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WHIRLPOOL CONSUMER SERVICES

Models AVM595 WH AVM595 BL
October 1998

WHIRLPOOL AUSTRALASIA CONSUMER SERVICES

SERVICE MANUAL
MICROWAVE OVEN Model AVM595 WH Version 8538 595 53291 Model AVM595 BL Version 8538 595 53491

Copyright © 2001 Whirlpool (Australia) Pty. Limited All rights strictly reserved. Reproduction or issue to third parties in any form whatsoever is not permitted without written authority of Whirlpool (Australia) Pty. Limited Whirlpool is a registered trademark of Whirlpool U.S.A. This documentation is intended only for qualified technicians who possess the required qualifications and are aware of the regulatory requirements applicable to servicing electrical appliances.
Whirlpool (Australia) Pty Limited A. B. N. 28 003 578 023 Part No. SM7020

WHIRLPOOL CONSUMER SERVICES

Models AVM595 WH AVM595 BL
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CONTENTS Page 3 3 3 3 3 4 5 5 5 6 7 7 7 8 8 8 9 10 10 10 10 10 11 12 13 14

SAFETY PRECAUTIONS INTRODUCTION SAFETY CAUTION - MICROWAVE RADIATION WARNING - HIGH VOLTAGE TECHNICAL DATA INSTALLATION REQUIREMENTS GENERAL EARTHING INSTRUCTIONS OPERATIONAL DESCRIPTION MICROWAVE AND LEAKAGE TESTS MICROWAVE TEST MICROWAVE LEAKAGE TEST TROUBLE SHOOTING GUIDE CAUTION AND IMPORTANT MICROWAVE LEAKAGE QUICK REFERENCE MAJOR COMPONENT TESTS HV TRANSFORMER HV CAPACITOR HV DIODE MAGNETRON INTERLOCK SWITCH SYSTEM EXPLODED VIEW PARTS LIST CIRCUIT DIAGRAM

WHIRLPOOL CONSUMER SERVICES
SAFETY PRECAUTIONS
INTRODUCTION

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Before leaving the factory each oven is carefully checked. It must however, be installed and used correctly. Despite all the steps taken to make the oven safe, the safety is dependent on the correct installation and the fact the user understands how to use and maintain the oven. The information in this section should be used as a reminder that the oven is safe and that anyone who uses it must first read the instructions for use in order to be able to use the oven correctly and obtain best results. SAFETY To avoid injury to yourself and damage to the appliance always work to the following rules when servicing an oven. Always disconnect the plug from the mains before starting work. If there is no plug, switch off the electrical supply at the control box. When you have finished servicing an oven and before you reconnect it to the mains make sure that: · all the internal connections are correct · the wires are insulated and not touching the door or the cabinet or anything sharp · all the earth connections are electrically and mechanical sound · do not modify or anyway interfere with the safety devices built-in to the oven · make sure that each replacement part you use conforms to the manufacturer's specifications. Do not start a repair if you have any doubt as to your ability to complete it. CAUTION - MICROWAVE RADIATION PERSONNEL SHOULD NOT BE EXPOSED TO THE MICROWAVE ENERGY WHICH MAY RADIATE FROM THE MAGNETRON, WAVEGUIDE OR ANTENNA IF THEY ARE IMPROPERLY USED OR CONNECTED. ALL INPUT AND OUTPUT MICROWAVE CONNECTIONS, WAVEGUIDES, FLANGES AND GASKETS MUST BE SECURE. NEVER OPERATE THE DEVICE WITHOUT A MICROWAVE ENERGY ABSORBING LOAD ATTACHED. NEVER LOOK INTO AN OPEN WAVEGUIDE OR ANTENNA WHILE THE DEVICE IS ENERGISED. NEVER OPERATE AN OVEN WITH THE CABINET OFF WITHOUT MEASURING THE MICROWAVE LEAKAGE AROUND MAGNETRON AND VISIBLE MICROWAVE CONNECTIONS (WELDING JOINTS.) Do not operate the oven if the following conditions exist: - the door does not close firmly against the door support because of the door being warped or the hinges damaged. - the door trims or seals are damaged - if there are any visible damage to the oven - if the door does not close properly Avoid operating the oven if known components in the interlock system, oven door or microwave generating assembly are known defective. They must be replaced. WARNING - HIGH VOLTAGE IT IS POSSIBLE TO COME IN CONTACT WITH LETHAL HIGH VOLTAGE WHEN WORKING WITH HV TRANSFORMER, HV CAPACITOR AND MAGNETRON. THEREFORE NEVER TRY TO MEASURE THE HIGH VOLTAGE. ALWAYS TAKE UTMOST CARE WHEN PERFORMING ELECTRICAL MEASUREMENTS INSIDE THE OVEN.

TECHNICAL DATA

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Models AVM595 WH AVM595 BL
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Dimensions of Cabinet
Height Width Depth 332 424 548 mm mm mm

Dimensions of Cavity
Height Width Depth Cavity Volume 225 340 345 27 mm mm mm I

Weight
Net Packed 22 24 kg kg

Electrical
Voltage Frequency Power consumption 230-240 50 1500 V Hz W

Power
Nominal Output Power Microwave frequency 850 2450 W Mhz

Timer
Electronic 99 min 59 sec

WHIRLPOOL CONSUMER SERVICES
INSTALLATION REQUIREMENTS GENERAL
The oven should be placed on a flat and stable surface Place the oven away from high temperature and steam sources.

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Clearance of at least 50mm on each side must be provided to allow adequate ventilation. The microwave oven must be plugged directly to a 3-pin wall receptacle which is properly earthed. The power source must be 230 - 240V 50Hz 10A single phase.

EARTHING INSTRUCTIONS IMPORTANT: DISCONNECT POWER BEFORE SERVICING, RECONNECT ALL EARTHING DEVICES.
All mechanical parts of this appliance capable of conducting electricity are earthed. In the event of an electrical short circuit, earthing reduces the risk of electric shock. This appliance is equipped with a cord having an earthing wire with a earthed plug. The plug must be plugged into an outlet that is properly installed and earthed.

WARNING: IMPROPER USE OF THE EARTHING PLUG MAY RESULT IN ELECTRICAL SHOCK.
If earthing wires, screws, straps, clips, nuts or washers used to complete a path to earth are removed for service, they must be returned to their original positions and properly fastened.

EARTHING SPECIFICATION:
Leakage current: 0.5mA max. Earth path resistance:0.1 ohm max.

WHIRLPOOL CONSUMER SERVICES
OPERATIONAL DESCRIPTION

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The following describes the basic operation of the appliance. Please refer to the schematic diagram when reading: Food is placed inside the oven and the door is closed. "Start" button is not pressed: Primary and secondary interlock switches are closed. Monitor switch is open. Door switch is closed. Relay 1 and Relay 2 are both open. When the timer is set for a certain cooking time, cook power is set and the "Start" button pressed: Relay 1 is closed. AC power is supplied to the cavity lamp, fan motor and turntable motor. Depending on the power level setting, AC power is supplied to the HV transformer through Relay 2 with the duty cycle corresponding to the power level setting. The display timer will start to count down. When the timer counts to Zero: Relay 1 and Relay 2 will be and all AC power to the motor, lamp and HV transformer will be cut. The control board buzzer will give a "beep" sound to give an OFF signal. When the door is open during cooking: Primary and secondary interlock switches are opened. Door switch is opened. The monitor switch is closed. The light will remain on but all other AC power will be cut. Pure microwave cooking: Ten power level settings are available for pure microwave cooking. This can be adjusted using the power switch on the touch foil. Power level control is achieved by switching the magnetron ON and OFF periodically. The oven works on 15 second cycle and the following indicate the correct ON/OFF timing. Power setting 10 (highest) 9 8 7 6 5 4 3 2 1 (lowest) ON time 100% approx 93% approx 87% approx 80% approx 67% approx 60% approx 53% approx 40% approx 33% approx 27%

MICROWAVE AND LEAKAGE TESTS

WHIRLPOOL CONSUMER SERVICES
MICROWAVE TEST

Models AVM595 WH AVM595 BL
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The following is a simple test to check if the appliance is generating microwave energy. This test is not intended to be an accurate test. An accurate measurement of output power must be performed under strict control following the IEC standard. In field service, accurate measurement of output power is usually not required. Prepare a glass beaker approximately 190mm in diameter with 3mm maximum wall thickness. Place exactly 1 litre of water at a temperature of 10 - 12 °C in the beaker. Measure the temperature of the water immediately before placing into the oven. Note: Run the oven for 2 to 3 minutes before starting the test to allow components to approach normal operating temperatures Start the oven and when the current has reached its maximum value, begin the one minute heating time. Again measure the temperature of the water while stirring. Approximate power output = Temperature rise x 70. (The answer will always be 15 to 20% lower than the rating i.e. 720 - 680 watts). If the calculated value is less than 680 Watts repeat the test. If the value is again low then the high voltage components should be checked and if necessary replaced. MICROWAVE LEAKAGE TEST TESTING EQUIPMENT · · 0.5 litre beaker High quality microwave meter

TESTING PROCEDURE Place 0.25 litres of water into the beaker and place it in the center of the oven. Turn on the microwave oven by setting the unit on full power. Hold the probe of the microwave meter perpendicular to the surface of the oven and scan it at the rate of 25mm/sec. Test the following areas for microwave leakage: Door and control panel All ventilation openings Microwave leakage should never exceed 5 mW/cm2. If leakage exceeds 5 mW/cm2, the unit must not be used until repaired. Record all data.

OVEN LEAKAGE REPAIR

WHIRLPOOL CONSUMER SERVICES
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If leakage is found to be above 5 mW/cm , the oven must not be operated until the necessary repairs have been performed and the oven retested.

TROUBLE SHOOTING GUIDE
CAUTION AND IMPORTANT
Before disassembling the oven, the oven power must be turned off. Remove the power plug of the oven from the outlet and wait for at least 3 minutes. When disassembling, service personnel should remove their watches and metal chains from their hands. Never touch the high voltage components and wire. Before checking or replacing, discharge the high voltage capacitor to oven chassis earthed with an insulated wire. Make sure that the wire is earthed to chassis side before short circuiting the capacitor terminal. Do not measure high voltage with a common voltmeter.

MICROWAVE LEAKAGE
Refer to LEAKAGE TEST regarding microwave leakage. If the leakage is greater than 2 5 mW/cm , it is necessary to repair the oven. If leakage is found worst at control panel, ventilation openings or oven bottom, check if there is any damaged parts or loose screws in the respective areas. If so, replace the damaged parts and fasten the screws. If leakage is found worst around the door perimeter, adjust the door hinges and the interlock support.

WHIRLPOOL CONSUMER SERVICES

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QUICK SERVICE REFERENCES
PROBLEM Cavity lamp does not light, but other electrical components (e.g. turntable) are working. Cavity lamp does not light, all other electrical components also do not work.

Oven seems working, food does not cook

Oven cooks for a short while and stop.

Turntable does not turn. User circuit breaker activates.

POINTS TO CHECK 1. Lamp failed. 2. Bad contact between lamp and lamp socket. 1. Power plug not in good connection with the socket. House fuse ruptured. No power supply. 2. Internal fuse ruptured. 3. Bad contact between fuse and fuse holder/clip. 4. Loose door hinge, door poorly adjusted, interlock poorly adjusted; causing internal fuse to rupture. 5. Short circuit within electrical circuit. Lamp filament short, HV transformer short, all causing fuse to rupture. 6. Bad contact in contacts or terminals of timer switch, primary and secondary interlock switch. 7. HV diode break down. 1. Defective magnetron (filament broken, filament short to earth etc.). 2. Earth wire of HV transformer broken. (One end of HV winding is normally connected to the core.) 3. Filament wire shorted to earth. 4. Filament wire broken. 5. Bad contact in magnetron terminals. 6. Defective control boards. 7. HV diode break down, causing a humming noise from transformer. 1. Cooling fan jammed. 2. Cooling fan motor open circuit. 3. Defective cooling fan control relay. 1. Defective turntable motor. 2. Turntable shaft deformed. 1. High leakage in electrical components (mostly motor).

WHIRLPOOL CONSUMER SERVICES
MAJOR COMPONENT TESTS HV TRANSFORMER
Remove lead wire. Measure the resistance of the winding using an ohmmeter Primary winding 3 ohm (approx.) Secondary winding 100 ohm (approx.) Filament winding 0 ohm (approx.)

Models AVM595 WH AVM595 BL
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HV CAPACITOR
Remove lead wire Measure the resistance using an ohmmeter set to R*1000 Terminal to terminal should momentary indicates several ohms but gradually increases to infinity. Terminal to case should show infinity.

HV DIODE
Remove lead wire. Measure forward resistance, normal diode show continuity. Measure reverse resistance, normal diode show infinite resistance.

MAGNETRON
Remove lead wire. Install the magnetron gasket in the correct position. Check that the gasket is in good condition. Measure the resistance of the filament terminals. Normal magnetron should be less than 1 ohm. Measure the resistance between the filament terminal to chassis. Normal magnetron should be infinity.

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Models AVM595 WH AVM595 BL
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INTERLOCK SWITCH SYSTEM
Oven door status Open Close Primary switch Open Close Secondary switch Open Close Monitor switch Close Open

The interlock and monitor switches positions are not service adjustable. If the screws on the hinges of the oven door are loosen, the door may not be in a correct position. In this case, the interlock switches cannot be operated by the latch pins of the door when the door is shut. To repair the door, remount the door and fasten the screws on the door hinges. The monitor switch is provided to monitor the operation of the primary interlock switch. If the primary switch fails to operate when the door is open, the monitor switch will form a short circuit across the supply and the fuse in the oven will rupture. An electric arc may form across the switch contacts of the primary interlock switch, the secondary switch and the monitor switch. The switches may then be damaged. If the fuse is blown due to the failure of the primary interlock, repair the failed mechanical parts and replace all the interlock switches.

IMPORTANT After replacement of any part of the interlock and monitor circuit:
Check if the microswitches are turned ON and OFF by the latches as specified in the table above. Apply sealant to the screws and nuts of the door hinges. Check microwave leakage. Check if the oven will turn off instantly when the door button is pushed to the position where the door latches leave the interlock switches.

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Models AVM595 WH AVM595 BL
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EXPLODED VIEW

WHIRLPOOL CONSUMER SERVICES
PARTS LIST
Item Part No Description AVM595 WH AVM595 BL 001 0 4819 442 39108 4819 902 39723 Cabinet 001 1 4819 404 79411 4819 404 79411 Bracket 001 2 4819 902 00714 4819 902 00714 Holder 011 0 4819 462 88055 4819 462 88055 Foot 040 0 4819 417 19596 4819 417 19596 Hinge, upper 040 1 4819 417 19597 4819 417 19597 Hinge, lower 121 0 4819 442 39112 4819 442 39112 Door, inner 121 1 4819 459 48867 4819 459 48867 Door frame 130 0 4819 404 79412 4819 404 79412 Door lock 130 1 4819 492 68825 4819 492 68825 Spring 130 2 4819 528 38457 4819 528 38457 Cam 133 0 4819 535 38157 4819 535 38157 Lock 141 0 4819 902 00718 4819 902 00726 Oven glass outer 142 0 4819 442 39113 4819 442 39113 Inner glass PE 143 0 4819 459 48866 4819 902 00725 Door frame outer 246 0 4819 418 79728 4819 418 79728 Turntable glass 264 0 4819 535 78142 4819 535 78142 Crosspiece 305 0 4819 902 00719 4819 902 00727 Switch 320 0 4819 902 00721 4819 902 00728 Cover 321 0 4819 902 00644 4819 902 00644 Display glass 404 0 4819 131 58019 4819 131 58019 Magnetron 404 1 4819 462 38901 4819 462 38901 Cover 404 2 4819 404 79413 4819 404 79413 Holder 406 0 4819 361 18292 4819 361 18292 Motor for rotary plate 412 0 4819 902 00716 4819 902 00716 Transformer, HT 420 0 4819 902 00583 4819 902 00583 Capacitor HT 0.95µF 421 0 4819 902 00535 4819 902 00535 Filter, mains 421 1 4819 902 00717 4819 902 00717 Cable 426 0 4819 130 38078 4819 130 38078 Diode HV MW 441 0 4819 361 18452 4819 361 18452 Fan motor 441 1 4819 404 79414 4819 404 79414 Holder 443 0 4819 515 28197 4819 515 28197 Fan 490 0 4819 902 00715 4819 902 00715 Cable, mains 500 0 4819 902 00722 4819 902 00722 Control unit 561 0 4819 282 48274 4819 282 48274 Thermostat 125°C 562 0 4819 282 48248 4819 282 48248 Thermostat 165°C 562 1 4819 902 00713 4819 902 00713 Holder 632 0 4819 902 00577 4819 902 00577 Switch 633 0 4819 902 00611 4819 902 00611 Switch 651 0 4819 134 28051 4819 134 28051 Lamp 743 0 4819 462 38899 4819 462 38899 Fan motor cover 770 0 4819 462 38898 4819 462 38898 Air guide 770 1 4819 462 38897 4819 462 38897 Air guide 770 2 4819 462 38896 4819 462 38896 Air guide 774 0 4819 442 39109 4819 442 39109 Cover upper wave guide 774 1 4819 442 39111 4819 442 39111 Cover lower wave guide 794 0 4819 532 68844 4819 532 68844 Spacer

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WHIRLPOOL CONSUMER SERVICES
CIRCUIT DIAGRAM

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