Amana P1199603M Service Manual Download Page 37

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Disassembly

RS5320014 Rev. 0

WARNING

To avoid risk of electrical shock, personal injury, or
death, disconnect power to oven and discharge
capacitors before following any disassembly procedure.

Fan Blade

1. Remove top mounting clip from end of shaft.
2. Pull blade off shaft.
3. When reinstalling blade, push blade on shaft and

rotate to insure clearance between fan blade and
motor mounting bolt.

H.V. Board

1. Unplug connectors.
2. Disconnect wires from terminals E1, E2, and E3.
3. Disconnect sense loop wire from cavity thermal

protector.

NOTE: Be sure to route wire through sensing loop when

replacing high voltage board.

Red Wire

to Cavity TCO

Current

Sense

Loop

High Voltage Board

Mounting

Clips

4. Disconnect seven mounting clips, by pushing clips

away from the board.

Cavity Thermal Protector (TCO)

1. Removing inner side panel by removing four

mounting screws.

2. Remove thermal protector mounting screw

(protective covering inside of cavity must be held).

3. Disconnect wiring.

Power Cord

1. Remove outer case assembly.
2. Disconnect wiring.
3. Remove strain relief by compressing with pliers.
4. Remove power cord.

Component Location

Wave Guide

Antenna
Gear

Antenna Motor
(Under Bracket)

Low Voltage Circuit Board

Extended
Memory Board

Cavity Light
Cover

Wave Guide

Antenna
Gear

Three Magnetron Model - Top View

Wave Guide

Antenna
Gear

Antenna Motor
(Under Bracket)

Low Voltage Circuit Board

Extended
Memory Board

Cavity Light
Cover

Two Magnetron Model - Top View

Summary of Contents for P1199603M

Page 1: ...pliance technicians only Amana does not assume any responsibility for property damage or personal injury for improper service procedures done by an unqualified person RC519M P1199603M RC519M P1199604M This Base Manual covers International Commercial Microwave Ovens with 50 Hz Refer to individual Technical Sheet for information on specific models ...

Page 2: ...roperty damage from improper service procedures If performing service on your own product assume responsibility for any personal injury or property damage which may result To locate an authorized servicer please consult your telephone book or the dealer from whom you purchased this product For further assistance please contact CONSUMER AFFAIRS DEPT OR 1 319 622 5511 or 1 800 843 0304 AMANA APPLIAN...

Page 3: ...observed before and during servicing to avoid possible exposure to excessive microwave energy or electrical shock disconnect power to oven A Do not operate or allow oven to be operated with 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 Interlock operation Proper door closing Seal and ...

Page 4: ...st Mode 24 H V System Test 24 Diagnosing Individual H V System Components 24 Door Cycles and Magnetron Hours 25 Test Modes Power Test Traditional Test Method 26 Microwave Energy Leakage Testing Equipment 27 Procedure For Measuring Radiation Leakage 27 Measurement With the Outer Panel Removed 27 Measurement With a Fully Assembled Oven 27 Record Keeping and Notification After Measurement 27 Troubles...

Page 5: ...5 RS5320014 Rev 0 Important Safety Information ...

Page 6: ...RS5320014 Rev 0 6 Important Safety Information ...

Page 7: ...7 RS5320014 Rev 0 Important Safety Information ...

Page 8: ...ment compartment Some types of failures will leave a charge in these capacitors and the discharge could cause a reflex action which could make you injure yourself 7 In the area of the transformer capacitor diode and magnetron there is HIGH VOLTAGE When the unit is operating keep this area clean and free of anything which could possibly cause an arc or earthing etc 8 Do not for any reason defeat th...

Page 9: ... m e r i u q e R r e w o P s t n e m e r i u q e R r e w o P s t n e m e r i u q e R r e w o P s t n e m e r i u q e R r e w o P s t n e m e r i u q e R r e w o P e s a h P e s a h P e l g n i S z H 0 5 r e w o P t u p n I s t t a W 0 0 9 2 s g n i t a R l a c i r t c e l E c a V 0 3 2 s n o i s n e m i D r o i r e t n I n e v O s n o i s n e m i D r o i r e t n I n e v O s n o i s n e m i D r o i...

Page 10: ... television etc to obtain stronger signal reception Earthing Instructions This appliance MUST be earthed If an electrical short circuit occurs earthing reduces risk of electric shock by providing an escape wire for the electric current The cord for this appliance has an earthing wire with an earthing plug Place the plug into an outlet that is properly installed and earthed Do not use a two prong a...

Page 11: ...s pads press directly on number for Variable Time Entry and reduced power cooking START Use to start Variable Time Entry program or restart interrupted cooking cycle STOP RESET Use to exit programming mode and stop cooking during cooking cycle Readout Display EOC End of Cycle Lights at end of cooking cycle PAUS Pause indicator Lights during cooking pause P Displays at programming entry point when ...

Page 12: ...If oven is programmed to pause in middle of cooking cycle oven signals 3 times and shows PAUS When oven pauses open door manipulate food close door and press START pad to continue operation If oven fan is operating during pause press START pad to resume operation without opening oven door or manipulating food If oven fan is not operating during pause open oven door and press START pad to resume op...

Page 13: ...l 7 Press START pad 8 At end of cycle open oven door Changing Preset Number Pads 1 Open oven door Display shows door If door is closed or RESET pad is pressed before finishing programming sequence oven exits programming mode 2 Press pad 1 for five seconds After five seconds signal sounds Display shows P and active menu 3 Press ADD pad 4 Press desired menu pad Display shows active menu 5 Press desi...

Page 14: ...oking time and power level if power level other than 100 is desired 7 Press STATUS pad 8 Enter desired cooking time and power level 9 Repeat steps 6 9 for additional stages 10 Press START pad 11 Press RESET pad or close oven door Programming Pause during Stage s Pause cooking during each or any stage to manipulate food Pause occurs halfway through stage 1 Open oven door Display shows door If door ...

Page 15: ...s closed or RESET pad is pressed before finishing programming sequence oven exits programming mode 2 Press pad 1 for five seconds After five seconds signal sounds Display shows P and active menu 3 Press desired number pad to be deleted 4 Press DELETE pad twice All cooking stages and power levels for this item are set to zero Display shows P 5 Press RESET pad or close oven door to exit programming ...

Page 16: ...tone Off OP 10 Continuous tone OP 11 5 continuous tones OP 12 5 tones 5 cycles OP 13 Tone when pad is Off OP 20 pressed On OP 21 Control panel resets when Off OP 30 door is opened On OP 31 End of cycle signal Loud OP 40 Medium OP 41 User time limit Off OP 50 On OP 51 As shipped from factory 5 Press STATUS pad to change option Press START pad to save changes 6 Repeat steps 4 5 to change additional ...

Page 17: ... Approximately 40 Ω or more Infinite Infinite 12548808 Capacitor Discharge Capacitors Remove wires from capacitor terminals and connect ohmmeter set on highest resistance scale to terminals Also check between each terminal and capacitor case Between Terminals Meter should momentarily deflect towards zero then return to over 5 MΩ IF no deflection occurs or if continuous deflection occurs replace ca...

Page 18: ...ately 1 3 Ω 1 Ω 70 Ω Infinite resistance should be indicated if not replace transformer R0150102 Antenna motor Remove all wires from motor Measure resistance across terminals Approximately 10 KΩ R0150155 Interlock switch Type 1 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 Secondary Logic Primary Monitor Dummy Door Open Disconnect wires to switch With door open measure resistance from Terminal 2 to terminal...

Page 19: ...tor Plugged In J2 Pin 5 violet to ground J2 Pin 6 J2 Pin 7 blue to ground J6 Pin 6 orange to Pin 1 white J6 Pin 5 yellow to Pin 1 white J6 Pin 1 white to Pin 3 red 27 VDC Ground 18 VDC 240 volts output to blower and antenna motors when line voltage is 240 V 220 volts output to auto transformer for blower and antenna motors when line voltage is 220 V Line voltage 12261708 1 1 1 J1 J2 J3 J4 J5 1 1 L...

Page 20: ...aces 1 2 should be about 0 ohms Ribbon Cable Side Touch Panel Keypad Ribbon Trace Ribbon Trace Keypad Ribbon Trace Ribbon Trace Stop Reset 3 1 4 2 6 6 7 0 4 5 7 6 10 Start 4 10 4 7 8 8 5 6 5 7 10 9 5 10 2 8 9 3 8 10 P1199603M 1 9 10 P1199604M To test touch panel for proper operation 1 Identify ribbon traces for selected touch panel using chart 2 Resistance betw een selected traces 0 ohms 3 Pressin...

Page 21: ... Do not touch any parts of the circuitry on the P C Board circuit since static electric discharge may damage this control panel Always touch yourself to earth while working on this panel to discharge any static charge in your body 6 220 240 Vac is present in the high voltage board terminals of power relay and primary circuit of low voltage transformer 7 When troubleshooting be cautious of possible...

Page 22: ...c S1 Watchdog Membrane Touch Panel Watchdog circuit verifies touch panel entry Possible Causes 1 Shorted top touch panel 2 Shorted side touch panel Testing 1 Disconnect power from oven 2 Disconnect one touch panel ribbon cable from the L V circuit board 3 Plug oven in open and close door to activate oven 4 Wait approximately 60 seconds If S1 does not appear in display replace the disconnected touc...

Page 23: ...le between low voltage board and extended memory board 3 Inoperative high voltage board 4 Inoperative low voltage board 5 Inoperative extended memory board PCE6 Communication Failure NOTE Before scheduling service for this complaint instruct customer to unplug oven for one minute reconnect and retest If unit operates properly no further service is required If this error code does not disappear pos...

Page 24: ... The triac drive will be activated after a minimum of 100 milliseconds A 62 seconds full power cook cycle will begin for the selected H V system Display with H V System 1 Activated 2 Press pad 1 again to de activate H V System 1 3 Press pad 2 to activate H V System 2 4 Press pad 2 again to de activate H V System 2 5 Press pad 3 to activate H V System 3 6 Press pad 3 again to de activate H V System...

Page 25: ...eadings will vary MENU1 MENU2 H V System 1 2 MENU1 MENU3 H V System 1 3 MENU1 MENU2 MENU3 H V System 1 2 3 Door Cycles and Magnetron Hours Press TIME ENTRY pad once for door cycles NOTE Door cycle counter advances one number for every 100 door cycles Example Display reads 156 x 100 15 600 Actual door cycles Press TIME ENTRY pad again for H V section 1 hours Press TIME ENTRY pad again for H V secti...

Page 26: ...n for the unit being tested Example 1550 watts output using the traditional power test for model RC519MP 300 watts 3 magnetrons X 100 watts 1850 Approximate IEC 705 results Always perform power test three times for accuracy changing the water after each test is performed Variation or errors in the test procedure will cause a variance in the temperature rise Additional power tests should be made if...

Page 27: ...ment must be strictly observed In addition the leakage reading must be recorded on the service repair ticket while at the customer s location Equipment Electromagnetic radiation monitor 600 cc glass beaker Procedure For Measuring Radiation Leakage Note before measuring Do not exceed meter full scale deflection Leak monitor should initially be set to the highest scale To prevent false readings the ...

Page 28: ...on No power applied to oven power cord Blown oven fuse check interlock switch module operation monitor test Inoperative cavity thermal cut out Inoperative low voltage circuit board Inoperative high voltage circuit board Broken or improper wire connections 1 2 3 4 5 6 No MENU1 Error Code Appears No Refer to Display Diagnostics page 22 Yes Inoperative interlock switch module contacts 4 5 Inoperative...

Page 29: ...ervicing unless testing requires it Stand By Condition Open oven door Oven light is on optional Antenna motors operate Inoperative autotransformer Binding or inoperative antenna motor Binding or inoperative blower motor Broken or improper wire connections 1 2 3 4 Yes Yes No No Blower motors operate Stand by Condition normal proceed to Cook Condition Yes Yes No ...

Page 30: ...o heat Inoperative or misadjusted interlock switch module Inoperative magnetron thermal cutouts Inoperative capacitors Inoperative high voltage board Inoperative high voltage transformer Broken or improper wire connections 1 2 3 5 6 7 NO Place a cup of water in oven and close door Flashing Yes Error code appears after about 8 seconds Refer to Display Diagnostics Display starts counting down Inoper...

Page 31: ...above Outer Door y Outer Door Assembly The outer door assembly consists of the outer door outer window and lens retainer These components are available only as a complete assembly Inner Door Ring Assembly 1 Remove latch handle 2 Remove outer door assembly 3 Remove 5 hinge screws securing inner door ring assembly Inner Door Ring Assembly The door ring assembly consists of the inner door ring the in...

Page 32: ...placing thumbs in front of shield Press firmly toward back and carefully lower front of shield away from antenna Pull shield forward out of back slots and out of oven 3 Replace grease shield by fitting tabs into slots at top of oven back Lift and press front of shield until shield snaps into place Outer Case 1 Remove screws in side and back 2 Slide outer case back and lift off Top Touch Panel Asse...

Page 33: ...NOTE Nylon washers must be installed below gears Top Antenna Motor 1 Remove outer case 2 Remove three antenna gears 3 Disconnect motor wiring 4 Remove three stirrer motor bracket mounting rivets The motor and bracket are replaced as one part NOTE Gears are aligned by aligning the arrows to the dots on gears Antenna Matching Antenna Motor Rivet Standard Antenna Early Production Antenna Motor Rivet ...

Page 34: ...nting screw 3 Remove wires from thermal protectors and magnetron 4 Remove center air baffle by removing two mounting screws located in top of the oven do not attempt to remove air baffle at this time 5 Remove four magnetron mounting nuts 6 Remove magnetron and center air baffle 7 When replacing the magnetron verify the wire mesh gasket is reinstalled NOTE When reinstalling magnetron slide left air...

Page 35: ...mal protector 3 Remove 1 8 allen screw phillips screw used to mount thermal protectors Bottom Access Panel 1 Place oven on side or back 2 Remove single bottom screw Bottom Stirrer Motor 1 Remove bottom access panel 2 Remove antenna gear 3 Disconnect brown motor wires from white and orange chassis wires 4 Remove two mounting rivets and remove motor NOTE Do not remove bottom antenna gear when removi...

Page 36: ... Autotransformer H V circuit board Fuses Blower Wheel and Motor 1 Remove outer case 2 Remove back panel 3 Remove auto transformer 4 Remove wiring to blower motor 5 Remove the one blower assembly mounting screw located under the support brace and remove assembly 6 Remove three mounting screws located under blower housing assembly 7 Remove assembly from oven 8 Loosen the 1 8 inch allen set screw sec...

Page 37: ...ity TCO Current Sense Loop High Voltage Board High Voltage Board Mounting Clips 4 Disconnect seven mounting clips by pushing clips away from the board Cavity Thermal Protector TCO 1 Removing inner side panel by removing four mounting screws 2 Remove thermal protector mounting screw protective covering inside of cavity must be held 3 Disconnect wiring Power Cord 1 Remove outer case assembly 2 Disco...

Page 38: ...Baffle Center Left Air Baffle Left Air Baffle Center Right Air Baffle Magnetron TCO Bottom Air Duct Middle Baffle Control TCO Control TCO Magnetron TCO Three Magnetron Model Side View Top Rear Magnetron Bottom Magnetron Interlock Switch Assembly Top Right Air Baffle Center Left Air Baffle Center Right Air Baffle Magnetron TCO Bottom Air Duct Middle Baffle Control TCO Control TCO Magnetron TCO Two ...

Page 39: ...To avoid risk of electrical shock personal injury or death disconnect power to oven and discharge capacitors before following any disassembly procedure Wave Guide Antenna Gear Antenna Motor Under Bracket Bottom View Alternate Diode Location ...

Page 40: ...NSOR WIRE CODE HIGH VOLTAGE LOW VOLTAGE COLOR CODE RED RD ORANGE OR YELLOW YL GREEN GN BLUE BU VIOLET VT BLACK BK BROWN BR GRAY GY WHITE WH WIRING DIAGRAM PART NO 12535201 J2 J1 J4 EXTENDED MEMORY BOARD NOT ON ALL MODELS J2 J1 GY YL BU WH GN YL GY WH LT BU BU OR GN BR RD PK VT PINK PK J1 J2 J4 J5 J6 E1 HI VOLT BOARD TERMINAL BUSHING RD RD BR BK YL RD BR VT GN BU OR WH BK OR YL RD WH GN BK YL RD BR...

Page 41: ...ECONDARY J1 7 J1 6 J6 3 L1 BLOWER MOTOR ANTENNA MOTOR BOTTOM COM J6 1 E1 J6 5 J6 6 CURRENT SENSING COIL J5 4 J5 1 J5 2 J1 1 GND 1 G 2 1 G 2 1 G 2 L2 LINE FILTER L1 L2 HI VOLT BOARD SELF RESETTING CONTROL TCOS 3 230 2 220 3 230 2 220 F MAGNETRON 2 TOP REAR RECTIFIER F RECTIFIER RECTIFIER CAPACITOR RESISTOR CAPACITOR RESISTOR CAPACITOR RESISTOR 230V 50Hz 3 WIRE AUTO TRANSFORMER HI VOLT BOARD 240 220...

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