Daewoo KOR-1P5CBA User manual

Service Manual
Microwave Oven
Model: KOR-1P5CBA
DAEWOO ELECTRONIC CO., LTD.
S/M No. : R1P5CBA001
http : //svc.dwe.co.kr Sep. 2002

2
PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE
EXPOSURE TO EXCESSIVE MICROWAVE ENERGY
(a)Do not operate or allow the oven to be operated with the door open.
(b)Make the following safety checks on all ovens to be serviced before activating the magnetron or other
microwave source, and make repairs if 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.
TABLE OF CONTENTS
SAFETY AND PRECAUTIONS........................................................................................................................................3
FOR SAFE OPERATION...........................................................................................................................................3
FOR SAFE SERVICE PROCEDURES .....................................................................................................................3
SPECIFICATIONS ............................................................................................................................................................4
EXTERNAL VIEW.............................................................................................................................................................5
OUTER DIMENSION.................................................................................................................................................5
FEATURE DIAGRAM.................................................................................................................................................6
CONTROL PANEL.....................................................................................................................................................7
INSTALLATION ................................................................................................................................................................8
OPERATIONS AND FUNCTIONS ...................................................................................................................................9
DISASSEMBLY AND ASSMBLY...................................................................................................................................10
INTERLOCK MECHANISM AND ADJUSTMENT.........................................................................................................17
TROUBLE SHOOTING GUIDE......................................................................................................................................18
MESUREMENT AND TEST............................................................................................................................................22
MEASUREMENT OF THE MICROWAVE POWER OUTPUT................................................................................22
MICROWAVE RADIATION TEST ...........................................................................................................................23
COMPONENT TEST PROCEDURE.......................................................................................................................24
WIRING DIAGRAM.........................................................................................................................................................25
PRINTED CIRCUIT BOARD...........................................................................................................................................26
CIRCUIT CHECK PROCEDURE.............................................................................................................................26
PCB CIRCUIT DIAGRAM ........................................................................................................................................29
P.C.B. LOCATION NO.............................................................................................................................................30
EXPLODED VIEW AND PARTS LIST...........................................................................................................................31
DOOR ASSEMBLY..................................................................................................................................................31
CONTROL PANEL ASSEMBLY..............................................................................................................................31
TOTAL ASSEMBLY.................................................................................................................................................31

SAFETY AND PRECAUTIONS
CAUTION : This Device is to be Serviced Only by Properly Qualified Service Personnel. Consult the Service
Manual for Proper Service Procedures to Assure Continued Safety Operation and for Precautions
to be Taken to Avoid Possible Exposure to Excessive Microwave Energy.
1. FOR SAFE OPERATION
Damage that allows the microwave energy (that cooks or heats the food) to escape will result in poor cooking and
may cause serious bodily injury to the operator.
IF ANY OF THE FOLLOWING CONDITIONS EXIST, OPERATOR MUST NOT USE THE APPLIANCE.
(Only a trained service personnel should make 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 allowed 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 APPLIANCE UNTIL YOU HAVE READ THIS SERVICE MANUAL.
2. FOR SAFE SERVICE PROCEDURES
1) If the oven is operative prior to servicing, a microwave emission check should be performed 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, importer or assembler,
(b) repair the unit at no cost to the owner,
(c) attempt 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 and CDRH immediately.
3
CAUTION
MICROWAVE RADIATION
PERSONNEL SHOULD NOT BE EXPOSED TO THE MICROWAVE ENERGY WHICH MAY RADIATE
FROM THE MAGNETRON OR OTHER MICROWAVE GENERATING DEVICE IF IT IS IMPROPERLY
USED OR CONNECTED. ALL INPUT AND OUTPUT MICROWAVE CONNECTIONS. WAVEGUIDES
FLANGES AND GASKETS MUST BE SECURED. NEVER OPERATE THE DEVICE WITHOUT A
MICROWAVE ENERGY ABSORBING LOAD ATTACHED. NEVER LOOK INTO AN OPEN WAVEGUIDE
OR ANTENNA WHILE THE DEVICE IS ENERGIZED.

4
SPECIFICATIONS
MODEL KOR-1P5CBA
POWER SUPPLY 120V~60HZ, SINGLE PHASE WITH EARTHING
MICROWAVE 1600 W
POWER GRILL
CONSUMPTION COMBINATION
MICROWAVE ENERGY OUTPUT 1100 W
MICROWAVE FREQUENCY 2450MHz
OUTSIDE DIMENSIONS (W X H X D) 560X344X483mm (22.0X13.5X19 in.)
CAVITY DIMENSIONS (W X H X D) 369X221X400mm (14.5X8.7X15.7 in.)
NET WEIGHT APPROX. 16.5kg (36.4lbs)
TIMER 59min. 99sec.
FUNCTION SELECTIONS MICROWAVE
POWER SELECTIONS 4 LEVELS
CAVITY VOLUME 1.2 Cu. Ft
* Specifications are subject to change without notice.

5
EXTERNAL VIEW
560 483
344
1. OUTER DIMENSION

35 4 7 8 1
62
6
11Safety interlock system
22Door viewing screen - Allows viewing of food. The screen is designed so that light can pass through, but not the
microwave.
33Door hook - When the door is closed, it will automatically shut off. If the door is opened while the oven is
operating, the automatically shut off.
44Oven cavity
55Door seal - Door seal maintains the microwave energy within the oven cavity and prevents microwave leakage.
66Plate tray - Made of special heat resistant glass. Food in a proper receptacle is placed on this tray for cooking.
77Stirrer cover - This is located on the ceiling with the stirrer fan.
88Inlet cover - Protect the air hole from splashes of cooking foods.
2. FEATURE DIAGRAM

7
PROGRAM DEFROST
STOP/CLEAR
CHECK DOUBLE
QUANTITY POWER
START/ +30SEC
11 1
12 2
13 3
14 4
15 5
16 6
17 7
18 8
19 9
20 10
1
3
4
7
8
2
5
6
9
11Display - Cooking time, power level, indicators are displayed.
22Program - Used to save cooking data.
33Defrost - Used to defrost foods for time.
44Time Set Pad - Used to set the cooking time or cook preprogrammed cooks.
55Check - Used to check cooking data.
66Double Quantity - Used to extend programmed cooking time.
77Power - Used to set power level.
88Stop/Clear - Used to stop the oven operation or to delete the cooking data.
99Start/+30sec - Used to start the oven and also used to set a reheat time.
3. CONTROL PANEL

8
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 be overheated
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, antenna, or
feeder and 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
•Check your local power source.
This microwave oven requires a current of approximately 14.5 amperes, 120Volts, 60Hz grounded outlet.
1. A short power-supply cord is provided to reduce the risks resulting from becoming entangled in or trippping over a
longer cord.
2. Longer cord sets or extension cords are available and may be used if care is exercised in their use.
3. If a long cord or extension cord is used:
1) The marked electrical rating of the cord set or extension cord should be at least as great as the electrical rating
of the appliance.
2) The extension cord must be a grounding type 3-wire cord.
3) The longer cord should be arranged so that it will not drape over the counter top or tabletop where it can be
pulled on by children or tripped over unintentionally.
6. Examine the oven after unpacking for any damage such as:
A misaligned door, broken door or a dent in cavity.
If any of the above are visible, DO NOT INSTALL, and notify dealer immediately.

9
OPERATIONS AND FUNCTIONS
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. 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.
5. Each time a pad is touched, a BEEP will sound to acknowledge the touch.
6. The oven automatically cook on full power unless set to a lower power level.
7. The display will show : 0 when the oven is plugged in.
8. When the STOP/CLEAR pad is touched during the oven operation, the oven stops cooking and all information
retained.
To erase all information touch, the STOP/CLEAR pad once more. If the oven door is opened during the oven
operation, all information is retained.
9. If the START pad is touched and the oven does not operate, check the area between the door and 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 touching the POWER pad. The chart shows the display, the power level and the percentage
of power.
Make sure the oven is properly installed and plugged into the electrical outlet.
Touch POWER pad. Power level(Display) Approximate Percentage of Power
Once 100 100%
Twice 80 80%
3 times 60 60%
4 times 40 40%

10
DISASSEMBLY AND ASSEMBLY
Cautions to be observed when 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 grounding.
Do not operate on a 2-wire extension cord.
The microwave oven is designed to be used with grounded.
It is imperative, therefore, to make sure it is grounded
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 15A 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 : Service personnel should remove their watches whenever working close to or replacing the magnetron.
WARNING :When servicing the appliance, take care when touching or replacing high potential parts because of
electrical shock or exposing microwave. These parts are as follows - HV Transformer, Magnetron,
HV Capacitor.
SHORT

11
1. To remove cabinet
1) Remove three screws on cabinet back.
2) Push the cabinet backward.
2. To remove door assembly
1) Remove two screws which secure the stopper hinge top.
2) Remove the door assembly from top plate of cavity.
3) Reverse the above for reassembly.
NOTE : After replacing the door assembly, perform a check of correct alignment with the hinge and cavity front plate.

12
3. To remove door parts.
REF NO. PART CODE PART NAME DESCRIPTION Q’TY REMARK
A01 3511610610 DECORATOR DOOR SUS T0.4 1
A02 7001401011 SCREW MACHINE PAN 4*10 MFZN 2
A03 3512206200 FRAME DOOR ABS 1
A04 3517008100 BARRIER SCREEN*O GLASS T3.2 1
A05 3516602100 DOOR PLATE SBHG-1A T0.7 1
A06 3517007600 BARRIER SCREEN*I PE T0.1 1
A07 3512302310 GASKET DOOR LUPOL2300 1
A08 3516004100 SPECIAL SCREW T1 TRS LR4 POLE 4*10 MFZN 2
A09 3513101200 HOOK POM 1
A10 3515101800 SPRING HOOK PW1 1
A11 3512604800 HANDLE DOOR ABS CR COATING 1
A12 3513586900 LABEL AL1020 T0.5 1
A13 3515204900 STOPPER HINGE*T AS KOC-1B0K0S 1
A12
A11
A01 A02 A03
A08
A07A06A05A13A04
A09
A10
(1) Remove the gasket door from door weld as.
(2) Remove the barrier screen inner from weld as.
(3) Remove the door frame from door weld as.
(4) Remove the stopper hinge top from door weld as.
(5) Remove the spring and the hook.
(6) Remove the barrier screen outer from door frame.
(7) Reverse the above steps for reassembly.
Door Assembly
KOR- 1P5CBA : 3511718600

13
4. Method to reduce the gap between the door seal and the oven front surface.
(1) To reduce gap located on part ‘A’.
•Loosen two screws on stopper hinge top, and then push
the door to contact the door seal to oven front surface.
•Tighten two screws.
(2) To reduce gap located on part ‘B’.
•Loosen two screws on stopper hinge under, and then
push the door to contact the door seal to oven front
surface.
•Tighten two screws.
A
B
NOTE : A small gap may be acceptable if the microwave leakage does not exceed 4mW/cm
2
.

14
5. To remove control panel parts.
REF NO. PART CODE PART NAME DESCRIPTION Q’TY REMARK
B01 3511610410 DECORATOR C-PANEL SUS T0.4 1
B02 351852400 SWITCH MEMBRANE KOR-1P5CBA
B03 3516728510 CONTROL PANEL ABS AF-348, VT-0826 1
B04 3514328300 PCB AS KOR-1P5CBA 1
B05 7122401211 SCREW TAPPING T2S TRS 4X12 MFZN 4
(1) Remove the screw which secure the control panel, push up two snap fits and draw forward the control panel assembly.
(2) Remove four screws which secure the PCB assembly to control panel.
(3) Disconnect membrane tail from the connector of the PCB assembly.
(4) Detach membrane from the control panel.
(5) Pull out the decorator c-panel from the control panel.
(6) Reverse the above steps for reassembly.
Control panel Assembly
KOR- 1P5CBA : 3516728710

15
NOTE : Never install the magnetron without the metallic gasket plate which is packed with each magnetron to
prevent microwave leakage. Whenever repair work is carried out on magnetron, check the microwave
leakage. It shall not exceed 4mW/cm
2
for a fully assembled oven with door normally closed.
Metalic
gasket
plate
Cooling fin
Filament
terminal
<MAGNETRON>
Stub
Magnetron antenna
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.
◆ High voltage circuit wiring
7. To remove magnetron.
1) Remove a screw which secure the magnetron.
2) Remove the magnetron.
3) Reverse the above steps for reassembly.

16
8. To remove wind guide assembly.
1) Remove a screw which secure the wind guide assembly.
2) Draw forward the wind guide assembly.
3) Pull the fan from the motor shaft.
4) Remove two screws which secure the motor shaded pole.
5) Remove the motor shaded pole.
6) Reverse the above steps for reasembly.
9. To remove H.V.transformer.
1) Remove four screws holding the H.V.transformer.
2) Remove the H.V.transformer.
3) Reverse the above steps for reassembly.

17
INTERLOCK MECHANISM AND ADJUSTMENT
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) Primary interlock switch
When the door is closed, the hook locks the oven door. If the door is not closed properly, the oven will not operate.
When the door is closed, the hook pushes the button of the microswitch. Then the button of the primary interlock switch
bring it under ON 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 NO condition. The lock lever presses the button of the secondary interlock switch to bring
it under ON condition.
(3) Adjustment steps
a) Loosen the one mounting screw.
b) Adjust interlock switch assembly position.
c) Make sure that lock lever moves smoothly after adjustment is completed.
d) Tighten completely two mounting screws.
ADJUSTMENT :
Interlock monitor switch
When the door is closed, the interlock monitor switch should be changed (NO condition) before other switches are closed.
When the door is opened, the interlock monitor switch should be changed (NC condition) after other switches are opened.
NOTE :
Microwave emission test should be performed after adjusting interlock mechanism.
If the microwave emission exceed 4mW/cm
2
, readjust interlock mechanism.

18
TROUBLE SHOOTING GUIDE
Following the procedure below to check if the oven is defective or not.
1) Check grounding 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 tranformer, disconnect one load wire from these
parts and check continuity with the AC plug removed. To do otherwise may result in a false reading or damage to
your meter.
(TROUBLE 1) Oven does not operate at all : any inputs can not be accepted.
NOTE : When electric parts are checked, be sure the power cord is not inserted the wall outlet.
Check wire harness, wiring and connection of the terminals and power cord before check the parts listed below.
CONDITION CHECK
Check continuity of interlock
monitor switch with door closed
Check continuity of of primary
interlock switch contact with door
partially open until interlock
monitor switch contact close
Malfunction of
interlock
monitor switch
Shorted
contacts of
primary
interlock switch.
RESULT
Continuity
No Continuity
Replace fuse
CAUSE REMEDY
Replace
NOTE 1
Fuse blows.
Replace
NOTE 1
Defective low
voltage
transformer
0Ωor infinite
Approx.
260~320
(normal)
Replace
Check continuity of primary
winding of low voltage
transformer
Defective high
voltage capacitor
Normal Replace
Disconnect one side of the lead
wire connected form high
voltage transformer to the high
voltage capacitor and operate
the unit
Continuity
Defective high
voltage
transformer
Fuse again
blows
Replace

19
CONDITION CHECK
Check continuity of magnetron Defective
magnetron
RESULT
No
Continuity
CAUSE REMEDY
Replace
Outlet has
proper
voltage Fuse
does not
blow.
CONDITION CHECK
Check continuity of primary
interlock switch Malfunction of
primary interlock
switch
RESULT
No
Continuity
CAUSE REMEDY
Adjust or
replace
Oven lamp
do not turn
on
Check continuity of secondary
interlock switch Malfunction of
secondary
interlock
switch
No
Continuity Adjust or
replace
Check D.C. voltage being
supplied to RELAY (RY2) coil Defective touch control circuit
0 V Replace
Faulty contacts of
RELAY (RY2) or
open relay coil
Approx.
15 VDC Replace
Display do not shown
countdown Malfunction of
secondary
interlock switch
Replace
Check continuity of
power supply cord Open power
supply cord
No
Continuity Replace
Defective touch
control circuit
Normal Replace
NOTE 1
All these switches must be replaced at the same time, please refer to “Interlock Mechanism And Adjustment”.
(TROUBLE 2) Display shows all figures selected, but oven does not start cooking, even though desired program and
time are set and start pad is tapped.

20
CONDITION CHECK RESULT
Check continuity of high
voltage capacitor terminals
with wires removed
Continuity
CAUSE
Defective high
voltage
transformer
REMEDY
Replace
No
microwave
oscillation
Check continuity of high voltage
rectifier in forward and backward
direction with DC megger
Continuity in
backward
direction
Defective high
voltage rectifier Replace
Connect megger leads to
magnetron terminal and
magnetron body
Continuity Defective
magnetron Replace
Check resistance of primary and
secondary coil of high voltage
transformer
0 Ωor ∞Defective high
voltage
transformer
Replace
Check continuity of magnetron
with wires removed
No
Continuity Defective
magnetron
Replace
Check continuity of filament
terminal of high voltage
transformer
No
Continuity Defective high
voltage
transformer
Replace
Check D.C. voltage being
supplied to RELAY (RY1) coil
0 V Defective touch
control circuit
Replace
Approx
15 VDC Faulty
contacts or
RELAY (RY1)
or open
relay coil
Replace
(TROUBLE 3) No microwave oscillation even though fan motor rotates.