Kelvinator KM-200D Service Manual

Service Manual

Microwave Oven

Model: KM-200D

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SAFETY AND PRECAUTIONS........................................................................................................... 2

1. FOR SAFE OPERATION .............................................................................................................. 2

2. FOR SAFE SERVICE PROCEDURES ......................................................................................... 2

SPECIFICATIONS............................................................................................................................... 3

EXTERNAL VIEW................................................................................................................................ 4

1. OUTER DIMENSION..................................................................................................................... 4

2. FEATURE DIAGRAM.................................................................................................................... 5

3. CONTROL PANEL........................................................................................................................ 6

INSTALLATION................................................................................................................................... 7

OPERATIONS AND FUNCTIONS....................................................................................................... 8

DISASSEMBLY AND ASSEMBLY...................................................................................................... 9

INTERLOCK MECHANISM AND ADJUSTMENT............................................................................... 16

TROUBLE SHO OTING GUID E ....... ... ......... ... .................. ... .................. .. ......... ... ... ......... ... ......... ... ... .. 17

MEASUREMENT AND TEST............................................................................. ......... ......... ......... ..... . 21

1. MEASUREMENT OF THE MICROWAVE POWER OUTPUT ...................................................... 21

2. MICROWAVE RADIATION TEST................................................................................................. 22

3. COMPONENT TEST PROCEDURE............................................................................................. 23

WIRING DIAGRAM.............................................................................................................................. 24

PRINTED CIRCUIT BOARD................................................................................................................ 25

1. CIRCUIT CHECK PROCEDURE .................................................................................................. 25

2. P.C.B. CIRCUIT DIAGRAM........................................................................................................... 29

3. P.C.B. LOCATION NO .................................................................................................................. 30

EXPLODED VIEW AND PARTS LIST................................................................................................. 32

1. DOOR ASSEMBLY....................................................................................................................... 32

2. CONTROL PANEL ASSEMBLY.................................................................................................... 32

3. TOTAL ASSEMBLY....................................................................................................................... 32

(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 power to the microwave oven 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.

PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE
EXPOSURE TO EXCESSI VE MICR OWAV E ENERGY

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SAFETY AND PRE CAU T IONS

1. FOR SAFE OPERATION

Dam age that allows the microwave energy (that cooks or heats the food) to escape will re s u lt in poor cooking and m ay cause
serious bodily injury to the operator.
IF ANY OF THE FOLLO W ING CONDITIONS EXIST, OPERATOR MUST NOT USE THE APPLIANCE.
(Only a trained service personnel should m ake repairs.)

1) A broken door hinge.

2) A broken door viewing screen.

3) A broken front panel, oven cavity.

4) A loosened door lock.

5) A broken door lock.
The door gasket plate and oven cavity surface should be kept clean.
No grease, soil or spatter should be allow ed to build up on these surfaces or inside the oven.
DO NOT ATTEMPT TO OPERATE THIS APPLIANCE WITH THE DOOR OPEN. The microwave oven has concealed switches
to make sure the power is turned off when the door is opened. Do not attempt to defeat them .
DO NOT ATTEMPT TO SERVICE THIS APPLIANC E UNTIL YO U HAVE READ THIS SERVICE M ANUAL.

2. FOR SAFE SERVICE PROCEDURES

1) If the oven is operative prior to servicing, a m icrowave emission check should be perform ed prior to servicing the oven.

2) If any certified oven unit is found to servicing, a microwave emission check should be performed prior to servicing the oven.

(a) inform the manufacturer, im porter or assembler,
(b) repair the unit at no cost to the owner,
(c) attem pt to ascertain the cause of the excessive leakage,
(d) tell the owner of the unit not to use the unit until the oven has been brought into compliance.

3) If the oven operates with the door open, the service person should tell the user not to operate the oven and contact the

manufacturer im m ediately.

IMPORTA NT

The wire in this mains lead coloured in accordance with the following code.
Green-and-yellow : Earth

Blue : Neutral
Brown : Live

As the colours of the wires in the m anins lead of this appliance may not correspond with the coloured markings
identifying the terminals in your plug, proceed as follows.
The wire which is coloured green-and-yellow m ust be connected to the termianl in the plug which is marked with the
letter ‘E’, earth symbol or coloured green-and-yellow.
The wire which is coloured blue m ust be connected to the terminal which is marked w ith the letter ‘N’ or
coloured black.
The wire which is coloured brow n m ust be connected to the terminal w hich is m arked with the letter ‘L’ or
coloured red.

This oven is designed for counter-top use only.

NOTE

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SPECIFICATIONS

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SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

MODEL KM-200D

POW ER SU PPLY 230V-50Hz, SINGLE PHA SE W ITH EARTHING

POW ER
CONSUMPTION

MICROWAVE1200W
GRILL

COMBINATION
MICROWAVE ENERGY OUTPUT800W
MICROWAVE FREQUENCY 2450MHz
OUTSIDE DIMENSIONS (W X H X D)465 x 279 x 360mm (18.3 x 11.0 x 14.2 in.)
CAVITY DIMENSIONS (W X H X D)290 x 220 x 306 mm (11.4 x 8.7 x 12.0 in.)
NET WEIGHTAPPROX. 13Kg ( 28.7lbs.)
TIMER 59 min. 00 sec.
FUNCTION SELECTIONS MICROWAVE
POW E R SELEC TIONS 5 LEVELS
CAVITY VOLUME0.7 Cu.Ft.

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EXTERNAL VIEW

1. OUTER DIMENSION

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EXTERNAL VIEW

2. FEATURE DIAGRAM

1. DOOR SEAL

Door seal surfaces prevent microwaves escaping from the oven cavity.

2. DOOR HOOK

When door is closed, it will automatically shut off. If door is opened while oven is operating, m agnetron tube will
immediately stop operating.

3. DOOR SCREEN

Allows viewing of food. The screen is transparent to light, but prevents m icrowaves escaping.

4. SPATTER SHIELD

Protects the microwave outlet from splashes of cooking foods.

5. OVEN LAMP

Automatically turns on during oven operating.

6. SAFETY INTERLOCK SYSTEM

7. CONTROL PANEL

8. GLASS COOKING TRAY

Made of special heat resistant glass. The tray can be easily removed for cleaning. Make sure it is correctly positioned
(indentation) before operating. P lace food in a suitable container(dish) on the tray.

9. OVEN FRONT PLATE

10. DOOR OPENING BUTTON

To open the door, push the door opening button.

11. ROLLER GUIDE

Supports the glass cooking tray.

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EXTERNAL VIEW

3. CONTROL PANEL

1. Display -

Cooking tim e, power level, indicators and present tim e are displayed.

2. D ef ro s t -

Used to defrost foods by weight or time.

3. Power -

U sed to s e t power le vel.

4. Auto cook -

Used to cook using a program or to reheat.

5. S tart/Easy cook -

Used to start the oven operation and also increase the reheat time by 30 seconds.

6. S top/C lear -

Used to stop the oven operation or to erase all entries.

7. C lock -

U s ed to s et c lo ck.

8. D ial Knob -

Used to set the time and weight.

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INSTALLATION

1. Steady, flat location

This microw ave oven should be set on a steady, flat surface.
This microw ave oven is designed for counter top use only.

2. Leave space behind and side

All air vents should be kept a clearance. If all vents are covered during operation, the oven may overheat and, eventually,
cause failure.

3. Away from radio and TV sets

Poor television reception an d radio interfere nc e m ay result if the oven is located close to a TV, radio, an tenna or feeder a nd so on .
Position the oven as far from them as possible.

4. Away from heating appliances and water taps

Keep the oven away from hot air, steam or splash when choosing a place to position it, or the insulation might be adversely
affected and breakdowns occur.

5. Power supply

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Check your local pow er source.

This m icrowave oven requires a current of approximately 6 am peres, 230 Volts, 50 Hz.

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Power supply cord is about 0.8 meters long.

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The voltage used must be the sam e as specified on this oven. Using a higher voltage may result in a fire or other accident

causing oven dam age. Using low voltage will ca us e s lo w c oo k ing . We a r e n o t re s ponsible for dam age resulting from use
of this oven with a voltage of ampere fuse other than those specified.

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This appliance is supplied with cable of special type, which, if damaged, must be repaired with cable of same type.

Such a cable can be purchased from Yapay and must be installed by a Qualified Person.

6. Examine the oven after unpacking for any dam age such as:

A m isaligned door, broken door or a dent in cavity.
If any of the above are visible, DO NOT INSTALL, and notify dealer immediately.

7. Do n o t o pe ra t e the ov e n if it is c o lde r t h an r o o m tem pe ra t u re

(This m ay occur during delivery in cold w eather.) Allow the oven to become room temperature before operating.

This appliance m ust be earthed. In the event of an electrical short circuit, earthing reduces the risk of the electric shock by
providing an escape wire for the electric current. This appliance is equipped with a cord having a earthing wire with a earthing
plug. The plug m ust be plugged into an outlet that is properly installed and earthed.

WARNING

Improper use of the earthing plug can result in a risk of electric shock. Consult a qualified electrician or serviceman if
the earthing instructions are not completely understood, or if doubt exists as to whether the appliance is properly
earthed, and either : If it is necessary to use an extension cord, use only a 3-wire extension cord that has a 3-blade
earthing plug, and a 3-slot receptacle that will acc e p t t h e p lu g o n th e appliance. The m arked rating of the extension
cord should be equal to or greater than the electrical rating of the appliance, or Do not use an extension cord.

EARTHING INSTRUCTIONS

8

1. Connect the main lead to an electrical outlet.

2. After placing the food in a suitable container, open the oven door and put it on the glass tray.
The glass tray must always be in place during cooking.

3. Close the door securely.

4. When the oven door is opened, the light turns off.

5. The oven door can be opened at any time during operation by touching the door release button on the control panel.
The oven will automatically shut off. To restart the oven, close the door and then touch Start button.

6. Each time a button is touched, a BEEP will sound to acknowledge the touch.

7. The oven automatically cook on full power unless set to a lower power level.

8. The display will show “:0” when the oven is plugged in.

9. Time clock returns to the present time when the cooking time ends.

10. When the Stop/Clear button is touched during the oven operation, the oven stops cooking and all information retained.

To erase all information (except the present time), touch the

Stop/Clear button

once more. If the oven door is opened

during the oven operation, all information is retained.

11. If the Start button is touched and the oven does not operate, check the area between the door and door seal

for obstructions and make sure the door is closed securely.
The oven will not start cooking until the door is completely closed or the program has been reset.

Wattage output chart

The power level is set by pressing the Power button. The chart shows the display, the power level and the percentage of power.

Touch Power button Power level (Display) Approximate Percentage of Power

Once P-HI 100 %

Twice P-80 80 %
3 times P-60 60 %
4 times P-40 40 %
5 times P-20 20 %

OPERATIONS AND FUNCTIONS

Make sure the oven is properly installed and plugged into the electrical outlet.

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DISASSEMBLY AND ASSEM BLY

Cautions to be observed wh en trouble shooting

Unlike many other appliances, the microwave oven is high-voltage, high-current equipment.
It is completely safety during normal operation. However, carelessness in servicing the oven
can result in an electric shock or possible danger from a short circuit.
You are asked to observe the following precautions carefully.

1. Always remove the power plug from the outlet before servicing.

2. Use an insulated screwdriver and ware rubber gloves when servicing the high voltage side.

3. Discharge the high voltage capacitor before touching any oven components or wiring.

(1) Check the earthed.

Do not operate on a two-wire extension cord.
The microwave oven is designed to be used with earthed.
It is imperative, therefore, to makes sure it is earthed properly
before beginning repair work.

(2) Warning about the electric charge in the high voltage capacitor.

For about 30 seconds after the operation stopped and electric
charge remains in the high voltage capacitor. When replacing
or checking parts, short between oven chassis and the negative
high terminal of the high voltage capacitor, by using a properly
insulated screwdriver to discharge.

4. When the 12A fuse is blown out due to the operation of the monitor
switch; replace primary interlock switch, secondary interlock switch
and interlock monitor switch.

5. After repair or replacement of parts, make sure that the screws are

properly tightened, and all electrical connections are tightened.

6. Do not operate without cabinet.

CAUTION

WARNING

Service personnel should rem ove their watches whenever working close to or replacing the m agnetron.

W hen servicing the appliance, need a care of touching or replacing high potential parts because of electrical shock or
exposing m icrowave. These parts are as follows - HV Transformer, Magnetron, H V Capacitor, HV D iode. HV Fuse.

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D ISASSE MBLY AND A SSE M B LY

1. To remove cabinet

1) Remove three screws on cabinet back.

2) Push the cabinet backward.

2. To remove door assembly

1) Remove a screw which secure the stopper hinge top.

2) Remove the door assembly from top plate of cavity.

3) Reverse the above for reassem bly.

NOTE

After replacing the door assembly, perform a check of correct alignm ent with the hinge and cavity front plate.

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D ISASSEMBLY AN D ASSEMBLY

3. To remove door parts.

(1) KM-200D

REF. NO PART CODE PART NAME DESCRIPTION QTY REMARK

A01 3512203800 FRAME D OO R ABS X R-401 H-2938 1
A02 3517003050 BARRIER-SCREEN *O ACRYL 1
A03 3515304610 SUPPO RTER B ARR -S*O PP 1
A04 3515204100 STOPPER HING E *T AS KOR-63150S 1
A05 3511705500 DOOR W ELD AS KOR-61150S 1
A06 3517002800 BARRIER-SCREEN *I POLYESTER T0.1 1
A07 3512300200 GASKET DOOR PP 1
A08 3513100700 HOOK POM 1
A09 3515101300 SPRING HO OK PW1 1

REF. NO PART CODE PART NAME DESCRIPTION QTY REMARK

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D ISASSE MBLY AND A SSE M B LY

1) Remove the gasket door from door plate.

2) Remove the barrier screen inner from door plate.

3) Remove the door frame from door plate.

4) Remove the stopper hinge top from door plate.

5) Remove the spring and the hook.

6) Remove the supporter barrier screen outer from door fram e.

7) Remove the barrier screen outer from door frame.

8) Reverse the above steps for reassembly.

4. Method to reduce the gap between th e door seal and the oven front surface.

1) To reduce gap located on part ‘A’.

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Loosen a screw on stopper hinge top, and then
push the door to contact the door seal to oven front surface.

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Tighten a screw.

2) To reduce gap located on part ‘B’.

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Loosen two screws on stopper hinge under, and then
push the door to contact the door seal to oven front surface.

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Tighten two screw s.

NOTE

A small gap m ay be acceptable if the microw ave leakage does not exceed 4mW/cm2.

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DISASSEMBLY AND ASSEMBLY

5. To remove control panel parts.

(1) KM-200D

REF. NO PART CODE PART NAME DESCRIPTION Q’TY REMARK

B01 3515501500 WINDOW DISPLAY PMMA 1
B02 3516719420 CONTROL PANEL ABS XR-401 H-2938 1
B03 3516907400 BUTTON FUNCTION ABS 1
B04 3516907600 BUTTON FUNCTION ABS 1
B05 3514321400 PCB SUB AS KOR-631R0S 1
B06 3514321300 PCB MAIN AS KOR-631R0S 1
B07 7122401211 SCREW TAPPING T2S TRS 4X12 MFZN 3
B08 7621301011 SCREW TAPPING T2 PAN 3X10 PW MFZN 4
B09 3513405210 KNOB VOLUME ABS 1
B10 3516907500 BUTTON FUNCTION ABS 1
B11 3513702700 LEVER DOOR OPEN ABS 1
B12 441G430171 SPRING BUTTON SWP DIA 0.7 1
B13 3516906900 BUTTON DOOR OPEN ABS 1

REF. NO PART CODE PART NAME DESCRIPTION Q’TY REMARK

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D ISASSE MBLY AND A SSE M B LY

1) Remove the screw which secure the control panel, push up tw o snap fits and draw forward the control panel assembly.

2) Remove the door open lever from the control panel.

3) Remove four screw s which secure the PC B assembly to control panel.

4) Disconnect membrane ta il from the connector of the P CB assembly.

5) Detach membrane from the control panel.

6) Remove door open button and button spring from the control panel.

7) Reverse the above steps for reassembly.

6. To remove high voltage capacitor.

1) Remove a screw which secure the grounding ring terminal

of the H.V.diode and the capacitor holder.

2) Remove the H.V. diode from the capacitor holder.

3) Reverse the above steps for reassembly.

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High voltage circuit wiring

7. To remove magnetron.

1) Remove a screw which secure the m agnetron.

2) Remove the magnetron.

3) Reverse the above steps for reassembly.

NOTE

Never install the magnetron without the metallic gasket plate which is packed with each magnetron to prevent
microw ave leakage. W henever repair work is carried out on m agnetron, check the microw ave leakage. It shall
not exceed 4m W /cm

2

for a fully assembled oven with door normally closed.

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D ISASSEMBLY AN D ASSEMBLY

8. To remove wind guide assem bly.

1) Remove a screw for earthing.

2) Remove the noise filter from the wind guide.

3) Remove a screw which secure the w ind guide assembly.

4) Draw forward the w ind guide assembly.

5) Pull the fan from the motor shaft.

6) Remove two screws which secure the motor shaded pole.

7) Remove the motor shaded pole.

8) Reverse the above steps for reassembly.

9. To remove H.V.transform er.

1) Remove four screw s holding the H.V.transformer.

2) Remove the H.V.transformer.

3) Reverse the above steps for reassembly.

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INTER L OCK MECHANISM AND AD JU STM E NT

The door lock mechanism is a device which has been specially designed to completely eliminate microwave radiation when
the door is opened during operation, and thus to perfectly prevent the danger resulting from the leakage of microwave.

(1) P rima r y interlock switch

Wh e n the do or is c lo se d, the h ook l o cks t h e o v en d o or. If the d oo r i s n ot c lo se d p r operl y, th e oven will n ot o pera te.
When the door is closed, the hook pushes the button of the microswitch. Then the button of the primary interlock switch
bring it un der O N condition.

(2) Secondary interlock switch and interlock monitor switch

When the door is closed, the hook pushes the lock lever downward. The lock lever presses the button of the interlock
monitor switch to bring it under N O condition and presses the button of the secondary interlock switch to bring it under
O N con dit ion.

(3) Ad jus tment st ep s

a) Loosen the one mounting screw.
b) Adjust interlock switch assembly position.
c) Make sure that lock lever moves smoothly after adjustm ent is completed.
d) Tighten completely one mounting screw.

ADJUSTME NT

Interlock monitor switch

W hen the door is closed, the interlock monitor sw itch should be changed(NO condition) before other switches are closed.
W hen the door is opened, the interlock monitor switch should be changed(NC condition) after other switches are opened.

NOTE

Microwave emission test should be perform ed after adjusting interlock mechanism. If the microwave emission exceed
4mW/cm

2

, readjust interlock m echanism.

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TROUBLE SHOOTING GUIDE

Following the procedure below to check if the oven is defective or not.

1) C heck earthing before trouble checking.

2) Be careful of the high voltage circuit.

3) Discharge the high voltage capacitor.

4) When checking the continuity of the switches, fuse or high voltage transformer, disconnect one lead wire from these parts
and ch ec k co ntinuity with the AC plug rem o ve d. To do otherwise may resu lt in a false reading or da mage to y ou r m e ter.

(TR OUB LE 1)

Ove n do es no t ope rate at all : any inputs c an no t be acce pted .

NOTE

W hen electric parts are checked, be sure the power cord is not inserted the wall outlet.
Check wire harness, wiring and connected of the term inals and power cord before check the parts listed below.

CHECK RESULT CAUSE REMEDY

Fuse blow s.

Continuity

No C ontinuity

Continuity

0 infinite

Ω

or

Approx.

150~310

(norm al)

Replace
NOTE 1

Replace
NOTE 1

Replace

Replace

Check continuity of

prim ary winding of low

voltage transformer

Malfunction

of interlock

monitor

switch

Defective low

voltage

transformer

Check continuity of
inte rlock mon itor switch
with door closed
(COM NC)

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Check continuity of primary
inte rlock switch contact
with door partially open
until interlock m onitor switch
contact clos e
(COM<->NO )

Shorted contacts
of primary
inte rlock switch.

Fuse again

blows

Disconnect high voltage
fuse and operate the unit

Defective high

voltage transformer

CONDITION

No C ontinuity

Replace
NOTE 1

Check continuity of both
prim ary and secondary
interlock switch w ith door
colosed

Malfunction of
inte rlock switch

No C ontinuity

Continuity



TROUBLE SHOOTING GUIDE

( TROU BL E 2 )

Display shows all figures selected, but oven does not start cooking, even though desired program and tim e

are set and start pad is tapped.

CONDITION

CHECK RESULT CAUSE REMEDY

Outlet has
proper voltage
Fuse does not

blow.

Check continuity of

magnetron

No

Continuity

Defective

magnetron

Replace

No

Continuity

Normal

Defective touch

control circuit

Open pow er

supply cord

Replace

Check continuity of
power supply cord

Adjust

Check continuity of

noise filter board

No

Continuity

Defective line

filter board

Replace

NOTE

All these switches must be replaced at the same tim e, please refer to “Interlock Mechanism And Adjustm ent”.

CONDITION

CHECK RESULT CAUSE REMEDY

Turn table

motor and

oven lamp do

not turn on

No

Continuity

Adjust or

replace

Adjust or

replace

Replace

Replace

Malfunction

of primary

interlock

switch

No

Continuity

0 V

Approx.
15 VDC

Check continuity of

primary interlock sw itch

Check continuity of

secondary interlock and

D .O .M . sw itche s

Che ck D .C. voltage

being supplied to

RELAY (RY2) coil

Malfunction
of secondary
interlock and

D.O.M . switch

Defective

touch control

circu it

Faulty

contacts of

RELAY

(RY2) or open

relay coil



TROUBLE SHOOTING GUIDE

(

TROUBLE 3 )

N o micr o wave o sc illat ion ev en tho ug h f a n mot o r rota t es .

C O NDIT ION

CHECK RESULT

Continuity

Continuity in

backward

direction

0 Ω

or

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No

Continuity

No

Continuity

0 V

Approx

15 VDC

CAUSE

Defective

high voltage

transform er

Defective

high voltage

rectifier

Defective

magnetron

Defective

magnetron

Defective

high voltage

transform er

Defective

high voltage

transform er

Defective

touch control

circuit

Faulty

contacts or

RELAY

(RY1) or open

relay c o il

REMEDY

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

No microwave

oscillation

Check continuity of high

vo lta g e re c tifie r in

forw ard and backward

direction with D C

megge r

Check continuity of high

voltage capacitor

te rmin a ls w ith wires

rem o ved

Connect megger leads to

magne tron terminal and

magne tron body

Ch eck resistance of

prim ary and secondary

coil of high voltage

transformer

Check continuity of

magne tron w ith wires

rem oved

Check continuity of

filament term inal of high

voltage transformer

Ch eck D .C. voltage

being sup plied to

RELAY (RY1) coil

Continuity

Check continuity of high

voltage fuse

No C ontinuity

Replace high voltage fuse



TROUBLE SHOOTING GUIDE

( TROUBLE 4 )

The following visual conditions indicate a probable defective touch control circuit or membrane switch

assembly

1. Incomp lete segments,

1) Segments missing.

2) Partical segments missing.

3) Digit flickering other than normal display slight
flickering.

4) “ : 0 ” does not display when power is on.

2. A distinct change in the diplay are not on when they
numbers is the display.

3. One or m ore digits in the diplay are not on w hen they should be.

4. Display indicates a number different from one touched.

5. Specific num bers (for example 2 or 3) will not display when the panel is touched.

6. Display does not count down or up with time cooking or clock operation.

7. Oven is programmable and cooks norm ally but no display shows.

8. Display obviously jumps in time while counting down.

9. Display counts dow n noticeably too fast while cooking.

10. Display does not show the tim e of day when clear pad is touched.

11. Oven lamp and turntable motor do not stop although cooking is finished. Check if the RELAY 2 contacts close if they are

close, replace touch control circuit.

CONDITION

CHECK RESULT CAUSE REMEDY

Display does

not show
program ming
at all, even if

keyboard is

touched.

Normal

Replace

control box

sub-assembly

Replace the

membrane

keyborad

Malfunction

of touch
control circuit
of control box
sub-assembly

Abnormal

Check each pad for

continuity of the

mem brane keyboard

for the following
keyboard check

procedure

Malfunction of

the mem brane

keyboard

NOTE

Before following the particular steps listed above in the trouble shooting guide for the m em brane keyboard’s, failure,
please check for the continuity of each wire-harness between the m embrane keyboard and P.C.B. assembly.

M/W DEF. Lock

g



ME ASUREME NT AND TE ST

1. MEASUREMENT OF THE MICROWAVE POWER OUTPUT

Microwave output power can be checked by indirectly measuring the temperature rise of a certain amount of water exposed
to the microwave as directed below.

PROCEDURE

1. Microwave power output measurement is m ade with the m icrowave oven supplied at rated voltage and operated at its
maximum m icrowave pow er setting with a load of 1000 ± 5cc of potable water.

2. T h e w a te r is co nta in e d in a cy lin d ric a l b o ro s ilic a te g la s s v e s sel h a v in g a ma x imum mate ria l th ic k n e ss o f 3 m m and an

outside diameter of approximately 190 m m .

3. The oven and the empty vessel are at ambient temperature prior to the start of the test. The initial temperature of the

water is 10 ± 2 °C (50 ± 3.6 ° F ). It is measured imm ediately 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 shelf, w hich is in the low est normal position.

4. Microwave power is switched on.

5. Heating tim e should be exactly A seconds.

(Refer to table as following)

Heating time is m easured while the
microw ave generator is operating at
full power. The filament heat-up time
for m agnetron is not included.

6. The initial and final temperature of water is selected

so that the maximum difference between the ambient
and final water temperature is 5K.

7. The microwave power output P in watts is calculated

from the follow ing formula:

 

T is difference between initial and ending temperature.



t is the heating time.
The power measured should be B (Refer to SPECIFIC ATIONS) W ± 10.0 %.



Heating time for power output:

A (second) 706460 5652494744424038
B (W) 600 650 700 750 800 850 900 950 1000 1050 1100

P = 4187 X T



CAUTION

1. W ater load should be m easured exactly to 1 liters.

2. Input power voltage should be exactly specified voltage (Refer to SPE CIFICAT IONS).

3. A m bient temperature should be 20

± 2°C (68 ± 3.6 °F)



MEASUR E MENT AND TE ST

2. MICROWAVE RADIATION TEST

PROCEDURE

1. Prepare Microwave Energy Survey M eter,
600cc glass beaker, and glass thermometer
100°C (212°F ).

2. Pour 275cc ±15cc of tap water initially at 20 ± 5 ° C
(68 ± 9°F) in the 600 cc glass beaker with an inside
diameter of approx. 95 mm(3.5 in.).

3. Place it at the center of the tray and set it in a cavity.

4. Close the door and operate the oven.

5. Measure the leakage by using M icrowave Energy
Survey M eter with dual ranges, set to 2450MHz.

1) Measured radiation leakage m ust not exceed the

value prescribed below. Leakage for a fully assembled
oven with door normally closed m ust be less than 4mW /cm

2

.

2) When measuring the leakage, always use the 5 cm (2 in.) space cone with probe. Hold the probe perpendicular to the

cabinet and door. Place the space cone of the probe on the door, cabinet, door seem , door viewing screen, the exhau st
air vents and the suction air vents.

3) Measuring should be in a counter-clockwise direction at a rate of 1 in./sec. If the leakage of the cabinet door seem is

unknown, m ove the probe more slow ly.

4) When measuring near a corner of the door, keep the probe perpendicular to the areas m aking sure the probe end at

the base of the cone does not get closer than 2 in. from any metal. If it does not, erroneous reading may result.

CAUTION

1. M ake sure to check the microwave leakage before and after repair of adjustment.

2. Always start m easuring of an unknown field to assure safety for operating personnel from m icrowave energy.

3. Do not place your hands into any suspected microwave radiation field unless the safe density level is known.

4. Care should be taken not to place the eyes in direct line with the source of m icrowave energy.

5. Slowly approach the unit under test until the radiom eter reads an appreciable m icrowave leakage from the unit
under the test.



MEASUR E MENT AND TE ST

3. COMPONENT TEST PROCEDURE



High voltage is present at the high voltage terminal of the high voltage transformer during any cooking cycle.



It is neither necessary nor advisable to attempt measurem ent of the high voltage.



Before touching any oven components or wiring, always unplug the oven from its power source and discharge the capacitor.

1. H igh voltage transformer

1) Remove connections from the transformer terminals and check continuity.

2) Normal readings should be as follows :
Secondary w inding ... A pprox. 110 ±10%
Filament winding ... Approx. 0



Prim ary winding ... Approx. 1



2. H igh voltage capacitor

1) Check continuity of capacitor with meter on the highest O H M scale.

2) A no r mal c ap acito r will s ho w co n t inu i ty for a shor t t ime, and then indicate 10M



once the capacito r charged.

3) A shorted capacitor will show continuous continuity.

4) An open capacitor will show constant 10M.

5) Resistance betw een each terminal and chassis should be infinite.

3. H igh voltage diode

1) Isolate the diode from the circuit by disconnecting the leads.

2) With the ohm meter set on the highest resistance scale measure the resistance across the diode terminals. Reverse
the m eter leads and again observe the resistance reading. M eter with 6V, 9V or higher voltage batteries should be
used to check the front-back resistance of the diode, otherwise an infinite resistance may be read in both directions. A

normal diode's resistance will be infinite in one direction and several hundred k



in the other direction.

4. Magnetron

For com plete m agnetron diagnosis, refer to “Measurement of the Microwave Power O utput. " Continuity checks can only
indicate and open filament or a shorted magnetron. To diagnose for an open filament or a shorted m agnetron,

1) Isolate m agnetron from the circuit by disconnecting the leads.

2) A continuity check across magnetron filament terminals should indicate 0.1



or less.

3) A continuity check between each filament terminal and magnetron case should read open.

5. Fuse

If the fuse in the prim ary and monitor switch circuit is blown w hen the door is opened, check the primary and monitor
switch before replacing the blow n fuse. In case the fuse is blown by an improper switch operation, replace the defective
switch and fuse at the same time. R eplace just the fuse if the switches operate normally.



WIRING DIAGR AM



PRINTED CIRCUIT BOARD

1. CIRCUIT CHECK PROCEDURE

1. Low voltage transformer check

The low voltage transformer is located on the P.C.B.
Measuring condition: Input voltage: 230 V / Frequency: 50Hz

2. Voltage Check

- Key check point

- Check method

Terminal Voltage LOAD NO LOAD
4 - 7 AC 12.6 V AC 14.7 V

NO CHECK POINT REMARK

1 IC1 PIN 2,21,30,34 -5VDC

2

IC1 PIN 35

T : 20ms( 50Hz)

3

IC1 PIN 31 OR 32

T : 250 ns( 4MH z)

NO MEASURE POINT WAVE FORM REMEDY REMARK

1 MP1 D C -5V± 0.25V Replace VL1, EC1 NO LOAD
2 MP2 D C -12V±2.0V Replace EC 2, D6,11,12 NO LOAD

NOTE

1. Refer to Circuit Diagram (point 4).

2. Secondary side voltage of the low voltage transformer changes in proportion to fluctuation of power source voltage.

3. Th e allowable tolerance of the secondary voltage is within 5% of nominal voltage.

NOTE

Each measure point must be measured with GND points.



PRINTED CIRCUIT BOARD

MP1

MP2

Measure Poin t



PRINTED CIRCUIT BOARD



PRINTED CIRCUIT BOARD

3. When there is no microwave oscillation

1) When touching

START

pad, oven lamp does not turn on.

Fan motor do not rotate, but cook indicator in display comes on.



Cause :

RELAY 2

does not operate.  ref e r to Ci r c u i t Di a gr a m ( P oint 3)

- Check method

2) When touching

START

pad, oven lamp turns on.

Fan motor and turntable rotate and cook indicator in display com es on.



Cause :

RELAY 1

does not operate.  ref e r to Ci r c u i t Di a gr a m ( P oint 2 )

- Check method

4. When the door is opened during operation, the count down timer does not stop.



refer to Circuit Diagram ( Point 1 )

- Check method

5. When the digital clock does not operate properly.



refer to Circuit Dia gram ( Point 5 )



If clock does not keep exact time, you must check resistor R15,16, zener diodeZD1.

PO INT
STATE

A B

RELAY 2

ON - 5VDC GND

RELAY 2

OFF GND - 12VDC

P OINT
STATE

A B

RELAY 1

O N -5V DC GN D

RELAY 1

OFF GND -12VDC

POINT
STATE

A B

1) D O O R O PEN OPEN -5VDC

2) DOOR CLOSED CLOSE GND

CHECK NO METHOD REMEDY

1

Check the stage(ON,OFF) of the door open monitor switch by resistance
me as urement.

Replace door open monitor sw itch.

POINT WAVE FORM

A T: 20 ms(50Hz)



PRINTED CIRCUIT BOARD

2. P.C.B. CIRCUIT DIAGRAM

30

PRINTED CIRCUIT BOARD

3. P.C.B. LOCATION NO

(1) KM-200D

NO NAME SYMBOL SPECIFICATION PART CODE Q'TY

1 BUZZER BZ1 BM-20K 3515600100 1
2 C ARRAY CA1 5P(4) 102 M 50V CN4XB-102M 1
3 C ELECTRO EC1 16V RSS 100uF CEXF1C101V 1
4 C ELECTRO EC2 25V RSS 1000uF CEXF1E102V 1
5 CONNECTOR WAFER CN1 YW396-02AV 3519150520 1
6 CONNECTOR WAFER CN3 YW396-05AV 3519150510 1
7 CONNECTOR WAFER CN2 HLEM15S-1 4CW215SBD0 1
8 CONNECTOR WAFER CN101 HLEM15R-1 4CW215RBD0 1

9 DIODE D1~6, 8~10 1N4148 DZN4148--- 9
10 DIODE D11, 12 1N4004A DZN4004A-- 2
11 DIODE ZENER ZD1 MTZ 5.1VB 1/2W DZTZ5R1B-- 1
12 DIODE ZENER ZD2 MTZ 3.9VB 1/2W DZTZ3R9B-- 1

13

LED DISPLAY DP1 DDG-631H DDDG631H-- 1

PCB MAIN M160 82X139.9 3514321100 1
14 PCB SUB M161 70X122 3514321200 1
15 R ARRAY RA1 5P(4) 1/8 100K J RA-85X104J 1
16 R CARBON FILM R1~R7 1/6W 330 5% RD-AZ331J- 7
17 R CARBON FILM R8,10,12,14,20,101,102 1/6W 1K 5% RD-AZ102J- 7
18 R CARBON FILM R11 1/6W 100K 5% RD-AZ104J- 1
19 R CARBON FILM R13 1/6W 100 5% RD-AZ101J- 1
20 R CARBON FILM R15~17 1/6W 10K 5% RD-AZ103J- 3
21 R CARBON FILM R18 1/6W 1M 5% RD-AZ105J- 1
22 R CARBON FILM R19 1/4W 27 5% RD-4Z270J- 1
23 IC REGULATOR VL1 MC7905C 1MC7905C-- 1
24 TRANSISTOR Q1~5, 8~10 KRA-106M TZRA106M-- 8
25 TRANSISTOR Q6 KTA-1270Y TZTA1270Y- 1
26 TRANS POWER LVT1 DMR-631FS 5EPV035303 1
27 WIRE COPPER J1-J17, J101 1/0.52 TIN COATING 85801052GY 18
28 WIRE FLAT WF1 1.25X15X90XCWH WSJ-159007 1
29 SW TACT SW102~107 KPT-1115AM 5S50101Z93 6
30 SW ROTARY SW101 SDB161PVB17F123636 5S10109002 1
31 IC MICOM IC1 TMP47C440BN-NG04 13GS631R00 1
32 RESONATOR CERA CR1 KBR-4.0MSTF 5PKBR40MKS 1
33 SW RELAY RY1 G5G-1A DC12V 5SC0101121 1
34 SW RELAY RY2 G5B-1 DC12V 5SC0101110 1
35 C CERA C6 102 50V Z AXIAL CCZB1H102K 1
36 C CERA C1~5, C7 104 50V Z AXIAL CCZF1H104Z 6

31

NO NAME SYMBOL SPECIFICATION PART CODE Q'TY

PRINTED CIRCUIT BOARD



EXPLO DED VIEW AND PARTS LIST

1. DOOR ASSEMBLY

Refer to Disassembly and assem bly.

2. CONTROL PANEL ASSEMBLY

Refer to Disassembly and assem bly.

3. TOTAL ASSEMBLY



EXPLODED VIEW AND PARTS LIST

(1) KM-200D

REF NO PART CODE PART NAME DESCR IPTION Q'TY

A00 3511710300 DOO R A S KOR-63150S 1
B00 3516720940 CO NTR O L PANEL AS KOR-631R0S 1
F01 3510801310 C ABINET PCM T 0.36 GE 1
F02 7112401011 SCRE W TAPPING T1 TRS 4*10 MFZN 3

F03

3516109000 CAVITY WELD A S CAV ITY WELD AS 1

3516109600 CAVITY JOINT AS C AVITY W ELD AS 1
F04 7112401011 SCRE W TAPPING T1 TRS 4*10 MFZN 1
F05 7122401211 S CRE W TAPPING T 2S TRS 4*12 MFZN 1
F06 7122401211 S CRE W TAPPING T 2S TRS 4*12 MFZN 1
F07 7112401011 SCRE W TAPPING T1 TRS 4*10 MFZN 2
F08 35113AEQ0D CO RD PO W ER AS 3X0.75 70X70 100-RTML 1
F09 4413A90012 C LAMP PO W ER CO RD NYLO N66 1
F10 7112401011 SCRE W TAPPING T1 TRS 4*10 MFZN 1

F11 7122401211 SCREW TAPPING T 2S TRS 4*12 MFZN 1

F12

4415D67620 FUSE 250V 12A 65TS 1

4415D67120 FUSE 250V 12A MDA 1
F13 3518606200 N O ISE-FILTER DWLF -M12 1
F14 7121403011 S CRE W TAPPING T 2S PAN 4X30 MFZN 2

F15

3963513100 M O TOR SH AD ED POLE 230V 17W OE M-10DW C2-A07 1

3963512310 M O TOR SH AD ED POLE 230V 20W MW10CA -M02 1
F16 3512517000 G U IDE WIND P P 1
F17 3511800300 FAN PP+30%GLASS 1
F18 3518002200 M A GNE TRO N 2M218H(MF)I 1
F19 3516004000 SPECIAL SC REW T2 BOLT FLANGE 5X12 DAC RO 1
F20 7S422X4081 SPECIAL SCREW TT2 TR S 4*8 SE MFZN 1
F21 3513003200 H OLDE R HV CA PACITO R SEC C T 0.6 1
F22 3518302200 C APACITOR HV 2100VAC 0.98uF #187 1
F23 3518400400 D IODE H V HVR-1X-3AB 12KV #187 1
F24 3518701100 FU SE H V 5KV 0.55A HV-41A55-02 1
F25 3518113700 TR ANS HV DY-N80S0-63T 1
F26 3516003700 SPECIAL SC REW TT3 HEX 4X8 FLG MFZN 4
F27 3510311700 BASE SBHG T0.8 1
F28 7112401011 SCRE W TAPPING T1 TRS 4*10 MFZN 5
F29 3512100900 FO OT PP DASF-130 2
F30 7S422X4081 SPECIAL SCREW TT2 TR S 4X8 SE MFZN 1
F31 3515201101 S TOPPE R H INGE *U SCP-1 T2.5 1
F32 4415A17352 SW M ICRO VP-533A-OF SPN O #187 200G 1



F33 4415A66910 SW M ICRO VP-531A-OF/SZM-V16-FA -61 1
F34 4415A17352 SW M ICRO VP-533A-OF SPN O #187 200G 1
F35 3513702600 LE VER LO CK POM 1
F36 3513811700 LO CK POM 1
F37 4415A17352 SW M ICRO VP-533A-OF SPN O #187 200G 1
F38 3513601600 LA MP BL 240V 25W T25 C7A H187 1
F39 7121400611 S CRE W TAPPING T 2S PAN 4X6 MFZN 1
F40 3966310100 M O TOR S YNC RO 220V 2.5W GM -16-24FD12 1

3966310110 M O TO R SYNC R O 220V 2.5W M2LJ49ZT52 1
F41 3518905300 TH ERM O STAT OFF:75 ON:65 H #187 NB 1
F42 3513003400 H O LDER THER MO S TAT PBT 1
F43 3516003700 SPECIAL SC REW TT3 HEX 4X8 FLG MFZN 1
F44 3511406200 C O VER W AVE GUIDE HEATPROOF PP 1
F45 3517400620 C O UPLER XAREC 1
F46 3514700710 R O LLER TEFLON 3
F47 3512517300 G JIDE RO LLER PP 5113MF6 A353B 1
F48 3517203600 TR AY GLASS 1

REF NO PART CODE PART NAME DESCR IPTION Q'TY

EXPLODED VIEW AND PARTS LIST