Whirlpool AVM595 WH User manual

WHIRLPOOL CONSUMER SERVICES Models AVM595 WH
AVM595 BL
October 1998
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 Part No. SM7020
A. B. N. 28 003 578 023
WHIRLPOOL AUSTRALASIA
CONSUMER SERVICES
SERVICE MANUAL
MICROWAVE OVEN
Model AVM595 WH
Version 8538 595 53291
Model AVM595 BL
Version 8538 595 53491

WHIRLPOOL CONSUMER SERVICES Models AVM595 WH
AVM595 BL
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CONTENTS
Page
SAFETY PRECAUTIONS 3
INTRODUCTION 3
SAFETY 3
CAUTION - MICROWAVE RADIATION 3
WARNING - HIGH VOLTAGE 3
TECHNICAL DATA 4
INSTALLATION REQUIREMENTS 5
GENERAL 5
EARTHING INSTRUCTIONS 5
OPERATIONAL DESCRIPTION 6
MICROWAVE AND LEAKAGE TESTS 7
MICROWAVE TEST 7
MICROWAVE LEAKAGE TEST 7
TROUBLE SHOOTING GUIDE 8
CAUTION AND IMPORTANT 8
MICROWAVE LEAKAGE 8
QUICK REFERENCE 9
MAJOR COMPONENT TESTS 10
HV TRANSFORMER 10
HV CAPACITOR 10
HV DIODE 10
MAGNETRON 10
INTERLOCK SWITCH SYSTEM 11
EXPLODED VIEW 12
PARTS LIST 13
CIRCUIT DIAGRAM 14

WHIRLPOOL CONSUMER SERVICES Models AVM595 WH
AVM595 BL
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SAFETY PRECAUTIONS
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 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

WHIRLPOOL CONSUMER SERVICES Models AVM595 WH
AVM595 BL
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Dimensions of Cabinet
Height 332 mm
Width 424 mm
Depth 548 mm
Dimensions of Cavity
Height 225 mm
Width 340 mm
Depth 345 mm
Cavity Volume 27 I
Weight
Net 22 kg
Packed 24 kg
Electrical
Voltage 230-240 V
Frequency 50 Hz
Power consumption 1500 W
Power
Nominal Output Power 850 W
Microwave frequency 2450 Mhz
Timer
Electronic 99 min 59 sec

WHIRLPOOL CONSUMER SERVICES Models AVM595 WH
AVM595 BL
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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 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 Models AVM595 WH
AVM595 BL
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OPERATIONAL DESCRIPTION
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 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%
MICROWAVE AND LEAKAGE TESTS

WHIRLPOOL CONSUMER SERVICES Models AVM595 WH
AVM595 BL
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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.
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 Models AVM595 WH
AVM595 BL
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If leakage is found to be above 5 mW/cm2, 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
5 mW/cm2, 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 Models AVM595 WH
AVM595 BL
Page 9 of 14
QUICK SERVICE REFERENCES
PROBLEM POINTS TO CHECK
Cavity lamp does not light, but other
electrical components (e.g. turntable) are
working.
1. Lamp failed.
2. Bad contact between lamp and
lamp socket.
Cavity lamp does not light, all other
electrical components also do not work.
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.
Oven seems working, food does not cook 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.
Oven cooks for a short while and stop. 1. Cooling fan jammed.
2. Cooling fan motor open circuit.
3. Defective cooling fan control relay.
Turntable does not turn. 1. Defective turntable motor.
2. Turntable shaft deformed.
User circuit breaker activates. 1. High leakage in electrical
components (mostly motor).

WHIRLPOOL CONSUMER SERVICES Models AVM595 WH
AVM595 BL
Page 10 of 14
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.)
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.