S/M No.

Training Manual
PRODUCT : Microwave Oven MODEL : ALL model

DAEWOO ELECTRONICS CO., LTD.

http : //svc.dwe.co.kr
Jun . 2002

Contents
1. PRINCIPLES ......................................................................................1 2. CLASSIFICATION ..............................................................................6 3. CONTAINERS .....................................................................................8 4. BASIC STRUCTURE ..........................................................................9 5. BASIC CIRCUIT AND FUNCTIONS ................................................10 6. HOW TO CHECK MAJOR COMPONENTS .....................................17 7. MAJOR TROUBLE SHOOTING .......................................................19 8. CAUTIONS ON USING THE MICROWAVE OVEN ..........................23 9. NEW MODELS WITH SPECIAL FUNCTION ...................................24

1. PRINCIPLES
1-1 Origin of Concept of the Microwave Oven

A major characteristic of mankind that animals do not have is the use of "fire". Since the World War II, mankind has gained access to various kinds of new fires, the most outstanding of which is the nuclear technology. The microwave heating technology, being used for the microwave oven, is also one of the new fires.

The microwave oven has first been introduced to the market in 1945, by RAYTHEON Company of U.S.A. in the name of RADAR RANGE. The idea is said to have been inspired by the chocolate molten in the pocket of an engineer by the influence of the microwave from a RADAR.

The traditional heating method like burning of firewood, charcoal and petroleum of heating by electric heater depends on surface heating in which the surface of the objects being heated gets heat through flame of heat wave(infrared ray), and the inner contents of the objects gradually through thermal conduction inside the material.

On the contrary, the microwave heating technology is the internal heating technology, in which microwave(a kind of electromagnetic wave) penetrates and is absorbed into the objects being heated(like food), thereby heating them from inside.

The microwave heating technology has the following advantages compared with the traditional heating technology : 1 short time to heat 2 high thermal efficiency because only the objects being heated are heated 3 almost nonexistent heating of the heating equipment itself 4 better safety to users due to the reason described in 3

The microwave heating technology, with the above advantages, being a clean and energy saving technology, is used widely for medicinal purposes as well as industrial purposes including food treatment, various drying processes, molding and sterilization processes.

1-2 Thermal source of the Microwave Oven

The energy source of the microwave oven is the electromagnetic wave. TV(UHF and VHF), radio, stereo audio equipment, and the high frequency treatment equipment used for treating neuralgia or rheumatism are all everyday examples of devices using electromagnetic wave.

The electromagnetic wave is changed into the picture by TV, into voice by radio or stereo audio equipment, and into heat by the microwave oven.

microwave oven 2,450 MHz changed into heat

TV VHF : 30 ~ 300 MHz UHF : 300 ~ 3000 MHz changed into picture the and voice

use of electromagnetic wave

1.0 0.8 0.6 0.4 0.2 0.0

radio 560 ~ 800 KHz changed into voice

medicinal equipment 2,450 MHz changed into heat

The electromagnetic wave is emitted from the antenna of the magnetron of the microwave oven. The frequency of this electromagnetic wave is 2,450MHZ, i.e. there is a 2,450,000,000 oscillations (change of polarity between + and -) per second. The electromagnetic wave vibrates the water molecules contained inside the food, which generates friction heat. This friction heat propagates all over the food and cooks it. The electromagnetic wave energy thus changes into high efficiency thermal energy.

electromagnetic wave

magnetron (vacuum tube)

dish container food

If wood is rubbed against wood.

If hand is rubbed against hand.

If water molecules in the food is rubbed against other water moecules while rotating

The friction heat is generated

1-3 Characteristic of Electromagnetic Wave

The ability to heat only the food without heating the container comes from the ingenious use of the characteristic of the electromagnetic wave.

- Electromagnetic wave is absorbed by water.

absorption

Electromagnetic wave always travels straight. However, if electromagnetic wave meets materials containing water, it is absorbed by the water and generates heat. Microwave oven uses this characteristic to heat materials.

- Electromagnetic wave penetrates porcelain of glass.

penetration

Electromagnetic wave penetrates materials that do not contain water like porcelain of glass.

- Electromagnetic wave is reflected when it meets metals.

reflection

Electromagnetic wave is reflected when it meets metallic surface. Thus, if container with metallic surface is used, food inside the container will not get heated. Using aluminum foils to wrap the tail of a fish when cooking is the example of using this characteristic, not to burn it due to too much heating.

Also, traditional cooking methods like "boil water in the pot" or "fry eggs in the frying pan" depend on the principle of thermal conduction. That is, heat from gas fire, charcoal fire or electric heater is first conveyed to the pot or frying pan and then conveyed to food. However, microwave oven generates friction heat inside food and heats only the food itself. Since heat is generated from inside, time to heat is much reduced compared with traditional heating method. That is also why heat loss is reduced.

microwave oven

pot or frying fan

Only food, inside and outside, is heated at the same time.

Heat is transmitted to pot first, then to water, and then to food.

2. CLASSIFICATION
Microwave ovens can be classified into household use / professional use by use, single function / multiple function by function, mechanical / electronic by control mechanism, and turn table type / stirrer fan type by method of electromagnetic wave distribution. They can also be classified by capacity or by existence of output switching.

2-1 Classification by function single function microwave oven microwave oven

multiple functions microwave oven microwave oven + toaster

microwave oven + oven

microwave oven + oven + grill

microwave oven + oven + grill + toaster

microwave oven + oven + grill + steam cooker

microwave oven + oven + grill + home bakery

2-2 Classification by Control Mechanism

Mechanical

Electronic

After the timer knob and output level adjusting knob are set to desired value, the microwave oven operates until the timer motor reaches the set time, with the set output level.

Operation is made by using touch buttons on the control panel. Users can program their own inputs by themselves, thus operation is various.

2-3 Classification by Method of Electromagnetic wave distribution Turn table type Stirrer fan type

Food dish is rotated so that every part of food receives electromagnetic wave and is well cooked.

Stirrer fan installed in the ceiling of cavity rotates to distribute electromagnetic wave emission.

3. CONTAINERS
materials of containers - thermo-resistant glass (pyroceramic of pyrex) - thermo-resistant ceramic, porcelain - china pot or gratin dish - normal ceramic porcelain of for microwave oven cooking - can be used but may be broken. If cooled down abrubtly, - can be used. for heater cooking - can be used but may be broken. If cooled down abrubtly, - can be used.

- can be used but those with gold plating, silver plating or silver foil can cause sparks and must not be used. - can be used but those with big difference in thickness along its shape can be broken easily and must not be used. (like reinforced glass or cup glass) - can be used but should be able to endure 120 degree celsius. - cannot be used since they causes sparks.

- can be used.

- normal glass

- cannot be used.

- thermo-resistant plastic (PP) - metals like aluminum and foil, gridiron or metal skewer - wood, bamboo or paper

- cannot be used.

- can be used but those with wooden or plastic handles cannot be used. - cannot be used since they will be scorched or burned. - can be used.

- cannot be used since they will be scorched or burned. - cannot be used normally but can be used to reduce the effect of electromagnetic wave, like wrapping the tails of fish. - can be used but must not be used to wrap food like meat or a fry that requires high temperature to cook.

- aluminum foil

- wrap

- cannot be used since they will be melt.

* Containers that cannot be used : normal plastic containers (styrols, pp, melamin, penolic, urease or lacquer ware)

4. BASIC STRUCTURE
assembly

1 cabinet

2 control panel

3 door

4 chassis

5 bottom plate

6 harness wiring

5. BASIC CIRCUIT AND FUNCTIONS

5-1 Basic circuitry (example)

5-2 Power Supply Circuit

The power supply circuit is provided to supply power to the microwave oven and consists of the power cord with plug and the line noise filter for EMI protection. Especially, the power cord with plug should be of three prongtype (live/neutral/ground). The ground wire of the cord should be well grounded to the microwave oven chassis and the ground prong of the plug should be well grounded to the ground pole of the socket outlet.

5-3 Interlock Monitor System

The interlock monitor system is a device to prevent electromagnetic wave emission generated by the magnetron from leaking outside the cavity, even when the door is opened while the primary interlock switch is out of order. That is, if the primary interlock switch is out of order and its contacts are closed, the interlock monitor switch will operate to form a closed loop, thus blowing out the main fuse. This cuts off the power input to the microwave oven, stopping the oscillating operation of the magnetron. This switch is an important safety device.

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when door is open, normal

when primary switch is out of order

5-4 Control Circuit This circuit is provided for adjusting cooking time and output level ; in case of mechanical type, by rotating the knob, the cooking time and output level are adjusted. For example, suppose that the desired output level is level 5 and maximum output is 850W. The oscillation time and output are as follows. Output adjustment switch (V.P.C : variable power controller) is switched on and off with a cycle time of 30 sec. Variable power setting (HIGH) (MED HIGH) (MEDIUM) (DEFROST) (WARM) ON/OFF time, sec. 30.0 / 0 23.2 / 6.8 16.5 / 13.5 9.8 / 20.2 5.0 / 25.0 Power 850 W 657 W 468 W 278 W 142 W % 100% 77.3% 55.0% 32.7% 16.7%

In case of electronic type, a microprocessor is provided for control, so adjustment is more various. Power level 1 2 3 4 5 6 7 8 9 10 "ON/OFF time, sec 3/26 5/24 8/21 11/18 14/15 17/12 20/9 23/6 26/3 29/0 Power (W) 88 147 234 322 410 498 586 674 762 850 % 10.3% 17.2% 27.6% 37.9% 48.3% 58.6% 69.0% 79.3% 89.7% 100%

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5-5 Overheating Protection Device Overheating protecton device is the safety device consisting of a magnetron thermostat or a cavity thermostat. It cuts off the power when the magnetron or the cavity is overheated, and switches power ON again when temperature goes down. The ON/OFF temperature of the thermostats are different between each model.

5-6 High Voltage Generator The magnetron needs an oscillation power (DC 4000V) and a filament power (AC 3.4V). The high voltage generator consists of a high voltage transformer, a high voltage capacitor, and a high voltage diode. AC 2000V voltage generated at the secondary winding of the high voltage transformer is boosted to halfwave DC 4000V by the high voltage capacitor and the high voltage diode and then supplied to the magnetron. The following are a circuit diagram and an exploded view of the high voltage generator. circuit diagram exploded view

OR FA H.V. FUSE H.V. CAPACITOR

H.V. DIODE

MAGNETRON

WIRING COLOR OR: ORANGE H.V. TRANSFORMER

When repair is needed, it should be done after disconnecting power plug from the socket outlet and discharging the high voltage capacitor. To discharge it, shortcircuit the two parts indicated by the arrow.

SHORT

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5-7 Microwave Generator

Microwave generator is a magnetron : it receives power from the high voltage generator and generates 2,450 MHZ microwave. Care should be taken to the following when it should be replaced. Metallic gasket plate should not be lost.

5-8 How to measure microwave output power (IEC 705 clause 12)

P = 4,187Mw(T2 - T1) + 0.55Mc(T2-T0) / t

Mw : Mass of the Water (1000g 5g) Mc : Mass of the Container t : Heating time (sec.)

To : Ambient Temp. (20C 2C) T1 : Initial Temp. of Water (10C 1C) T2 : Final Temp. of Water

Heating time(t) of microwave oven can be approximately calculated by following.

t = 4,187 x 10 / 900 = 47 Here 1) T2 = 20, T1 = 10 and T0 = 20 2) Power output is 900W 3) The filament heat-up time for magnetron is excluded

* Power output vs Heating time Power output (P) Heating time (t) 600 70 650 64 700 60 750 56 800 52 850 49 900 47 950 44 1000 42 1050 40 1100 38

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5-9 Leakage (Radiation) test (IEC 335-2-25 Clause 32)

1) Conditions 1 Load : 275 15g (20 2C) 2 Beaker : 600cc (85mm Diameter) 3 Location : The center of tray 4 The limit of leakage : 5mW/cm2 (4mW/cm2 : DAEWOO)

5-10 Installation

1) Steady, flat location This microwave oven should be set on a steady, flat surface. 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 oven failure. 3) Away from Radio and TV sets Poor television reception and radio interference may result if the oven is located close to a TV, Radio, or Antenna, feeder and so on. 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) The minimum height of free space necessary above the top surface of the oven shall be maintained according to user manual.

5-11 Efficiency

E = OUTPUT / INPUT x 100%

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5-12 The Principles of Oscillating Magnetron

The primary of high voltage transformer is 230V. for example N1 = 230 turns N2 = 2200 turns by formula V2 / V1 = N2 / N1 = I1 /I2 V2 = V1 x N2 / N1 = 230 x 2200/ 230 2200V

The secondary of high voltage is approx. 2200V. High voltage capacitor has the function which store the electric charge and high voltage diode has the function which rectify the current. By these functions, AC 2200V is changed into approx DC 4.1KV. DC 4.1KV is applied to the anode of magnetron. 3 volts is generated from the filament winding of the high voltage transformer.

by formula N1 = 230 turns N2 = 3 turns by formula V2 / V1 = N2 / N1 V2 = V1 x N2 / N1 = 230 x 3/ 230 3V

This filament voltage is applied to the magnetron to heat the magnetron filament

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5-13 The explanation for major components are as follows.

Fan motor : This component has the function which cools the magnetron and transformer. If fan motor is out of order, temperature is rising so abrupt that the magnetron thermostat or H.V. Fuse will be cut off. In case of not having the magnetron thermostat, the stuffs (coupler, roller guide) inside the cavity may be melted. Geared motor : This component has the function which distributes the microwave uniformly and has the foods cooked well. Cavity lamp : This component has the function which lights the inside cavity Noise filter : This component has the function which filters conductive noise flowing from line to line. Oven thermostat (Cavity thermostat) : This is the device which protects the appliance during the abnormal operation Fuse : This is the component which protects the set on breaking out overcurrent, the break down of insulation, short, ets. H.V.Fuse : This is the component which protects overcurrent from H.V. Transformer to H.V. Capacitor. Timer : This is the component which controls the time and output power. Transformer H.V. : This is the component which transforms 230V general input into 2000V.

i.e. the transformer has pass core for leakage flux to obtain the stable power source.

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6. HOW TO CHECK MAJOR COMPONENTS

Components should be checked only after removing the power plug from the socket outlet, discharging the high voltage capacitor and disconnecting power lead wires from the components. components magnetron points to be checked both ends of the filament result normal : less than 1

RX1

filament housing

normal :

R X 1000

high voltage transformer

primary winding
RX1

normal : 0

secondary winding

normal : about 100

RX1

primary winding and core

RX1

normal :

filament and core

normal :

R X 1000

high voltage capacitor

pin to pin

normal : ammeter should show

R X 1000

some resistance value for a moment but then should go to abnormal : or 0 always

pin to case
R X 1000

normal : abnormal : 0

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components thermostat

points to be checked

result normal : 0 abnormal :

RX1

fan motor
RX1

normal : abnormal : 0

high voltage diode

forward direction

normal : continuity abnormal : 0

R X 1000

reverse direction

normal : abnormal : continuity

R X 1000

fuse (including high voltage fuse)

RX1

normal : 0 abnormal :

safety switch

NC. NO Type
NC NO

switch off

switch

(door open) (door close)

NC NO

COM

NO. Type
COM NO

(CHECK) COM-NO

RX1

RX1

NC. Type
NC COM

(CHECK) COM-NC

RX1

RX1

light bulb (lamp)

RX1

normal : abnormal : 0

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7. MAJOR TROUBLE SHOOTING

Symptom 1) After the oven is started, the lamp does not light and fan motor does not operate points to check check if fuse blown. result if blown if OK required actions replace fuse

check if power plug is properly connected to socket outlet check lamp filament

if not connected

make connection

if cut it off if OK

replace lamp

check lamp wiring check fan motor

if improper wired if abnormal if OK

repair wiring replace fan motor

check fan motor wiring

if improper wired if OK

repair wiring

check safety switch

if abnormal if OK

replace safety switch or adjust door positioning

in case of electronic type check relay if abnormal if OK replace relay replace PCB assembly

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Symptom 2) Operation is normal but food is not heated

points to check check wiring of high voltage transformer and magnetron.

result if improper if OK

required actions repair wiring

check high voltage fuse

if fuse blown if OK

replace fuse

check high voltage capacitor

if abnormal if OK

replace capacitor

check high voltage diode

if abnormal if OK

repair diode

check resistance of high voltage transformer

if abonormal if OK

replace transformer

check magnetron

if abnormal

replace magnetron

In case of electronic type, check main relay.

if abonormal if OK

replace main relay

Check power input to main relay (DC 12V or 24V)

if improper

replace main relay driver transistor

if OK

replace PCB assembly

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Symptom

points to check check input power if OK

result

required actions

3) Incase of electronic type, power plug is inserted but the display is not lighted:

check if power plug is properly connected to socket outlet

if abnormal

replace socket outlet

Or in case that start button is pressed but the oven does not operate.

check fuse

if fuse blown if OK

replace fuse

check secondary voltage of low voltage transformer

if fuse abnormal if OK

repair transformer replace PCB assembly

if fuse is again blown if abnormal if OK adjust door positioning or replace safety switch

check safety of interlock system

check for short circuit in internal wiring or components

if short circuit found

correct the problem

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Symptom 4) In case of electronic type, function keys are pressed but the microwave oven does not operate

points to check check contacts of membrane switch

result if abnormal if OK

required actions replace membrane switch

check connector between membrane switch and PCB

if abnormal if OK

repair connection replace PCB assembly

check door-open limit switch

if abnormal

adjust door positioning

if OK

repalace door-open limit switch

5) There are sparks in cavity

check if there are food residue on spatter shield

if abnormal

clean or replace spatter shield

if OK

check if container is metallic

use proper container

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8. CAUTIONS ON USING THE MICROWAVE OVEN

1) BE CAREFUL ON INSTALLATION It should be earthed. To protect electric shock, the earth should be installed. Electric capacity Use a plug receptacle more than 15A. Don't use other appliance at the receptacle at the same time. If use like that, house breaker will be cut off.

2) FOR SAFE USE The prohibition of use except the purpose of cooking. Don't use the tree, paper, bar, handkerchief, etc, in the dry. If you heat these stuffs, it causes fume, ignition and fire. Don't cook the eggs in the shell and bottle with not opening.

3) THE RIGHT METHOD TO CLEAN THE SET THE DOOR - should be cleaned with a damp cloth do not use aerosol cleaners, caustic cleaners or abrasive powder cleaning agents as this may scrach the surface and impair vision into the oven. THE OUTER CASING - is cleaned with mild soap and damp cloth. Do not use any type of abrasive cleaner. THE DOOR SEAL AREA - must also be kept particulary cleaning to ensure a tight seal to keep in microwave. THE GLASS TURNTABLE - can be easily removed for cleaning at the sink. Wipe up spillovers with a paper towel or cloth before removal of the turntable. INTERIOR SURFACE - is cleaned with soft cloth and warm water. Do not use any abrasive cleaner. For heavier soil, use baking soda or a mild soap : rinse throughly with hot water.

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9. NEW MODELS WITH SPECIAL FUNCTION

9.1 Microwave Oven with Ultraviolet Lamp, Models KOR-633V and KOR-637V

1) UV light Description - Ultraviolet processing involves the use of radiation from the ultraviolet region of the electromagnetic spectrum for purposes of disinfection. Typically, the wavelength for UV processing ranges from 100 to 400nm. UVA: 315 to 400 nm - changing in human skin and lead to tanning UVB: 280 to 315 nm - causing skin burning and eventually lead to skin cancer UVC: 200 to 280 nm - inactivating bacteria and virus and lead to kill them, germicidal range Property - Germicidal properties of UV radiation are mainly due to DNA mutations induced through absorption of UV light by DNA molecules. It is primarily useful for sterilization and/or sanitation of air , the surfaces of various material and water or liquid. UV light can not transmit glass, steel, plastic, and vinyl, etc, and so shall be irradiated directly onto the object to sanitize well.

2) Application Germicidal lamp( UV Lamp ) efficiently emits a large amount of ultraviolet rays 253.7nm which have excellent germicidal effect. This lamp has structures and electrical characteristics similar to those of general fluorescent lamps used for illumination but use ultraviolet ray glass which efficiently transmits ultraviolet ray at 253.7nm. The models KOR-633V and KOR-637V have two separate function such as microwave cooking and uv sanitizing, however separately operate by different key button on control panel. The UV system consists of electrical components such as UV lamp, Ballast, and Glow starter and mechanical parts such as lamp cover and socket. The UV lamp rated 4W and Glow starter are equipped on top side of the oven cavity and irradiate the UV light through multi-pierced holes. The Ballast is equipped on base plate. Circuit diagram
Glow Starter

GS

GL Germicidal Lamp

Ballast

AC POWER INPUT

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9.2 Convection Oven with 3 Dimensional Power Heating System, Models KOC-1B0K and KOC-910K

1) Construction 3 powerful heaters are equipped on three sides of the oven cavity. These heaters heat up instantly allowing even distribution inside the oven and cook beautiful results, browned to perfection.

TOP HEATER QUARTZ HEATER (550W x 2EA)

REAR HEATER QUARTZ HEATER (550W x 2EA) CONVECTION FAN

BOTTOM HEATER SHEATHED HEATER (400W)

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2) Function - Three Grills Cooking > Browning Grill : The QUARTZ grill heats up instantaneously allowing your dishes to be cooked quicker and tastier. > Crisp Grill: The bottom grill heats the base of your food directly and makes it crispy at the same time. > Double Grill: With the top and bottom grill working simultaneously, grilling is done on both sides of the food - 5 Combinations Cooking

COMBI. 1 CONVECTION + M/W

COMBI. 2 CONV. + CRISP GRILL + M/W

COMBI. 3 CONV. + DOUBLE GRILL

COMBI. 4 BROWNING GRILL + M/W

COMBI. 5 DOUBLE GRILL + M/W

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