Whirlpool Microwave Oven 512 Users Manual

AVM512 AVM512

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SERVICE Whirlpool Europe

Customer Services

Model AVM 512

Version 8538 512 62291 Page

Introduction safety 2

Technical data 3

Text/Legend 4 - 8

Spare part list 9

Exploded view 10

Wiring diagram 11

Service Manual

Microwave oven

AVM 512

AVM 512

This documentation is only intended for qualified technicians who are aware of the respec-

tive safety regulations.

Date: 11.11.1998 Subject to modification

Document-No.: 4812 714 12457

SERVICE

11.11.1998 / Page 2 AVM 512 Whirlpool Europe

Doc. No: 4812 714 12457 8538 512 62291 Customer Service

Introduction safety

INTRODUCTION

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 electric supply at the control box.

When you have finished servicing an oven 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 mechanically 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 ENERGIZED.

NEVER OPERATE AN OVEN WITH 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 is 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 ELECTRIC

MEASUREMENTS INSIDE THE OVEN.

SERVICE Whirlpool Europe AVM 512 11.11.1998 / Page 3

Customer Service 8538 512 62291 Doc. No: 4812 714 12457

Technical data

Electrical

Voltage 230 V

Frequency 50 Hz

Power consumption 1350 W

Power

Output power 850 W

Microwave frequency 2450 MHz

Timer

Electronic 99 min. 99 sec.

10-level microwave power level

4-stage programmed cooking

SERVICE

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Doc. No: 4812 714 12457 8538 512 62291 Customer Service

Text/Legend

INSTALLATION REQUIREMENTS

GENERAL

The oven should be placed on a flat and stable surface

Place the oven away from high temperature and steam sources.

Clearance of at least 5cm (2”) on each side must be provided to allow adequate ventilation.

The microwave oven must be plugged directly to a 3-prong wall receptacle which is properly grounded.

The power source must be 220V 50Hz 8A single phase.

GROUNDING INSTRUCTIONS

IMPORTANT:

DISCONNECT POWER BEFORE SERVICING, RECONNECT ALL GROUNDING DEVICES.

All mechanical parts of this appliance capable of conducting electricity are grounded. In the event of an

electrical short circuit, grounding reduces the risk of electric shock. This appliance is equipped with a cord

having a grounding wire with a ground plug. The plug must be plugged into an outlet that is properly installed

and grounded.

WARNING:

IMPROPER USE OF THE GROUNDING PLUG MAY RESULT IN ELECTRICAL SHOCK.

If grounding wires, screws, straps, clips, nuts or washers used to complete a path to ground are removed for

service, they must be returned to their original positions and properly fastened.

GROUNDING SPECIFICATION:

Leakage current: 0.5 mA max.

Ground path resistance: 0.1 ohm max.

OPERATIONAL DESCRIPTION

The following describe 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 switch are opened. Door switch is opened. The monitor switch is closed. All

AC power will be cut.

Pure microwave cooking:

10 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.

SERVICE Whirlpool Europe AVM 512 11.11.1998 / Page 5

Customer Service 8538 512 62291 Doc. No: 4812 714 12457

MICROWAVE AND LEAKAGE TESTS

MICROWAVE TEST

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 and necessary.

Prepare a glass beaker with a diameter of approx. 190 mm round. with a max. 3 mm wall thickness.

Fill the beaker with exact 1 liter of cold water with an temperature of 10-12 ˚C measure the temperature

of the water before placing into the oven.

Start the oven for 1 min. on full power (only microwave) check the time by your writwatch after the

magnetron takes full power (Ampere meter).

The unit should be heated up 2-3 times before the test starts.

Check the water temperature under stirring the water and calculate the difference to the start temperature.

˚C x 70(multiplicator)=watt

Please take under consideration that always the measured power output is 15-20% lower than the rating plate

shows. 850 W = 720-680 W if the measured output is below this rate please repeat the measurement.

LEAKAGE TEST

TESTING EQUIPMENT

0.5l beaker.

Microwave tester of high quality.

Power setting ON time

10(highest) 100%

9 approx 93%

8 approx 87%

7 approx 80%

6 approx 67%

5 approx 60%

4 approx 53%

3 approx 40%

2 approx 33%

1 (lowest) approx 27%

SERVICE

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Doc. No: 4812 714 12457 8538 512 62291 Customer Service

TESTING PROCEDURE

Place 0.25l 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 tester to the surface of the oven and scan it at the rate of 2.5 cm per sec.

Test the following areas for microwave leakage:

- round and across the door glass and control panel.

- all ventilation openings.

The leakage should never exceed 5 mW/cm2.

Record all data.

OVEN LEAKAGE REPAIR

If leakage figure is found above 5 mW/cm2.

The unit has to be set out of function, until the unit is repaired and finally saefty tested.

Service engineer should notify the Service Management immediately.

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 grounded with an insulated

wire. Make sure that the wire is grounded to chassis side before short circuiting the capacitor terminal.

Do not measure high voltage with a common voltmeter.

SERVICE Whirlpool Europe AVM 512 11.11.1998 / Page 7

Customer Service 8538 512 62291 Doc. No: 4812 714 12457

QUICK SERVICE REFERENCES

MAJOR COMPONENT TESTS

HV TRANSFORMER

Remove lead wire.

Measure the resistance of the winding using an ohm meter

Primary winding 3 ohm (approx.)

Secondary winding 100 ohm (approx.)

Filament winding 0 ohm (approx.)

HV CAPACITOR

Remove lead wire

Measure the resistance using an ohm meter set to R*1000

Terminal to terminal should momentary indicates several ohms but gradually increases to infinite.

Terminal to case should show infinite.

PROBLEM POINTS TO CHECK

Cavity lamp does not light, but

other electrical components

(e.g. turntable) are working.

Lamp burnt.

Bad contact between lamp and lamp socket.

Cavity lamp does not light, all

other electrical components

also do not work.

Power plug not in good connection with the socket.

No power supply.

Fuse blown.

Bad contact between fuse and fuse holder/clip.

Loose door hinge, door poorly adjusted, interlock poorly

adjusted; causing fuse to be blown.

Short circuit within electrical circuit.Lamp filament short,

HV transformer short, all causing fuse blown.

Bad contact in contacts or terminals of timer switch,

primary and secondary interlock switch.

HV diode break down.

Oven seems working, food

does not cook Defective magnetron (filament broken, filament short to

ground etc.).

Ground wire of HV transformer broken.

Filament wire short to ground.

Filament wire broken.

Bad contact in magnetron terminals.

Defective control boards.

HV diode break down, giving a hum noise.

Oven cooks for a short while

and stop. Cooling fan jammed.

Cooling fan motor open circuit.

Defective cooling fan control relay.

Turntable does not turn. Defective turntable motor.

Turntable shaft deformed.

User circuit breaker activates. High leakage in electrical components (mostly motor).

SERVICE

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Doc. No: 4812 714 12457 8538 512 62291 Customer Service

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 infinite.

INTERLOCK SWITCH SYSTEM

IMPORTANT: The installation of the interlock and monitor switches is required by Federal regulations.

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 blow. 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.

Oven door

status Primary

switch Secondary

switch Monitor

switch

Open Open Open Close

Close Close Close Open

SERVICE Whirlpool Europe AVM512 11.11.1998 / Page 9

Customer Service 8538 512 62291 Doc. No: 4812 714 12457

Spare part list

Model AVM 512

Service No. 853851262291

Version 853851262291

Pos. No. 12NC Code Description from to

002 0 4819 902 00561 Lid

002 2 4819 902 00568 Plate

002 3 4819 902 00571 Pin

002 4 4819 902 00569 Bushing

011 0 4819 902 00694 Foot

011 1 4819 902 00566 Cap

040 0 4819 902 00445 Hinge,upper

040 1 4819 902 00444 Hinge,lower

121 0 4819 902 00326 Door,inner

121 1 4819 902 00599 Door frame inner

130 0 4819 902 00579 Holder

130 9 4819 902 00597 Hook connector

131 0 4819 902 00596 Lockingmechn. upper

131 1 4819 902 00595 Lockingmechn. lower

131 2 4819 902 00594 Pivot door pin

141 0 4819 902 00484 Oven glass outer

142 0 4819 450 58454 Glass inner (PE plate)

143 0 4819 459 48923 Door frame

255 0 4819 902 00654 Turntable glass

264 0 4819 902 00529 Ring turn table

264 1 4819 902 00582 Wheel

264 2 4819 902 00528 Shaft

320 0 4819 902 00683 Control panel

321 0 4819 902 00644 Display glass

332 0 4819 902 00557 Button door

404 0 4819 902 00614 Magnetron

406 0 4819 902 00695 Motor turn table

406 3 4819 902 00567 Gasket

412 0 4819 902 00556 Transformer HV

420 0 4819 902 00583 Capacitor HV 0.95UF

421 0 4819 902 00679 Filter

426 0 4819 218 38038 Diode HV

426 1 4819 902 00574 Diode double way

440 0 4819 902 00696 Propeller,motor

443 0 4819 902 00592 Fan wheel

443 1 4819 902 00591 Support fan

490 0 4819 902 00298 Cable,mains SAA Plug

490 4 4819 902 00563 Clip wire sadle

490 5 4819 902 00604 Strain relief

490 6 4819 404 79411 Bracket for cable

500 0 4819 214 78684 Control unit

561 0 4819 902 00586 Thermostat magnetron

562 0 4819 902 00636 Thermostat

620 0 4819 902 00682 Switch plate

632 0 4819 902 00609 Switch security

632 1 4819 902 00447 Lever

633 0 4819 902 00611 Switch

651 0 4819 134 28051 Lamp

743 0 4819 902 00575 Air guide

900 5 4819 902 00585 Holder filter board

904 0 4819 902 00589 Sleeve

910 9 4819 902 00565 Pin

930 0 4819 902 00581 Spring,tension

930 1 4819 902 00598 Spring

930 3 4819 902 00601 Spring,compres.

SERVICE

11.11.1998 / Page 10 AVM 512 Whirlpool Europe

Doc. No: 4812 714 12457 8538 512 62291 Customer Service

Exploded view

SERVICE Whirlpool Europe AVM 512 11.11.1998 / Page 11

Customer Service 8538 512 62291 Doc. No: 4812 714 12457

Wiring diagram