SERVICE MANUAL - Commercial Catering Spares
Contents
1. Keo 7 Aepoy I PA II y N N UN W AA UU 000 KAN HEH DOILOU SEIN aporg Paso AN 10 10eden 1001 suonrtpuoo NO SINA AH Wee JANI AS LULU JUU A Km JOJSUB TNO CND I IdL CdL YouIMg Ca Pa A9O0 13JUT Krepuoaag 1 Aepoy N DVN WOO L kL Gell UBH i Ld J punoip s wa 11 qo I O E gt JOJON 1010W 14317 ZHOS rmog L L Ay ne NOETDV ON G VOI ANI WOO s OSIN O m O o O OO YMS youmg youmg youmg Edil IL TeunIsyL JONUOMN MN0f193u TEULISUL HUN J9I1 OSION LON Leroy Arewmnid UdAO J0 SIS9IY USMIUJ ureIgelg SUMM HILIMS INVESIIW NIFBILBML 10 EM E1000 EM S1000 amp EM E1000 EM S1000 amp EM E1000 VV PAR EM S1000 amp EM E1000 This illustration for reference only Door Assembly must be replaced No individual parts are available except items 1 3 7 and 8 15 EM S1000 amp EM E1000 Parts List for EM S1000 PTT 6 MO E0240 McaPlats 1 0040 P11 7 MO S0075K Re LC MO SO075R P11 8MO S1187 GearMotr TTmoo TMOS137 PT aw oe LEI P11 12 432 0 2210 06200 A _ Stirrer Assy 1 432 0 2210 06000 A P13 6 MO M1044 Mercme2. OR THE CIRCUIT BREAKER TRIPS AFTER BEING RESET ONCE WITH THE HOUSE CIRCUIT UNLOADED EXCEPT FOR THE OVEN THE INTERLOCK SWITCHES MUST BE REPLACED AS A GROUP THIS IS BECAUSE THE SHORT CIRCUIT WILL HAVE DAMAGED THESE IMPORTANT SWITCHES SEE INTERLOCK SWITCH REMOVAL NOTE IF INTERLOCKS HAVE BEEN REPLACED IT IS VERY IMPORTANT TO MAKE A MICROWAVE LEAKAGE CHECK OF THE DOOR SEE THE MICROWAVE LEAK AGE SECTION IN THIS MANUAL FAN SHROUD FUSE MOUNTED ON TOP OF THE NOISE FILTER Noise Filter u 1 Unplug the power cord remove the outer cabinet and discharge the capacitor 2 Remove the fuse 3 A blown fuse can be diagnosed with an ohmmeter 4 Replace with a 10 Amp fuse NOTE USE ONLY A NORMAL BLOW 20 AMP TUBULAR CERAMIC FUSE SUCH AS THE LITTELFUSE 3140120 20A DO NOT USE A SLOW BLOW FUSE INTERLOCK AND MONITOR SWITCH REMOVAL If for any reason one of the interlock switches fail all three must be replaced as a group 1 Unplug the power cord remove the outer cabinet and discharge the capacitor Open the door 2 Remove the air guide from the front side of the magnetron The air guide is secured to the right side of the oven cavity with a 2 piece plastic pin 3 The switches are all mounted on a single plastic bracket and are held in position with plastic tabs 4 Remove screws holding plastic switch bracket to oven chassis 5 After the switch bracket has been removed the tabs can be seen By applyi
3. TO P13 8 MO S0555 Fuse280V10A M00805 P13 9 MO R0439 FanCasng 1 MO0 R0439 P 258 TCITC oe BA TCT pa Ben Sow amerre P14 ejaxetene seew o o ierre P 6 MO M1018 Door Spring TMOM08 P15 BE TRUSSBT Tapping Screws 2 49 TRUSSBT Pe G 3 8BBTC screw BBB 17 Parts List for EM E1000 Pu 6 MO E0241 MicaPlie 1M0g0241 PTT Mosok s G MO S0078k PTT 8 Mo 51028 Gear Moir IT motor 1 MO 51028 PT 94x8PCTC Sow ET P13 6 MO M1044 M t MOTO P13 8 MO S0555 Fuse280V10A 1 MO S0555 P13 9 MO R0439 FanCasing 1 MO0 R0439 P13 258 TCITC oe BA TCT pa 6 4x8 TSTO B Sorew LATE pa S4x8TCTC Sow f4x6T1CC P 6 MO M1018 DoorSping TMO M08 P15 BE IRUSS Tappingsoews 24X5TRUSS Pe G 38BBTC seew BB 18
4. cabinet DESCRIPTION amp FUNCTION OF COM PONENTS FAN MOTOR The fan motor drives a blower fan which draws cool air through the back of the oven This cool air is directed through the air ducts surrounding the magnetron tube to cool the magnetron Some of the air is then exhausted directly through the bottom vents However a portion of this air is channeled through the cavity to remove the steam and vapors given off from heating food OVEN LIGHT The oven light illuminates the interior of the cavity so the food can be visually examined through the door POWER TRANSFORMER The purpose of the power transformer is to pro vide the filament voltage for heating the mag netron filaments as well as to produce the high voltage needed for magnetron tube operation During a cook cycle the 230 Volts AC applied to the primary winding is converted to approxi mately 3 22 Volts AC on the filament winding The same 230 Volts AC primary input is con verted to approximately 2070 Volts AC on the high voltage secondary winding of the power transformer CAUTIONS AFTER REMOVING THE CABI NET DISCHARGE THE CAPACITOR BY PLACING AN INSULATED SCREWDRIVER ACROSS THE TERMINALS PRIMARY SWITCH The primary protective switch interlock is acti vated by the latch when the door is closed The switch in the open position when the door is open interrupts the current to the magnetron Closing the door will close the interlock switch and normal o
5. the 4 magnetron to oscillate and produce the 2450 MHz cooking freguency The microwave energy produced by the mag netron tube is channeled through a waveguide into the cavity past the diffuser and finally into a cavity where the load is placed to be heated When the timer has completed the selected cooking time the timer switch opens The cir cuits are open to the light timer fan motor and power transformer and the microwave energy is no longer produced Five beeps signal the end of the cook cycle DOOR amp INTERLOCK ADJUSTMENTS DOOR ADJUSTMENTS The door adjustment on all microwave ovens is very important to prevent any excessive leak age The microwave leakage levels should be checked after all door interlock switches and associated repairs are made See the Microwave Radiation Test Section in this man ual for proper testing procedures The following door adjustments must be fol lowed LATCH amp CATCH ASSEMBLY ADJUST MENTS CAUTION AFTER REMOVING THE CABI NET DISCHARGE THE CAPACITOR BY PLACING AN INSULATED SCREWDRIVER ACROSS THE TERMINALS To make proper latch and catch assembly adjustment 1 Disconnect the power to the unit remove the cabinet and discharge the capacitor by placing an insulated screwdriver across the terminals 2 Open the door 3 Loosen the screws that secure the plastic interlock bracket until the assembly can be moved freely back and forth 4 Hold the door closed secu
6. uum envelope destroyed and air has entered the tube This will cause internal arcing With continued use the transformer will eventually fail and the circuit fuse will blow OPERATION FAULTS OPEN FILAMENTS A magnetron with an open filament will produce no heating power An open filament lead or dead filament trans former will give the same indication as an open filament in the magnetron This possibility should be eliminated before the magnetron is considered open INTERNAL PLATE CATHODE SHORT A shorted magnetron will give the same indica tions as the loss of vacuum MODING Moding occurs when the magnetron momentar ily operates at a different frequency and a high er voltage than designed Moding results in low heating power Moding is usually caused by the cathode losing emission characteristics LOW POWER Low emission will result in low cooking power Food will require a longer than normal cooking time It can be detected by a lower than normal water temperature rise LOW EMISSION Caused by wearout of the emission charac teristics of the directly heated cathode The tube current does not get high enough to cause the tube to oscillate with normal line voltage Everything will appear normal but the tube will not heat SAFETY PRECAUTIONS FOR DISASSEM BLY AND REPAIR Cautions to be observed when trou bleshooting Unlike many other appliances the microwave oven is a high voltage high current piece
7. RANSFORMER KV MAGNETRON CAPACITOR CHASSIS N D magnetron filament terminals Measure the resistance across the two magnetron filament terminals with the ohmmeter set on RX1 If a normal resistance of less than 1 ohm between magnetron terminals is indicated on the meter make a Power Transformer Test If high resistance or infinite resistance is indi cated between the magnetron terminals replace the magnetron assembly DIODE CHECK 1 Set volt ohmmeter to read ohms using RX10 000 or higher scale 2 Check resistance between the diode termi nals Reverse leads and check again There should be considerable difference minimum of 1 2 of scale between the two readings approximately a 10 to 1 ratio If reversing the leads does not change the reading replace the diode The diode may be checked in the unit but one lead must be removed Some high impedance vacuum tube V T M or solid state F E T meters may show an acceptable diode as defective These meters will normally show high ohms open in both lead positions NOTE METERS WITH LESS THAN A 6 OR DIODE TRANSFORMER KV E MAGNETRON CAPACITOR CHASSIS 9 VOLT BATTERY ARE USUALLY NOT ADE OUATE FOR CHECKING THE FRONT TO BACK RESISTANCE OF THE DIODE THE METER SHOULD BE CHECKED WITH A DIODE KNOWN
8. SANYO COMMERCIAL MICROWAVE OVEN EM S1000 SERVICE MANUAL GE CAUTION Before servicing the oven read the Safety Precautions section on page 2 of this manual SPECIFICATIONS CONTENTS MODEL EM S1000 s an A T Power Source 230V AC 50Hz a N General Information endende Max Output Power 1000 watts Microwave Radiation Test I aaa Cavity Size 0 8 cu ft Safety Precautions for Disassembly and Repair Overrall Dimensions 520 W x412 D x296 H mm Description A Function of Components Net Weight 17 kgs Electrical Operation ococccoionnccnnornnncocarenos Door amp Interlock Adlustmments aa naene nan aaneen Model EM E1000 Component Test ProcedurcS i i uses id eii bli Power Source 230V AC 50Hz Disassembly amp Replacemont orparts Wiring Diagram ooooooccconoccccnnooccconancconnacaninancnnanos Max Output Power 1000 watts Schematic Diagram Cavity Size 1 0 cu ft Exploded View Overall Dimensions 520 W x 412 D x296 H mm Exploded View Parts List Net weight 17 kgs Product Code No EM S1000 ECO 1 437 602 04 EM S1000 EUK 1 437 602 05 EM E1000 NOTICE This service information is intended for use by a service technician who is familiar with proper and safe procedures to be followed when repairing any electrical or gas appliance and who is equipped with proper tools and testing devices Repairs covered in this publication and made by uninformed persons can result in hazar
9. TO BE GOOD BEFORE JUDGING A DIODE TO BE DEFECTIVE BECAUSE OF AN INFINITE RESISTANCE READING IN BOTH DIRECTIONS If continuity is indicated in both directions or if an infinite resistance is read in both directions the diode is probably defective and should be replaced If the diode check is normal go to Magnetron Check CHECKING H V DIODES ALTERNA TIVE METHOD Many times the diode you check as open is probably good We have found that many of you are checking them out on the wrong scale of your meter or that your meter is physically not able to check the H V diodes we use in our microwave ovens We are therefore providing an alternate test method for checking diodes in which you do not need a meter All you need is a jumper cord and a 40 watt light bulb A simple test set up like this will easily check H V diodes 40W yst The test procedure is 1 Connect an alligator clip to each terminal of diode 2 Plug in cord a If the bulb doesn t light the diode is open 6 b If bulb lights normally both ways when leads are reversed diode is shorted c A normal diode will produce a dim light when the leads are placed on the diode in one direction Before making any checks get a known good diode and make a test for comparison CAPACITOR TESTS If the capacitor is open no high voltage is avail able to the magnetron A shorted capacitor nor mally causes high line current which should trip the wal
10. access cover by en gaging the long tab into the slot provided on the bottom plate and secure the other end with an M4 self tapping screw Dear ASSEMBLY REMOVAL Disconnect power from the unit remove the cabinet and discharge the capacitor 2 Open the door and carefully remove the choke cover Remove door 3 Reverse the above procedure to install the new door assembly 4 The microwave sealing strips located on the door must not be removed or damaged SS E I um di la CHOKE COVER La DOOR Ka fi T I DSA PLASTIC Ap HINGE WASHER IMPORTANT AFTER THE DOOR HAS BEEN REPLACED THE INTERLOCKS MUST BE ADJUSTED PROPERLY SEE INTERLOCK ADJUSTMENTS SECTION BEFORE OPER ATING THE OVEN NOTE AFTER REPAIRS HAVE BEEN MADE IT IS VERY IMPORTANT TO MAKE A MICROWAVE LEAKAGE CHECK OF THE DOOR SEE THE MICROWAVE RADIATION TEST SECTION IN THIS MANUAL CONTROL PANEL ASSEMBLY REMOVAL AND REPLACEMENT 1 Unplug the power cord remove the cabinet and discharge the capacitor Open the door 2 Remove screw securing control panel to front of oven chassis 3 Toreassemble reverse the above process If provided be sure to reinstall the green ground wire under screw ELECTRONIC CONTROLLER ASSEM BLY REMOVAL 1 Disconnect power from the unit Remove the cabinet and discharge the capacitor 2 Remove screw at top that holds the control pan
11. agnetron is designed to prevent an over heated condition in the tube due to fan failure obstructed air ducts etc Under normal operating conditions the thermal protector remains closed However If abnor mally high temperatures within the magnetron approach a critical level the thermal protector will interrupt the circuit to the magnetron When the magnetron has cooled to a safe operating temperature the thermal protector closes and a cook or defrost cycle can be resumed HALF WAVE VOLTAGE DOUBLER CIRCUIT The half wave rectification circuit consists of a diode package and a single capacitor The 2070 Volts AC from the high voltage secondary wind ing is rectified to approximately 3680 Volts DC peak voltage needed for magnetron operation 1 Diode a diode is a solid state device that allows current flow in one direction but pre vents current flow in the opposite direction 2 Capacitor a capacitor is able to store elec tric energy as well as pass AC and block DC current WATER TEMPERATURE RISE CHECK The following procedure should be followed when low power is suspected in the oven but all other operations including cooking light opera tion appear normal Power output of the magnetron can be meas ured by performing a water temperature rise check This test will reguire a guart glass cup and an accurate mercury thermometer or ther mocouple type temperature tester For accu rate results the following procedure must b
12. ds developing due to improper assembly or adjustment While mak ing such repairs persons not having the proper background may subject themselves to the risk of injury or electrical shock which can be serious or even fatal A Ifthe oven is operative prior to servicing a microwave emission check should be performed prior to servicing the oven B Inform the manufacturer importer or assembler of any certified oven unit found to have a microwave emission level in excess of 5 mW cm2 Repair any unit found to have excessive emission levels at no cost to the owner see 21 CFR 1004 2 and attempt to ascertain the cause of the excessive leakage The owner of the unit should be instructed not to use the unit until the oven has been brought into compliance C Ifthe oven operates with the door open 1 tell the user not to operate the oven and 2 contact the manufacturer and or importer and CDRH immediately D Remember to connect the monitor switch after replacement and to check interlock monitor continuity IMPORTANT NOTE TO THE CONSUMER The manufacturer will not be responsible for injury or property damage arising from service performed by anyone other than author ized Service Centers If you perform service on your own products you must assume responsibility for personal injury or property damage which may result 02 03 REFERENCE NO SM 2400012 a Do not operate or allow the oven to be operated with the door open b Make the following safe
13. e fol lowed carefully 1 Fill a measuring cup with one guart of tap water and measure temperature of the water with a thermometer or thermocouple tester Stir the temperature probe through the water until the temperature stabilizes Record the temperature of the water and remove the temperature probe 2 Place the measuring cup in the oven and put the oven into the cook high cycle for exactly two 2 minutes Allow the water to heat 3 Remove cup from the oven and again meas ure temperature making sure to stir the tem perature probe through the water until max imum temperature is recorded 4 Subtract the cold water temperature from the hot water temperature The result should be 25 F 4 F or between 21 F to 29 F rise in temperature If the water temperature is accurately measured and tested for the reguired time period the test result will indi cate if the magnetron tube has low power output low rise in water temperature which would extend cooking time or high power output high rise in water temperature which would reduce cooking time Because cooking times can be adjusted to compensate for power output the magnetron tube assembly should be replaced only if the water temperature rise test indicates a power output well beyond the normal limits This test is only accurate if the power supply line voltage is 120 Volts while the oven is operating ALTERNATE TEST METRIC Use same procedure as in preceding para grap
14. el to the oven chassis 3 Controller can be replaced by removing screws through rear of control panel and replacing with new control wire for wire Reverse above steps to reinstall 4 NOTE The only replaceable parts on the controller are the complete PCB assembly and the keyboard assembly No other parts are available 5 When replacing a keyboard assembly be sure to attach it to the PCB panel THERMAL PROTECTOR REMOVAL 1 Unplug the power cord remove the outer cabinet and discharge the capacitor 2 Disconnect the connectors from the ther mal protector terminals 3 Remove the thermal protector mounting screw 4 Remove the thermal protector 5 Reverse procedure to replace MAGNETRON ASSEMBLY REMOVAL 1 Unplug the power cord remove the cabinet and discharge the capacitor 2 Remove the air guides and thermal protec tor from the magnetron RF GASKET 3 Remove the four magnetron mounting screws from the side of oven cavity 4 Disconnect wire leads from magnetron and replace on new magnetron wire for wire 5 Reverse the above procedure to reinstall new magnetron and reassemble NOTE DO NOT LOSE SCREWS THEY ARE M4 METRIC IMPORTANT DO NOT OPERATE THE OVEN WITH THE MAGNETRON DISASSEMBLED FROM THE WAVEGUIDE IMPORTANT MAKE SURE WIRE GASKET IS PRESENT BEFORE INSTALLING MAG NETRON peog Aa NN LO O IS 00 ON
15. hs except as noted 1 Use 1000 ML water 2 Timerfor two minutes 3 Same 4 Water temperature will be between 8 F to 12 F higher ELECTRICAL OPERATION By closing the door the primary and secondary interlock switches close and monitor switch opens The closed switches allow line voltage to flow through the 20 amp fuse to interlock to magnetron thermal switch At this point line voltage splits and power is applied to primary side of high voltage transformer oven cavity light fan motor and timer To complete the circuit two things must happen to energize the above Components The timer must be set which will close timer contacts and the door must be closed which activates the interlock switches At this time line voltage to neutral is applied across high voltage pri mary timer oven light and fan The 230 Volt AC input to the primary winding of the power transformer is converted to approxi mately 2070 Volts AC output from the high volt age secondary winding At the same time the filament secondary winding of the power trans former provides 3 32 Volts AC to heat the mag netron filaments The 2070 Volts AC output from the power trans former high voltage secondary winding is sent to a half wave doubling circuit comprised of a single diode and capacitor where approximate ly 4140 Volts DC peak voltage is provided to the magnetron tube The negative 4140 Volts DC applied to the cathode of the magnetron tube causes
16. ied and meas ured across transformer PRIMARY Jl amen WINDING CATHODE F 4 LOW VOLTAGE 3 35V AC D FA HIGH CURRENT FILAMENT VOLTAGE CHECK An operational test can be made in order to determine the amount of filament voltage pro duced by the power transformer CAUTION APPROXIMATELY 2070 VOLTS AC ARE PRESENT AT THE HIGH VOLTAGE TER MINAL OF THE POWER TRANSFORMER DURING COOK HIGH CYCLE OBSERVE CAUTION AT ALL TIMES 1 With oven power cord unplugged and cab inet removed discharge the capacitor with an insulated screwdriver 2 Remove the high voltage lead that con nects the capacitor to the high voltage ter minals NOTE DURING TEST OPERATION KEEP METER HANDS ETC WELL AWAY FROM THE HIGH VOLTAGE TERMINALS OF THE POWER TRANSFORMER 3 With alligator clips connect a meter capa ble of measuring up to 10 Volts AC across the magnetron filament terminals 4 Apply power to the oven and put the oven into cook high cycle to get a filament volt age reading A normal indication should be approximately 2 8 to 3 75 Volts AC Unplug the oven before disconnecting the meter leads 5 If a normal 2 8 to 3 75 Volts AC reading was indicated on the meter go to step 6 6 If the input voltage is normal but no fila ment voltage is present replace the power transformer 7 W filament voltage is normal unplug the power cord discharge the capacitor rein
17. ift the cabinet from the unit STAR a WASHER SERRATED HEAD SCREW NOTE ALL DISASSEMBLY AND REPLACE MENT OF PARTS BEGINS WITH THE CABI NET REMOVED CAUTION UNPLUG THE OVEN AND DIS CHARGE THE CAPACITOR BEFORE REMOVING ANY OF THE COMPONENTS IMPORTANT DO NOT OPERATE THE OVEN IF THE DOOR DOES NOT FIT PROPERLY THE WAVEGUIDE AND OVEN ARE NOT INTACT THE R F GASKET IS MISSING THE R F GASKET IS LOCATED AROUND THE DOME OF THE MAGNETRON TUBE TO PREVENT ANY LEAKAGE BETWEEN THE MAG NETRON TUBE AND THE WAVEGUIDE HIGH VOLTAGE DIODE REMOVAL 1 Discharge the capacitor by shorting across each terminal 2 Remove one lead from capacitor 3 Remove screw which holds other lead with offset screwdriver 4 Replace wire for wire if replacement is used Observe proper diode polarity The arrow on diode should point to the capaci tor bracket 5 Toreinstall reverse above procedure FAN ASSEMBLY REMOVAL 1 Disconnect the two lead wires from the fan motor 2 Remove fan shroud by removing shroud mounting screws 3 Remove the two motor assembly mounting screws secured to the back cabinet 4 The entire fan assembly can then be removed 5 Remove the fan blade by pulling the fan blade from the motor shaft 6 To reassemble and install reverse the above procedure Be sure to glue the fan blade onto the motor shaft CAPACITOR REMOVAL 1 Discharge the capacitor 2 Remove the screw s from capacit
18. ion we have tried to lay these tests out in a logical sequence so that you can iso late any suspected high voltage problem 1 Unplug oven from its power source 2 After removing the cabinet discharge the capacitor by shorting the two capacitor ter minals together with an insulated screw driver 3 Visually check the high voltage wiring for proper connections Refer to wiring dia gram for proper wiring sequence CAUTIONS HIGH VOLTAGES ARE PRE SENT DURING THE COOK HIGH CYCLE SO EXTREME CAUTION SHOULD BE OBSERVED WHEN TESTS ARE COMPLETE ALWAYS UNPLUG THE OVEN FROM ITS POWER SOURCE AND DISCHARGE THE CAPACITOR NOTE DO NOT TOUCH ANY OVEN COM PONENTS OR WIRING DURING OVEN OPERATION POWER TRANSFORMER TESTS TRANSFORMER INPUT VOLTAGE CHECK An operational test can be made in order to determine whether or not primary power is being applied to the transformer CAUTION APPROXIMATELY 1840V AC IS PRESENT AT THE HIGH VOLTAGE TERMI NAL OF POWER TRANSFORMER DURING COOK CYCLE OBSERVE CAUTION AT ALL TIMES 1 With the oven power cord unplugged and 5 cabinet removed discharge the capacitor with an insulated screwdriver 2 With alligator clips connect a meter capable of measuring at least 230V AC across the input terminals to the transformer HIGH VOLTAGE TERMINALS 230V AC FILAMENT SC 3 Plug oven in and set for regular cook opera tion If all primary circuits are functioning properly 230V should be appl
19. l circuit breaker or blow the line fuse An ohmmeter can be used to check for a short ed or open capacitor 1 With an ohmmeter set on the highest scale measure the resistance between the two capacitor terminals The meter should indi cate continuity between the terminals for a short time and should indicate an open cir cuit once the capacitor is charged Reversing the meter leads should give the same indication 2 If the ohmmeter indicates continuity between the capacitor terminals at all times or if no meter deflection occurs at all the capacitor should be replaced NOTE THE OHMMETER SHOULD BE SET ON THE HIGHEST RESISTANCE SCALE WHEN MAKING A CAPACI TOR CHECK CAPACITORS WITH INTERNAL RESISTOR CAN SHOW A RESISTANCE AS LOW AS TWO 2 MEGOHMS MAGNETRON THERMAL PROTECTOR MAGNETRON CAPACITOR CHASSIS TEST Unless an overheat condition exists a continu ity check across the thermal protector contacts should indicate a closed circuit The thermal protector opens at approximately 150 C 302 F if used DISASSEMBLY amp REPLACEMENT OF PARTS CABINET REMOVAL 1 Disconnect the power cord from the wall outlet 2 Remove the screws from the rear edges of the case When replacing screws make sure at least one screw has a star washer or serrated head on it for proper grounding 3 Slide the cabinet back about one inch 4 L
20. lliliters or 9 ounces of tap water in a 2 cup measuring cup 2 Place the container in the center of the oven cavity on the glass tray 3 Set power control for microwave Cook high or 100 operation Set timer for 3 minutes 4 Close the door securely and start the oven 5 Perform the proper adjustment and opera tions check with the microwave leakage meter refer to the operation instructions with the meter Check the oven by moving the probe starting at the top right hand side of the door clockwise no faster than one inch per second back to the starting position Also a check over the entire visu al screen must be made Ge EN AN Probe Speed One inch per second max IMPORTANT MICROWAVE LEAKAGE CHECK MUST BE PERFORMED ON THE REAR VENTS AND SIDE VENTS NOTE THE METER PROBE MUST BE HELD APPROXIMATELY TWO INCHES FROM THE POINT OF MEASUREMENT THIS IS ACCOMPLISHED BY THE USE OF A TWO INCH 5 cm PLASTIC SPACER THAT IS SUP PLIED WITH THE METER IT IS NORMALLY ATTACHED TO THE PROBE 6 The maximum allowable microwave leak age level is 5mW cm2 by government stan dard IMPORTANT IF THE READING IS OVER 2 mW cm2 REFER TO THE DOOR AND INTER LOCK ADJUSTMENTS SECTION IN THIS MAN UAL THE DOOR IS DESIGNED FOR LEAKAGE OF LESS THAN 1 mW cm ADJUSTMENTS SHOULD BE MADE TO BRING ALL READINGS TO BELOW 1 mW cm MAGNETRON FAILURE MODES LOSS OF VACUUM This is a case where the tube has had the vac
21. n If any of the above conditions exist DO NOT OPERATE THE OVEN Call your local author ized service representative If none of the above conditions exist proceed with properly installing the oven A minimum clearance of 3 on both sides and 1 on top and rear must be observed This will allow proper internal ventilation of the unit Also do not remove the legs because of the possibil ity of restricting the ventilation WARNING ELECTRICAL GROUNDING INSTRUCTIONS This appliance is equipped with a three prong grounding plug for your protection against shock hazard and must be plugged directly into a properly grounded receptacle Use a properly polarized and grounded three hole receptacle as is required by NATIONAL ELECTRICAL CODES on all new construction NOTE APPLIANCE MUST BE GROUNDED For the safety of the user it is required that all major appliances requiring electricity for opera tion be electrically grounded in accordance with the National Electrical Code ANSI C1 1981 3 PRONG GROUNDING PLUG WALL RECEPTACLE POWER SUPPLY CORD WITH 3 PRONG GROUNDING PLUG SS SI Y Pp SZ Check all code rules and regulations for connect ing the appliance to be certain the installation con forms with all local municipal and state codes as well as local utility regulations Where a two prong wall receptacle is encoun tered it is the personal responsibility of the user to contact a qualified electrician and ha
22. ng slight pressure the switch will release from the switch bracket 6 Remove switches and replace wire for wire Reverse above to reinstall CAUTION WHEN REPLACING THE INTER LOCK SWITCHES BE SURE THE MOUNT ING TABS ARE NOT BROKEN BENT OR OTHERWISE DEFICIENT IN THEIR ABILITY TO PROPERLY RETAIN THE INTERLOCK SWITCHES IMPORTANT DO NOT OPERATE THE OVEN UNTIL THE INTERLOCKS ARE PROPERLY ADJUSTED SEE DOOR AND INTERLOCK ADJUSTMENTS SECTIONS IMPORTANT THE INTERLOCK SWITCHES MUST MEET STRICT FEDERAL REOUIRE MENTS FOR RELIABLE OPERATION IT IS EXTREMELY IMPORTANT THAT ANY OUES TIONABLE SWITCHES BE REPLACED WITH THE EXACT SAME TYPE OBTAINED FROM THE FACTORY SERVICE PARTS DIVISION DEFECTIVE SWITCHES MUST BE REN DERED INOPERATIVE BY TWISTING ONE OF THE TERMINALS TURNTABLE OR STIRRER MOTOR AND DRIVE REMOVAL 1 Unplug the power cord remove the outer cabinet and discharge the capacitor 2 Remove the glass tray and plastic turntable assembly from the oven cavity MODEL EM E1100 3 Turn the oven upside down Remove the motor access cover Upon initial service the cover which is an integral part of the bottom plate must be cut free Use wire cutters to cut the 4 integral tabs Be careful of sharp edges 4 Remove the 2 screws securing the motor Withdraw the motor and disconnect the 2 lead wires from the motor 5 Reverse the above procedure to reinstall new parts note the following 6 Replace the motor
23. of equipment lt is completely safe during normal operation However carelessness in servicing the oven can result in an electric shock or pos sible danger from a short circuit You are asked to observe the following precau tions carefully 1 Always remove the power plug from the out let before servicing 2 Use an insulated screwdriver and wear rub ber 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 when grounded It is imperative therefore to make sure it is grounded properly before beginning repair work a Short 2 Warning about the electric charge in the high voltage capacitor For about 60 seconds after the operation stops an electric charge remains in the 3 high voltage capacitor When replacing or checking parts create a short between oven chassis and the negative high termi nal of the high voltage capacitor by using a properly insulated screwdriver to dis charge it 4 When the 10 Amp fuse is blown out due to the operation of the monitor switch replace primary and secondary interlock switches monitor switch and relay 2 5 Afterrepair or replacement of parts make sure that the screws are properly tight ened and all electrical connections are tightened 6 Do not operate without
24. or mounting bracket and swing it out of the way 3 If replacement capacitor is used replace wire for wire 4 To reassemble reverse the above proce dure It is important for high voltage clear ance that the capacitor be firmly seated For proper capacitor testing procedure see Component Test Procedures POWER TRANSFORMER REMOVAL 1 Unplug the power cord remove the outer case and discharge the capacitor 2 Disconnect all the leads to the transformer primary secondary and filament Remove the support bracket at the top of the trans former 3 Remove mounting screws from the under side of the chassis that fastens the trans former and lift the transformer out 4 Toreinstall reverse the above procedure It is important that screws be tight since they are the ground return for the high voltage winding REMOVAL OF THE OVEN LIGHT SOCKET LIGHT BULB 1 Unplug the power cord Remove the outer cabinet and discharge the capacitor 2 Remove the socket bulb mounting screw 3 Remove socket bulb assembly Remove wires from socket bulb terminals NOTE BULB IS PART OF SOCKET AND MUST BE REPLACED AS AN ASSEMBLY 4 Replace wires on terminals of new socket and replace socket bulb by reinstalling the mounting screw REPLACING THE FUSE IMPORTANT IF THE 10 AMP FUSE BLOWS REFER TO THE TESTING PROCE DURE DO NOT REPLACE IT UNTIL THE PROBLEM IS CORRECTED ALSO IF AT ANY TIME THE OVEN FUSE BLOWS DUE TO AN OVEN FAULT
25. or seals or door trim are damaged 3 If there is any visible damage to the oven Do not operate the oven if the front frame of the oven is dirty or if the interlocks are loose Microwave leakage may be present if these conditions exist Do not operate the oven if 1 any door gaskets or trim surrounding the oven door or control panel are missing 2 the waveguide and oven cavity are not intact 3 the door does not close properly Avoid operating the oven if known components in the interlock oven door or microwave generting transmission assembly are defective They must be replaced After the above precautions have been taken proceed with normal repair procedures Remember that high voltage is present so use caution to avoid electrical shock MICROWAVE RADIATION TEST NOTE A MICROWAVE LEAKAGE CHECK SHOULD BE PERFORMED AFTER ANY REPAIRS OR ADJUSTMENTS HAVE BEEN MADE ON THE DOOR FRONT FRAME AND OR INTERLOCK SWITCHES IMPORTANT IF THE READING IS OVER 2 mW cm2 REFER TO THE DOOR AND INTER LOCK ADJUSTMENTS SECTION IN THIS MAN UAL THE DOOR IS DESIGNED FOR LEAKAGE OF LESS THAN 1 mW cm ADJUSTMENTS SHOULD BE MADE TO BRING ALL READINGS TO BELOW 1 mW cm The microwave leakage measurement equip ment manufacturers presently acceptable are NARDA SIMPSON and HOLADAY More infor mation on these units can be obtained from the respective equipment manufacturers TO PERFORM MICROWAVE LEAKAGE CHECK 1 Fill 275 mi
26. ower to the unit remove the cabinet and discharge the capacitor 2 With the ohmmeter set on the RX1 scale take continuity readings as noted below A Condition 1 Door open Test Ohmmeter check from SISC to SISNO indicates open circuit B Condition Door closed Test Ohmmeter check from SISC to SISNO indicates short circuit 3 If the switch does not operate as described above replace all the switches and relay2 Repeat the above tests WARNING FOR CONTINUED PROTECTION AGAINST EXCESSIVE RADIATION EMIS SION REPLACE ONLY WITH PARTS AS DESCRIBED IN THE PARTS LIST CAUTION WHEN REPLACING THESE SWITCHES USE ONLY FACTORY REPLACE MENT PARTS REPLACING WITH ANY OTHER PART WILL VOID THE WARRANTY AND MAY CAUSE INJURY TO THE USER MONITOR MIDDLE SAFETY SWITCH TEST 1 Disconnect power to the unit Remove the cabinet and discharge the capacitor 2 With the ohmmeter set on the RX1 scale take continuity readings as noted below A Condition Door open Test Ohmmeter check from MSC to MSNC indicates open circuit B Condition Door closed INTERLOCK Test Ohmmeter check from MSC to MSNC indicates short circuit 3 If the switch does not operate as described above replace all the switches and relay2 Repeat the above tests COMPONENT TEST PRO PRIMARY INTERLOCK SWITCH LOOSEN SCREWS SECONDARY INTERLOCK SWITCH J DOOR CLOSED J DOOR OPEN HIGH VOLTAGE COMPONENT OPERA TIONAL TEST In this sect
27. perations can be continued UPPER INTERLOCK SECONDARY LOWER INTERLOCK SWITCH The secondary protective interlock switch is located behind the front control panel and is acti vated when the door is closed When the door is open this switch will interrupt the circuit MONITOR SWITCH This interlock switch disables the control panel if the door is open or the catch is out of adjust ment or the primary interlock switch fails If for some reason the primary switch and sec ondary switch stick in the closed position and the door were to be opened the circuit would be shorted through the normally closed safety switch This would blow the fuse MIDDLE INTERLOCK If there appears to be an interlock switch prob lem but the fuse is not blowing refer to the Component Test Procedure Section in this service manual NOTE IF THE INTERLOCK SWITCHES ARE REPLACED THE CATCH MUST BE ADJUST ED SEE DOOR AND INTERLOCK ADJUST MENTS SECTION FOR PROPER ADJUST MENT PROCEDURE DEFECTIVE SWITCHES SHOULD BE DESTROYED TO PREVENT POSSIBLE FUTURE USE IMPORTANT IF AT ANY TIME THE OVEN FUSE BLOWS DUE TO AN OVEN FAULT OR THE CIRCUIT BREAKER TRIPS AFTER BEING RESET ONE TIME WITH THE HOUSE CIRCUIT UNLOADED EXCEPT FOR THE OVEN THE INTERLOCK SWITCHES MUST BE REPLACED AS A GROUP THIS IS BECAUSE THE SHORT CIRCUIT CURRENTS WILL HAVE DAMAGED THESE IMPORTANT SWITCHES MAGNETRON THERMAL PROTECTOR The magnetron thermal protector located on the m
28. rely 5 Move the plastic catch toward the door until it stops and door is latched Next move the catch toward the back panel making sure it is snug against door latch Check by open ing and closing the door Using an ohmme ter place the leads of the meter across the terminals of the monitor switch As the door is opened your meter should show a short as the door is closed it should show an open circuit 6 Tighten and secure the plastic bracket with screws 7 To be totally sure that switches are func tioning properly see Primary Secondary Interlock Switch and Monitor Switch Test Procedures DO NOT ATTEMPT TO ADJUST INTERLOCK SWITCHES WITH OVEN ENERGIZED IF THIS WARNING IS NOT OBSERVED HIGH LEVELS OF MICROWAVE LEAKAGE MAY BE PRESENT NOTE IF THE INTERLOCKS ARE REPLACED THEY MUST BE ADJUSTED SEE INTERLOCK ADJUSTMENTS SECTION FOR PROPER ADJUSTMENT PROCE DURE PRIMARY UPPER SWITCH TEST 1 Disconnect power to the unit Remove the cabinet and discharge the capacitor 2 With the ohmmeter set on the RX1 scale take continuity readings as noted below A Condition Door open Test Ohmmeter check from LC to MSC indicates open circuit B Condition Door closed Test Ohmmeter check from LC to MSC indicates short circuit 3 Ifthe switch does not operate as described above replace all the switches and relay2 Repeat the above tests INTERLOCK SECONDARY LOWER INTERLOCK SWITCH TEST 1 Disconnect p
29. stall the high voltage lead and refer to the Magnetron Filament Test PO LEEREN e PRIMARY HITINY FILAMENT WINDING CATHODE a a LOW VOLTAGE 3 35V AC HIGH CURRENT N D HIGH VOLTAGE WINDING CONTINUITY CHECK POWER TRANSFORMER One side of the power transformer high voltage secondary winding is connected to oven chas sis ground The other end of the high voltage secondary has one terminal with a red lead Since approximately 2070 Volts AC are present at the high voltage secondary terminal during a cook high cycle it is not recommended that the high voltage measurements be attempted Normally a continuity check of high voltage secondary winding will be sufficient to deter mine the condition of the secondary winding 1 With oven unplugged discharge the capacitor and remove the high voltage lead from the power transformer high voltage secondary terminal 2 With an ohmmeter set on the RX1 scale measure the resistance between the high voltage terminal of the power transformer and oven chassis ground The reading should indicate around 80 ohms 3 If extremely low resistance is indicated or if extremely high or infinite resistance is indicated with the continuity test replace the power transformer A shorted trans former will blow the fuse MAGNETRON FILAMENT TEST Disconnect the high voltage leads from the DIODE T
30. ty 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 microwave power for any service test or inspection within the microwave generating compartments check the magnetron waveguide or transmission line and cavity for proper alignment integrity and connections d Any defective or misadjusted compo nents in the interlock monitor door seal PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EX POSURE TO EXCESSIVE MICROWAVE ENERGY and microwave generation and transmis sion 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 INSTALLATION INSTRUCTIONS IMPORTANT BEFORE THE UNIT IS INSTALLED INSPECT THE OVEN AND DETERMINE IF ANY OF THE FOLLOWING DAMAGE CONDITIONS EXIST 1 The door does not close firmly against the door support because the door is warped or the hinge is damaged 2 Either the door seals or the trim is dam aged 3 If there is any visible damage to the ove
31. ve it replaced with a properly grounded three prong wall receptacle in accordance with the National Electrical Codes DO NOT use a two prong adapter since proper grounding is not assured even ifthe ground wire or metal tab is connected to the outlet box The use of an extension cord is not recom mended However if it is necessary to use an extension cord it must be a type s with 3 num ber 14 wires and have a 3 prong grounded plug The extension cord should not drape over a countertop where it can be pulled on or tripped over accidentally Under no circumstances should the rounded ground prong be removed from the plug Failure to comply with the above could result in a serious shock hazard GENERAL INFORMATION IMPORTANT BEFORE PROCEEDING THE FOLLOWING INFORMATION MUST BE CAREFULLY READ TO AVOID POSSIBLE EXPOSURE TO MICROWAVE RADIATION Before servicing the oven unplug the oven remove the cabinet and take a continuity read ing of the interlock switches to assure they are operating properly Refer to the Component Test Section in this service manual Also it is very important to insure that the door seals are not damaged If a microwave leakage instrument is available check the oven for any possible microwave leakage Do not operate the oven if the following condi tions exist 1 The door does not close firmly against the door support because of the door being warped or the hinge is damaged 2 2 The do
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