Kenmore 721.63684, 721.63683, 721.63689, 721.63682 Service Manual

TECHNICAL FLASH

R

BASIC SERVICE MANUAL

FOR

MICROWAVE HOOD COMBINATION

MODEL 721. 63682 721. 63683 721. 63684 721. 63689

FEBRUARY, 2003

CAUTION

WARNING TO SERVICE TECHNICIANS

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 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, 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.

•Proper operation of the microwave ovens requires that the magnetron be assembled to the wave guide and cavity. Never operate the magnetron unless it is properly installed.

•Be sure that the magnetron gasket is properly installed around the dome of the tube whenever installing the magnetron.

•Routine service safety procedures should be exercised at all times.

•Untrained personnel should not attempt service without a thorough review of the test procedures and safety information contained in this manual.

FOREWORD

Read this Manual carefully. Failure to adhere to or observe the information in this Manual may result in exposing yourself to the Microwave Energy normally contained within the oven cavity.

MODEL 721. 63682 721. 63683 721. 63684 721. 63689

TABLE OF CONTENTS
	(Page)
SAFETY PRECAUTIONS .........................................................................................................	Inside front page
SPECIFICATIONS......................................................................................................	.........................	1-1
CAUTIONS .........................................................................................................	..............................	2-1
INSTALLATIONS.....................................................................................................	..........................	3-1
OPERATING INSTRUCTIONS.......................................................................................................................		4-1
CONTROL PANEL .................................................................................................................................		4-1
CONTROL PANEL INSTRUCTIONS .....................................................................................................		4-2
OVERALL CIRCUIT DIAGRAM..................................................................................................	..............	5-1
SCHEMATIC DIAGRAM................................................................................................................		5-1
MATRIX CIRCUIT FOR TOUCH KEY BOARD ......................................................................................	5-2
GENERAL INFORMATION FOR SERVICE ................................................................................................	...	6-1
GENERAL PRECAUTIONS IN USE .....................................................................................................	.	6-1
TRIAL OPERATION ......................................................................................................	...............	6-1
FEATURES AND SPECIFICATIONS FEATURES.................................................................................	6-1
SERVICE INFORMATION .............................................................................................................................		7-1
PRECAUTIONS AND REPAIR SERVICE TIPS .....................................................................................	7-1
MICROWAVE LEAKAGE TEST .............................................................................................................		7-2
POWER OUTPUT MEASUREMENT .....................................................................................................	7-	3
DISASSEMBLY INSTRUCTIONS ..........................................................................................................		7-4
INTERLOCK SYSTEM ..........................................................................................................................		7-12
INTERLOCK CONTINUITY TEST ...................................................................................................	....	7-14
TEST AND CHECKOUT PROCEDURES AND TROUBLESHOOTING.................................................	7-15
A. TEST PROCEDURES.........................................................................................................	....	7-15
B. CHECKOUT PROCEDURES.....................................................................................................	7-19
C. TROUBLESHOOTING .............................................................................................................		7-22
EXPLODED VIEW ........................................................................................................	........................	8-1
REPLACEMENT PARTS LIST ......................................................................................................	......	8-8
SCHEMATIC DIAGRAM OF PCB .......................................................................................................		8-16
PRINTED CIRCUIT BOARD ....................................................................................................	........	8-17
PCB PARTS LIST...................................................................................................................................		8-18

	SPECIFICATIONS
Rated Power Consumption			1400W maximum (Microwave oven+Cook top lamps+Ventilation fan)
Microwave Output			1200W (IEC 60705)
Frequency			2,450 MHz ± 50 MHz
Power Supply		120 VAC, 60 Hz
Rated Current		12 Amp. (Microwave oven+Cook top lamps+Ventilation fan)
Magnetron Cooling		Forced Air Cooling
Rectification			Rectification Voltage Double Half-Wave
Door Sealing			Choke System
Safety Devices		Thermostat:
			Open at 110		°C ± 5 °C
			Close at 0		°C ± 5 °C
			Fuse(20A)
			Primary Interlock Switch
			Secondary Interlock Switch
			Interlock Monitor Switch
Inverter			P1-1019, 120 V
Magnetron			2M261
Cook top Lamp		120 V, 20 W (Halogen)
Cavity Lamp		125 V, 30 W or 40 W
Timer			Digital, up to 99 min. 99 sec. (in each cooking stage)
Tray			Tempered Safety Glass
Overall Dimensions	29		15	/16 ”(W)x16		7		3	”(D)
						/16		”(H)x15 /8
Oven Cavity Size	23		1/2 ”(W)x103 /16 ”(H)x141/2 ”(D)
Effective Capacity of Oven Cavity	2.0 Cu.ft.
Accessories		Owner’s Manual & Cooking Guide, Installation Manual,
			Exhaust Adapter, Exhaust Damper, Mounting Kit and Filter,
			Rotating Ring Assembly, Glass Tray, Metal Rack.
			SWITCH CHART
			PRIMARY					SECONDARY	INTERLOCK
SWITCH MODE			INTERLOCK				INTERLOCK		MONITOR
			SWITCH					SWITCH		SWITCH
CONDITIONS			COM					COM		COM
			NO					NO		NC
DOOR OPEN
DOOR CLOSED

NOTE: Use the above switch chart with circuit diagram on page 5-1.

1-1

CAUTIONS

Unlike other appliances, the microwave oven is high-voltage and high-current equipment. Though it is free from danger in ordinary use, extreme care should be taken during repair.

•DO NOT operate on a 2-wire extension cord during repair and use.

•NEVER TOUCH any oven components or wiring during operation.

•BEFORE TOUCHING any parts of the oven, always remove the power plug from the outlet.

•Remove your watches whenever working close to or replacing the Magnetron.

•DO NOT touch any parts of the control panel circuit. A resulting static electric discharge may damage this P.C.B.

•NEVER operate the oven with no load.

•NEVER injure the door seal and front plate of the oven cavity.

•NEVER put iron tools on the magnetron.

•NEVER put anything into the latch hole and the interlock switches area.

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 connection.

All input and output microwave connections, waveguide, flange, and gasket must be secure never operate the device without a microwave

energy absorbing load attached.

Never look into an open waveguide or antenna while the device is energized.

•Proper operation of the microwave oven requires that the magnetron be assembled to the waveguide and cavity. Never operate the magnetron unless it is properly installed.

•Be sure that the magnetron gasket is properly installed around the dome of the tube whenever installing the magnetron.

ANTENNA

Gasket

COOLING FIN

FILAMENT

TERMINALS

MAGNETRON

CHASSIS GROUND

MAGNETRON

THE OVEN IS TO BE SERVICED ONLY BY PROPERLY QUALIFIED SERVICE PERSONNEL.

2-1

INSTALLATIONS

BEFORE YOU BEGIN, READ THE FOLLOWING INSTRUCTIONS COMPLETELY AND CAREFULLY.

PRECAUTIONS ON INSTALLATION

A.Plug the power supply cord into a 120V AC, 60Hz, single-phase power source with a capacity of

at least 20 amperes.

B.Avoid placing the unit in a location where there is

direct heat or splashing water.

C.Install the unit on the mounting plate firmly.

D.Place the unit as far away as possible from TV, radio, etc. to prevent interference.

GROUNDING INSTRUCTIONS

For personal safety, this appliance must be fully grounded at all times.

In the event of an electrical short circuit, grounding reduces the risk of electrical shock.

The plug must be plugged into an outlet that is properly installed and grounded.

CAUTION

This unit is equipped with a 3-prong plug for your safety. If the wall outlet is a grounded 3-hole type, the unit will be grounded automatically.

Plug with Ground

Prong

Properly Polarized

and Grounded

Outlet

WARNING

Improper use of the grounding plug can result in a risk of electric shock.

Do not, under any circumstances, cut or remove the third ground prong from the power cord plug.

3-1

OPERATING INSTRUCTIONS

CONTROL PANEL

1

2

3

6

7

10

12

15

17

18

20

23

24

26

4

5

8

9

11

13

14

16

19

21

22

25

27

28

4-1

CONTROL PANEL INSTRUCTIONS

1.Display. The display includes a clock and indicators to tell you time of day, cooking time settings, cook powers, quantities, weights, and cooking functions selected.

2.Popcorn. Touch this pad to pop popcorn with the

sensor feature. The oven’s sensor will tell the oven how long to cook depending on the amount of humidity it

detects from the popcorn.

3.Pizza. Touch this pad to reheat one or several slices of pizza without entering a cook time or power.

4.Vegetable. Touch this pad to cook without entering a cook time or power.

5.Potato. Touch this pad to cook potatoes without entering a cook time or power.

6.Frozen Entree. Touch this pad to cook a 10to 21ounce frozen entree without entering a cook time or

power.

7.Dinner Plate. Touch this pad to cook without entering a cook time or power.

8.Sure Simmer. Touch this pad to simmer soups, casseroles, stews, and other liquid foods.

9.Number Pads. Touch number pads to enter cooking times, cook powers, quantities, weights, or food categories.

10.Cook Time. Touch this pad followed by Number Pads to set a cooking time.

11.Power. Touch this pad after the cook time has been set, followed by a Number Pad to set the amount of microwave energy released to cook the food. The

higher the number, the higher the microwave power or “cooking speed.”

12.Add Minute. Touch this pad to cook for 1 minute at 100% cook power, or to add extra minutes at the set cook power to your cooking cycle.

13.Less. Touch this pad to subtract 10 seconds of cook time each time you press it.

14.More. Touch this pad to add 10 seconds of cook time each time you press it.

15.Start. Touch this pad to start a function. If you open the door after the oven begins to cook, retouch Start.

16.Stop/Clear. Touch this pad to erase an incorrect command, cancel a program during cooking, or to clear the Display.

17.Auto Cook. Touch this pad to cook microwavable foods without entering a cook time or power.

18.Auto Reheat. Touch this pad to reheat microwavable foods without entering a cook time or power.

19.Hold Warm. Touch this pad to keep hot, cooked foods safely warm in your oven for up to 99 minutes, 99

seconds. Hold Warm can be used by itself, or it can automatically follow a cooking cycle.

20.Clock. Touch this pad to enter the time of day.

21.Auto Defrost. Touch this pad followed by Number Pads to thaw frozen meat by weight.

22.Express Defrost. Touch this pad to express defrost. “GROUND BEEF 1.0 LBS TOUCH START” will

appear in the display.

23.Kitchen Timer. Touch this pad to set the Kitchen Timer.

24.Melt. Touch this pad to melt chocolate, cheese, butter, or marshmallows.

25.Soften. Touch this pad to soften ice cream, cream cheese, butter, or frozen juice.

26.Vent On/Off. Touch this button to turn the fan on or off.

27.Vent 5 Speed. Touch this button to choose one of 5 fan speeds.

28.Light High/Night/Off. Touch this button to turn the light on high, night, or off.

NOTE: If you try to enter incorrect instructions, you will not hear any tones. Touch STOP/CLEAR and re-enter the

instructions.

4-2

OVERALL CIRCUIT DIAGRAM

SCHEMATIC DIAGRAM

5-1

MATRIX CIRCUIT FOR TOUCH KEY BOARD

	1	2	3	4	5	6	7
1	2	3	4	5	6	7
8
N.C	FROZEN	N.C	HOLD	EXPRESS	SURE	N.C
	ENTREE		WARM	DEFROST	SIMMER
9
VENT	VENT	LIGHT	DINNER	N.C	SOFTEN	MELT
ON/OFF	5 SPEED		PLATE
10
VEGETABLE	AUTO	POTATO	AUTO	ADD	PIZZA POPCORN
	REHEAT		DEFROST	MINUTE
11
N.C	AUTO	N.C	KITCHEN	CLOCK	MORE	LESS
	COOK		TIMER
12
POWER	COOK	STOP/	START	8	9	0
	TIME	CANCEL

13

5-2

GENERAL INFORMATION FOR SERVICE

GENERAL PRECAUTIONS IN USE

A.Never operate the unit when it is empty.

Operating the oven with no load may shorten the life of the magnetron. Whenever cooking dry foods

(dried fish, bread, etc.) or a small amount of food, be sure to put a glass of water into the cooking compartment. The glass turntable may become hot

after operating, be careful when touching it.

B.Aluminum foil should be avoided because it will disrupt cooking and may cause arcing. However, small pieces may be used to cover some parts of

food to slow the cooking. Any aluminum foil used should never be closer than 2.5 cm to any side wall of the oven.

TRIAL OPERATION

After installation, the following sequences and results should be checked carefully.

A.Put a container filled with water (about 1 liter) into the oven, and close the door tightly.

B.Set cooking time for 10 minutes by touching “1”

and then “0” three times. “1, 0, 0, 0” appears in the display window.

C. Touch the START key.

Make sure the cavity light comes on. The unit will begin cooking and the display window will show the time counting down by seconds.

D.After about 5 minutes, make sure the primary interlock switch, the secondary interlock switch and the interlock monitor switch operate properly by opening and closing the door several times. Touch the START key each time the door is closed.

E.Continue operating the unit. Two short and a long beep sound signal is heard when the time is up. The unit will shut off automatically.

F.Confirm the water is hot.

G.Finally, measure the output power according to “POWER OUTPUT MEASUREMENT” on

page 7-3.

FEATURES AND SPECIFICATIONS FEATURES

A.The safety systems incorporated in this model are:

(1)Primary interlock switch

(2)Secondary interlock switch

(3)Interlock monitor switch

(4)Choke system

(5)Oven cavity thermostat

(Note: This thermostat located on the oven cavity will open and stop the unit from operation only if a high temperature is reached, such as, a fire created by overcooking food.)

B.Any one of 10 power output levels ranging 0W to 1200W can be selected by the touch control and electronic computer system.

C.Cooking time can be displayed on the digital readout.

D.Three different cooking stages (Include Defrost) can be changes from one cooking stage to another. This is made possible with the memory function of the microprocessor.

6-1

SERVICE INFORMATION

PRECAUTIONS AND REPAIR SERVICE TIPS

PRELIMINARY

A.SINCE NEARLY 4000 VOLTS EXISTS IN SOME CIRCUITS OF THIS UNIT REPAIRS SHOULD BE CARRIED OUT WITH GREAT CARE.

The filament leads of magnetron carry High Voltage with respect to ground. Extreme caution must be exercised. Never plug the unit into a power source to determine which component is defective in high voltage section.

B.TO AVOID POSSIBLE EXPOSURE TO MICROWAVE ENERGY LEAKAGE, THE FOLLOWING PRECAUTIONS MUST BE TAKEN BEFORE SERVICING.

(1)Before the power is applied:

(a)Make sure the primary interlock switch, the secondary interlock switch and the interlock monitor switch operate properly by opening and closing the door several by opening and closing the door several times.

(b)Make sure the perforated screen and the dielectric choke of the door are correctly and firmly mounted.

(2)After power is applied:

(a)Make sure the interlock switch mechanism

is operating properly by opening and closing the door.

(b)Check microwave energy leakage must be below

the limit of 5 mW/cm

2 .

(All service adjustments should be made for

minimum microwave energy leakage

readings).

(3) Do not operate the unit until it is completely repaired, if any of the following conditions exist. The unit must not be operated.

(a)The door does not close firmly.

(b)The hinge is broken.

(c)The door seal is damaged.

(d)The door is bent or warped, or there is any other visible damage on the unit that may cause microwave energy leakage.

NOTE: Always keep the seal clean.

(e)Make sure that there are no defective parts in the interlock mechanism.

(f)Make sure that there are no detective parts in the microwave generating and transmission assembly (especially waveguide).

(4)The following items should be checked after the unit is repaired:

(a)The interlock monitor switch is connected correctly and firmly.

(b)The magnetron gasket is properly positioned and mounted.

(c)The waveguide and the oven cavity are intact. (no microwave energy leakage)

(d)The door can be properly closed and the safety switches work properly.

(e)The unit must stop when the door is opened or the time is up.

The unit must not be operated with any of the above components removed or by-passed.

7-1

MICROWAVE LEAKAGE TEST

CAUTIONS

•Be sure to check microwave leakage prior to servicing the oven if the oven is operative prior to servicing.

•The service personnel should inform the manufacture importer, or assembler of any certified oven unit found to have a microwave emission level in excess of 5 mW/cm2 and should repair any unit

found to have excessive emission levels at no cost to the owner and should ascertain the cause of the excessive leakage. The service personnel should

instruct the owner not to use the unit until the oven has been brought into compliance.

•If the oven operates with the door open, the service

personnel should;

-Tell the user not to operate the oven

-Contact the manufacturer and CDRH (Center for Devices and Radiological Health) immediately. NOTE: Address on CDRH

Office of Compliance (HFZ-312)

Center for Devices and Radiological Health

1390 Piccard Drive Rockville, Maryland 20850

•The service personnel should check all surface and vent openings for microwave emission testing.

•Check for microwave energy leakage after every servicing. The power density of the microwave radiation leakage emitted by the microwave oven should not exceed 1mW/cm.sq. And always start measuring of an unknown field to assure safety for operating personnel from radiation leakage. NOTE: The standard is 5mW/cm.sq. while in the customer’s home. 1mW/cm.sq. stated here is manufacturer’s own voluntary standard for units in customer’s home.

EQUIPMENT

•TESTER (VOLTS-DC, AC, Ohmmeter)

•Microwave survey meter

- Holaday HI-1500

HI-1501 - Narda 8100

8200

• 600 cc non conductive material beaker (glass or

plastic), inside diameter: approx. 8.5 cm (3 1/2 in.)

• Glass thermometer: 100°C or 212°F (1 deg scale)

MEASURING MICROWAVE ENERGY

LEAKAGE

•Pour 275±15cc of 20±5°C(68±9°F) water in a beaker which is graduated to 600 cc, and place the beaker on the oven.

•Set the energy leakage monitor to 2,450 MHz and use it following the manufacturer's recommended test procedure to assure correct result.

•When measuring the leakage, always use the 2-inch (5cm) spacer supplied with the probe.

•Operate the oven at its maximum output.

•Measure the microwave radiation using and electromagnetic radiation monitor by holding the probe perpendicular to the surface being measured.

Move probe along shaded area.

Probe scanning speed

Less than 2.5 cm/sec. ( 1 in/sec)

7-2

MEASUREMENT WITH THE OUTER CASE REMOVED

(1) When you replace the magnetron, measure for microwave energy leakage before the outer case is installed and after all necessary components are replaced or adjusted. Special care should be taken in measuring the following parts.

-Around the magnetron

-The waveguide

WARNING: AVOID CONTACTING ANY HIGH

VOLTAGE PARTS.

NOTE WHEN MEASURING

(1)Do not exceed meter full scale deflection.

(2)The test probe must be removed no faster than 1 inch/sec (2.5cm/sec) along the shaded area, otherwise a false reading may result.

(3)The test probe must be held with the grip portion of the handle. A false reading may result if the operator’s hand is between the handle and the probe.

(4)When testing near a corner of the door, keep

the probe perpendicular to the surface making sure the probe horizontally along the oven surface, this may possibly cause probe damage.

MEASUREMENT WITH A FULLY				RECORD KEEPING AND NOTIFICATION
ASSEMBLED OVEN
				AFTER MEASUREMENT
(1)	After all components, including the outer
				(1)	After adjustment and repair of any microwave
	panels, are fully assembled, measure for
					energy interruption or microwave energy blocking
	microwave energy leakage around the door
					device, record the measured values for future
	viewing window, the exhaust opening and air
					reference. Also enter the information on the
	inlet openings.
					service invoice.
(2)	Microwave energy leakage must not exceed the
				(2)	Should the microwave energy leakage not be
	values prescribed below.
					more than 1 mW/cm	2 after determining that all
	NOTES:
					parts are in good condition, functioning properly
	Leakage with the outer panels removed - less
					and genuine replacement parts which are listed in
	than 5 mW/cm	2 .
					this manual have been used.
	Leakage for a fully assembled oven (“Before		the
				(3)	At least once a year, have the electromagnetic
	latch switch (primary) is interrupted”) with the door
					energy leakage monitor checked for calibration
	in a slightly opened position - less than 1 mW/cm			2 .
					by its manufacturer.

POWER OUTPUT MEASUREMENT

(1) Microwave power output measurement is made

with the microwave oven supplied at its rated voltage and operated at its maximum microwave power setting with a load of (1000±5) g of potable water.

(2)The water is contained in a cylindrical borosilicate glass vessel having a maximum material thickness

of 1/8” (3 mm) and an outside diameter of approximately 7.6” (190mm).

(3)The oven and the empty vessel are at ambient Temperature(T0) prior to the start of the test.

(4)The initial temperature (T1) of the water is

(10±1)°C (50°F) It is measured immediately before the water is added to the vessel. After addition of the water to

the vessel, the load is immediately placed on the center of the turntable which is in the lowest position and the microwave power switched on.

(5)	The time t for the temperature of the water to rise
	by a value	T of (10±1)°K is measured, where t is the
	time in seconds and	T is the temperature rise.
	The initial and final water temperatures are selected so
	that the maximum difference between the final water
	temperature and the ambient temperature is 5°K.
(6)	The microwave power output P in watts is calculated
	from the following formula :

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

is measured while the microwave generator is

operating at full power. Magnetron filament heat-up time is not included. (about 5 sec)

(7)The water is stirred to equalize temperature throughout the vessel, prior to measuring the final water temperature.

(8)Stirring devices and measuring instruments are selected in order to minimize addition or removal of heat.

Where

P is the microwave power output, in watts: Mw is the mass of the water, in grams: Mc is the mass of the container, in grams: T0 is the ambient temperature, in °C:

T1 is the initial temperature of the water, in °C: T2 is the final temperature of the water, in °C:

t is the heating time in seconds, excluding the magnetron filament heatup time.

WATER LOAD

GLASS TRAY

7-3

DISASSEMBLY INSTRUCTIONS

IMPORTANT NOTES:

UNIT MUST BE DISCONNECTED FROM ELEC-

TRICAL OUTLET WHEN MAKING REPAIRS, RE-

PLACEMENTS, ADJUSTMENTS AND CONTIN-

UITY CHECKS.

WHEN RECONNECTING THE WIRE LEADS TO

ANY PART, MAKE SURE THE WIRING CONNE-

CTIONS AND LEAD COLORS ARE CORRECTLY

MATCHED ACCORDING TO THE OVERALL CIR-

CUIT DIAGRAM. (ESPECIALLY SWITCHES AND

HIGH VOLTAGE CIRCUIT.)

A.REMOVING POWER AND CONTROL CIRCUIT BOARD (Figures 1, 2 and 3)

(1)Remove a screw securing the control panel assembly to the oven cavity.

(2)Remove the control panel with pushing it upward.

(3)Remove the connectors (CN1), and sensor (CN5)

wire leads (RY2, CN2, CN4) from the circuit board.

Control Panel

Screw

Circuit Board

(CN4) (CN5)

(CN2)

(RY2)

Power Transformer

(CN1)

Figure 1

(4) Remove 3 screws securing the circuit board.

Circuit Board

Figure 2

(5)Remove the FPC connector from the terminal socket following “HOW TO REMOVE THE FPC CONNECTOR” on the next page.

(6)Remove the circuit board from the control bracket carefully.

Control Bracket

FPC Connector(CN3)

Circuit Board

Figure 3

7-4