Sanyo EMP495WSSS860259 Schematic

		File No :
SUPPLEMENT OF
	Microwave Oven EM-P495WS (U.S.A.)
SERVICE MANUAL

The following parts are different from the parts on model EM-P415WS (SM-860251)

Key	Part No.			Description
No.
CAVITY PARTS
2 4	617	198	5580	Sensor Assy
2 5	617	198	5542	Duct, Sensor Assy
DOOR PARTS
1	617	207	6294	Door Cover
2	617	207	6300	Door Panel

Key	Part No.				Description
No.
CONTROL PANEL PARTS
1	617	221	5853		Control Sheet
2	617	219	4578		Touch Key Board
3	617	207	6317		Control Frame
4	617	207	0377		Control Base
6	617	223	4816		Power & Control Circuit Board
9	617	207	0353		Door Release Lever
*	617	221	9424		Operating Instruction

*617 223 5882 Carton Box Complete

*	617 223 5844 Name Plate
	Product Code No.		437 499 03

See the Service Manual of EM-P415WS (SM-860251) except the items described in this Service Manual.

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, andconnections.

(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.

REFERENCE NO. SS-860259

CONTROL CIRCUIT BOARD

(Part No. 617 223 4816)

0 0 1 6 3

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CONTROL CIRCUIT BOARD

(Part No. 617 223 4816)

Key No.		Order Part No.			Description	Q’ty
INTEGRATED CIRCUIT.
IC11	409		459	4407	IC LM8853-369SP	1
IC12	409		057	3000	IC UPC358C	1
TRANSISTORS.
Q11 ~ 13	405		004	3000	2SA564A-Q-TP	3
Q101	405		082	4609	DTA123YS-TP	1
Q102,105,107	405 000			1802	DTA143XS-TP	3
Q104	405		035	4809	2SC1685-Q-TP	1
Q106	405		141	4106	DTC114YSA-TP	1
Q103	405		000	5602	DTC143XS-TP	1
DIODES.
D11 ~ 13	407		012	0309	IN4003-TP	3
D101 ~ 107	407		012	4406	ISS133-TP	9
251, 252
ZD14	407		051	4405	GZS13Y-AT1	1
ZD11	407		057	0500	RD5.6ESB3	1
ZD12	407		160	6802	HZS27NB1	1
ZD13, 101	407		132	2306	HZS3.9NB2	2
CAPACITORS.
C258	403		109	3109	Ceramic, 100PK,	1
					± 5%, 50V.
C251, 252	403		069	1207	Ceramic, 1000PK,	4
255, 256					+80 -20%, 50V.
C102	403		002	4708	Ceramic, 0.1mfd,	1
					± 5%, 25V.
C103 ~ 105,	403		069	8305	Ceramic, 0.01mfd,	4
257					± 5%, 50V.
C101	403		147	8807	Electrolytic, 1mfd,	1
					± 20%, 50V.
C13	403		147	8609	Electrolytic, 47mfd,	1
					± 20%, 10V.
C253, 254	403		152	7406	Electrolytic, 47mfd,	2
					± 20%, 16V.
C11, 12	403		188	8408	Electrolytic, 470mfd,	2
					± 20%, 25V.
RESISTORS.
R101, 107		401	012	5609	Carbon, 1K ohms	8
114,123~127					± 5%, 1/4W.
R15, 102		401	012	6903	Carbon, 10K ohms	5
108,109,116					± 5%, 1/4W.
R128 ~ 130		401	012	8006	Carbon, 100K ohms	3
					± 5%, 1/4W.
R16, 17		401	013	5202	Carbon, 1.2K ohms	2
					± 5%, 1/4W.
R56, 58		401	013	6308	Carbon, 12K ohms	2
					± 5%, 1/4W.
R259, 260		401	014	5102	Carbon, 15K ohms	2
					± 5%, 1/4W.

Key No.			Order Part No.			Description	Q’ty
RESISTORS.
R13, 14			401	016	2505	Carbon, 220 ohms	2
						± 5%, 1/4W.
R105, 11			401	016	3700	Carbon, 2.2K ohms	2
						± 5%, 1/4W.
R104, 106			401	016	4707	Carbon, 22K ohms	2
						± 5%, 1/4W.
R111, 112			401	016	9603	Carbon, 27 ohms	2
						± 5%, 1/4W.
R115			401	017	1705	Carbon, 2.7K ohms	1
						± 5%, 1/4W.
R110			401	018	2701	Carbon, 330 ohms	1
						± 5%, 1/4W.
R113			401	018	3708	Carbon, 3.3K ohms	1
						± 5%, 1/4W.
R117~122			401	020	1907	Carbon, 4.7K ohms	6
						± 5%, 1/4W.
R103,			401	020	2805	Carbon, 47K ohms	3
51, 53						± 5%, 1/4W.
R12			401	021	2903	Carbon, 5.6K ohms	1
						± 5%, 1/4W.
R18, 19			401	023	0600	Carbon, 82 ohms	5
253, 254, 261						± 5%, 1/4W.
R252			401	103	3309	MT-Film, 1.47K ohms	1
						± 1%, 1/6W.
R251			401	112	4106	MT-Film, 1.54K ohms	1
						± 1%, 1/6W.
R255, 256			401	155	7706	MT-Film, 2.05K ohms	2
						± 1%, 1/6W.
R257, 258			401	155	7805	MT-Film, 820K ohms	2
						± 1%, 1/6W.
RESISTORS BLOCKS.
RB251			617	122	9066	Resistor Network	1
MISCELLANEOUS.
B Z 1			420	000	6800	Buzzer PKM22EPT-2001.	1
V S T 1			407	118	5505	Varistor ENC 471D-10A.	1
DT1			617	220	9784	Display Tube.	1
RL1			617	137	9358	Relay, OJE-SH-112LM.	1
RL2			617	141	0549	Relay, DEC DU12D1-1PR.	1
R S 1			617	128	3372	Ceramic Oscillator.	1
S 1			617	169	4109	Connector.	1
S 1 0 1			617	126	8959	Connector, 11P, Male.	1
S 2 0 1			617	002	4396	Connector, 3P, Male.	1
S 1 0 2			617	111	1392	Connector, 2/3P, Male.	1
P T 1			617	178	3933	Step-Down Transformer	1
						P6TK-N101.
2			617	079	4107	Spacer.	1
J1 ~ 4			617	079	4299	Jumper.	4
J101 ~ 110			617	079	4237	Jumper.	1 0

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OVERALL CIRCUIT DIAGRAM

		For Parts or Service Contact
		SANYO FISHER SERVICE COMPANY
		21605 Plummer Street,
JUNE ‘99. 1200 LT Printed in Singapore	- 3 -	Chatsworth, CA91311 U.S.A.

File No :

SERVICE MANUAL Microwave Oven EM-P415WS (U.S.A.)

	Product Code No.		437 499 00

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, andconnections.

(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.

REFERENCE NO. SM-860251

CAUTION

For microwave energy emission

On every service calls, check for microwave energy emission, must be made according to the following manner.

Measurement of energy emission

Measurement must be made with the microwave oven operating at its maximum output and containing a load of 275±15 milliliters of tap water initially at 20o±5o celsius (68 ±9oF) placed within the cavity at the center.

NOTE : The water container must be a 600 milliliter beaker and made of an electrically none conductive material such as glass or plastic.

The cook tray must be in place when measuring emission.

A properly operating door and seal assembly will normally register emission on greater than 4mW/cm2 to allow for measurement uncertainty with the cooking shelf or tray in place.

All repairs must be performed in such a manner that microwave energy emission are minimal.

Follow the instructions supplied with a detector being used and performed an R.F. emission test around the door front and edges and all edges and vent of the outer case. The cabinet (wrapper) must be in place and the oven fully assembled.

When performing emission survey, with the meter on FAST RESPONSE the movement of a detector probe shall not exceed one (1) inch per second.

In the area emitting the highest reading, switch the meter to SLOW RESPONSE, and take a reading for minimum of three (3) seconds. We recommended the pattern outline shown below when the door surface is surveyed.

NOTE : Periodically check to be sure that the probe tip is not worn or dirty.

The following U.S. standard applies to microwave ovens : 21 CFR 1030.10, Performance Standard for Microwave Ovens.

It requires that the power density of the microwave radiation emitted by a microwave oven shall not exceed five (5) milliwatts per square centimeter at any point 5 centimeter (about 2 inches) or more from the external surface of the oven.

All microwave ovens exceeding the emission level of 4mW/cm2 must be reported to Dept. of Service for microwave ovens and the manufacturer immediately and the owner should be told not to use the microwave oven until it has been repaired completely.

If a microwave oven is found to operate with the door open, report to Dept. of Service, the manufacturer and CDRH* immediately. Also tell the owner not to use the oven.

*CDRH : Center for Device and Radiological Health.

The interlock monitor switch acts as the final safety switch protecting the customer from microwave radiation. If the interlock monitor switch operates to blow the fuse with interlocks failed, you must replace all interlock switches primary and secondary interlock switches and the monitor switch with new ones because the contacts of those interlock switches may be melted and welded together.

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- TABLE OF CONTENTS -

Adjustment Procedures ...................................................	1	Test Procedures and Troubleshooting ....................	4 ~ 10
Specifications ..................................................................	2	Disassembly Instructions .......................................	11	~	14
Power Output Measurement ...........................................	2	Exploded View and Parts List ................................	15	~	20
Precautions and Repair Service Tips ..............................	2	Overall Circuit Diagram ..........................................			21
Circuit Diagram ...............................................................	3

1. ADJUSTMENT PROCEDURES

TO AVOID POSSIBLE EXPOSURE TO MICROWAVE ENERGY LEAKAGE, THE FOLLOWING ADJUSTMENT OF THE INTERLOCK SWITCHES SHOULD BE MADE ONLY BY AUTHORIZED SERVICE PERSONNEL.

The SANYO service center should have the designated detector to measure the microwave energy leakage after the repair or adjustment.

NOTE : Detector to be used at the service center is NARDA 8100, 8200 or the equivalent.

PRIMARY INTERLOCK SWITCH, INTERLOCK MONITOR SWITCH AND DOOR SENSING SWITCH ADJUSTMENT

(Figure 1)

(1)Loosen 2 screws securing the Lever Stopper.

(2)Adjust the Lever Stopper position so that it is pushed forward and pull backward until there is about zero gap between the Latch Lever and the switch body on the Primary Interlock Switch and at the same time there is about zero gap between the Door Latch and the switch body on the Door Sensing Switch when the Door Latch is securely locked.

(3)Tighten the Lever Stopper screws securely.

(4)Make sure the Interlock Monitor Switch closes after the Primary Interlock Switch opens when the Door is opened very slowly, according to “CHECKOUT PROCEDURE FOR SWITCHES” on page 6.

(5)Make sure the Interlock Monitor Switch opens before the Primary Interlock Switch closes when the Door is closed very slowly, according to “CHECKOUT PROCEDURE FOR SWITCHES” on page 6.

(6)Make sure the microwave energy leakage should be no greater than 4mW/cm2 to allow for measurement uncertainty when measured with a detector.

(All service adjustments must be made for minimum microwave energy leakage readings.)

NOTE : If the Interlock Monitor Circuit operates and at the same time the Fuse blows with the Door opened, be sure to replace the Control Circuit Board because Relay 2 on the Control Circuit Board, the Door Sensing Switch and the electric circuit related on the Door Sensing Switch, which act as Secondary Interlock Switch.

Door

Latch

Lever Stopper

Door

Sensing

Switch

Interlock

Monitor

Switch

Screws

Latch	Primary
Lever	Interlock
Figure 1	Switch

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2. SPECIFICATIONS

4. PRECAUTIONS AND REPAIR SERVICE TIPS

Rated Power Consumption ..	1650W.
Microwave Output ................	1100W.
Frequency .............................	2,450MHz±50MHz.
Power Supply ........................	120V±12V, 60Hz.
Rated Current .......................	14 Amp.
Safety Devices .....................	Thermal Fuse open at
	332°F (167°C) for Cavity.
	Thermal Protector open at
	275°F (135°C) for Magnetron.
	Fuse (Cartridge Type 20A)
	Primary Interlock Switch,
	Door Sensing Switch and
	Relay 2.
	Interlock Monitor Switch.
Timer .....................................	Electronic Digital, up to
	99 min. 99 sec.
Overall Dimensions ................	205/8”(W) x 161/2”(D) x 113/8”(H)
Oven Cavity Size ..................	133/4”(W) x 145/8”(D) x 81/4”(H)
Turn Table Diameter ..............	107/8”
Effective Capacity of
Oven Cavity ..........................	1.1 Cubic Feet.
Net Weight ...........................	Approx. 34.1 Lbs.

3. POWER OUTPUT MEASUREMENT

NOTE

The power output specification, 1100W. on this model is measured with IEC measurement. The power output is measured with two (2) liters water is equivalent to 1100W. in measurement with IEC, when measured with the following power output.

(1)Fill two beakers (glass or plastic) with each one liter of tap water (about 20°C) and measure the water temperature. (Use a thermometer with a 1/10 degree gauge).

(2)Place the beakers side by side in the center of the glass tray.

(3)Close the door, set the “TIME” for two minutes. (“200” in the display window). Touch the “START” key and heat the water exactly for two minutes.

(4)Take the beakers out, immediately stir the water and measure the water temperature respectively.

(5)Calculate the temperature rise of water in each beaker. Then calculate the average value of two temperature rises.

Output power can be calculated by the equation : Power Output (W) = 70 x ∆ t

Where ∆ t is an average temperature rise in degrees Centigrade.

(6)Power Output shall be in the following range :

	Average Temperature Rise	Power Output
Minimum	22.9°F (12.7°C)	889W
Maximum	29.3°F (16.3°C)	1141W

(7)Power Output is affected by the line voltage under load. For correct Power Output measurement, the line voltage under load must be 120±1 volts.

PRELIMINARY

A.SINCE NEARLY 2,000 VOLTS EXISTS IN SOME CIRCUITS OF THIS MICROWAVE OVEN, REPAIRS SHOULD BE CARRIED OUT WITH GREAT CARE.

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

(1)Before the power is applied :

(a)Open and close door several times to make sure the primary interlock switch, the interlock monitor switch and the door sensing switch operate properly.

(Listen for the clicking sound from the switches). Make sure the interlock monitor switch closes after the primary interlock switch is opens when the door is opened. (See pages 1 and 6).

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

(2)After the power is applied :

(a)Open and close the door to see if the interlock mechanism operates properly.

(b)Check microwave energy leakage with a leakage detector and confirm the energy leakage should be no greater than 4mW/cm2 to allow for measurement uncertainty.

(3)Do not operate the unit until it is completely repaired, if any of the following conditions exists :

(a)Door does not close firmly against the cavity front.

(b)The hinge is broken.

(c)The choke dielectric or the door seal is damaged.

(d)The door is bent or warped, or there is any other visible damage to the oven that may cause microwave energyleakage.

NOTE : Always keep the seal clean.

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

(f)Make sure there are no defective 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 on the magnetron is properly positioned.

(c)Waveguide and oven cavity are intact (no leakage of microwave energy).

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

(e)The oven must be stopped when the door is opened or the time is up.

The oven must not be operated with any of the above components removed or bypassed.

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