Kuppersbusch EMW 7505.0 User manual

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Service Manual: H4-70-14-02
Responsible: D. Rutz KÜPPERSBUSCH HAUSGERÄTE AG
Email: [e-mail]
Phone: [phone] Kundendienst
Fax: [phone] Postfach 100 132
Date: 15.04.2003 45801 Gelsenkirchen

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Contents
1. Safety......................................................................................................................................... 4
2. Features and installation ......................................................................................................... 5
2.1 Disposing of the packaging and your old appliance ........................................................ 5
2.2 Features .......................................................................................................................... 5
2.3 Technical data ................................................................................................................. 5
2.4 Ventilation........................................................................................................................ 6
2.5 Installation ....................................................................................................................... 6
3. Functions .................................................................................................................................. 8
3.1 Control panel ................................................................................................................... 8
3.2 Setting the clock .............................................................................................................. 8
3.3 Timer ............................................................................................................................... 8
3.4 Cooking and Reheating................................................................................................... 9
3.5 Rapid Defrost .................................................................................................................. 9
3.6 Rapid Start .................................................................................................................... 10
3.7 Children’s safety device / Start blocking........................................................................ 10
3.8 Exceeding time limits..................................................................................................... 10
4. Cleaning .................................................................................................................................. 11
5. Components............................................................................................................................ 12
5.1 Safety precautions - microwave energy ........................................................................ 12
5.2 Housing ......................................................................................................................... 13
5.3 Microswitches................................................................................................................13
5.4 Magnetron ..................................................................................................................... 14
5.5 Fan and fan motor ......................................................................................................... 15
5.6 Power board..................................................................................................................17
5.7 Safety thermostats ........................................................................................................ 17
5.8 Front panel and display ................................................................................................. 18
5.9 Door............................................................................................................................... 19
5.10 Fixation system and turntable motor ............................................................................. 20
6. Measuring the output power of the magnetron ................................................................... 21
7. Component check .................................................................................................................. 22
7.1 Magnetron check - Resistance measurement............................................................... 22
7.2 High-voltage transformer............................................................................................... 22
7.3 High-voltage capacitor................................................................................................... 22
7.4 Diode ............................................................................................................................. 23
7.5 Microwave leak test....................................................................................................... 23
8. Troubleshooting ..................................................................................................................... 24
8.1 Fault codes.................................................................................................................... 24
8.2 Faults, causes and remedy ........................................................................................... 26

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1. Safety
Danger!
All work and repairs may only be carried out by a qualified service technician.
Incorrect repairs can be extremely dangerous for the user!
To prevent electric shocks, please observe the following tips:
• In the event of faults, housing and frame may be live!
• Touching live components inside the appliance may cause dangerous currents to flow through your
body!
• Prior to repairs, disconnect the appliance from the mains!
• When inspecting live parts, an earth leakage circuit breaker must be used at all times!
• The ground wire resistance must not exceed that specified in the standard! It is of vital importance for
ensuring the safety of people and the functioning of the appliance.
• On completion of repairs, an inspection must be carried out in accordance with VDE 0701
[Association of German Electrical Engineers] or the corresponding regulations for your country!
• On completion of repairs, a function and impermeability inspection must be carried out.
• On completion of the repair work a leak rate measurement must be made!
Attention!
It is essential to observe the following notes :
• Always disconnect the appliance from the mains before starting repair work! Always use
an earth leakage circuit breaker if tests are required while the appliance is energised.
• Do not take any measurements in the high-voltage circuit during operation. Risk to life
and limb!
• The mains plug of the microwave oven must always be accessible!
Sharp edges! Use protective gloves.
Components may be electrostatic!
Observe handling precautions!
Electric connection
• Only connect the appliance to socket outlets with a fuse of at least 16 A. Also check that the main
fuse of your home has a minimum output of 16 A so that it does not suddenly blow during operation
of the microwave oven.
• Before operation, check whether the mains voltage is the same as that indicated on the name/rating
plate of the appliance and whether the socket outlet is effectively earthed. The manufacturer
assumes no liability for damage which occurs through the non-observance of these regulations.

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2. Features and installation
2.1 Disposing of the packaging and your old appliance
The packaging material for transport is fully recyclable.
Recycling the packaging saves raw materials and reduces the amount of waste. Disposed appliances
still contain useful materials. Take your old appliance to a recycling collection point. Please make your
old appliances unserviceable before disposing of it, to prevent it from misuse.
2.2 Features
• Light and modern design in stainless steel or aluminium look
• Easiest built in system
• Available for different cupboard widths
• Thin glass door
• Control panel on the top
• Big cooking cavity with interior lighting, 20 cm round plates or
39 cm oval plates possible to use
2.3 Technical data
Voltage / Frequency 230V - 50Hz
Power consumption 6,7 A
Total electrical connection 1300 W
Microwave output 750 W (max) (4 levels)
Power consumption 1300 W
Appliance dimensions (WxHxD) 495 x 382 x 313 mm approx.
Niche dimensions (WxHxD) 460 x 362 x 300 mm approx.
Cooking cavity dimensions (WxHxD) 370 x 205 x 290 mm approx. (22 litre capacity)
Weight approx. 20 kg
Electronic timer 30 min.

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2.4 Ventilation
The appliance has no ventilation slits at the sides of the
front panel. The air flow takes place as shown in the
illustration.
2.5 Installation
Please see the illustration for the exact installation dimensions.
Appliance dimensions
Height 382 mm
Width 495 mm
Depth 313 mm
Ventilation
Aspiration
Aspiration
Air transport
Air transport
Air flow
Thickness of the structure 16-21 mm

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Procedure
Plug in the appliance and place it in the middle of the
cupboard.
Fix the product, by turning the screw with a 2mm allen-key,
which is coming with the product as shown in the
illustration.
The microwave oven will be centered and fixed
automatically by the new fixing system.

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3. Functions
3.1 Control panel
1 POWER for setting the power level (0, 160, 350, 500, 750 W)
2 JET DEFROST for selecting “Rapid Defrost”
3 + / - to set weight, time and clock
4 STOP to pause cooking and access test mode
5 START Start of the “Rapid Defrost” function, normal start or after the food has been
turned during the “Rapid Defrost” period.
6 Clock 24 hour mode
3.2 Setting the clock
Keep the door open while setting the clock. This gives you 5 minutes to complete the setting. Otherwise,
each step must be accomplished within 30 seconds.
1. Press the CLOCK button until the left-hand digits (hour) flicker.
2. Press the PLUS or MINUS button to set the hour.
3. Press the CLOCK button again until the right-hand digits (minutes) flicker.
4. Press the PLUS or MINUS button to set the minutes.
5. Press the CLOCK button again to confirm the setting.
3.3 Timer
Use this function when you need a kitchen timer to measure exact time for various purposes.
1. Press the PLUS or MINUS button to set the desired time.
2. Press the POWER button repeatedly to set the power to 0 W.
3. Press the START button.
An acoustic signal will be heard when the timer has finished to count down.
1
5
33
4
26

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3.4 Cooking and Reheating
Use this function for normal cooking and reheating.
1. Press the PLUS or MINUS button to set the desired time.
2. Press the POWER button repeatedly to set the desired power level.
3. Press the START button.
Once the cooking process has been started the time can easily be increased in 30-second steps by
pressing the START button. Each press increases the time with 30 seconds. You may also alter the time
by pressing the PLUS or MINUS button to increase or decrease the time. Pressing the POWER button
may also change the power level.
An acoustic signal will be heard when the cooking has finished and “END” is shown in the display.
The signal will sound once a minute for 10 minutes, after which all of the functions will automatically be
stopped.
Attention! Once the cooking process has been completed, the fan, the lamp and the rotating plate
will remain switched on until:
• the door is opened (the ventilator and the lamp will remain switched on when the door
is open);
• a function button or the POWER button is pressed;
• the 10 minutes have lapsed.
3.5 Rapid Defrost
Rapid Defrost schould only be used if the netweight of the froozen food is between 100 - 2000 g.
1. Press the JET DEFROST button.
2. Press the PLUS or MINUS button to set the weight of the food.
3. Press the START button.
The oven stops and prompts you to “TURN FOOD ” once the time set is up. Open the door, turn the
food, close the door and restart by pressing the START button. The oven continues automatically after
2 minutes if the door hasn't been opened.
If:
• the weight is lesser than 100g or greater than 2 kg, choose 160 W when defrosting and follow the
procedure for “Cooking and Reheating”;
• the food is warmer than the deep-freeze temperature (+18°C), choose lower weight of the food;
• the food is colder than the deep-freeze temperature (+18°C), choose higher weight of the food.

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3.6 Rapid Start
This function is used for quick reheating of foods with a high water content such as clear soups, tea ...
Press the START button: the appliance starts with full microwave power and the cooking time is set to
30 seconds. Each additional press increases the time with 30 seconds to a maximum duration of
3 minutes. You may also alter the time by pressing the PLUS or MINUS button to increase or decrease
the time.
3.7 Children’s safety device / Start blocking
The appliance will lock either after it has been switched off or one minute after switching to the standby
mode, and it will not be possible to restart it. In order to restart the oven, the door must firstly be opened
and then closed again immediately. If it is not closed again immediately, “DOOR” will appear on the
display.
3.8 Exceeding time limits
The following time intervals apply:
1 minute after closing the door and
10 minutes after opening the door, after which the appliance will switch over to the standby mode.
10 minutes after the cooking process has been completed.
The timer can be reset after interruptions by opening and closing the oven door and by pressing the
POWER button.

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4. Cleaning
Prior to all maintenance or cleaning work always pull out the mains plug and wait
until the appliance has cooled down.
Please heed the safety instructions on “Components” on page 12.
The cooking cavity is made of stainless steel and therefore
cleaning is extremely easy. Always keep the cover panel of the
microwave outlet opening free of oil and grease splashes.
Never use scouring agents, metal wool or sharp metal objects
for cleaning the cavity. Moreover, make sure that no water or
liquid cleaning agent enters the waste air and vapour extractor
slits on the top of the appliance. No alcohol, scouring agents or
ammonia-containing cleaning agents are to be used for
cleaning the inside and outside of the door.
To ensure perfect closing, always keep the inside of the door
clean and make sure that dirt and food residues are not
jammed between the door and the appliance front.
Regularly clean the fresh air openings on the rear of the
appliance and the surface under the turntable so that they do
not become clogged with dust and dirt over the course of time.
The turntable and the corresponding holder should also be
removed for cleaning and the bottom of the microwave oven
cleaned from time to time.
Clean the turntable and the holder with normal washing-up
liquid. Adding some lemon juice to a cup of water, placing this
on the turntable and boiling for a few mninutes can eliminate
odours inside the oven.
Do not operate the oven without the turntable in place.
Do not immerse the turntable after prolonged heating in
cold water, it would break owing to the severe temperature
shock.
The turntable support, the turntable and its cover and the baby
bottle holder are dishwasher safe.

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5. Components
5.1 Safety precautions - microwave energy
Service technicians must never be exposed to the microwave radiation which can be
emitted by the magnetron or other components producing microwaves if the appliance
is not connected correctly or is operated improperly.
All microwave terminals for input and output, the wave guide and all flanges and seals
must be fastened and sealed correctly.
Never operate the appliance without having placed items in the cooking cavity which
absorb the microwaves.
Never look into an open waveguide or an antenna when the magnetron is under voltage.
The appliance must never be operated without the housing or with the door open.
If the fuse blows, always block the system operability first (all microswitches) before the
appliance is switched on again. If a microswitch is defective, always replace all
microswitches.
Before activation of the magnetron or before repair work, check the following points:
• If the door does not close properly and does not fit the frame because it is distorted or because the
hinges have been damaged.
• If the door or the door seal are damaged.
• If the appliance shows obvious signs of damage.
All defective or incorrectly set components in the locking, control, door locking, microwave generator and
transmission systems must be repaired, replaced or correctly set. Service technicians must first remove
their watches for all work on or near the magnetron.
• Attention! The high-voltage capacitor could still be electrically charged about 30 sec. after the
appliance has been switched off. It is advisable to discharge the capacitor each time through
both poles using a suitably insulated cable. Secondary power circuits of the transformer have
a high voltage and a low amperage and for this reason it is extremely dangerous to work near
these components if the appliance is plugged into the mains. Never touch cables with your
bare hands or with non-insulated tols when the appliance is in operation.
• Do not measure the electric voltage of a high-voltage circuit or magnetron filament.
• Make sure that the door is not loose or is missing. If the screws are not tightened fully, this could lead
to the discharge of microwaves.
• Before you switch on the appliance, check that all electric connections are tight.
• Ensure with a reasonable procedure that no microwaves are emitted.
• Do not insert any metal objects either through the lamp gap or through any other gap as such objects
could act as an antenna and could result in the emission of microwaves.

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5.2 Housing
After removing 11 screws on top and on the sides of the
cavity, remove the cover by lifting the sides and pull the
cover to the rear.
5.3 Microswitches
The 3 microswitches are mounted on holders on the right
side of the door behind the front wall.
The 2 holders are fixed with two screws behind the door.
Both holders are additionally clipped on the side wall of the
cavity (see the arrow).

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Maybe you have to bend the plate (see the small picture on
the left) to remove the lower holder.
5.4 Magnetron
To remove the magnetron disconnect the power board, the
fan motor connection and the primary connections of the
HT-transformer.
Remove the support which is fixed with 3 screws from
outside (see the arrow)
Disconnect the HT-transformer from the magnetron and
the HT-capacitor.

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Then remove the two screws on the rear panel of the
appliance and remove the HT-transformer (see the
arrows). Then the magnetron can be disassembled by
removing the 4 screws on the side wall (see the arrows).
Magnetron with holder, screws and overheat protection
(NTC).
HT-transformer with HT-diode (A)
HT-capacitor on the mounting plate (B)
5.5 Fan and fan motor
Disconnect the fan, shown by the arrow and remove the
support (see the description “Magnetron” on page 14).
AB

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4. Then remove the top panel of the fan housing by
unclipping it.
5. The wheel can pulled out from housing as shown by the
arrow.
6. Behind the fan wheel are two screws to remove the fan
motor from the support.
After disassembly the fan divides in
1top panel
2housing
3fan motor
4fan wheel
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5.6 Power board
Disconnect the power board and remove it with the support
(see “Magnetron” on page 14).
Then the power board is removable from it’s frame by removing
two screws on the board.
5.7 Safety thermostats
The cavity safety thermostat is located in front of the power
board at the cavity top panel. It is just to disconnect and clip out
of the frame.
A second safety thermostat is located on top of the magnetron
channel.
Both will open the circuit if the temperature rises to more than
115 °C, the only difference is the position of the terminals. On
the cavity they are vertical and on the magnetron they are
horizontal.

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5.8 Front panel and display
Disconnect the two flat cables from the display on the power
board.
To disassemble the front panel you have to remove 6 screws
(see the arrows and the screwdriver).
Remove the 4 screws at the bottom plate of the display and
remove the plate too.
After removing the 2 screws on the display, unclip the board.
Then the panel divides in 4 components and the clock setting
knob (see the arrow).

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5.9 Door
After removing the front panel remove the screw on top hinge
of the door.
Open the door, tip it, then lift the door to remove it from the
bottom hinge.
To disassemble the handle remove the two screws on the
inside of the door.

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5.10 Fixation system and turntable motor
To reach the fixation system remove the 6 screws which are
highlighted with arrows. Then the back panel can be pulled
away.
To remove the fixation system lie the microwave oven on the
door; take care of glass and handle. Don’t remove the nut of
the fixation system (see circle above).
Bottom plate is fixed like a clip system (see the arrows).
To reach the turntable motor just cut out the foreseen part of the
bottom plate (1). Then disconnect the motor (2) and remove the
2 screws (3).
To re-assemble the motor plate you have to fix the plate with
2 screws.
1
2
3
3
Turntable motor and it’s gasket