colored in accordance with the following code:

• Green/Yellow: Earth

• Blue: Neutral

• Brown: Live

General Information

Plug

Electrical Power Cord

Receptacle

230 V / 13 AMP

Equipment requires a

230 VAC, 50 Hz, 13 amp power supply

Do not use a extension cord. If the product power cord is too short, have a qualified electrician install a three-prong receptacle. This unit should be plug into a separate 230 VAC / 50 Hz power supply. If other equipment is on the same circuit, an increase in cooking times may be required and fuse can be blown.

Model Identification

When contacting provide product information located on rating plate. Record the following:

Model Number: _____________________ Manufacturing Number: _____________________ Serial or S/N Number: _____________________ Date of purchase: _____________________ Dealer’s name and address: _____________________

Service

Keep a copy of sales receipt for future reference or in case warranty service is required. To locate an authorized servicer contact your local product distributor or vist the Web site at www.amanacommercial.com.

Warranty service must be performed by an authorized servicer. We also recommend contacting an authorized servicer, if service is required after warranty expires.

230 VAC, 50 Hz, 16 amp power supply

Equipment requires a

Plug

Parts and Accessories

Purchase replacement parts and accessories over the phone. To order accessories for your product contact your local product distributor or vist the Web site at www.amanacommercial.com.

Component Testing Procedures

Transformer

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect power to oven and discharge capacitor before servicing, unless testing requires it.

Illustration Component Test Results

Thermal cutout Disconnect all wires from TCO.

Capacitor

Diode assembly

Magnetron

Measure resistance across terminals.

Magnetron TCO..........................................

Cavity TCO.................................................

Discharge Capacitors

Remove wires from capacitor terminals and connect ohmmeter, set on highest resistance scale to terminals.

Also check between each terminal and capacitor case.

Discharge Capacitors

Remove diode lead from capacitor and connect ohmmeter.

Reverse leads for second test.

Discharge Capacitors

Open at 138°C (280°F) and

closed at 82°C (180°F)

Opens at 117°C (243°F)

Between Terminals: Meter should momentarily deflect towards zero then return to over 5 MΩ.Ifnodeflection occurs, or if continuous deflection occurs, replace capacitor.

Terminal to Case: Infinite resistance Infinite resistance should be measured in one direction and 50KΩ or more in the opposite direction.

NOTE: Analog meter must contain a battery of 6 volts minimum.

Between Terminals: Less than 1 Ω

Blue

White

IN OUT

Light Brown

Dark Brown

Remove wires from magnetron and connect ohmmeter to terminals. Also check between each terminal and ground.

Fan motor Remove all wires from motor.

Measure resistance across coil. ...............

Discharge Capacitors

1 COM

Primary

230 V

Line filter

H.V.

Secondary

Filament

OUT

Remove all wires from terminals. Measure resistance from:

Primary #1 to #2 .....................................

Secondary #4 to transformer base plate.

Filament #5 to #6 ....................................

Disconnect wire from terminals. Measure resistance of the following terminals:

Blue to White..........................................

Dark Brown to Light Brown....................

Each terminal to ground measures Infinite resistance. NOTE: This test is not conclusive. If oven does not heat and all other components test good replace the magnetron and re-test.

Approximately 40 Ω

Approximately < 1 Ω Approximately 83 Ω <1 Ω

<1Ω <1Ω

Component Testing Procedures

A B C J

F K

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect power to oven and discharge capacitor before servicing, unless testing requires it.

Illustration Component Test Results

Fault Codes

Pin #1

Interlock switch assembly

8 2

3 5

HV / LV board

P1 connector used for touch panel ribbon

Disconnect wires to switch. With door open measure resistance from:

Terminal 2 to 3 Secondary .................

Terminal 5 to 4 Primary......................

Terminal 7 to 8 Monitor ......................

With door closed measure resistance from:

Terminal 2 to 3 Secondary .................

Terminal 5 to 4 Primary......................

Terminal 7 to 8 Monitor ........................

After verifying or replacing the module, re-connect wires to switch and check operation of monitor circuit before operating the oven.

F1 − ............................................................

F2 − ............................................................

F3 − ............................................................

F4 − ............................................................

F5 − ............................................................

F6 − ............................................................

All Models

Line voltage to control board

P2 connector

Pin 1—Pin 3.......................................

Output drive voltage to triac

Triac terminals Gate—T1....................

Fan relay (controls blower motor, oven light)

Control board Terminals C—J.............

Cook relay

Control board Terminals F—K...........

Infinite Ω Infinite Ω Indicates continuity

Indicates continuity Indicates continuity Infinite Ω

Replace H.V. / L.V. Board Replace H.V. / L.V. Board Replace H.V. / L.V. Board Replace H.V. / L.V. Board Replace Touch Panel Replace H.V. / L.V. Board

Line voltage (All Conditions) 0 VAC (Idle)

0.9 VAC (Cook)

Line voltage (Idle) 0 VAC (Cook)

Line voltage (Idle) 0 volts (Cook)

Touch panel

Continuity is indicated as 100 Ω and below. Pin 1: is considered Ground

16021518 Rev. 0

Pad

1 2 3 4 5 6 7 8 9 0 Start Stop/Reset X2 Time Entry Hold Defrost Medium Medium HI

Pins

8&10 7&10 6&10 5&10 4&10 3&10 8&9 7&9 6&9 5&9 4&9 4&8 6&8 7&8 3&8 6&7 5&7 4&7

Measurement

Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity

+ 26 hidden pages

Amana Menumaster DFS11E Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual