Panasonic NN-GS595A User manual

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ORDERNO.PHAMOS0511035C3
MicrowaveOven
NNGS595A
CHP(HongKong)
CYP(Singapore)
CMP(Malaysia)
CTP(Thailand,Indonesia)
CYT(Others)
CKT(UAE)
CPT(Iran)
CKP(Kuwait,Doha,Qatar,Oman,Bahrain,Pakistan)
CZP(CISCountries)
©2005PanasonicHomeAppliancesMicrowaveOven(Shanghai)Co.,Ltd.
Allrightsreserved.Unauthorizedcopyinganddistributionisaviolationoflaw.

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10/24/2016 XMLServiceManual
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10/24/2016 schemat1.png(540×753)
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10/24/2016 schemat2.png(540×753)
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2DESCRIPTIONOFOPERATING
SEQUENCE
2.1Variablepowercookingcontrol
HighVoltageInverterPowerSupply(U)controlsoutputpowerbythesignalfromDigitalProgrammerCircuit(DPC).Powerrelay
alwaysstaysON,butPWM(pulsewidthmodulation)signalcontrolsmicrowaveoutputpower.
NOTE:
TheON/OFFtimeratiodoesnotcorrespondwiththepercentageofmicrowavepowersinceapproximately2secondsare
requiredforheatingofmagnetronfilament.
VariablePowerCooking
POWER SETTING OUTPUTPOWER(%) APPROX. MANUALMICROWAVEDUTY
ON(SEC) OFF(SEC)
HIGH 100% 22 0
MEDIUMHIGH 70% 22 0
MEDIUM 55% 22 0
MEDIUMLOW 40% 22 0
LOW 20% 13 9
DEFROST 30% 17 5
2.2InverterpowersupplycircuitNEWH.V.
TheInverterPowerSupplycircuitpoweredfromthelinevoltage,220V50HzACinputsupplies4,000VDCtothemagnetrontube,
andfunctionsinplaceoftheH.V.transformer,theH.V.capacitorandH.V.diode.
1.TheACinputvoltage220240V50HzisrectifiedtoDCvoltageimmediately.
2.DCvoltagewillbesuppliedtotheswitchingdevicescalledIGBT.ThesedevicesareswitchedONOFFbythe20to40
KHzPWM(pulsewidthmodulation)signalfromthemicrocomputerintheDPC.
3.ThisdrivestheHighvoltagetransformertoincreasevoltageupto2,000VAC.
4.Thenthehalfwavedoublervoltagerectifiercircuit,consistingoftheH.V.diodesandcapacitors,generatesthe
necessary4,000VDCneededforthemagnetron.
5.Outputpowerofthemagnetrontubeisalwaysmonitoredbythesignaloutputfromthecurrenttransformerbuiltintothe
invertercircuit.
6.ThissignalisfedbacktothemicrocomputerintheDPCtodetermineoperatingconditionsandoutputnecessaryto
controlPWMsignaltotheInverterPowerSupplyforcontroloftheoutputpower.
2.3Steamdefrost,Autocook&Steamreheat
WhentheAutoControlfeatureisselectedandtheStartpadistapped:
1.Thedigitalprogramercircuitdeterminesthepowerlevelandcookingtimetocompletecookingandindicatesthe
operatingstateinthedisplaywindow.Tableshowsthecorrespondingcookingtimesforrespectiveservingby
categories.
SteamDefrost
SELECTEDWEIGHT COOKINGTIME
1.0kg 15min.20sec.
AutoCook(Rice)
SELECTEDWEIGHT COOKINGTIME
0.2kg 20min.00sec.

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2.Whencookingtimeinthedisplaywindowhaselapsed,theoventurnsoffautomaticallybyacontrolsignalfromthe
digitalprogrammercircuit.
2.4Oven
ThedigitalprogrammercircuitcontrolstheONOFFtimeoftheheaterinordertocontrolovencavitytemperature.
1.Afterselectingdesiredovencavitytemperatureandpressing[Start]pad,ahighlevelsignalcomesoutmicrocomputer
andappliestopowerrelays,RY4andRY5.
2.WhenRY4&RY5switchtoON,powersourcevoltageisappliedtotheupperandlowerheaters,andtheheatersturn
on.
3.Thedigitalprogrammercircuitsensestheovencavitytemperaturethroughoventempsensor(thermistor).Whenthe
oventemperaturereachesthesettemperature,DPCstopssupplyinghighlevelsignaltothepowerrelays,andthe
heatersturnoff.
4.Aftertheupperandlowerheatersturnoff,theoventemperaturewillcontinueincreasingforawhileandthendecrease
asshowninFigure.
Whentheoventemperaturedropsbelowthesettemperature,thedigitalprogrammercircuitsensesthesignaland
startssupplyingahighlevelsignaltopowerrelaysagain.
2.5Combinationcookcontrol
Combinationcookingisaccomplishedbymicrowaveandgrillcooking(upperheater)beingdonesynchronouslyduringone
combinationcookingcycle.Onecombinationcookingcycleis33seconds.
1.Duringcombinationcooking,thedigitalprogrammercircuitcontrolspowerrelayRY4&RY5ʼsONOFFtime.Inallthree
combinationcookingcategories,powerrelayRY1alwaysstayon,butRY5ʼsONOFFtimeasshowninFigure.
COMBINATION CATEGORY GRILL(RY5) MICROWAVE(RY1)
ON(sec.) OFF(sec.)
COMBINATION CATEGORY GRILL(RY5) MICROWAVE(RY1)
ON(sec.) OFF(sec.)
1 33 0 ON
2 24 9 ON
3 18 15 ON
2.6IRreheat
Thetemperatureoffoodbeingheatedisdetectedbyaninfrared(IR)sensorandyoudonothavetosettime.
2.6.1HowtoreadtemperaturebyIRsensor
IRsensorcanreadfoodtemperaturewithouttouching,IRraysareemittedfromfood.IRsensoristogeneratetemperaturerelated
electricsignaloutputandmicrocomputeristoconvertactualtemperature.

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2.6.2Operation
IRsensorismountedontoprightofovencavitythroughthehole.Itscansallovercookingshelf.IRsensorhas8eyesandcanread
ovenshelflefttorightatthetime.ThenIRsensorisdesignedtoscanfronttobacktocoverallovershelf.(19points)

2.7Steamfunction(microsteam&steamreheat)
2.7.1WaterSupply
Waterinwatertankwillbepumpedoutandsupplytothesteamgenerationheaterlocatedinsidebackbottomofovencavity.
2.7.2Operation
Whenpressing[start]pad,ovenpreheatwillstartandthenwatersupplybegins.Itwilltake1minuteforpreheating.Whenpreheatis
completed,itwillturnintoactualcookingprocess.Duringheating,thetemperaturesensor(Thermistor)locatedonsteamheaterwill
monitorsteamheatertemperatureandwhenitexceeds95°C,theadditionalwaterwillbesuppliedtomaintainmoisture/steam
withinovencavity.

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3CAUTIONSTOBEOBSERVEDWHEN
TROUBLESHOOTING
Unlikemanyotherappliances,themicrowaveovenisahighvoltage,highcurrentdevice.Itisfreefromdangerinordinaryuse,
thoughextremecareshouldbetakenduringrepair.
Caution
Servicemenshouldremovetheirwatcheswheneverworkingclosetoorreplacingthemagnetron.
3.1Checkthegrounding
Donotoperateonatwowireextensioncord.Themicrowaveovenisdesignedtobegroundedwhenused.Itisimperative,
therefore,toensuretheapplianceisproperlygroundedbeforebeginningrepairwork.
3.2Inverterwarnings
DANGER,HIGHVOLTAGEANDHIGHTEMPERATURE(HOT/LIVE)OFTHEINVERTERPOWERSUPPLY(U)
TheHighVoltageInverterPowerSupplyhandlesveryhighvoltageandcurrentforthemagnetrontube.Thoughitisfreefrom
dangerinordinaryuse,extremecareshouldbetakenduringrepair.
Thealuminumheatsinkisalsoenergizedwithhighvoltage(HOT),donottouchwhentheACinputterminalsareenergized.The
powerdeviceCollectorisdirectlyconnectedtothealuminumheatsink.
ThealuminumheatsinkmaybeHOTduetoheatenergy,therefore,extremecareshouldbetakenduringservicing.
H.V.Inverterwarning
WARNINGFORINVERTERPOWERSUPPLY(U)GROUNDING
ChecktheHighVoltageInverterPowerSupplycircuitgrounding.Thehighvoltageinverterpowersupplycircuitboardmusthavea
properchassisground.Theinvertergroundingbracketmustbeconnectedtothechassis.Iftheinverterboardisnotgroundeditwill
exposetheusertoveryhighvoltagesandcauseextremeDANGER!Besurethattheinvertercircuitisproperlygroundedviathe
invertergroundingbracket.

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Groundingoftheinvertercircuitboard
WARNING!DISCHARGETHEHIGHVOLATGECAPACITORS
Forabout30secondsaftertheovenisturnedoff,anelectricchargeremainsinthehighvoltagecapacitorsintheInverterPower
Supplycircuitboard.
Whenreplacingorcheckingparts,removethepowerplugfromtheoutletandshorttheinverteroutputterminalofthemagnetron
filamentterminalstothechassisgroundwithaninsulatedhandlescrewdrivertodischarge.Pleasebesuretotouchthechassis
groundsidefirstandthenshorttotheoutputterminals.
Dischargingthehighvoltagecapacitors
WARNING
Thereishighvoltagepresentwithhighcurrentcapabilitiesinthecircuitsoftheprimaryandsecondarywindings,chokecoiland
heatsinkoftheinverter.Itisextremelydangeroustoworkonornearthesecircuitswiththeovenenergized.DONOTmeasurethe
voltageinthehighvoltagecircuitincludingthefilamentvoltageofthemagnetron.
WARNING
Nevertouchanycircuitwiringwithyourhandorwithaninsulatedtoolduringoperation.
3.3Partreplacement
Whenanypartorcomponentistobereplaced,alwaysensurethatthepowercordisremovedfromthewalloutlet.
3.4Whenthe10Afuseisblownduetotheoperationof
theshortswitch
WARNING
Whenthe10A220Vfuseisblownduetotheoperationoftheinterlockmonitorswitch,replaceallofthecomponents(primarylatch
switch,shortswitchandpowerrelayB(RY1)).
1.Thisismandatory.Referto“adjustmentsandmeasurements”forthelocationoftheseswitches.
2.Whenreplacingthefuse,confirmthatithastheappropriateratingforthesemodels.

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3.Whenreplacingfaultyswitches,besurethemountingtabsarenotbent,brokenordeficientintheirabilitytoholdthe
switches.
3.5Avoidinsertingnails,wireetc.throughanyholesin
theunitduringoperation
Neverinsertawire,nailoranyothermetalobjectthroughthelampholesonthecavityoranyholesorgaps,becausesuchobjects
mayworkasanantennaandcausemicrowaveleakage.
3.6Confirmafterrepair
1.Afterrepairorreplacementofparts,makesurethatthescrewsoftheoven,etc.areneitherloosenormissing.
Microwavemightleakifscrewsarenotproperlytightened.
2.Makesurethatallelectricalconnectionsaretightbeforeinsertingtheplugintothewalloutlet.
3.Checkformicrowaveenergyleakage.(Refertoprocedureformeasuringmicrowaveenergyleakage).
CAUTIONMICROWAVERADIATION
USECAUTIONNOTTOBECOMEEXPOSEDTORADIATIONFROMTHEMICROWAVEMAGNETRONOROTHERPARTS
CONDUCTINGMICROWAVEENERGY.
IMPORTANTNOTICE
Thefollowingcomponentshavepotentialsabove2000Vwhiletheapplianceisoperated.
Magnetron
Highvoltagetransformer(Locatedoninverter(U))
Highvoltagediodes(Locatedoninverter(U))
Highvoltagecapacitors(Locatedoninverter(U))
Payspecialattentiontotheseareas.
Whentheapplianceisoperatedwiththedoorhingesormagnetroninstalledincorrectly,themicrowaveleakagecanexceedmore
than5mW/cm2.Afterrepairorexchange,itisveryimportanttocheckifthemagnetronandthedoorhingesarecorrectlyinstalled.
3.7Sharpedges
Caution
Pleaseusecautionwhenunpacking,installingormovingtheunit,assomeexposededgesmaybesharptothetouchandcause
injuryifnothandledwithcare.

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4DISASSEMBLYANDPARTS
REPLACEMENTPROCEDURE
4.1Magnetron
1.Dischargethehighvoltagecapacitor.
2.Remove2screwsholdingreinforcebracketAonovencavity.
3.Remove2screwsholdingreinforcebracketBonovencavity.
4.Remove1screwholdingoventhermistoroncavitytopplate.
5.Remove1groundingscrewholdingACcordʼsearthlead.
6.Disconnect2highvoltageleadwiresfrommagnetronfilamentterminals.
7.Remove1screwholdingthermistoronmagnetron.
8.Remove1screwholdingairguideAonmagnetron,thenremoveairguideA.
9.Remove2screwsholdingairguideBonmagnetron&onbaseplaterespectively,thenremoveairguideB.
10.Disconnect2leadwiresfromfanmotorterminals.
11.Disconnectleadwiresfromfuseholderterminals.

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12.ReleaselockingtabsofreinforcebracketAhangingonbothsidesofovencavity,thenwithdrawthereinforcebracketA
outsideslightly.
NOTE:
PayattentiontothesharpedgesofreinforcebracketA.
13.HoldthereinforcebracketA,thenremove4screwsholdingmagnetron.
NOTE:
Afterreplacementofthemagnetron,tightenmountingscrewsproperlyinanxpattern,makingsurethereisnogapbetween
thewaveguideandthemagnetrontopreventmicrowaveleakage.
CAUTION
Whenreplacingthemagnetron,besuretheantennagasketisinplace.
CAUTION
When connecting 2filamentlead wiresto themagnetron terminals,be sure to connectthe
lead wires in the correct position. The lead wire of high volatge transformer should be
connectedto“Fterminal”and
theleadwirefromhighvoltage
capacitorshouldbeconnectedto
“FAterminal”.
4.2Digitalprogrammercircuit(D.P.C)AU,membrane
keyboardandpowerrelay
NOTE:
BesuretogroundanystaticelectricchargebuiltuponyourbodybeforehandlingtheDPC.
1.Drawoutwatertankfromescutcheonbase.
2.PullouttubeAconnectingtopumpfromcopperpipe.
3.RemoveallwiringconnectorsfromD.P.C.boardAU.
4.Remove1groundingscrewholdingoncavityfrontplate.
5.Openthedoorofoven,slidetheescutcheonbaseupwardandoutslightly.
6.Remove3screwsholdingD.P.C.boardAUonescutcheonbase.
7.ReleaseconnectorCN7ʼslockofD.P.C.boardAUbypushingbothleversinsideandpullupwardslightly,thenremove
flatcableofmembranekeyboard.
Toreplacemembranekeyboard
8.Usetoolssuchasknifeetc.topokefromtheedgeofescutcheonsheetandpeeloffescutcheonsheetandmembrane
keyboardcompletelyfromescutcheonbase.
NOTE:
1.Themembranekeyboardisattachedtotheescutcheonbasewithdoublefacedadhesivetape.Therefore,applyinghotair
suchasusingahairdryerisrecommendedforsmootherremoval.
2.Wheninstallingnewmembranekeyboard,makesurethatthesurfaceofescutcheonbaseiscleanedsufficientlysothat
anyproblems(shortedcontactsorunevensurface)canbeavoided.
4.3Digitalprogrammercircuit(D.P.C.)DUandlow
voltagetransformer
1.RemoveredconnectorCN9fromD.P.C.boardAU.

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2.RemovewhiteconnectorCN1fromD.P.C.boardDU.
3.Remove1screwholdingD.P.C.boardDUonreinforcebracketA.
4.Usetoolssuchaspincerstorejectthetabofplasticbracket.
5.RemoveD.P.C.boardDU.
6.Usingsolderwickoradesolderingtooland30Wsolderingironcarefullytoremoveallsolderfromtheterminalpinsof
thelowvoltagetransformerand/orpowerrelays.
NOTE:
Donotuseasolderingironordesolderingtoolofmorethan30wattsonD.P.C.contacts.
7.WithalltheterminalpinscleanedandseparatedfromD.P.C.contacts,removethedefectivetransformer/powerrelays.
Replacecomponentsmakingsureallterminalpinsareinsertedcompletely,thenresolderallterminalcontacts
carefully.
4.4H.V.Inverter
1.Dischargehighvoltageremaininginhighvoltagecapacitor.
2.Remove2screwsholdingreinforcebracketAonovencavity.
3.Remove2screwsholdingreinforcebracketBonovencavity.
4.Remove1screwholdingoventhermistoroncavitytopplate.
5.Remove1groundingscrewholdingACcordʼsearthlead.
6.Disconnect2highvoltageleadwiresfrommagnetronfilamentterminals.
7.UnplugconnectorCN701&CN702fromH.V.Inverterboard.
8.Disconnectleadwiresfromfuseholderterminals.
9.Disconnect2leadwiresfromcapacitorlocatedonreinforcebracketB.
10.Disconnect2leadwiresfromfanmotorterminals.
11.UnplugconnectorofACcordʼsNegativelead.
12.RemovewhiteconnectorCN1fromD.P.C.boardDU.
13.RemoveredconnectorCN9fromD.P.C.boardAU.
14.ReleaselockingtabsconnectingInverterbracketAwithInverterbracketB,detachbracketA&B.
15.Remove2screwsholdingH.V.InverteronInverterbracket.

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4.5Fanmotor
1.Disconnect2leadwiresfromfanmotorterminals.
2.Remove2screwsholdingairguideBonmagnetron&onbaseplaterespectively,thenremoveairguideB.
3.Remove2screwsholdingfanmotoranddetachfanmotorfromovenassy.
4.Removefanbladefromfanmotorshaftbypullingitstraightout.
4.6Upperheater
1.Disconnectleadwiresfrombothsidesofupperheaterterminals.
2.Remove1screwholdingheatersupportfromtheleftsideofmicrowaveoven.
3.Removetheupperheaterbypullingitout.

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4.7IRSENSOR
1.DisconnectconnectorCN5fromD.P.C.boardAU.
2.Remove1screwholdingIRSENSOR(U)onrightheaterpanel.
ToreplaceswingmotorofIRsensor
1.Releasethelockingleverofconnectoronswingmotor,thenremovedriveline.
2.Remove2screwsholdingswingmotoronmotormountingplate.
3.RemoveswingmotorfromIRsensorassy.
4.8Doorassembly
1.Removeleftandrightdoorkeyspringsfromdoorarmwithplier.
NOTE:
Pleasesupportdoorbeforeoperation.

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
2.Insertflatbladescrewdrivertoreleasehingepinfromlefthinge.
3.Slideoutlefthingepintoreleasethedoor.
4.Slideoutdoorarmsfromtheoventodisconnectdoorassembly.
5.Removedoorarmsfromthedoorassembly.
ToremovedoorC
6.Releasecatchhooks.
NOTE:
Afterreplacementofthedefectivecomponentpartsofthedoor,reassembleitandfollowtheinstructionbelowfor
properinstallationandadjustmentsoastopreventanexcessivemicrowaveleakage.Adjustmentofthedoor
assembly.
7.Whenmountingthedoortotheoven,besuretoadjustthedoorparalleltothecavityfrontplatebymovinghingesback
orfront.
NOTE:
UpperportionofdoorAshouldfirmlytouchthecavityfrontplatewithoutpushing.
4.9Pump
1.Drawoutwatertankfromescutcheonbase.
2.PullouttubeAconnectingtopumpfromcopperpipe.
3.RemoveallwiringconnectorsfromD.P.CboardAU.
4.Remove1groundingscrewholdingoncavityfrontplate.
5.Openthedoorofoven,slidetheescutcheonbaseupwardandoutslightly.
6.PullouttubeBfrominletofpump.
7.Remove2screwsholdingpumpbracketonescutcheonbase.

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8.Drawoutpumpbracketfrombottomrailofescutcheonbase.
9.Uplifttheafterbodyofpumpslightlytoreleasethetabsofpumpbracket,thendrawoutpump.
10.PullouttubeAfromoutletofpump.
Toinstallpump
1.Insertpumpintopumpbracket(Inletofpumpshouldbeclosetoharnessclaspofpumpbracket).
2.Pleaseconfirmifitisfittedwellafterinstalling.

NOTE:
Afterrepairing,wheninsertcopperpipeintotubeA,makesuretheinserteddepthshouldbenolessthan9mmtoprevent
tubeAfromslipping.

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4.10Stirmotor
1.Removetubesfrombothendsofcopperpipe.
2.Remove1screwholdingairguideBonthebase.
3.Removeleftandrightdoorkeyspringsfromdoorarm.
NOTE:
Pleasesupportdoorbeforeoperation.
4.Turnoverthemicrowaveovenandremoveallscrewsholdingbaseonovenassy&twohinges.
NOTE:
Donotremovetwoscrewsholdingleftandrighthingeonthebottomofcavityfrontplate.
5.Removebasefromovenassy.
6.Disconnet2leadwiresfromstirmotorterminals.
7.Remove2screwsholdingstirmotor.
4.11HeaterDU(steamheater)
1.Removetubesfrombothendsofcopperpipe.
2.Remove1screwholdingairguideBonthebase.
3.Removeleftandrightdoorkeyspringsfromdoorarm.
NOTE:
Pleasesupportdoorbeforeoperation.
4.Turnoverthemicrowaveovenandremoveallscrewsholdingbaseonovenassy&twohinges.
NOTE:
Donotremovetwoscrewsholdingleftandrighthingeonthebottomofcavityfrontplate.
5.Removebasefromovenassy.
6.Disconnect2leadwiresfromheaterDUterminals.
7.Remove1screwholdingthermistoronheaterDU.
8.Remove4screwsholdingheaterDU&thermalcutoutbracketonthebottomofovenassy.
ToinstallheaterDU
NOTE:

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1.PleasegreaseenoughsiliconevenlybetweentheinterfaceofheaterDUandbottomofovencavity.(about0.3mm
thickness),thisisforgoodconductibility.
2.Tighten4screwsandmakesurethereisnogapbetweenheaterDUandbottomofovencavity.
3.DonotforgettoscrewthethermalcutoutbracketalongwithheaterDu.
Toinstallthermistor
NOTE:
Beforeinstallingthermistor,pleasefillenoughsilicongreaseintotheinstallationholeofheaterDUforgoodconductibility.
4.12Lowerheater
1.Removetubesfrombothendsofcopperpipe.
2.Remove1screwholdingairguideBonthebase.
3.Removeleftandrightdoorkeyspringsfromdoorarm.
NOTE:
Pleasesupportdoorbeforeoperation.
4.Turnoverthemicrowaveovenandremoveallscrewsholdingbaseonovenassy&twohinges.
NOTE:
Donotremovetwoscrewsholdingleftandrighthingeonthebottomofcavityfrontplate.
5.Removebasefromovenassy.
6.Disconnect2leadwiresfromtherightsideoflowerheater.
7.Remove2screwslinkingtheterminalsoflowerheater.
8.Usetoolssuchasplierstoturnoutthetablocatedontheleftsideoflowerheater.