Amana Menumaster DS30E SERVICE MANUAL

Service

International Commercial Combination/Convection Microwave Oven with 230 V, 50 Hz

This Base Manual covers all International

Commerical Combination/Convection

Microwave Ovens with 230 V, 50 Hz.

Refer to individual Technical Sheet for information on specific models.

ACE530 UACE530 DS30E UDS30E UCA2000NT

Service Manual for Amana

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

RS5320016

Revision 0

December 2001

Important Information

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 manual. REVIEW ALL SERVICE INFORMATION IN THE

APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS.

Important Notices for Consumers and Servicers

To avoid risk of serious injury or death, repairs should not be attempted by an unauthorized personal, dangerous conditions (such as exposure to electrical shock) may result.

Amana will not be responsible for any injury or property damage from improper service procedures. If preforming service on your own product, assume responsibility for any personal injury or property damage which may result.

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

CONSUMER AFFAIRS DEPT. OR 1-319-622-5511 AMANA CALL and ask for AMANA, IOWA 52204 Consumer Affairs

If outside the United States contact:

AMANA ATTN: CONSUMER AFFAIRS DEPT AMANA, IOWA 52204, USA Telephone: (319) 622-5511 Facsimile: (319) 622-2180 TELEX: 4330076 AMANA CABLE: "AMANA", AMANA, IOWA, USA

WARNING

CAUTION

Recognize Safety Symbols, Words, and Labels

DANGER

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

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 or product or property

damage.

RS5320016 Rev . 0 2

Table of Contents

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

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

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

Product Information

Strirrer Blade ...................................................... 8

Blower/Fan Assembly ......................................... 8

Stirrer Cover ....................................................... 8

Door Interlock and Monitoring Switch .................... 8

Transformer High Voltage..................................... 8

High Voltage Capacitor ........................................ 8

High Voltage Diode (Rectifier) .............................. 8

Magnetron.......................................................... 8

Thermal Protectors ............................................. 8

Touch Panels ..................................................... 8

Triacs ................................................................ 8

RTD (Resistive Thermal Device) ........................... 8

Heating Elements ............................................... 8

Component Testing Procedures ................................. 9

Test Modes

Microwave Power Test ....................................... 13

Temperature Chart ............................................ 13

Convection Temperature Test ............................. 14

Convection Temperature Calibration .................... 14

Microwave Leakage Test.......................................... 15

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

Display Diagnostics

Error Codes ...................................................... 16

Service Test ........................................................... 17

Troubleshooting

Power up.......................................................... 19

Preheat/Convection Condition ............................ 19

Microwave Condition ......................................... 20

Disassembly

Door Handle ..................................................... 21

Outer Door ....................................................... 21

Inner Door Assembly......................................... 21

Hinge ............................................................... 21

Outer Case ...................................................... 22

Back Panel ...................................................... 22

Stirrer Cover ..................................................... 22

RTD (Resistance Thermal Device) ...................... 22

Top Touch Panel Assembly................................ 22

Side Touch Panel Assembly .............................. 23

High Voltage Circuit Board................................. 23

Interlock Switch Module .................................... 23

Adjustment ................................................ 23

Display Module................................................. 24

Magnetron........................................................ 24

Magnetron, Control, and

Fan Thermal Cutout (TCO) ................................. 24

Triacs .............................................................. 24

Microwave Blower Wheel and Motor ................... 24

Fan Blade ........................................................ 25

Transformer ...................................................... 25

Capacitor ......................................................... 25

Heater Box ....................................................... 25

Heating Elements ............................................. 25

Convection Fan and Motor ................................. 25

Fuse................................................................ 25

Power Cord ...................................................... 26

Light Socket ..................................................... 26

Line Filter......................................................... 26

Replacing Oven Light Bulb................................. 26

Component Location ............................................... 27

Appendix A

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

Amana • 2800 220thTrail • PO Box 8901 • Amana, Iowa • 52204 • Printed in the U.S.A.

3 RS5320016 Rev . 0

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.

Do not operate or allow oven to be operated with door open.

Make the following safety checks on all ovens to be serviced before activating the magnetron or other microwave source, and make repairs as necessary:

• 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

Before turning on microwave power for any service test or inspection within the microwave generating compartments, check the magnetron, waveguide or transmission line, and cavity for proper alignment, integrity, and connections.

Any failed 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.

Check microwave leakage to verify compliance with the federal performance standard should be performed on each oven prior to release to the 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.

WARNING

To avoid risk of electrical shock, personal injury or death; verify earthing instructions are followed.

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.

RS5320016 Rev . 0 4

Important Safety Information

5 RS5320016 Rev . 0

Important Safety Information

RS5320016 Rev . 0 6

Important Safety Information

7 RS5320016 Rev . 0

Product Information

Stirrer Blade

Distributes microwave energy throughout the cavity.

Blower/Fan Assembly

Circulates cooling air throughout the convection or microwave oven compartment and cavity.

Stirrer Cover

Covers and protects the stirrer blade assembly.

Door Interlock and Monitoring Switch

NOTE: When the line fuse is blown the Interlock Switch

Assembly must be replaced.

Interlock switch (assembly) mounts behind oven cavity front bulkhead. It is actuated by door hook and guide attached to the door.

Monitoring switch (contacts 7 and 8) is actuated by the door guide.

The secondary interlock switch (contacts 2 and 3) and primary interlock switch (contacts 4 and 5) are actuated by the door hook.

The secondary interlock switch is in series with the interlock monitoring switch in the monitor circuit.

If a malfunction occurs in the secondary interlock when door opens, current will flow through the monitor switch causing the oven fuse to open.

If a faulty door interlock switch has allowed current through the monitor switch, the switch assembly must be replaced (see interlock switch testing) before replacing fuse.

Transformer High Voltage

High voltage transformer is used in this unit, which supplies high voltage A.C. for operation of the magnetron tube.

High Voltage Capacitor

Doubles the A.C. output voltage from the high voltage transformer.

High Voltage Diode (Rectifier)

Is connected at the output side of the high voltage capacitor. It changes voltage from A.C. to D.C. It passes current in one direction and blocks it in the other. Also called a rectifier.

Magnetron

With filament voltage and high D.C. voltage from the output of the H.V. capacitor, diode junction the magnetron will put out an electomagnetic radio frequency of 2450 MHz to heat the food load in the oven.

Thermal Protectors

At a predetermined temperature the thermal cut-outs will open or close. The oven will indicate an error code in the display, initiate cooling fan operation, or prevent the generation of microwave energy.

• Magnetron thermal cut-out is mounted directly on the body of the magnetron

• Fan thermal cut-out is mounted directly on the exhaust duct

• Control thermal cut-out is mounted directly on the heater box

DANGER

To avoid severe personal injury or death avoid contacting any high voltage parts. The capacitors are at high voltage (4000 volt) potential and it is extremely important that they be grounded before handling.

RS5320016 Rev . 0 8

Touch Panels

Allows consumer operation and programming of oven.

Triacs

Triacs are controlled by high voltage circuit boards. Triacs control one side of the power line going to the high voltage power transformer and heating elements.

• Microwave triacs, heating elements A, and B triacs are mounted inside oven chassis behind oven cavity front bulkhead

RTD (Resistance Thermal Device)

Senses temperature inside oven cavity.

Heating Elements

Heating elements are used to produce convection heat.

Component Testing Procedures

WARNING

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

Illustration Component Test Results

MT2

MT1 GATE

Triac 1 (top) is for front element Triac 2 (middle) is for rear element Triac 3 (bottom) is for microwave

Thermal cutout Disconnect all wi res from TCO.

Diode

Triac Disconnect wires to triac.

Capacitor

Snubber assembly Disconnect wir es to snubber.

Measure resistance across ter m inals.

Control TCO.............................................

Fan TCO..................................................

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

Discharge Capacitor Remove diode lead from capacitor and

connect ohmmeter. Reverse leads for second test.

Measure resist ance from:

MT1 to MT2..........................................

MT1 to Gate..........................................

MT2 to Gate..........................................

All terminals to ground..........................

Measure voltage from:

MT1 to Gate Discharge Capacitor Remove wires from capac itor terminals and

connect ohmmeter, s et on highest resistance scale to terminals.

Also check between each terminal and

capacitor case.............................................

Measure resistance across terminals..........

Open at 300°F (149°C) and closed at 257°F (125°C) Open at 125°F (52°C) and closed at 160°F (71°C ) Open at 235°F (113°C) and closed at 150°F (66°C) Infinite resistance should be measured in one direction and 50KΩ or more in the opposite direc tion.

NOTE: Ohmmeter must contain a battery of 6 volts mini mum.

Caution - Do not operate oven with wire to terminal MT 2 removed.

Infinite Approximately 15 Ω, then reverse meter leads 30 Ω Infinite Infinite

0.8 VAC when energized If no voltage, check H.V. board and wi ring.

Between Terminals: Met er should momentarily deflect towards zero then return to over 5 MΩ. If no deflec tion occurs, or if continuous deflection occurs, replace capacitor.

Terminal to Case: Infinite resistance

Infinite

Magnetron

Microwave blower motor

Discharge Capacitor Remove wires from magnetron and connect

ohmmeter to terminals. Also check between each terminal and gr ound.

Remove all wires from motor.

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

Between Terminals: Less than 1 Ω Each terminal to gr ound measures

Infinite resistance. Note: This test is not conclusive. If oven does not heat and all other components test good replace the magnetron and retest.

Approximately 30 Ω

RS5320016 Rev. 0 9

Component Testing Procedures

WARNING

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

Illustration Component Test Results

COM

220

230

Transformer

Interlock switch

2 4

Convection blower motor

Door Closed

Secondary

Primary

Monitor

Discharge Capacitor

Remove all wires from terminals. Measure resist ance from:

230 to COM................................................

220 to COM................................................

230 to Ground.............................................

220 to Ground.............................................

Terminal 5 to 6............................................

Terminal 4 to Ground..................................

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

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

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

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

With door closed measure resi stance from:

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

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

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

Remove wires from motor. Measure resistance across

terminals A and B .......................................

< 1.5 Ω < 1.5 Ω Infinite Infinite < 1 Ω Approximately 70 Ω

Infinite Infinite Indicates continuity

Indicates continuity Indicates continuity Infinite

Approximately 20 Ω

Blue

IN OUT

Brown

Blue

Brown

Heating element assembly

Resistance ther mal device (RTD)

Lamp receptacle Test continuity of receptacle terminal s. Indicates cont inuity with bulb

Line filter

Disconnect wires from terminals. Measure resistance across heati ng

element.

Front element 1200 W ......................

Rear element 1500 W ......................

Front element 1100 W ......................

Rear element 1100 W ......................

Temperature

0°C (32°F)...................................................

177°C (350°F).............................................

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

Blue to Blue............................................

Brown to Brown......................................

Indicates continuity

44 Ω 35 Ω

48 Ω 48 Ω

Resistance 1000 Ω 1654 Ω

screwed in.

< 1 Ω < 1 Ω

RS5320016 Rev. 0 10

Component Testing Procedures

WARNING

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

Illustration Component Test Results

Side touch panel

Top touch panel

Continuity is indicated as 100 Ω and below.

Pad

1 2 3 4 5 6 7 8 9 0 Start Stop/Reset

Pad

Preheat Time Entry Temp Entry Power Level Stage Program Save Hidden Pad

Trace

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

Trace

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

Measurement

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

Measurement

Continuity Continuity Continuity Continuity Continuity Continuity Continuity

Wire har ness High voltage board

to display module harness

Display board

Test continuity of wires. Indicates cont inuity

Interlock

Pin 1

Connector

Side Touch Panel

Pin 1

Connector

H.V. board Connector

3.5 VAC should be indicated whenever the oven is plugged into a power supply.

If voltage is present and no display is indicated, replace display board. If no voltage is present, check wire harness connections and H.V. board.

RS5320016 Rev. 0 11

Pin 1

Top Touch Panel Connector

Component Testing Procedures

WARNING

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

H.V. board

Pin 1

Clip

Pin 1

Clip

Pin 1

Clip

Pin 50

Clip

Pin 1

Pin 28

Pin 1

Clip

Pin 1

Clip

In straight convection mode, both elements operate simultaneously. In combination mode, the rear element will operate simultaneously with either the microwave or front element.

Function Test Set-Up Meter

Probe Placement Results

Setting

Input to H.V. board At H.V. board Volts J1 pin 1 (Black wire)

Line voltage

& J1 pin 2 (Red wire)

Output to display

board

Disconnect J5 connector

Volts J5 pin 28 &

J5 pin 50

24 VDC

NOTE: For the following test, place oven in Service Test Mode (see page 27).

Relay Function Test Set-Up Meter

Probe Placement Results

Setting

K1 Cooling fan Disconnect

J2 connector

K2 Convection

motor

Disconnect J2 connector

K3 Cavity light Disconnect

J2 connector

K4 Heater A

(front)

Disconnect J3 connector

K7 Microwave Disconnect

J4 connector

K9 Heater B

(rear)

Disconnect J4 connector

Ohms J1 pin 1 (Black wire)

& J2 pin 4

Ohms J1 pin 1 (Black wire)

& J2 pin 3

Ohms J2 pin 1

& J2 pin 2

Test mode 5 off - no continuity

Test mode 5 on

< 1 Ω

Test mode 4 off - no continuity

Test mode 4 on

< 1 Ω

Test mode 6 off - no continuity

Test mode 6 on

< 1 Ω

Ohms E4 & J3 pin 3 Test mode 2 off - no continuity

< 1 Ω

Ohms J4 pin 4 &

J4 pin 5

Test mode 2 on Test mode 3 off - no continuity

Test mode 3 on

Ohms E6 & J4 pin 1 Test mode 1 off - no continuity

Test mode 1 on

< 1 Ω

RS5320016 Rev. 0 12

Test Modes

Microwave Power Test

(TRADITIONAL TEST METHOD)

Test Equipment Needed:

• Amana power test kit R0157397, Fahrenheit or

• Menumaster power test kit M95D5, Centigrade.

1. Place one rack in the oven using lowest rack position.

2. Fill the plastic container to the bottom of the 1000 ml. lines with cool tap water.

3. Using the thermometer; Fahrenheit or Centigrade, stir the water, measure and record the water temperature. IMPORTANT: Initial water temperature should be approximately 20°C (60°F).

4. Place the container on the center of the oven rack and heat the water for 62 seconds.

a. Close the door. b. Press Hidden Pad, 1, 3, 5, 7, 9. c. Press 3 to activate microwave mode. d. Display counts up to 62 seconds, and unit shuts off. e. Open the door.

5. Stir the water, measure and record the temperature of the water after heating time is completed.

6. Subtract the starting water temperature (Step 3) from the ending water temperature (Step 5) to obtain the temperature rise.

7. Refer to the Temperature Chart.

NOTES: • The IEC-705 test method requires precision measurements and equipment. It is not practical to

perform the IEC test in the field. To convert the traditional power test results to the approximate IEC-705 rating, take the traditional power test results and add 100 watts per magnetron for the unit being tested.

Example: 900  watts output using the traditional power test for model ACE530

+ 100  watts (100 watts X each magnetron) 1000  Approximate IEC-705 results

• Always perform power test three times for accuracy, changing the water after each test is performed.

• Variation or errors in the test procedure will cause a variance in the temperature rise. Additional power tests should be made if temperature rise appears marginal.

• Low line voltage will cause lower temperature rise.

Temperature Chart

ONE MINUTE, TWO SECONDS run time chart for units less than 1550 watts cooking power.

∆T Cooking ∆T Cooking (°F) Power Output (°F) Power Output

12 464 20 775 13 504 21 814 14 542 22 852 15 581 23 891 16 620 24 930 17 659 25 969 18 697 26 1007 19 736

∆T Cooking ∆T Cooking

(°C) Power Output (°C) Power Output

7 490 12 840 8 560 13 910 9 630 14 980 10 700 15 1050 11 770

13 RS5320016 Rev . 0

Test Modes

Convection Temperature Test

NOTE: It is absolutely necessary to own and use a

thermocouple type oven tester to accurately measure oven temperature. No other type of thermometer can take its place.

NOTE: Before testing an oven to check calibration,

inspect the RTD for proper mounting.

1. Place one wire rack in center position. Remove any other racks and utensils.

2. Clip thermocouple to the center rack and run lead outside oven door, or wrap thermocouple around rack and have tip of thermocouple extend upward towards top of cavity approximately 1".

3. Press PREHEAT ON/OFF pad.

4. Press PROGRAM SAVE pad.

5. Press TEMP pad.

6. Enter 230°C (450°F).

7. Allow oven to cycle one time.

8. Record high and low peaks from next two cycles.

NOTE: Display does not indicate if heating elements

are on or off.

Fahrenheit Example:

LOW HIGH

Cycle 1 440°F 460°F Cycle 2 439°F 461°F

879°F + 921°F = 1800°F

1800°F / 4 = 450°F average temperature

Convection Temperature Calibration

NOTE: It is normal for the average oven temperature to

vary from the oven setting by as much as 25°F (14°C). Difference will not effect cooking since recipes are written with this difference in mind.

Calibration

NOTE: Door must be closed.

1. Press HIDDEN PAD.

2. Press pads 1,3,5,7, 9.

3. Press "0" pad.

STG

ITEM POWER

C M

NOTE: Display will show the current offset setting.

4. Press the "0" pad to change the offset.

NOTE: Offset temperature range is +40°F to -40°F

and advances in 2 and 3° increments.

NOTE: Offset temperature range is +22°C to -22°C

and advances in 1 and 2° increments.

5. Press STOP/RESET pad to save offset changes. NOTE: Retest the oven after any offset changes are

made.

QTY

1 2 3 4

PREHEAT STANDBY

LMT

NOT READY

COOK LEVEL

Fahrenheit

Celsius

Celsius Example:

LOW HIGH

Cycle 1 230°C 240°C Cycle 2 230°C 240°C

450°C + 480°C = 930°C

930°C / 4 = 230°C average temperature

If the average temperature is too high or too low the oven temperature offset needs to be calibrated.

RS5320016 Rev . 0 14

Fahrenheit Example:

• Oven temperature is set for 450°F.

• Average of temperature test is 475°F.

• Offset setting must be reduced by 25°F.

• If offset is shown as 10°, press the "0" pad until -15 is shown in the display (10 – 25 = -15).

Celsius Example:

• Oven temperature is set for 230°C.

• Average of temperature test is 240°C.

• Offset setting must be reduced by 10°C.

• If offset is shown as 5°, press the "0" pad until -5 is shown in the display (5 – 10= -5).

Microwave Leakage Test

WARNING

Check for radiation leakage after servicing. Should the leakage be more than 4mW/cm2 inform Amana immediately. After repairing or replacing any radiation safety device, keep a written record for future reference, as required by D.H.H.S. and HEW regulations. This requirement must be strictly observed. In addition, the leakage reading must be recorded on the service repair ticket while at the customer’s location.

Equipment

• Electromagnetic radiation monitor

• 600 cc glass beaker

Procedure For Measuring Radiation Leakage

Note before measuring -

• Do not exceed meter full scale deflection. Leak monitor should initially be set to the highest scale.

• To prevent false readings the test probe should be held by the grip portion of the handle only.

• The scan speed is equal to one inch per antenna revolution or one inch per second if antenna speed is unknown.

• Areas to be checked are all door seal areas and any venting parts.

• Leakage with the outer panel removed, 4mW/cm2 or less.

• Leakage for fully assembled oven with door normally closed, 4mW/cm2 or less.

• Leakage for a fully assembly oven (before the latch switch (primary) is interrupted) while pulling the door, 4mW/cm2 or less.

Measurement With the Outer Case Removed

DANGER

To avoid risk of personal injury or death avoid contacting any high voltage components.

Whenever you replace the magnetron, measure for radiation leakage before the outer case is installed and after all necessary components are replaced or adjusted. Special care should be taken in measuring around the magnetron.

Measurement With a Fully Assembled Oven

After all components, including the outer panel are fully assembled, measure for radiation leakage around the door periphery, the door viewing window, the exhaust opening, and air inlet openings.

Record Keeping and Notification After Measurement

1. After any adjustment or repair to a microwave oven, a leakage reading must be taken. Record this leakage reading on the repair ticket even if it is zero.

2. A copy of the repair ticket and the microwave leakage reading should be kept by the repair facility.

1. Open the oven door and verify that there is only one rack in place on the bottom rack hooks.

2 . Pour 275 ± 15 cc (9 oz ± 1/2 oz) of 20 ± 5°C. (68±

9°F.) water in a glass beaker which is graduated to 600 cc and place the beaker in the center of rack.

3. Set the radiation monitor to 2450 MHz and use it following the manufacturer’s recommended test procedure to assure correct results.

4. While measuring the leakage, always use the two inch (5 cm) spacer supplied with the probe.

5. Press the start pad or turn on the timer and with the magnetron oscillating, measure the leakage by holding the probe perpendicular to the surface being measured.

15 RS5320016 Rev . 0

+ 32 hidden pages