Download Sharp KB-6015KS Service manual

KB-6015KS
KB-6015KK
KB-6015KW
SERVICE MANUAL
S25M246KB6015
MICROWAVE DRAWER
MODELS
KB-6015KS
KB-6015KK
KB-6015KW
KB-6015KS pictured
In the interest of user-safety the unit should be restored to its original condition and only parts identical to those specified
should be used.
WARNING TO SERVICE PERSONNEL:
This service manual is intended for use by persons having electrical and mechanical training and a level of
knowledge of these subjects generally considered acceptable in the appliance repair trade. Sharp Electronics
Corporation cannot be responsible, nor assume any liability, for injury or damage of any kind arising from the
use of this manual.
Microwave ovens contain circuitry capable of producing very high voltage and current. Contact with the
following parts may result in a severe, possibly fatal, electrical shock. (High Voltage Capacitor, High Voltage
Power Transformer, High Voltage Rectifier and Heat sink etc., and Magnetron, High Voltage Harness etc..)
TABLE OF CONTENTS
Page
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO
AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY ................... INSIDE FRONT COVER
BEFORE SERVICING ...................................................................................................... INSIDE FRONT COVER
WARNING TO SERVICE PERSONNEL ............................................................................................................... 1
MICROWAVE MEASUREMENT PROCEDURE .....................................................................................................2
FOREWORD AND WARNING ................................................................................................................................3
PRODUCT SPECIFICATIONS ............................................................................................................................... 4
SCHEMATICS ....................................................................................................................................................... 8
TEST PROCEDURES ............................................................................................................................................9
TOUCH CONTROL PANEL ASSEMBLY ............................................................................................................. 17
MICROWAVE DRAWER DISASSEMBLY ............................................................................................................ 25
WIRING DIAGRAMS ........................................................................................................................................... 31
PRINTED WIRING BOARDS ............................................................................................................................... 32
PARTS LIST ........................................................................................................................................................ 36
PACKING AND ACCESSORIES ......................................................................................................................... 40
SHARP ELECTRONICS CORPORATION
This document has been published to be used for after sales service only. The contents are subject to change without notice.
1
KB-6015KS
KB-6015KK
KB-6015KW
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.
BEFORE SERVICING
Before servicing an operative unit, perform a microwave emission check as per the Microwave Measurement Procedure outlined in this service manual.
If microwave emissions level is in excess of the specified limit, contact SHARP ELECTRONICS
CORPORATION immediately @1-800-237-4277.
If the unit operates with the door open, service person should 1) tell the user not to operate the oven and
2) contact SHARP ELECTRONICS CORPORATION and Food and Drug Administration's Center for
Devices and Radiological Health immediately.
Service personnel should inform SHARP ELECTRONICS CORPORATION of any certified unit found with
emissions in excess of 4mW/cm2. The owner of the unit should be instructed not to use the unit until the
oven has been brought into compliance.
2
KB-6015KS
KB-6015KK
KB-6015KW
WARNING TO SERVICE PERSONNEL
Range units contain circuitry capable of producing very high voltage and current, contact
with following parts may result in a severe, possibly fatal, electrical shock.
(Example)
High Voltage Capacitor, High Voltage Power Transformer, Magnetron, High Voltage
Rectifier Assembly, High Voltage Harness, Heating Elements, etc..
Read the Service Manual carefully and follow all instructions.
Before Servicing
1. Disconnect the power supply cord
remove cabinet.
2. Open the drawer and keep it open.
3. Discharge high voltage capacitor.
, and then
WARNING: RISK OF ELECTRIC SHOCK.
DISCHARGE THE HIGH-VOLTAGE
CAPACITOR BEFORESERVICING.
When the testing is completed,
1. Disconnect the power supply cord, and then remove
covers.
2. Open the drawer and keep it open.
3. Discharge high voltage capacitor.
4. Reconnect the leads to the primary of the power
transformer.
5. Reinstall the covers.
6. Reconnect the power supply cord.
7. Run the unit and check all functions.
After repairing
The high-voltage capacitor remains charged about 60
seconds after the oven has been switched off. Wait for 60
seconds and then short-circuit the connection of the highvoltage capacitor (that is the connecting lead of the highvoltage rectifier) against the chassis with the use of an
insulated screwdriver.
1. Reconnect all leads removed from components during
testing.
2. Reinstall the covers.
3. Reconnect the power supply cord.
4. Run the oven and check all functions.
Whenever troubleshooting is performed the power supply
must be disconnected. It may, in some cases, be necessary
to connect the power supply after the outer case has been
removed, in this event:
1. Disconnect the power supply cord, and then remove
neccessary covers.
2. Open the drawer and keep it open.
3. Discharge high voltage capacitor.
4. Disconnect the leads to the primary of the power
transformer.
5. Ensure that the leads remain isolated from other
components and oven chassis by using insulation tape.
6. After that procedure, reconnect the power supply cord.
1
Microwave ovens should not be operated empty. To test for
the presence of microwave energy within a cavity, place a
cup of cold water on the oven tray, close the drawer and set
the power to HIGH and set the microwave timer for two (2)
minutes. When the two minutes has elapsed (timer at zero)
carefully check that the water is now hot. If the water remains
cold carry out Before Servicing procedure and re-examine
the connections to the component being tested.
When all service work is completed and the oven is fully
assembled, the microwave power output should be checked
and a microwave leakage test should be carried out.
KB-6015KS
KB-6015KK
KB-6015KW
MICROWAVE MEASUREMENT PROCEDURE
A. Requirements:
1) Microwave leakage limit (Power density limit): The power density of microwave radiation emitted by a microwave oven
should not exceed 1mW/cm2 at any point 5cm or more from the external surface of the oven, measured prior to acquisition
by a purchaser, and thereafter (through the useful life of the oven), 5 mW/cm2 at any point 5cm or more from the external
surface of the oven.
2) Safety interlock switches:
Primary interlock relay switch shall prevent microwave radiation emission in excess of the requirement as above
mentioned. Secondary interlock relay and door sensing switch shall prevent microwave radiation emission in excess of
5 mW/cm2 at any point 5cm or more from the external surface of the oven.
B. Preparation for testing:
Before beginning the actual measurement of leakage, proceed as follows:
1) Make sure that the actual instrument is operating normally as specified in its instruction booklet.
Important:
Survey instruments that comply with the requirement for instrumentation as prescribed by the performance standard for
microwave ovens, 21 CFR 1030.10(c)(3)(i), must be used for testing.
2) Place the load of 275±15 ml (9.8 oz) of tap water initially at 20±5O C (68OF) in the center of the oven cavity.
The water container shall be a low form of 600 ml (20 oz) beaker with an inside diameter of approx. 8.5 cm (3-1/2 in.) and
made of an electrically nonconductive material such as glass or plastic.
The placing of this standard load in the oven is important not only to protect the oven, but also to insure that any leakage
is measured accurately.
3) Set the cooking control on Full Power Cooking Mode.
4) Close the drawer and select a cook cycle of several minutes. If the water begins to boil before the survey is completed,
replace it with 275 ml of cool water.
C. Leakage test:
Closed-drawer leakage test (microwave measurement):
1) Grasp the probe of the survey instrument and hold it perpendicular to the gap between the drawer and the body of the
oven.
2) Move the probe slowly, not faster than 1 in./sec. (2.5 cm/sec.) along the gap, watching for the maximum indication on the
meter.
3) Check for leakage at the drawer screen, sheet metal seams and other accessible positions where the continuity of the
metal has been breached (eg., around the switches, indicator, and vents).
While testing for leakage around the drawer, pull the drawer away from the front of the oven as far as is permitted by the
closed latch assembly.
4) Measure carefully at the point of highest leakage and make sure that the highest leakage is no greater than 4mW/cm2,
and that the primary interlock switch/secondary interlock relay does turn the oven OFF before any door movement.
NOTE: After servicing, record data on service invoice and microwave leakage report.
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KB-6015KS
KB-6015KK
KB-6015KW
SERVICE MANUAL
PRODUCT DESCRIPTION
MICROWAVE DRAWER
SCHEMATICS
KB-6015KS
KB-6015KK / KB-6015KW
FOREWORD
TEST PROCEDURE
This Manual has been prepared to provide Sharp Electronics Corp.
Service Personnel and Service Information for the MICROWAVE
DRAWER, KB-6015KS, KB-6015KK, and KB-6015KW.
TOUCH CONTROL PANEL
It is recommended that service personnel carefully study the entire text
of this manual so that they will be qualified to render satisfactory
customer service.
Check the interlock switches and the door seal carefully. Special
attention should be given to avoid electrical shock and microwave
radiation hazard.
MICROWAVE DRAWER
DISSASSEMBLY AND
ADJUSTMENT PROCEDURE
WIRING DIAGRAM
WARNING
Never operate the oven until the following points are ensured.
(A) The door is tightly closed.
(B) The door brackets and hinges are not defective.
(C) The door packing is not damaged.
(D) The door is not deformed or warped.
(E) There is not any other visible damage with the oven.
Servicing and repair work must be carried out only by trained service
personnel.
DANGER
Certain initial parts are intentionally not grounded and present
a risk of electrical shock only during servicing. Service
personnel - Do not contact the following parts while the
appliance is energized;
High Voltage Capacitor, Power Transformer, Magnetron, High
Voltage Rectifier Assembly, High Voltage Harness;
If provided, Vent Hood, Fan assembly, Cooling Fan Motor.
All the parts marked “*” on parts list are used at voltages more than
250V.
Removal of the outer wrap gives access to voltage above 250V.
All the parts marked “ Δ” on parts list may cause undue microwave
exposure, by themselves, or when they are damaged, loosened or
removed.
SHARP ELECTRONICS CORPORATION
SHARP PLAZA, MAHWAH,
NEW JERSEY 07430-2135
3
PARTS LIST
KB-6015KS
KB-6015KK
KB-6015KW
MICROWAVE DRAWER SPECIFICATION
ITEM
DESCRIPTION
Power Requirments
120 Volts
14.5 Amperes, 1000 watts
60 Hz
Single phase, 3 wire grounded
Power Output
1000 watts (IEC TEST PROCEDURE)
Operating frequency of 2450MHz
Cooking Cavity Dimensions
Width 17-11/32
Height 5-7/8"
Depth 17-1/8"
1.0 Cubic Feet
Case Dimensions
Width 30"
Height 15-9/32"
Depth 26-1/16"
Control Complement
Touch Control System
Clock ( 1:00 - 12:59 )
Timer (0 - 99 min. 99 seconds)
Microwave Power for Variable Cooking
Repetition Rate;
P-HI ................................................. Full power throughout the cooking time
P-90 .................................................................... approx. 90% of Full Power
P-80 .................................................................... approx. 80% of Full Power
P-70 .................................................................... approx. 70% of Full Power
P-60 .................................................................... approx. 60% of Full Power
P-50 .................................................................... approx. 50% of Full Power
P-40 .................................................................... approx. 40% of Full Power
P-30 .................................................................... approx. 30% of Full Power
P-20 .................................................................... approx. 20% of Full Power
P-10 .................................................................... approx. 10% of Full Power
P-0 ..................................................... No power throughout the cooking time
START/MINUTE PLUS pad, Defrost pad, Number selection pad, Micro-warm
pad, Power Level pad, Timer/Clock pad,Stop/Clear pad, Sensor Reheat, Sensor
Popcorn, Sensor Cook, Open pad, Close pad, Setup/Custom Help, On/Off,
Cotrol Lock, Reheat.
Oven Cavity Light
Yes
Safety Standard
UL Listed
FCC Authorized
DHHS Rules, CFR, Title 21, Chapter 1, Subchapter J
4
GENERAL INFORMATION
KB-6015KS
KB-6015KK
KB-6015KW
GROUNDING INSTRUCTIONS
This oven is equipped with a three prong grounding plug. It must be plugged into a wall receptacle that is properly installed
and grounded in accordance with the National Electrical Code and local codes and ordinances.
In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric
current.
WARNING:
Improper use of the grounding plug can result in a risk of electric shock.
Electrical Requirements
The electrical requirements are a 120 volt 60 Hz, AC only, 15 or 20 amp. fused electrical supply. It is recommended that a
separate circuit serving only this appliance be provided. When installing this appliance, observe all applicable codes and
ordinances.
Where a two-pronged wall-receptacle is encountered, it is the personal responsibility and obligation of the customer to
contacta qualified electrician and have it replaced with a properly grounded three-pronged wall receptacle or have a grounding
adapter properly grounded and polarized. If the extension cord must be used, it should be a 3-wire, 15 amp. or higher rated
cord. Do not drape over a countertop or table where it can be pulled on by children or tripped over accidentally.
CAUTION: DO NOT UNDER ANY CIRCUMSTANCES CUT OR REMOVE THE ROUND GROUNDING PRONG FROM
THIS PLUG.
Grounded
Receptacle Box
3-Pronged
Plug
Grounding Pin
3-Pronged Receptacle
KB-6015KS
NOTE:
The directed features are disabled after one minute when the oven is not in use. These features are automatically enabled
when the door is opened and closed or the STOP/ CLEAR pad is pressed.
5
KB-6015KS
KB-6015KK
KB-6015KW
OPERATION
DESCRIPTION OF OPERATING SEQUENCE
the secondary interlock switch and secondary interlock
relay and is mechanically associated with the drawer so
that it will function in the following sequence.
(1) When the drawer opens from the closed position, the
secondary interlock relay (RY2) and secondary interlock
switch open their contacts. And contacts of the relay
(RY1) remains closed. Then the monitor switch contacts
close.
(2) When the drawer is closed from the open position, the
monitor switch contacts open first. Then the contacts of
the secondary interlock switch and door sensing switch
close. And contacts of the relay (RY1) open.
If the secondary interlock switch and secondary interlock
relay (RY2) fail with the contacts closed when the drawer is
opened, the closing of the monitor switch contacts will form
a short circuit through the fuse, secondary interlock switch,
relay (RY1) and secondary interlock relay (RY2), causing
the fuse to blow.
The following is a description of component functions during
oven operation.
OFF CONDITION
Closing the drawer activates the door sensing switch and
secondary interlock switch. (In this condition, the monitor
switch contacts are opened.)
When oven is plugged in, 120 volts A.C. is supplied to the
control unit. (Page 8).
1. The display will show flashing "Enjoy Your Drawer
Touch Clear and Touch Clock".
To set any program or set the clock, you must first touch
the STOP/CLEAR pad. The display will clear, and " : "
will appear.
COOKING CONDITION
Program desired cooking time by touching the NUMBER
pads. Program the power level by touching the POWER
LEVEL pad and then a Number pad.
When the START pad is touched, the following operations
occur:
POWER LEVEL P-0 TO P-90 COOKING
When Variable Cooking Power is programmed, the 120 volts
A.C. is supplied to the power transformer intermittently
through the contacts of relay (RY-2) which is operated by the
control unit within a 32 second time base. Microwave power
operation is as follows:
1. The contacts of relays are closed and components
connected to the relays are turned on as follows.
(For details, refer to Page 8)
RELAY
RY-1
RY-2
VARI-MODE
Power 10(P-HI)
(100% power)
Power 9(P-90)
(approx. 90% power)
Power 8(P-80)
(approx. 80% power)
Power 7(P-70)
(approx. 70% power)
Power 6(P-60)
(approx. 60% power)
Power 5(P-50)
(approx. 50% power)
Power 4(P-40)
(approx. 40% power)
Power 3(P-30)
(approx. 30% power)
Power 2(P-20)
(approx. 20% power)
Power 1(P-10)
(approx. 10% power)
Power 0(P-0)
(0% power)
CONNECTED COMPONENTS
oven lamp/stir fan motor/fan motor
power transformer
2. 120 volts A.C. is supplied to the primary winding of the
power transformer and is converted to about 3.3 volts
A.C. output on the filament winding, and approximately
2370 volts A.C. on the high voltage winding.
3. The filament winding voltage heats the magnetron filament
and the H.V. winding voltage is sent to a voltage doubler
circuit.
4. The microwave energy produced by the magnetron is
channelled through the waveguide into the cavity feedbox, and then into the cavity where the food is placed to
be cooked.
5. Upon completion of the cooking time, the power
transformer, oven lamp, etc. are turned off, and the
generation of microwave energy is stopped. The oven
will revert to the OFF condition.
6. When the drawer is opened during a cook cycle, the
monitor switch, door sensing switch, secondary interlock
switch, relay (RY1) and secondary interlock relay are
activated with the following results. The circuits to the stir
fan motor, the cooling fan motor, and the high voltage
components are de-energized, the oven lamp remains
on, and the digital read-out displays the time still remaining
in the cook cycle when the door was opened.
7. The monitor switch electrically monitors the operation of
Note:
6
ON TIME
32 sec.
OFF TIME
0 sec.
30 sec.
2 sec.
26 sec.
6 sec.
24 sec.
8 sec.
22 sec.
10 sec.
18 sec.
14 sec.
16 sec.
16 sec.
12 sec.
20 sec.
8 sec.
24 sec.
6 sec.
26 sec.
0 sec.
32 sec.
The ON/OFF time ratio does not correspond with the
percentage of microwave power, because approx. 2
seconds are needed for heating of the magnetron
filament.
KB-6015KS
KB-6015KK
KB-6015KW
SENSOR COOKING CONDITION
2. The coil of shut-off relay (RY-1) is energized, but the
power transformer is not turned on.
3. After about 16 seconds, the cook relay (RY-2) is
energized. The power transformer is turned on,
microwave energy is produced and first stage is started.
The 16 seconds is the cooling time required to remove
any vapor from the oven cavity and sensor.
Using the SENSOR function, food is cooked without figuring
time, power level or quantity. When the oven senses enough
steam from the food, it relays the information to its
microprocessor which will calculate the remaining cooking
time and power level needed for best results. When the food
is cooked, water vapor is developed. the sensor "senses"
the vapor and its resistance increase gradually. When the
resistance reaches the value set according to the menu,
supplementary cooking is started.
The time of supplementary cooking is determined by experiment with each food category and inputted into the LSI. An
example of how sensor works: (Potatoes)
NOTE: During this first stage, do not open the drawer or
touch STOP/CLEAR pad.
4. When the sensor detects the vapor emitted from the
food, the display switches over to the remaining cooking
time and the timer counts down to zero.
At this time, the drawer may be opened to stir, turn or
season food.
5. When the timer reaches zero, an audible signal sounds.
The shut-off relay and cook relay are de-energized and
the power transformer, oven lamp, etc. are turned off.
6. Opening the drawer or touching the STOP/CLEAR pad,
the time of the day will reappear on the display and the
oven will revert to an OFF condition. When the timer
reaches zero, an audible signal sounds.
1. Potatoes at room temperature. Vapor is emitted very
slowly.
MIC
RO
WA
VE
2.Heat Potatoes. Moisture and humidity is emitted very
rapidly. You can smell the aroma as it cooks.
AH SENSOR
MIC
RO
WA
VE
3.Sensor detects moisture and humidity and calculates
cooking time and variable power.
Cooking Sequence.
1. Touch one of the SENSOR pads.
NOTE: The oven should not be operated on sensor
immediately after plugging in the unit. Wait two
minutes before cooking on SENSOR.
7
120VAC
60 Hz.
N
H
GND
GRN
"TO SOURCE"
L
N
"TO SOURCE"
LINE CROSS CAPACITOR 1.0 μF 275V
RESISTOR 470 kΩ 1/2W
FUSE
20A
NOISE FILTER
NOISE SUPRESSION COIL
RED
WHT
WHT
A5
A7
LOW VOLTAGR
TRANSFORMER
GRN
MICROWAVE DRAWER
BLK
ORG
MG
THERMAL
CUT-OUT
ORG
OVEN
THERMAL
CUT-OUT
CN501
1
CN501
3
ORG
2. Terminal that located to the right side on the lamp socket's back view
must be connected to neutral wire.
3. Only certain models use the absolute humidity sensor
4. Power Transformer (Finish Lead) terminal must be connected to HOT wire (RED)
LINE BYPASS CAPACITOR
0.0033 μF 250V
LINE BYPASS CAPACITOR
0.0033 μF 250V
BLK
WHT
GRY
SWITCHING REGULATOR
BLK
CN502 E1
1
E3
CN502
2
RED
CN502
H9
3
COM
N.O.
GRY
GRY
COM
A1
BLU
DM
B1
YLW
SECONDARY INTELOCK SWITCH
WHT
WHT
A3
CONTROL UNIT
H11
ORG
ORG
F3
1. Circuits / Wire Colors subject to change without notice.
"TO LOAD"
"TO LOAD"
N4
MICROWAVE DRAWER
DOOR OPEN-CLOSE
MOTOR
RY4
NOTES:
F1
HUMIDITY
SENSOR
RED
WHT
BLK
RED
F2
RED
N1
RY5
ORG
RY3
FAN MOTOR
PRIMARY INTERLOCK RELAY
BLK
BLK
ORG
N.O.
RY2
N2
FM
WHT
WHT
N3
BRN
WHT
SM
RY1
STARLER
MOTOR
N5
GRY
BLK
ORG
COM
RED
RED
GRN
GRN
M1
N.O.
GRN
M3
OL
WHT
GRY
M4
RED
GRN
GRN
WHT
OVEN LAMP
RED
N.C.
COM
WHT
GRY
GRN
GRN
GRY
MONITOR SWITCH
GRN
DOOR
POSITION
SWITCH
REAR
M5
BLU
DOOR
POSITION
SWITCH
FRONT
POWER TRANSFORMAR
GRY
GRY
8
MAGNETRON
H.V. RECTIFIER
DOOR
SENSING
SWITCH
KB-6015KS
KB-6015KK
KB-6015KW
CAPACITOR
1.00 μF
AC 2300V
TEST PROCEDURES
PROCEDURE
LETTER
A
KB-6015KS
KB-6015KK
KB-6015KW
COMPONENT TEST
TOUCH CONTROL PANEL ASSEMBLY TEST
The touch control panel consists of circuits including semiconductors such as LSI, ICs, etc. Therefore,
unlike conventional microwave ovens, proper maintenance cannot be performed with only a voltmeter
and ohmmeter.
In this service manual, the touch control panel assembly is divided into three units, Control Unit and
Keyboard Unit and Power Unit, and troubleshooting by unit replacement is described according to the
symptoms indicated.
Before testing,
1) Disconnect the power supply cord, and then disassemble as per "MICROWAVE DRAWER
DISASSEMBLY" page 25.
2) Open the drawer and block it open.
3) Discharge high voltage capacitor.
4) Disconnect the leads to the primary of the power transformer.
5) Ensure that these leads remain isolated from other components and oven chassis by using
insulation tape.
1. Keyboard Unit.
NOTE ;
1) Check Keyboard unit connection before replacement.
2) Reconnect all leads removed from components during testing.
3) Re-install the covers.
4) Reconnect the power supply cord after the covers are installed.
5) Run the oven and check all functions.
The following symptoms indicate a defective keyboard unit.
a) When touching the pads, a certain pad produces no signal at all.
b) When touching a number pad, two figures or more are displayed.
c) When touching the pads, sometimes a pad produces no signal.
If the Keyboard unit is defective.
1) Disconnect the power supply cord, and then remove covers.
2) Open the drawer and block it open.
3) Discharge high voltage capacitor.
4) Replace the Keyboard unit.
5) Reconnect all leads removed from components during testing.
6) Re-install the covers.
7) Reconnect the power supply cord after the covers are installed.
8) Run the oven and check all functions.
2. Control Unit
The following symptoms indicate a defective control unit. Before replacing the control unit, perform
the Keyboard unit test (Procedure B) to determine if control unit is faulty.
2-1 In connection with indicators
a) At a certain digit, all or some segments do not light up.
b) At a certain digit, brightness is low.
c) Only one indicator does not light.
d) The corresponding segments of all digits do not light up; or they continue to light up.
e) Wrong figure appears.
f) A certain group of indicators do not light up.
g) The figure of all digits flicker.
2-2 Other possible problems caused by defective control unit.
a) Buzzer does not sound or continues to sound.
b) Clock does not operate properly.
c) Cooking is not possible.
3. Power Unit or Touch Control Transformer
a) Fan motor, stirrer motor, oven lamp or electrical parts do not turn on or do not turn off.
b) Digital display on the control unit does not show anything.
When testing is completed,
1) Disconnect the power supply cord, and then disassemble as per "MICROWAVE DRAWER
DISASSEMBLY" page 25.
2) Open the drawer and block it open.
3) Discharge high voltage capacitor.
9
KB-6015KS
KB-6015KK
KB-6015KW
TEST PROCEDURES
PROCEDURE
LETTER
COMPONENT TEST
4)
5)
6)
7)
B
Reconnect all leads removed from components during testing.
Re-install the covers.
Reconnect the power supply cord after the covers are installed.
Run the oven and check all functions.
KEY UNIT TEST
1. Disconnect the power supply cord, and then remove outer case.
2. Open the drawer and block it open.
3. Discharge high voltage capacitor.
4. If the display fails to clear when the STOP/CLEAR pad is depressed, first verify the flat ribbon cable
is making good contact, verify that the door sensing switch (stop switch) operates properly; that is the
contacts are closed when the drawer is closed and open when the
<KEY UNIT>
drawer is open. If the door sensing switch (stop switch) is good, CN-J
TIMER
6
9
disconnect the flat ribbon cable that connects the key unit to the
J-12
CLOCK
control unit and make sure the drawer sensing switch is closed
1
8
0
J-11
(either close the drawer or short the door sensing switch connecter).
2
3
5
J-10
Use the Key unit matrix indicated on the control panel schematic
POWER
7
4
J-9
LEVEL
and place a jumper wire between the pins that correspond to the
SENSOR
OPEN
J-8
STOP/CLEAR pad making momentary contact. If the control unit
COOK
SENSOR SENSOR SET UP
responds by clearing with a beep the key unit is faulty and must be
J-7
REHEAT POPCORN CUSTOM
HELP
replaced. If the control unit does not respond, it is faulty and must
CONTROL
REHEAT DEFROST KEEP
LOCK
J-6
WARM
ON/OFF
be replaced. If a specific pad does not respond, the above method
START/
STOP/
CLOSE
J-5
MINUTE
CLEAR
may be used (after clearing the control unit) to determine if the
PLUS
J-4
control unit or key pad is at fault.
J-3
J-2
5. Reconnect all leads removed from components during testing.
J-1
6. Re-install the outer case (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
C
RELAY TEST
1.
2.
3.
4.
5.
6.
7.
Disconnect the power supply cord, and then remove outer case.
Open the door and block it open.
Discharge high voltage capacitor.
Disconnect the leads to the primary of the power transformer.
Ensure that these leads remain isolated from other components and oven chassis by using insulation tape.
After that procedure, re-connect the power supply cord.
Remove the outer case and check voltage between Pin Nos. 5 and 7 of the 4 pin connector (CN-A)
on the power unit with an A.C. voltmeter.
The meter should indicate 120 volts, if not check oven circuit.
RY1, RY2, RY3 and RY4 Relay Test
These relays are operated by D.C. voltage
Check voltage at the relay coil with a D.C. voltmeter during the microwave cooking operation.
DC. voltage indicated .................... Defective relay.
DC. voltage not indicated ............... Check diode which is connected to the relay coil. If diode is good,
control unit is defective.
RELAY SYMBOL
RY1
RY2
RY3
RY4
RY5
OPERATIONAL VOLTAGE
Approx.
Approx.
Approx.
Approx.
Approx.
26V
25V
26V
26V
26V
D.C.
D.C.
D.C.
D.C.
D.C.
CONNECTED COMPONENTS
Oven lamp / Common
Power transformer
Stirrer motor
Fan motor
Switching regurator for drawer motor
8.Disconnect the power supply cord, and then remove outer case.
9.Open the door and block it open.
10.Discharge high voltage capacitor.
11.Reconnect all leads removed from components during testing.
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TEST PROCEDURES
PROCEDURE
LETTER
COMPONENT TEST
12.Re-install the outer case (cabinet).
13.Reconnect the power supply cord after the outer case is installed.
14.Run the oven and check all function.
D
DEFROST TEST
WARNING : The oven should be fully assembled before following procedure.
(1) Place one cup of water in the center of the tray in the oven cavity.
(2) Close the drawer, touch the Defrost pad. Then select Steaks/Chops by touching the number pad 2.
And touch the number pad 5. (Now, weight 0.5lb is set.) And then touch the start pad.
(3) The oven is in Defrost cooking condition.
(4) The oven will operate as follows
WEIGHT
0.5lb
1ST STAGE
LEVEL
TIME
60%
20sec.
2ND STAGE
LEVEL
TIME
40%
20sec.
3RD. STAGE
LEVEL TIME
30%
45sec.
(5) If improper operation is indicated, the control unit is probably defective and should be checked.
E
PROCEDURES TO BE TAKEN WHEN THE FUSE ON THE PRINTED WIRING BOARD (PWB) IS
OPEN.
To protect the electronic circuits, this model is provided with a fuse added to the primary on the PWB.
1. Fuse check and repairs.
1) Disconnect the power supply cord.
2) Remove the outer case cabinet.
3)
4)
5)
6)
7)
8)
9)
10)
11)
Open the door and block it open.
Discharge high voltage capacitor.
If the Fuse is blown, replace power unit.
Make a visual inspection of the varistor. Check for burned damage. If the varistor has been burned,
replace the power unit.
Examine the touch control transformer with a tester for the presence of layer short-circuit (check
the primary coil resistance which is approximately 151.6Ω ± 10%). If any abnormal condition is
detected, replace the touch control transformer.
Reconnect all leads removed from components during testing.
Re-install the outer case (cabinet).
Reconnect the power supply cord after the outer case is installed.
Run the oven and check all functions.
2. Follow the troubleshooting guide given below, if indicator does not light up after above check and
repairs are finished.
1) Disconnect the power supply cord.
2) Remove the outer case cabinet.
3)
4)
5)
6)
Open the door and block it open.
Discharge high voltage capacitor.
Disconnect the leads to the primary of the power transformer.
Ensure that these leads remain isolated from other components and oven chassis by using
insulation tape.
7) After that procedure, re-connect the power supply cord.
8) Follow the troubleshooting guide given below for repair.
STEPS
OCCURRENCE
CAUSE OR CORRECTION
1
The rated AC voltage is not present between Check supply voltage and oven power cord.
Pin Nos. 5 and 7 of the 4-pin connecter (CN-A).
2
The rated AC voltage is present at primary
side of touch control transformer.
Touch control transformer or secondary circuit defective.
Check and replace touch control transformer or power unit .
9) Disconnect the power supply cord, and then remove outer case.
10) Open the door and block it open.
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TEST PROCEDURES
PROCEDURE
LETTER
COMPONENT TEST
11)
12)
13)
14)
15)
F
Discharge high voltage capacitor.
Reconnect all leads removed from components during testing.
Re-install the outer case (cabinet).
Reconnect the power supply cord after the outer case is installed.
Run the oven and check all functions.
AH SENSOR TEST
Checking the initial sensor cooking condition
WARNING : The oven should be fully assembled before following procedure.
(1) The oven should be plugged in at least two minutes before sensor cooking.
ο
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(2) Room temperature should not exceed 95 F (35 C).
(3) The unit should not be installed in any area where heat and steam are generated. The unit should not be
installed, for example, next to a conventional surface unit. Refer to the “INSTALLATION INSTRUCTIONS”
of the operation manual.
(4) Exhaust vents are provided on the back of the unit for proper cooling and air flow in the cavity. To permit
adequate ventilation, be sure to install so as not to block these vents. There should be some space for
air circulation.
(5) Be sure the exterior of the cooking container and the interior of the oven are dry. Wipe off any moisture
with a dry cloth or paper towel.
(6) The Sensor works with food at normal storage temperature. For example, chicken pieces would be at
refrigerator temperature and canned soup at room temperature.
(7) Avoid using aerosol sprays or cleaning solvents near the oven while using Sensor settings. The sensor
will detect the vapor given of by the spray and turn off before food is properly cooked.
(8) If the sensor has not detected the vapor of the food, ERROR will appear and the oven will shut off.
Water load cooking test
WARNING : The oven should be fully assembled before following procedure.
Make sure the oven has been plugged in at least two minutes before checking sensor cook operation. The
cabinet should be installed and screws tightened.
(1) Fill approximately 200 milliliters (7.2 oz) of tap water in a 1000 milliliter measuring cup.
(2) Place the container on the center of tray in the oven cavity.
(3) Close the drawer.
(4) Touch the TIMER/CLOCK pad once, the POWER LEVEL pad twice and the START pad once. And touch
the number pads 1 once and the number pad 4 once. Now, the oven is in the sensor cooking condition,
and "AH20" and "ON" will appear in the display.
(5) The oven will operate for the first 16 seconds, without generating microwave energy.
NOTE: ERROR will appear if the door is opened or STOP/CLEAR pad is touched during first stage of sensor
cooking.
(6) After approximately 16 seconds, microwave energy is produced.
If ERROR is displayed or the oven does not turn off, replace the AH sensor or check the control unit, refer to
explanation below. If the oven stops after 5 minutes and no ERROR code is displayed, then the AH sensor
is normal. Check other parts except the AH sensor.
TESTING METHOD FOR AH SENSOR AND/OR CONTROL UNIT
To determine if the sensor is defective, the simplest method is to replace it with a new replacement sensor.
(1) Disconnect the power supply cord, and then disassemble as per "MICROWAVE DRAWER
DISASSEMBLY" page 25.
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Open the drawer and block it open.
Discharge high voltage capacitor.
Remove the AH sensor.
Install the new AH sensor.
Reconnect all leads removed from components during testing.
Re-install the covers.
Reconnect the power supply cord after the covers are installed.
Reconnect the oven to the power supply and check the sensor cook operation as follows:
9-1. Fill approximately 200 milliliters (7.2 oz) of tap water in a 1000 milliliter measuring cup.
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TEST PROCEDURES
PROCEDURE
LETTER
COMPONENT TEST
9-2. Place the container on the center of tray in the oven cavity.
9-3. Close the drawer.
9-4. Touch the TIMER/CLOCK pad once, the POWER LEVEL pad twice and the START pad once. And
touch the number pads 1 once and the number pad 4 once.
9-5. The control panel is in automatic Sensor operation.
9-6. The oven turns off automatically, and the time for detecting moisture will be displayed.
If new sensor does not operate properly, the problem is with the control unit, and refer to explanation below.
CHECKING CONTROL UNIT
(1) Disconnect the power supply cord, and then disassemble as per "MICROWAVE DRAWER
DISASSEMBLY" page 25.
(2) Open the drawer and block it open.
(3) Discharge high voltage capacitor.
(4) Disconnect the sensor connector that is mounted to control panel.
(5) Then connect the dummy resistor circuit (see fig.) to the sensor connector of control panel.
(6) Disconnect the leads to the primary of the power transformer.
(7) Ensure that these leads remain isolated from other components and oven chassis by using insulation tape.
(8) After that procedure, re-connect the power supply cord.
(9) Check the sensor cook operation proceed as follows:
9-1. Close the door. Touch the TIMER/CLOCK pad once, the POWER LEVEL pad twice and the START
pad once. And touch the number pads 1 once and the number pad 4 once.
9-2. The control panel is in the sensor cooking operation.
9-3. After approximately 25 seconds, push plunger of select switch for more than 3 seconds. This
condition is same as judgement by AH sensor.
9-4. After approximately 3 seconds, the display shows “ X X . X X “ which is the time for detecting moisture.
If the above is not the case, the control unit is probably defective.
If the above is proper, the AH sensor is probably defective.
(10) Disconnect the power supply cord, and then remove covers.
(11) Open the drawer and block it open.
(12) Discharge high voltage capacitor.
(13) Disconnect the dummy resistor circuit from the sensor connector of control panel.
(14) Carry out necessary repair.
(15) Reconnect all leads removed from components during testing and repairing.
(16) Re-install the covers.
(17) Reconnect the power supply cord after the outer case is installed. Run the oven and check all functions.
(18) Carry out "Water load cooking test" again and ensure that the oven works properly.
R1, R2 : 22Ω ± 1% 1/2W
R3 : 4.3kΩ ± 5% 1/4W
R4 : 1MΩ ± 5% 1/4W
Plunger
NC
NO
F-1
F-2
To connector (F)
on Control Unit.
1
2
COM
COM NO
R1
3
F-3
R2
CONNECTOR
R3
R4
Sensor Dummy Resistor Circuit
13
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TEST PROCEDURES
PROCEDURE
LETTER
COMPONENT TEST
Refer to the disassembly instructions found on Page 16.
G
MAGNETRON ASSEMBLY TEST
1.
2.
3.
4.
5.
6.
7.
8.
9.
Disconnect the power supply cord.
Open the drawer and keep it open.
To discharge high voltage capacitor, wait for 60 seconds.
To test for an open filament, isolate the magnetron from the high voltage circuit. A continuity check across
the magnetron filament leads should indicate less than 1 ohm.
To test for a shorted magnetron, connect the ohmmeter leads between the magnetron filament leads and
chassis ground. This test should indicate an infinite resistance. If there is little or no resistance the
magnetron is grounded and must be replaced.
Reconnect all leads removed from components during testing.
Reassemble the unit.
Reconnect the power supply cord.
Run the oven and check all functions.
MICROWAVE OUTPUT POWER
The following test procedure should be carried out with the microwave oven in a fully assembled condition.
HIGH VOLTAGES ARE PRESENT DURING THE COOK CYCLE, SO EXTREME CAUTION SHOULD BE
OBSERVED.
Power output of the magnetron can be measured by performing a water temperature rise test. This test should
only be used if above tests do not indicate a faulty magnetron and there is no defect in the following
components or wiring: inverter unit. This test will require a 16 ounce (453cc) measuring cup and an accurate
mercury thermometer or thermocouple type temperature tester. For accurate results, the following procedure
must be followed carefully:
1. Fill the measuring cup with 16 oz. (453cc) of tap water and measure the temperature of the water with a
thermometer or thermocouple temperature tester. Stir the thermometer or thermocouple through the water
until the temperature stabilizes. Record the temperature of the water.
2. Place the cup of water in the oven. Operate oven at POWER 10(HIGH) selecting more than 60 seconds
cook time. Allow the water to heat for 60 seconds, measuring with a stop watch, second hand of a watch
or the digital read-out countdown.
3. Remove the cup from the oven and again measure the temperature, making sure to stir the thermometer
or thermocouple through the water until the maximum temperature is recorded.
ο
4. Subtract the cold water temperature from the hot water temperature. The normal result should be 28 to
ο
ο
ο
54 F (16 to 30 C) rise in temperature. If the water temperatures are accurately measured and tested for
the required time period the test results will indicate 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 time 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. The test is only accurate if the power supply line
voltage is 120 volts and the oven cavity is clean.
H
THERMAL CUT-OUT TEST
1.
2.
3.
4.
Disconnect the power supply cord.
Open the drawer and keep it open.
To discharge high voltage capacitor, wait for 60 seconds.
A continuity check across the thermal cut-out terminals should indicate a closed circuit unless the
ο
ο
temperature of the thermal cut-out reaches approximately 293 F(145 C).
An open thermal cut-out indicates overheating of the oven, exchange the oven thermal cut-out and
check inside of oven cavity and for improper setting of cooking time or operation of control unit. Check
for restricted air flow through the vent holes of the oven cavity, especially the cooling fan and air guide.
5. Reconnect all leads removed from components during testing.
6. Reassemble the unit.
7. Reconnect the power supply cord.
8. Run the unit and check all functions.
CAUTION: IF THE THERMAL CUT-OUT INDICATES AN OPEN CIRCUIT AT ROOM TEMPERATURE,
REPLACE THERMAL CUT-OUT.
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TEST PROCEDURES
PROCEDURE
LETTER
I
COMPONENT TEST
SECONDARY INTERLOCK SWITCH TEST
1.
2.
3.
4.
Disconnect the power supply cord.
Open the drawer and keep it open.
To discharge high voltage capacitor, wait for 60 seconds.
Isolate the switch and connect the ohmmeter to the common (COM.) and normally open (NO) terminal
of the switch. The meter should indicate an open circuit with the drawer open and a closed circuit with
the drawer closed. If improper operation is indicated, replace the secondary interlock switch.
5. Reconnect all leads removed from components during testing.
6. Reassemble the unit.
7. Reconnect the power supply cord.
8. Run the oven and check all functions.
J
STOP SWITCH TEST
STOP SWITCH
1. Disconnect the power supply cord.
2. Open the drawer and keep it open.
3. To discharge high voltage capacitor, wait for 60 seconds.
4. Isolate the switch and connect the ohmmeter to the common (COM.) and normally open (NO) terminal
of the switch. The meter should indicate an open circuit with the drawer open and a closed circuit with
the drawer closed. If improper operation is indicated, replace the stop switch.
5. Reconnect all leads removed from components during testing.
6. Reassemble the unit.
7. Reconnect the power supply cord.
8. Run the oven and check all functions.
NOTE: If the stop switch contacts fail in the open position and the door is closed, the cooling fan motor,
stirrer motor and oven light will be activated by RY1.
K
MONITOR SWITCH TEST
1.
2.
3.
4.
Disconnect the power supply cord.
Open the drawer and keep it open.
To discharge high voltage capacitor, wait for 60 seconds.
Before performing this test, make sure that the secondary interlock switch, according to the above
Switch Test Procedure. Disconnect the wire lead from the monitor switch (COM) terminal. Check the
monitor switch operation by using the ohmmeter as follows. When the drawer is open, the meter should
indicate a closed circuit. When the monitor switch actuator is pushed by a screw driver through the
lower latch hole on the front plate of the oven cavity with the drawer opened (in this condition the
plunger of the monitor switch is pushed in), the meter should indicate an open circuit. If improper
operation is indicated, the switch may be defective and both the monitor switch, plus fuse will need
to be replaced. After testing the monitor switch, reconnect the wire lead to the monitor switch (COM)
terminal and check the continuity of the monitor circuit.
5. Reconnect all leads removed from components during testing.
6. Reassemble the unit.
7. Reconnect the power supply cord.
8. Run the oven and check all functions.
MONITOR
SWITCH
(BLK)
Screw Driver
(RED)
Ohmmeter
(BRN,GRY)
(BRN,BLK)
SECONDARY
INTERLOCK
SWITCH
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TEST PROCEDURES
PROCEDURE
LETTER
L
COMPONENT TEST
BLOWN MONITOR FUSE TEST
1.
2.
3.
4.
Disconnect the power supply cord.
Open the drawer and block it open.
To discharge high voltage capacitor, wait for 60 seconds.
If the monitor fuse is blown when the drawer is opened, check the primary interlock switch, secondary
interlock switch and monitor switch according to the "TEST PROCEDURE" for those switches before
replacing the blown monitor fuse.
CAUTION: BEFORE REPLACING A BLOWN MONITOR FUSE, TEST THE SECONDARY INTERLOCK
SWITCH, STOP SWITCH AND MONITOR SWITCH FOR PROPER OPERATION.
If the monitor fuse is blown by improper switch operation, the monitor fuse and monitor switch must
be replaced with "monitor fuse and monitor switch assembly" part number FFS-BA018/KIT, even if the
monitor switch operates normally. The monitor fuse and monitor switch assembly is comprised of a
20 ampere fuse and switch.
5. Reconnect all leads removed from components during testing.
6. Reassemble the unit.
7. Reconnect the power supply cord.
8. Run the oven and check all functions.
M
POWER TRANSFORMER TEST
1.
2.
3.
4.
Disconnect the power supply cord.
Open the drawer and block it open.
Discharge high voltage capacitor.
Disconnect the primary input terminals and measure the resistance of the transformer with an
ohmmeter. Check for continuity of the coils with an ohmmeter. On the R x 1 scale, the resistance of
the primary coil should be less than 1 ohm and the resistance of the high voltage coil should be
approximately 90 ohms; the resistance of the filament coil should be less than 1 ohm.
5. Reconnect all leads removed from components during testing.
6. Reassemble the unit.
7. Reconnect the power supply cord.
8. Run the oven and check all functions.
(HIGH VOLTAGES ARE PRESENT AT THE HIGH VOLTAGE TERMINAL, SO DO NOT ATTEMPT TO
MEASURE THE FILAMENT AND HIGH VOLTAGE.)
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TOUCH CONTROL PANEL ASSEMBLY
OUTLINE OF TOUCH CONTROL PANEL
6) Power Source Circuit
This circuit generates voltages necessary in the control
unit from the AC line voltage.
In addition, the synchronizing signal is available in order
to compose a basic standard time in the clock circuit.
The touch control section consists of the following units.
(1) Key unit
(2) Control Unit
(3) Power unit
The principal functions of these units and the signals communicated among them are explained below.
Symbol
Voltage
VC
+5V
Application
LSI(IC1)
7) Relay Circuit
A circuit to drive the magnetron, fan motor, stirrer motor
and light the oven lamp.
Key unit
The key unit is composed of a matrix, signals generated in
the LSI are sent to the key unit from P10 - P17.
When a key pad is touched, a signal is completed through
the key unit and passed back to the LSI through P20 - P23
to perform the function that was requested.
8)
Buzzer Circuit
The buzzer is responsive to signals from the LSI to emit
audible sounds (key touch sound and completion sound).
Control Unit and Power Unit
Control unit consists of LSI, IC, reset circuit, indicator circuit,
power source circuit, relay circuit, buzzer circuit, synchronizing signal circuit, keyboard unit circuit, humidity sensor
circuit and back light circuit.
9) Synchronizing Signal Circuit
The power source synchronizing signal is available in
order to compose a basic standard time in the clock
circuit.
It accompanies a very small error because it works on
commercial frequency.
1) IC1 (LSI)
This is a microcomputer, responsible for controlling the
entire control unit.
10) Door Sensing Switch (Microwave drawer)
A switch to “tell” the LSI if the drawer is open or closed.
2) IC2
This is the IC to drive the Liquid Crystal Display.
11) Door Position Switch Front / Rear
The switch to “tell” the position of the Microwave drawer
door.
3) IC5
This is the IC to amplify the signal from the humidity
sensor.
12) Back Light Circuit
A circuit to drive the back light (Light emitting diodes
LD1- LD3).
4) Reset Circuit
This circuit generates a signal which resets the LSI (IC1)
to the initial state when power is supplied.
13) Humidity Sensor Circuit
This circuit detects moisture of the cooking food to allow
its automatic cooking.
5) Indicator Circuit
A circuit to drive the Liquid Crystal Displays (LCD1).
14) Microwave drawer door open-close Circuit
A circuit to drive the microwave drawer door open-close
motor.
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DESCRIPTION OF LSI (IC-1)
The I/O signal of the LSIis detailed in the following table.
Pin No.
Signal
I/O
Description
1-3
AN5- AN3
IN
Terminal to change cooking input according to the Model.
By using A/D converter contained in the LSI, DC voltage in accordance with the Model
in operation is applied to set up its cooking constant.
4
AN2
IN
Input signal which inform the drawer door is in the middle position between the opened
position and the closed position, to LSI from the door position switch rear.
5
AN1
IN
Turminal not used.
6
AN0
IN
Turminal not used.
7
CNVSS
IN
Power source voltage: 0V (GND).
VC voltage of power source circuit input. Connected GND.
8
RESET
IN
Auto clear terminal.
Signal is input to reset the LSI to the initial state when power is applied. Temporarily set
to “L” level the moment power is applied, at this time the LSI is reset. Thereafter set at “H”
level.
9
P62
OUT
10
P61
11
VSS
IN
Power source voltage: 0V (GND).
VS voltage of power source circuit input. Connected GND.
12
XIN
IN
Internal clock oscillation frequency setting input.
The internal clock frequency is set by inserting the ceramic filter oscillation circuit with
respect to Xout terminal.
13
XOUT
OUT
14
VCC
IN
Power source voltage: +5V.
VC voltage of power source circuit input.
15
P60
IN
Plus signal coming from the Microwave drawer door open-close motor is input into P60
as revolution number.
16
P37
IN
Input signal which communicates the drawer door open information to LSI from
the door position switch front.
Door opened; “L” level signal(0V).
Door closed; “H” level signal(+5V).
17
P36
OUT
18
TXOUT
OUT
Signal to change the rotational direction is output to the Microwave drawer door
open-close motor.
Signal to change the rotational speed is output to the Microwave drawer door open-close
motor.
19
P34
OUT
20
RXD2
IN
Input terminal to check the data of display.
Data signal from IC-2 is input to RXD2 to check the flow of the data.
21
TXD2
IN
Output terminal to send IC-2 the data.
The data of display is output to IC-2.
22
SCLK2
OUT
Clock timing signaI output terminal.
Clock timing signal is sent to IC-2.
23
P30
OUT
Signal to reset LSI.
Signal is output to reset IC-2.
24 - 25
COM3 - COM2
OUT
Turminal not used.
26
COM1
OUT
Common data signal.
Connected to LCD signal C5.
Turminal not used.
IN/OUT Turminal not used.
Internal clock oscillation frequency control output.
Output to control oscillation input of Xin.
Power source to drive the Microwave drawer door open-close motor is output.
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Pin No.
Signal
I/O
27
COM0
OUT
28
VL3
IN
29 - 31
P27- P25
OUT
Turminal not used.
32
SEG20
OUT
Segment data signal.
Connected to LCD segment S24.
33
P23
IN
Signal coming from touch key.
When any one of J-4 line keys on key matrix is touched, a corresponding signal from P10P17 will be input into P23. When no key is touched, the signal is held at "L" level.
34
P22
IN
Signal similar to P23.
When any one of J-3 line keys on key matrix is touched, a corresponding signal will be
input into P22.
35
P21
IN
Signal similar to P23.
When any one of J-2 line keys on key matrix is touched, a corresponding signal will be
input into P21.
36
P20
IN
Signal similar to P23.
When any one of J-1 line keys on key matrix is touched, a corresponding signal will be
input into P20.
37
P17
OUT
Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P20 - P23 terminal while one
of J-12 line key on matrix is touched.
38
P16
OUT
Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P20 - P23 terminal while one
of J-11 line key on matrix is touched.
39
P15
OUT
Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P20 - P23 terminal while one
of J-10 line key on matrix is touched.
40
P14
OUT
Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P20 - P23 terminal while one
of J-9 line key on matrix is touched.
41
P13
OUT
Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P20 - P23 terminal while one
of J-8 line key on matrix is touched.
42
P12
OUT
Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P20 - P23 terminal while one
of J-7 line key on matrix is touched.
43
P11
OUT
Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P20 - P23 terminal while one
of J-6 line key on matrix is touched.
44
P10
OUT
Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P20 - P23 terminal while one
of J-5 line key on matrix is touched.
45
P07
OUT
Fan motor (Drawer) driving signal.
To turn on and off relay(RY4).
“H” level: During fan motor ON.
“L” level: During fan motor OFF.
46
P06
OUT
Description
Common data signal.
Connected to LCD signal C4.
Connected VC (+5V).
Stirrer motor driving signal.
To turn on and off relay(RY3).
“H” level: During fan motor ON.
“L” level: During fan motor OFF.
19
ON
H: +5V
OFF
ON
L: GND
H: +5V
OFF
L: GND
KB-6015KS
KB-6015KK
KB-6015KW
Pin No.
Signal
I/O
47
P05
OUT
Description
Magnetron high-voltage circuit driving signal.
To turn on and off the cook relay(RY2). In 100%
power operation, the signals holds “H” level during
microwave cooking and “L” level while not cooking. In other cooking modes (90%, 80%, 70%,
60%, 50%, 40%, 30%, 20%, 10%, 0%) the signal
turns to “H” level and “L” level in repetition according to the power level.
Microwave cooking mode
VARI MODE
100% power
32 sec.
0 sec.
60sec.
0ec.
90% power
30 sec.
2 sec.
54sec.
6sec.
80% power
26 sec.
6 sec.
48sec.
12sec.
70% power
24 sec.
8 sec.
42sec.
18sec.
60% power
22 sec.
10 sec.
36sec.
24sec.
50% power
18 sec.
14 sec.
30sec.
30sec.
40% power
16 sec.
16 sec.
24sec.
36sec.
30% power
12 sec.
20 sec.
18sec.
42sec.
20% power
8 sec.
24 sec.
12sec.
48sec.
10% power
6 sec.
26 sec.
4sec.
56sec.
0% power
0 sec.
32 sec.
0sec.
60sec.
48-52
P04-P00
OUT
Used for initial balancing of the bridge circuit (absolute humidity sensor).
53
P57
OUT
Common relay driving signal. (Square Waveform : 60Hz)
To turn on and off the shut-off relays (RY1). The
square waveform voltage is delivered to the relay
(RY1) driving circuit.
54
P56
IN
Turminal not used.
55
TXD1
IN
Turminal not used.
56
RXD1
IN
Turminal not used.
57
P53
IN
Turminal not used.
58
P52
OUT
Signal to sound buzzer.
A: Key touch sound.
B: Completion sound.
C: When the oven stops so that the food can be
checked in Automatic cooking mode.
Other cooking mode
ON TIME OFF TIME ON TIME OFF TIME
16.7 msec.
H: +5V
L: GND
During cooking
0.1 sec
A
2.0 sec
B
1.0 sec
1.0 sec
H: +5V
C
L: GND
59
P51
IN
Input signal which communicates the drawer door close information to LSI.
Door opened; “H” level signal(+5V).
Door closed; “L” level signal(0V).
60
INT0
IN
Signal to synchronize LSI with commercial power source frequency.
This is the basic timing for all real time processing of LSI.
H : +5V
L : GND
16.7 msec.
61
AVSS
IN
A/D converter power source voltage.
The power source voltage to drive the A/D converter in the LSI.
62
VREF
IN
Reference voltage input terminal.
A reference voltage applied to the A/D converter in the LSI. Connected to +5V.
63
AN7
IN
AH sensor input.
This input is an analog input terminal from the AH sensor circuit, and connected to the A/
D converter built into the LSI.
64
AN6
IN
Used for initial balancing of the bridge circuit (absolute humidity sensor). This input is an
analog input terminal from the AH sensor circuit, and connected to the A/D converter built
into the LSI.
20
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KB-6015KW
HUMIDITY SENSOR CIRCUIT
(1) Structure of Humidity Sensor
The humidity sensor includes two thermistors as shown
in the illustration. One thermistor is housed in the closed
vessel filled with dry air while another in the open vessel.
Each sensor is provided with the protective cover made
of metal mesh to be protected from the external airflow.
potential at both F-3 terminal of the absolute humidity
sensor and AN6 terminal of the LSI. The voltage of AN7
terminal will indicate about +2.5V. This initial balancing is
set up about 16 seconds after the unit is put in the Sensor
Cooking mode. As the sensor cooking proceeds, the
food is heated to generate moisture by which the
resistance balance of the bridge circuit is deviated to
increase the voltage available at AN6 terminal of the LSI.
Then the LSI observes that voltage at AN7 terminal and
compares it with its initial value, and when the comparison
rate reaches the preset value (fixed for each menu to be
cooked), the LSI causes the unit to stop sensor cooking;
thereafter, the unit goes in the next operation automatically.
When the LSI starts to detect the initial voltage at AN7
terminal 16 seconds after the unit has been put in the
Sensor Cooking mode, if it is not possible to balance the
bridge circuit due to disconnection of the absolute humidity
sensor, ERROR will appear on the display and the
cooking is stopped.
ventilation opening for sensing
Thermistors
Sensing part
(Open vessel)
Sensing part
(Closed vessel)
1) Humidity sensor circuit
(2) Operational Principle of Humidity Sensor
The figure below shows the basic structure of an absolute
humidity sensor. A bridge circuit is formed by two
thermistors and two resistors (R1 and R2).
The output of the bridge circuit is to be amplified by the
operational amplifier.
Each thermistor is supplied with a current to keep it
ο
ο
heated at about 150 C (302 F), the resultant heat is
dissipated in the air and if the two thermistors are placed
in different humidity conditions they show different degrees
of heat conductivity leading to a potential difference
between them causing an output voltage from the bridge
circuit, the intensity of which is increased as the absolute
humidity of the air increases. Since the output is varied
every minute, it is amplified by the operational amplifier.
VC : +5V
R40
430
VA : +15V
F1
2
R4
3.5
7K
R43 1.8K
C
R2
Operational
amplifier
Output
voltage
+
S : Thermistor
open vessel
C : Thermistor
closed vessel
Absolute humidity (g/m 2 )
(3) Detector Circuit of Humidity Sensor Circuit
This detector circuit is used to detect the output voltage
of the absolute humidity circuit to allow the LSI to control
sensor cooking of the unit. When the unit is set in the
sensor cooking mode, 16 seconds clearing cycle occurs
than the detector circuit starts to function and the LSI
observes the initial voltage available at its AN6 terminal.
With this voltage given, the switches SW1 to SW5 in the
LSI are turned on in such a way as to change the
resistance values in parallel with R45 ~ R49. Changing
the resistance values results in that there is the same
21
R50 10K
AN7
R52 47K
LSI
(IC1)
R44 360K
52
R49 37.4K
Output voltage
R1
63
1
64
R48 75K
S
+
IC5
4
R45 620K
R46 300K
Absolute humidity vs,
output voltage characteristic
2
8
R51 47K
R47 150K
R3
D41
86
3
C42 0.1μF
S
2K
C
3.3
F3
R4
1
F2
D40
C. Thermistor in
closed vessel
S. Thermistor in
open vessel
51
50
49
48
AN6
SW1
P00
SW2
P01
SW3
P02
SW4
P03
SW5
P04
KB-6015KS
KB-6015KK
KB-6015KW
TOUCH CONTROL PANEL SERVICING
A. On some models, the power supply cord between the
touch control panel and the oven itself is so short that the
two can’t be separated. For those models, check and
repair all the controls (sensor-related ones included) of
the touch control panel while keeping it connected to the
oven.
B. On some models, the power supply cord between the
touch control panel and the oven proper is long enough
that they may be separated from each other. For those
models, it is possible to check and repair the controls of
the touch control panel while keeping it apart from the
oven proper; in this case you must short both ends of the
door sensing switch (on PWB) of the touch control panel
with a jumper, which activates an operational state that
is equivalent to the oven door being closed. As for the
sensor-related controls of the touch control panel,
checking them is possible if dummy resistor(s) with
resistance equal to that of the controls are used.
(2) Servicing the touch control panel with power supply
from an external power source:
Disconnect the touch control panel completely from the
oven proper, and short both ends of the door sensing
switch (on PWB) of the touch control panel, which
activates an operational state that is equivalent to the
oven door being closed. Connect an external power
source to the power input terminal of the touch control
panel, then it is possible to check and repair the controls
of the touch control panel it is also possible to check the
sensor-related controls of the touch control panel by
using the dummy resistor(s).
1. Precautions for Handling Electronic Components
This unit uses CMOS LSI in the integral part of the
circuits. When handling these parts, the following
precautions should be strictly followed. CMOS LSI have
extremely high impedance at its input and output terminals.
For this reason, it is easily influenced by the surrounding
high voltage power source, static electricity charge in
clothes, etc. and sometimes it is not fully protected by the
built-in protection circuit.
In order to protect CMOS LSI.
1) When storing and transporting, thoroughly wrap them in
aluminium foil. Also wrap all PW boards containing them
in aluminium foil.
2) When soldering, ground the technician as shown in the
figure and use grounded soldering iron and work table.
approx. 1M ohm
2. Servicing of Touch Control Panel
We describe the procedures to permit servicing of the
touch control panel of the microwave oven and the
precautions you must take when doing so. To perform
the servicing, power to the touch control panel is available
either from the power line of the oven itself or from an
external power source.
(1) Servicing the touch control panel with power supply
of the oven:
CAUTION:
THE HIGH VOLTAGE TRANSFORMER OF THE
MICROWAVE OVEN IS STILL LIVE DURING
SERVICING AND PRESENTS A HAZARD.
Therefore, before checking the performance of the touch
control panel,
1) Disconnect the power supply cord, and then remove
outer case.
2) Open the door and block it open.
3) Discharge high voltage capacitor.
4) Disconnect the leads to the primary of the power
transformer.
5) Ensure that these leads remain isolated from other
components and oven chassis by using insulation
tape.
6) After that procedure, re-connect the power supply
cord.
After checking the performance of the touch control
panel,
1) Disconnect the power supply cord.
2) Open the door and block it open.
3) Re-connect the leads to the primary of the power
transformer.
4) Re-install the outer case (cabinet).
5) Re-connect the power supply cord after the outer
case is installed.
6) Run the oven and check all functions.
3. Servicing Tools
Tools required to service the touch control panel
assembly.
1) Soldering iron: 30W
(It is recommended to use a soldering iron with a
grounding terminal.)
2) Oscilloscope: Single beam, frequency range: DC10MHz type or more advanced model.
3) Others: Hand tools
4. Other Precautions
1) Before turning on the power source of the control unit,
remove the aluminium foil applied for preventing
static electricity.
2) Connect the connectors of the key unit to the control
unit being sure that the lead wires are not twisted.
3) After aluminium foil is removed, be careful that
abnormal voltage due to static electricity etc. is not
applied to the input or output terminals.
4) Attach connectors, electrolytic capacitors, etc. to
PWB, making sure that all connections are tight.
5) Be sure to use specified components where high
precision is required.
22
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PRECAUTIONS FOR USING LEAD-FREE SOLDER
1. Employing lead-free solder
The "Main PWB" of this model employs lead-free solder. This is indicated by the "LF" symbol printed on the PWB and
in the service manual. The suffix letter indicates the alloy type of the solder.
Example:
Indicates lead-free solder of tin, silver and copper.
2. Using lead-free wire solder
When repairing a PWB with the "LF" symbol, only lead-free solder should be used. (Using normal tin/lead alloy solder
may result in cold soldered joints and damage to printed patterns.)
As the melting point of lead-free solder is approximately 40oC higher than tin/lead alloy solder, it is recommend that a
dedicated bit is used, and that the iron temperature is adjusted accordingly.
3. Soldering
As the melting point of lead-free solder (Sn-Ag-Cu) is higher and has poorer wettability, (flow), to prevent damage to the
land of the PWB, extreme care should be taken not to leave the bit in contact with the PWB for an extended period of
time. Remove the bit as soon as a good flow is achieved. The high content of tin in lead free solder will cause premature
corrosion of the bit. To reduce wear on the bit, reduce the temperature or turn off the iron when it is not required.
Leaving different types of solder on the bit will cause contamination of the different alloys, which will alter their
characteristics, making good soldering more difficult. It will be necessary to clean and replace bits more often when using
lead-free solder. To reduce bit wear, care should be taken to clean the bit thoroughly after each use.
23
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KB-6015KW
COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE
WARNING AGAINST HIGH VOLTAGE:
Microwave ovens contain circuitry capable of producing very high voltage and current. Contact with the following parts
may result in severe, possibly fatal, electric shock.
(Example)
High Voltage Capacitor, Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..
WARNING:
To Avoid possible exposure to microwave energy, please follow the instructions below
before operating the oven.
1. Disconnect the power supply cord.
2. Make sure that a definite” click” can be heard when the
microwave oven drawer is unlatched. (Hold the drawer
in a closed position with one hand, then pull the drawer
open, this causes the latch leads to rise, it is then
possible to hear a “click’ as the drawer switches operate.)
3. Visually check the drawer and cavity face plate for
damage (dents, cracks, signs of arcing etc.).
2.
3.
4.
5.
6.
Drawer latch hook is damaged.
The drawer gasket or seal is damaged.
The drawer is bent or warped.
There are defective parts in the drawer interlock system.
There are de fective parts in the microwave generating
and transmission assembly.
7. There is visible damage to the oven.
Do not operate the oven:
1. Without the RF gasket (Magnetron).
2. If the wave guide or oven cavity are not intact.
3. If the drawer is not closed.
Carry out any remedial work that is necessary before
operating the oven.
Do not operate the oven if any of the following conditions
exist:
1. Drawer does not close firmly.
WARNING FOR WIRING
To prevent an electric shock, take the following precautions:
1. Before wiring:
1) Disconnect the power supply cord.
2) Open the drawer.
3) Wait 60 seconds, then discharge the high voltage
capacitor.
2. Don’t let the wire leads touch to the following parts:
1) High voltage parts:
Magnetron, High voltage transformer, High voltage
capacitor and High voltage rectifier assembly.
2) Hot parts:
Oven lamp, Magnetron, High voltage transformer and
Oven cavity.
24
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MICROWAVE DRAWER DISASSEMBLY
WARNING: Follow all safety precautions as stated at the beginning of this Service
Manual before proceeding!
1. Before removing Microwave Drawer, take measures to protect
the Drawer louver by either removing the louver or by letting
the louver over hang off flat protected surface (Fig 1).
Fig. 1
Louver
2. Open the Drawer to access the 4 mounting screws holding the
unit on to the wall or cabinet opening. (Fig 1).
3. Close Drawer and carefully pull the unit out from opening and
unplug the power supply cord.
screws
4. Remove top cover. (Fig 2).
5. Remove air cover from back of unit, then both side cabinets. (Fig 2).
Top plate
6. Remove exhaust duct and back plate. (Fig 2).
Exhaust duct
Right side panel
Back cover
Air cover
Fig. 2
Cavity
Left side panel
NOTE: You now have access to various components for the Drawer.
25
KB-6015KS
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7. To remove the Control Panel Frame Assembly,
remove the 6 screws holding the CP frame to the C/P
angle in the back (Fig 3).
Fig. 3
8. Unsnap the top C/P frame assembly away from the C/P
frame and unplug all wires. The C/P frame assembly is
now free.
At this point, you will have access to all parts of the Microwave Drawer.
26
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KB-6015KW
STOP SWITCH, SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH REMOVAL
1. Follow the Microwave Drawer disassembly as previously
stated
2. Open the drawer and keep it open.
3. To discharge the high voltage capacitor, wait for 60
seconds.
4. Remove the screw holding the latch hook to the oven
flange.
5. Remove the latch hook from the oven flange.
6. Disconnect the wire leads of each switch.
7. Remove each switch from the latch hook by pushing the
one (1) stopper tab holding each switch.
8. Now, each switch is free.
Re-install
1. Re-install each switch in its place. The secondary interlock
switch is in the lower position and the monitor switch is in
the top position, located on the left side of the unit. The
door sensing switch by itself on the right side of the unit.
2. Re-connect wire leads to each switch. Refer to pictorial
diagram.
3. Secure the latch hooks with mounting screws to oven
flange.
4. Make sure that the monitor switch is operating properly
and check continuity of the monitor circuit. Refer to
chapter "Test Procedure" and "Adjustment procedure".
Latch Hook Left
Latch Hook Right
STOP SWITCH, SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH ADJUSTMENT
1. Follow the Microwave Drawer disassembly as previously
stated
2. Open the drawer and keep it open.
3. To discharge the high voltage capacitor, wait for 60
seconds.
4. If the door sensing switch, secondary interlock switch
and monitor switch do not operate properly due to a
misadjustment, the following adjustment should be made.
6. Loosen the screw holding latch hook to the oven cavity
flange.
7. With drawer closed, adjust latch hook by moving it back
and forth, and up and down. In and out play of the door
allowed by the upper and lower position of the latch hook
should be less than 0.5mm. The vertical position of the
latch hook should be adjusted so that the secondary
interlock switch is activated with the drawer closed. The
horizontal position of the latch hook should be adjusted
so that the monitor switch and drawer sensing switch are
activated with the drawer closed.
8. Secure the screws with washers firmly.
9. Check all of the switches operation. If any switch has not
activated fully, you will need to adjust the slide rail
attached to the Microwave cavity.
10.This is done by following the steps to remove the
"DRAWER/SLIDE RAIL REMOVAL" on page 28. After
you have removed the slide rails, loosen the "2" screws
holding the slide rail to the Microwave cavity and tilt the
front end up and the rear end down, then tighten the
screws (Fig. S-1).
11.Check and assure that the cap nuts on the Drawer
Support Angles are centered when passing through the
cavity face plate.
After adjustment, check the following.
1. In and out play of door remains less than 0.5mm when in
the latched position. First check upper position of latch
hook, pushing and pulling upper portion of drawer toward
the oven face. Then check lower portion of the latch hook,
pushing and pulling lower portion of the door toward the
oven face. Both results (play in the door) should be less
than 0.5mm.
2. The secondary interlock switch switch interrupt the circuit
before the door can be opened.
3. Monitor switch contacts close when door is opened.
4. Door sensing switch contacts open when door is opened.
5. Reassemble the unit and check for microwave leakage
around door with an approved microwave survey meter.
(Refer to Microwave Measurement Procedure.
Fig. S-1
27
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KB-6015KW
DRAWER/SLIDE RAIL REMOVAL
DRAWER ASSEMBLY AND CHOKE REMOVAL
1. Follow the Microwave Drawer disassembly as previously
stated
2. Open the drawer and keep it open.
3. To discharge the high voltage capacitor, wait for 60 seconds.
4. Remove the both right and left side panels.
5. Remove (2) Drawer Support Covers from Choke Cover as
shown in (Fig. D-1).
6. Insert a putty knife (thickness of about 0.5mm) into the gap
between the choke cover and the door frame.
7. Carefully slide choke cover away from drawer as far as
possible.
8. Remove (6) screws from all (3) drawer Support Angles as
shown in (Fig. D-2).
9. Unhook Drawer Support Angles from drawer, then remove.
10.Now, the door assembly is free and the Choke Cover can
now be removed.
Fig. D-1
NOTE:
To remove only the
Microwave Drawer, follow steps
1, 2, 5, 8, 9 & 10
as instructed under
"DRAWER ASSEMBLY AND
CHOKE REMOVAL".
Fig. D-2
DRAWER SUPPORT ANGLE REMOVAL
1. Remove Drawer Assembly and Choke Cover as stated in
"DRAWER ASSEMBLY AND CHOKE REMOVAL".
2. Remove (2) screws from right or left Latch Angle Assembly,
then remove Angle assembly (Fig. D-4).
3. Separate Slide Rails by moving inside lever of Slide Rails.
The Slide Rail will now separate by pulling straight forward
and out (Fig. D-3).
4. At this point, you can replace either Latch Angle Assy or
Latch Angles.
To reassemble, just reverse the above order.
After reassembly, do the following.
(A) Make sure that drawer sensing switch, secondary
interlock switch and monitor switch are operating
properly. (Refer to chapter "Test Procedures".)
(B) An approved microwave survey meter should be used
to assure compliance with proper microwave radiation
emission limitation standards.
After any servicing, make sure of the following :
1. Drawer latch heads smoothly catch latch hook through latch
holes and that latch head goes through center of latch hole.
2. Deviation of door alignment from horizontal line of cavity face
plate is to be less than 1.0mm.
3. Drawer is positioned with its face pressed toward cavity face
plate.
4. Reassemble the unit and check for microwave leakage
around drawer with an approved microwave survey meter.
(Refer to Microwave Measurement Procedure.)
Note: The drawer on a microwave oven is designed to act
as an electronic seal preventing the leakage of
microwave energy from oven cavity during cook
cycle. This function does not require that door be
air-tight, moisture (condensation)-tight or light-tight.
Therefore, occasional appearance of moisture, light
or sensing of gentle warm air movement around
oven drawer is not abnormal and do not of
themselves indicate a leakage of microwave energy
from oven cavity.
28
Fig. D-3
Fig. D-4
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KB-6015KK
KB-6015KW
SWITCH ANGLE REMOVAL/ADJUSTMENT
Fig. S-1
SWITCH ANGLE REMOVAL
(Locate either the right or left switch angle)
1.
2.
3.
4.
Follow the Microwave Drawer disassembly as previously stated
Open the drawer and keep it open.
To discharge the high voltage capacitor, wait for 60 seconds.
To remove switch, remove screw (1) holding switch to switch angle (Fig. S-1).
5. To replace switch angle, remove bottom cover and remove the 2 screws
holding the switch lever (Fig. S-2).
6. Proceed in reverse to reinstall.
7. Adjust switch.
Fig. S-2
ACTUATOR REMOVAL/ADJUSTMENT
1.
2.
3.
4.
Follow the Microwave Drawer disassembly as previously stated
Open the drawer and keep it open.
To discharge the high voltage capacitor, wait for 60 seconds.
Locate either the right or left actuator and remove the 2 screws holding the actuator to the door support
angles.
5. Relpace with the new actuator (Fig. A-3).
Actuator adjustment
6. It is very critical that proper adjustment is made to actuator.
7. Adjust each actuator to fully depress ("0" gap) switch lever switches on left and right side (Fig. A-4).
NOTE: If this adjustment is not adjusted correctly, it will effect the performance of the Auto Drawer.
Fig. A-3
Fig. A-4
29
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AUTO DRAWER GEAR REMOVAL
1.
2.
3.
4.
5.
5.
6.
7.
Follow the Microwave Drawer disassembly as previously stated
Open the drawer and keep it open.
To discharge the high voltage capacitor, wait for 60 seconds.
Unhook wiring Auto Drawer Gear.
Remove the (4) screws holding the auto drawer gear to the bottom cavity angle (Fig. G-1).
Pull drawer gear from cavity angle.
The drawer gear is now free.
Proceed in reverse to reinstall the Auto Drawer Gear taking care that the gear teeth are set into the
cavity angle correctly.
Fig. G-1
RACK GEAR REMOVAL
1.
2.
3.
4.
Follow the Microwave Drawer disassembly as previously stated
Open the drawer and keep it open.
To discharge the high voltage capacitor, wait for 60 seconds.
Remove the Microwave Drawer by following steps 1, 2, 5, 8, 9 & 10 as instructed under
"DRAWER ASSEMBLY AND CHOKE REMOVAL".
5. Remove the (3) screws holding the Rack Gear to the bottom slide rail (Fig. G-2).
7. Proceed in reverse to reinstall the new Rack Gear.
Fig. G-2
30
MICROWAVE DRAWER WIRING DIAGRAM
31
KB-6015KS
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KB-6015KS
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2
1
CN-A
2.5A
A-7
3
T1
PA154DR
FUSE
AC 120V
60Hz
5
CN-H
D4
D1
VR
H-1
D3
8 D2
C1
+
1000uF/50V
VRS1
10G471K
A-5
1
6
D1 -- D4
1N4002L x4
5
0.1uF/50V
C2
A
4
3
A
K-1
GND
H-3
K-3
INT
B
H-2
B
K-2
RY5
D12
SW Reg.
PWR
H-8
K-8
C
C
502-3
H- 9
E-3
J10
H-11
SW Reg. OUT
+24V
RY2
D
D
N.O.
D5
MICRO
COM
E
K-4
H-6
K-6
E
RY1
D7
N.O.
COM
J11
0.1u
250V
(C11)
COM
(O.L)
H-4
1/2W
120
(R11)
F
<NOTE>
: IF NOT SPECIFIED, 1SS270A
( ) : NOT INSERT PARTS
B-1
SM
1/2W
120
: CHECK POINTS
RY3
D10
0.1u
250V
(C10)
(R10)
B-3
G
F
G
A-1
H-5
K-5
H-7
K-7
D11
RY4
FM
A-3
H
H
Figure S-2. Power Unit Circuit
1
2
4
3
32
5
6
E-3
N-1
N-2
N-3
N-4
N-5
E-1
+24V
+24V
CW/CCW
PWM
FG
GND
GND
SLIDE M
K-8
K-7
K-5
M-5
K-6
M-3
M-2
M-1
K-4
M-6
M-7
M-4
F-1
F-2
F-3
K-2
SW Reg.
PWR
(RY5)
FM
(RY4)
SM
(RY3)
DOOR
POS. SW.
REAR
COM
(O.L./MICRO)
(RY1)
DOOR SW.
(CLOSE)
MICRO
(RY2)
DOOR
POS. SW3.
DOOR
POS. SW.
FRONT
AH SENSOR
INT
K-3
CN-F
+
CN-M
CN-N
CN-E
2K
ZD2
HZU16B2
6
5
Q21
KRA224S
+
7
100
100
R95
R96
-
Q25
Q26
Q95
KRA102S
1
C20
1.5K
R69
KRC101S
KRC101S
KRC101S
KRC101S
R24
10K
Q23
4
8
Q22
10K
R56
10K
R58
KIA358
+
3
IC-5
2
VA
KRC101S
R22
270
C21
10uF/35V
Q97
D20
R43
1.8KF
KRC101S
Q20
+
-
3.32KD
R41
10K
R21
R40
4.7K
R20
+
C3
C42
R42
10uF/35V
3.57KD
C43
620K
+
R44
360KF
I
P07
P06
AN2
P57
P51
P05
AN1
4.7K
R97
Q96
KRC101S
O
P60
TXout
P36
P34
47K
R51
10K
R50
C
+
47K
R52
4.7K
R34
(J2)
(J4)
(J6)
4.7K
J3
4.7K
J5
P03
P02
P01
P00
P57
20
P56
TXD1
RXD1
P53
P52
P51
INT0
AVSS
VREF
AN7
AN6
AN3
AN4
AN5
LD3
4.7K
ZD4
60
55
50
4.7K
R12
IC-1
C13
Q6
KTC3875
20
25
30
: CHECK POINTS
CF1
4MHz
SEG20
P25
P26
P27
VL3
COM0
COM1
COM2
COM3
P30
SCLK2
TXD2
RXD2
P34
TXout
P36
4.7K
R15
Q7
KTC1027
30
Figure S-3. Control Unit Circuit
: 1/10W J%(CHIP)
: 0.1u/50V(CHIP)
: 1SS355(CHIP)
: NOT INSERT PARTS
(R36)
(R35)
<NOTE> IF NOT SPECIFIED
4.7K
LD2
Q5
KRA117S
LD1
J1
KRC101S
Q24
VC
R11
R8
P00
300K
R45
10uF/35V
0.01u/50V
R14
C12
KIA78L05BP
C10
4.7K
50V
0.01u
390 2W
P01
GND
C40
C90
45
Q2
KTC1027
R7
D19
D97
5
10uF/35V
C7
R46
C11
10
C6
150KF
P02
R47
75KF
P03
R48
R68
430
1W
(C22)
D40
37.4KF
P04
R49
D41
C45
SP
C9
0.01u/50V
R13
35
D22
D21
Q4
R16
R6
R23
4.7K
4.7K
4.7K
R57
R55
R99
C52
40
Flash:10K
Mask:0
(IC-6)
C51
C23
P62
(R37)
C8
C44
HZU3.6B2
R18
(C30)
P61
(R38)
R17
4.7K
4.7K
P04
P05
P06
P07
P10
P11
P12
P13
P14
P15
P16
P17
P20
P21
P22
P23
15
AN5
AN4
AN3
AN2
AN1
AN0
CNVSS
RESET
P62
P61
VSS
XIN
XOUT
VCC
P60
P37
VCC
TEST
SCL
SDA
8
7
6
5
1
2
3
4
A0
A1
A2
VSS
D2
R109 15K
R110 15K
R111 15K
P20
15K
P22
R108
P21
P23
VCC
BUSY
SCLK
TXD
RXD
RESET
VPP
CE
VSS
1
2
3
4
5
6
7
8
9
CN-X (IC-1)
R112
270K
R5
R113
270K
200 1w x2
R114
270K
4.7K
R27
R28
4.7K
P10
P11
P12
P13
P14
P15
P16
P17
15K
R107
15K
R106
15K
R105
15K
R104
15K
R103
15K
R102
15K
R101
15K
R100
CN-J
<CONTROL UNIT>
VCC
P30 (23Pin)
P31 (22Pin)
P32 (21Pin)
P33 (20Pin)
RESET (8Pin)
CNVSS (7Pin)
AN1 (5Pin)
VSS
4.7K
R29
1
J-1
J-2
J-3
J-4
J-5
J-6
J-7
J-8
J-9
J-10
J-11
J-12
0
LCD
60
55
50
IC-2
4.7K
R32
20
25
30
OPEN
SENSOR
POPCORN
SENSOR
COOK
SENSOR
REHEAT
START/
MINUTE
PLUS
4
7
STOP/
CLEAR
3
2
KEEP
WARM
8
1
DEFROST
9
CF2 4MHz
C15
SEG20
SEG21
SEG22
SEG23
VL3
COM0
COM1
COM2
COM3
P30
P31
P32
P33
P34
P35
P36
CLOSE
CONTROL
LOCK
ON/OFF
SET UP
CUSTOM
HELP
POWER
LEVEL
5
0
TIMER
CLOCK
31
RLCDSA137DRZZ
6
<KEY UNIT>
4.7K
R31
REHEAT
R30
SEG3
SEG2
SEG1
SEG0
P57
SCLK1
TXD1
RXD1
P53
P52
P51
INT0
AVSS
VREF
AN7
AN6
45
CN-K
D95
R115
270K
5
K-1
C41
D96
10uF
35V
C100
50V 330p
3.3K
R98
5
4.7K
4
4.7K
C103
33
C101
4
C102
3
50V 330p
40
4.7K
C
R33
2
3
50V 330p
2
50V 330p
35
C5
C4
S24
COM1
COM0
SEG20
R26
S23
S22
S21
S20
S19
S18
S17
S16
S15
S14
S13
S12
S11
S10
S9
S8
S7
S6
S5
S4
S3
S2
S1
S0
10
1
SEG4
SEG5
SEG6
SEG7
SEG8
SEG9
SEG10
SEG11
SEG12
SEG13
SEG14
SEG15
SEG16
SEG17
SEG18
SEG19
C3
C2
C1
C0
H
15
1
AN5
AN4
AN3
AN2
AN1
AN0
CNVSS
RESET
P62
P61
VSS
XIN
XOUT
VCC
P60
P37
G
SEG23
F
SEG0
SEG1
SEG2
SEG3
SEG4
SEG5
SEG6
SEG7
SEG8
SEG9
SEG10
SEG11
SEG12
SEG13
SEG14
SEG15
SEG16
SEG17
SEG18
SEG19
SEG20
SEG21
SEG22
E
COM3
D
COM0
COM1
COM2
B
4.7K
A
VR
KB-6015KS
KB-6015KK
KB-6015KW
5
6
A
B
C
6
D
E
F
G
H
KB-6015KS
KB-6015KK
KB-6015KW
1
2
4
3
5
6
A
A
B
B
2
RY2
D12
C
D7
RY1
CNH
C
RY5
1
DIP
11
D5
R3
1
J11
C10
J10
N.O.
D
COM.
Q1
D
N.O.
COM.
R10
R1
ZD1
C2
1
RY3
CNB
D10
D3
D2
D1
D4
C1
8
1 D11
1
3
RY4
E
R11
E
T1
VRS1
4
3
P
7
CNA
C11
F
FUSE
F
2.5A
3
G
G
H
H
Figure S-4. Printed Wiring Board of Power Unit
1
2
4
3
34
5
6
1
2
35
3
4
5
6
H
H
R5
1
R6
2
1
1
R7
WHA
6
CNK
C3
+
C3
+ C21
C4
R22
C20
C2
9
8
G
1
+
+
CNM
1
2
ZD4
C5
C6
C8
+
C8
12
11
R34
R46
1
R18
R21
R106
R105
R104
CNJ
CF1
CF1
16
C13
R107
R103
R102
R101
R100
C44
D41
C54
D40
R42
2
J2
2
1
3
J1
J3
J4
J6
K
R40
4
CNF
3
3
1
C0
C0
R115
C103
R114
C102
R112
C100
R113
C101
R41
+
C90
C90
R68
R98 R96
R99 R95
1
C90
S0
C3
S0
C41
C30
C43
R44
Q24
Q95
1
R36
R38
R37
R35
IC6 5
1
R43
C42
C40
Q96
3
CNF
17
R52
5
R50
R40
R108
1 IC5
R109 R110 R111
R51
32
1
1
4
SP
R69
CNN
CNN
SP
5 1
D96 K
D95 K
D97 K
Q97
R97
5
S0
1
CNE
LCD
LCD
CNE
3
3
R15
D21
K
F
E
D
Q7
B C E
D22
E C B
Figure S-5. Printed Wiring Board of Control Unit
R11
C10
R45
64
R14
D19 K
D20 K
C7
C11
R13
C12
R17
C9
K
Q6
Q5
5
Q4
I C O
R8
CNX
1
8
Q3
I C O
C5
C6
CNX
C21
Q3
O C I
9
8
R8
Q4
O C 1
2
Q20
C51
R56
R55
R47
R48
R49
49
48
IC1
33
12
11
CNJ
K D2
Q2
R6
WHA
6
Q25
Q21 Q23
Q22
Q26
8
1
CNM
7
C22 C23 C52
R21 R24 R58
R20 R23 R57
Q2
B C E
K
ZD2
R5
C B
1
1
2
CNK
G
F
E
D
C
6
5
S24
C4
C5
S24
C4
C5
R29
R28
R27
R26
64
R16
17
CF2
1
R31
16
C15
5
49
B
IC2
6
32
48
33
Q7
C
B
7
CF2
R30
R33
R32
8
7
8
A
A
1
3
2
4
5
6
KB-6015KS
KB-6015KK
KB-6015KW
KB-6015KS
KB-6015KK
KB-6015KW
CONTROL PANEL PARTS LIST
Δ” may cause undue microwave exposure.
Note: The parts marked “Δ
The parts marked “*” are used in voltage more than 250V.
REF. NO.
1-1
1-2
1-2
1-3
1-3
1-3
1-4
1-5
1-6
1-7
PART NO.
§
DPWBFB136MRU0
FUNTKB444MRK0
FUNTKB446MRK0
FPNLCB502MRK0
FPNLCB504MRK0
FPNLCB505MRK0
PCOVPB140MRP0
PCUSGB059MRP0
LANGTB111MRP0
XEPSD30P10XS0
M
M
M
M
M
M
M
M
M
M
"§" MARK: PARTS DELIVERY SECTION
DESCRIPTION
Q'TY CODE
Control unit
Key unit [KB6015KS] [KB6015KK]
Key unit [KB6015KW]
C/P frame assy [KB6015KS]
C/P frame assy [KB6015KK]
C/P frame assy [KB6015KW]
C/P cover
C/P cushion
C/P angle
Screw
1
1
1
1
1
1
1
1
1
4
CONTROL PANEL
1-4
1-5
1-7
1-6
1-7
1-7
1-1
1-3
1-7
1-2
36
BY
AS
AS
AX
AX
AX
AM
AB
AM
AA
KB-6015KS
KB-6015KK
KB-6015KW
MICROWAVE DRAWER PARTS LIST
Δ” may cause undue microwave exposure.
Note: The parts marked “Δ
The parts marked “*” are used in voltage more than 250V.
REF. NO.
Δ
*
3- 1
3- 2
3- 3
3- 4
3- 5
3- 6
3- 7
3- 8
3- 9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
3-21
3-22
3-23
3-24
3-25
3-26
3-27
3-28
3-29
3-30
3-31
3-32
3-33
3-33
3-33
3-34
3-35
3-36
3-37
3-38
3-39
3-40
3-41
3-42
3-43
3-44
3-45
3-46
3-47
3-48
3-49
3-50
3-51
3-52
3-53
3-54
3-55
3-56
3-57
3-58
3-58
3-58
PART NO.
§
RTRN-B084MRE0
RV-MZA288WRE0
FDTCTA234WRKZ
FFS-BA018/KIT
XOTSE40P08000
TCAUAB050MRR0
LHLD-B028MRF0A
DPWBFB137MRU0
LANGTB073MRP0
LX-CZ0052WRE0
GCABDB006MRP0
PDUC-B141MRP0
PDUC-B142MRP0
PDUC-B004MRP0
PDUC-B148MRP0
FCOVPB002MRY0
PCLICB003MRE0
MSLIFB001/KIT
LANGTB120MRP0
LANGTB113MRP0
GCOVHB051MRF0
PSKR-B018MRP0
PFILWB005MRP0
LANGTB076MRP0
FC-QZB048MRK0
LBNDKB007MRP0
XCBSD30P08000
XOTSE40P12000
LANGTB114MRP0
LANGQA581WRPZ
XJTSD40P16000
XEPSD30P10XS0
DDORFB098MRK0
DDORFB102MRK0
DDORFB103MRK0
PSHEPB184MRE0
FFAN-B008MRK0
FANGTB010MRK0
FANGTB011MRK0
GCABUB146MRP0
GCABUB145MRP0
PCOVPB143MRP0
LX-NZB006MRE0
XHTSD40P08RV0
TCAUKB001MRR0
FMOTEA499WRKZ
LANGTB077MRP0
RTHM-A135WRZZ
FW-VZB267MRE0
PHOK-A079WRF0
PCUSGB066MRP0
PHOK-A080WRF0
MLEVPA214WRF0
QSW-MA---WRE0
QSW-MA085WRE0
QSOCLB010MRE0
XEPSD30P10XS0
FPWBFA380WRKZ
RLMPTA071WRE0
JHNDPB058MRT0
JHNDPB059MRT0
JHNDPB060MRT0
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
"§" MARK: PARTS DELIVERY SECTION
DESCRIPTION
Transformer
Magnetron
Sensor assy
Monitor switch (V-16G-2C25) with fuse (20A) assembly
Screw
Monitor caution label
Power supply unit holder
Power supply
Oven lamp angle
Screw/washer
Back plate
Mag duct
Sensor duct
Exhaust duct A
Exhaust duct B
Stir cover assy
Canoe clip
Slide rail
Door support angle A
Door support angle B
Door support cover
Magnetron air guide
Lamp filter
Partition angle
HVC assy
HVC band
Screw
Screw
Partition angle L
Noise unit angle
Screw
Power unit assy screw
Door assy [KB6015KS]
Door assy [KB6015KK]
Door assy [KB6015KW]
Sealer film
Stirrer fan assy
Latch angle assy R
Latch angle assy L
Side cabinet L
Side cabinet R
Air cover
Cap nut
Screw
Stirrer cover cleaning label
Fan motor
Fan motor angle
Thermal cut-out
Harness assy
Latch hook R
Cushion
Latch hook L
Switch lever L
Monitor switch - must replace by assy. (3-4)
Switch
Lamp socket
Screw
Noise filter unit
Oven lamp
Door handle [KB6015KS]
Door handle [KB6015KK]
Door handle [KB6015KW]
37
Q'TY CODE
1
1
1
1
1
2
1
2
1
6
1
1
1
1
1
1
3
3
2
1
2
1
1
1
1
1
3
79
1
1
4
2
1
1
1
1
1
1
1
1
1
1
6
4
1
1
1
2
1
1
1
1
1
1
4
1
4
1
1
1
1
1
BE
BK
AP
AF
AA
AD
AH
BD
AF
AA
BB
AE
AK
AK
AF
AM
AB
AU
AK
AK
AB
AC
AB
AK
AP
AB
AA
AA
AK
AD
AA
AA
BD
BD
BD
AQ
AK
AH
AH
AY
AY
AE
AA
AA
AA
AZ
AG
AD
BE
AH
AB
AF
AK
AE
AE
AG
AA
AM
AF
BC
BC
BC
KB-6015KS
KB-6015KK
KB-6015KW
REF. NO.
3-59
3-60
3-61
3-61
3-61
3-62
3-63
3-64
3-65
3-66
3-67
3-68
3-69
3-70
3-71
3-72
3-73
3-74
3-75
3-76
PART NO.
§
FGLSPB002MRY0
GCOVHB052MRF0
PDIF-B053MRT0
PDIF-B054MRT0
PDIF-B055MRT0
RMOTDA261WRZZ
TCAUHB009MRR0
FANGTB012MRK0
LANGTB105MRP0
MACT-B001MRF0
MACT-B002MRF0
DPWBFC441WRKZ
NGERRB002MRF0
FROLPB029MRK0
LHLD-B031MRF0
LANGTB108MRP0
PCOVPB130MRP0
LANGTB109MRP0
TLAB-B056MRR0
PCOVPB142MRP0
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
DESCRIPTION
Oven tray assy
Choke cover
Louver [KB6015KS]
Louver [KB6015KK]
Louver [KB6015KW]
Stirrer motor
User caution label
Auto drawer gear assy
Switch angle
Actuator R
Actuator L
SW power supply
Rack gear
Door support roller assy
Switch PSU holder
Louver angle
Cover
Side angle
Menu label
Top cover
38
Q'TY CODE
1
1
1
1
1
4
1
1
2
1
1
1
2
1
1
1
1
2
1
1
BK
AM
AX
AX
AX
AH
AA
BH
AE
AD
AD
CM
BS
AG
AC
AK
AG
AG
AA
AW
KB-6015KS
KB-6015KK
KB-6015KW
2
1
4
3
6
5
MICROWAVE DRAWER
3-28
3-14
3-28
A
3-28
A
3-28
3-40
3-55
3-73
3-49
3-76
3-11
3-28
3-68
3-28
3-28
3-28
3-71
B
B
3-27
3-28
3-28
3-15
3-28
3-28
3-3
3-25
3-46
3-28
3-44
3-12
3-22
3-30
3-13
3-62
3-10
3-28
3-2
3-29
3-28
3-48
3-1
3-7
3-28
3-28
3-28
3-42
C
3-54
3-26
3-56
3-28
3-28
3-57
3-9
3-24
3-27
3-4
3-39
3-45
3-28
3-18
3-63
3-46
3-53
3-36
3-28
3-32
3-8
C
3-6
3-28
3-10
3-28
3-52
3-19
3-10
3-51
3-28
3-41
3-74
3-23
3-50
3-32
3-66
3-53
3-18
D
3-42
3-6
D
3-28
3-35
3-53
3-74
3-43
3-28
3-65
3-37
3-38
3-27
3-16
3-28
3-18
3-28
3-10
3-17
3-5
3-42
3-42
3-70
3-21
3-32
3-28
3-67
E
3-65
E
3-20
3-41
3-41
3-19
3-53
3-60
3-27
3-33
3-21
3-69
3-64
3-34
F
F
3-59
3-28
3-31
G
3-28
G
3-72
3-28
3-61
3-58
3-47
3-28
3-75
3-31
Actual wire harness may be different from illustration.
H
H
MICROWAVE DRAWER HARNESSES
1
2
3-28
4
3
39
5
6
KB-6015KS
KB-6015KK
KB-6015KW
PACKING PARTS LIST
Δ” may cause undue microwave exposure.
Note: The parts marked “Δ
The parts marked “*” are used in voltage more than 250V.
REF. NO.
2- 1
2- 2
2- 3
PART NO.
§
TINSEB416MRK0
TINSEB417MRR0
XTPUW50P35000
M
M
M
DESCRIPTION
Operation manual
Installation sheet
Wood screws
40
"§" MARK: PARTS DELIVERY SECTION
Q'TY CODE
1
1
4
AM
AD
BC
KB-6015KS
KB-6015KK
KB-6015KW
PACKING
TOP COVER
SUPPORT CORNERS
2-1
OPERATION MANUAL
2-2 INSTALLION SHEET
PACKING CASE
2-3 WOOD SCREWS
SUPPORT CORNERS
SUPPORT CORNERS
SUPPORT CORNERS
BOTTOM COVER
Non-replaceable items
41
KB-6015KS
KB-6015KK
KB-6015KW
COPYRIGHT © 2005 BY SHARP CORPORATION
ALL RIGHTS RESERVED.
No part of this publication may be reproduced, stored in retrieval systems, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording,
or otherwise, without prior written permission
of the publisher.
2005 SHARP CORP. (5R2.00E) Printed in U.S.A
42