Goldstar Mv-1525b, Mv-1525w Service Manual

MICROWAVE OVEN

SERVICE MANUAL

MODEL: MV-1525W,

CAUTION

http://www.LGEservice.com

BEFORE SERVICING THE UNIT, READ THE

SAFETY PRECAUTIONS IN THIS MANUAL.

MV-1525B

CAUTION

SAFETY PRECAUTIONS

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.

• Proper operation of the microwave ovens requires that the magnetron be assembled to the

wave guide and cavity. Never operate the magnetron unless it is properly installed.

• Be sure that the magnetron gasket is properly installed around the dome of the tube whenever

installing the magnetron.

• Routine service safety procedures should be exercised at all times.

• Untrained personnel should not attempt service without a thorough review of the test

procedures and safety information contained in this manual.

FOREWORD

Read this Manual carefully. Failure to adhere to or observe the information in this Manual may result in exposing yourself to the Microwave Energy normally contained within the oven cavity.

TABLE OF CONTENTS

(Page)

SAFETY PRECAUTIONS ......................................................................................................... Inside front page

SPECIFICATIONS.......................................................................................................................................... 1-1

CAUTIONS..................................................................................................................................................... 2-1

INSTALLATIONS............................................................................................................................................ 3-1

OPERATING INSTRUCTIONS....................................................................................................................... 4-1

CONTROL PANEL ................................................................................................................................. 4-1

CONTROL PANEL INSTRUCTIONS ..................................................................................................... 4-2

OVERALL CIRCUIT DIAGRAM...................................................................................................................... 5-1

SCHEMATIC DIAGRAM......................................................................................................................... 5-1

MATRIX CIRCUIT FOR TOUCH KEY BOARD...................................................................................... 5-2

GENERAL INFORMATION FOR SERVICE................................................................................................... 6-1

GENERAL PRECAUTIONS IN USE ...................................................................................................... 6-1

TRIAL OPERATION ............................................................................................................................... 6-1

FEATURES AND SPECIFICATIONS FEATURES................................................................................. 6-1

SERVICE INFORMATION ............................................................................................................................. 7-1

PRECAUTIONS AND REPAIR SERVICE TIPS..................................................................................... 7-1

MICROWAVE LEAKAGE TEST............................................................................................................. 7-2

POWER OUTPUT MEASUREMENT ..................................................................................................... 7-3

DISASSEMBLY INSTRUCTIONS .......................................................................................................... 7-4

INTERLOCK SYSTEM .......................................................................................................................... 7-12

INTERLOCK CONTINUITY TEST.......................................................................................................... 7-14

TEST AND CHECKOUT PROCEDURES AND TROUBLE SHOOTING................................................ 7-15

A. TEST PROCEDURES................................................................................................................ 7-15

B. CHECKOUT PROCEDURES..................................................................................................... 7-18

C. TROUBLE SHOOTING.............................................................................................................. 7-21

EXPLODED VIEW.......................................................................................................................................... 8-1

REPLACEMENT PARTS LIST............................................................................................................... 8-8

SCHEMATIC DIAGRAM OF PCB .......................................................................................................... 8-15

PRINTED CIRCUIT BOARD .................................................................................................................. 8-16

PCB PARTS LIST................................................................................................................................... 8-17

1-1

Rated Power Consumption 1,500W maximum (Microwave oven only)

1,600W maximum (Microwave oven+Cook top lamps+Ventilation fan)

Microwave Output

1000W (IEC 705 TEST PROCEDURE) Adjustable 100W through 1000W, 10 steps

Frequency 2,450 MHz

50 MHz Power Supply 120 VAC, 60 Hz Rated Current 13 Amp. (Microwave oven only)

14 Amp. (Microwave oven+Cook top lamps+Ventilation fan) Magnetron Cooling Forced Air Cooling Rectification Rectification Voltage Double Half-Wave Door Sealing Choke System Safety Devices Magnetron Thermal Fuse:

Open at 109

4°C

Oven Cavity Thermostat:

Open at 110

50°C Fuse(20A) Primary Interlock Switch Secondary Interlock Switch Interlock Monitor

Magnetron 2M246-310GF or 2M248E High Voltage Capacitor Capacitor: 1.0µF, 2.1 KV AC High Voltage Diode Diode; 350mA, 9.0 KV Cook top Lamp 125 V, 30 W or 40 W Cavity Lamp 125 V, 30 W or 40 W Timer Digital, up to 99 mim. 99 sec. (in each cooking stage) Tray Tempered Safety Glass

Overall Dimensions 29

/16”(W)x167/16”(D)x153/8”(H)

Oven Cavity Size 19

/8”(W)x145/32”(D)x815/16”(H)

Effective Capacity of Oven Cavity 1.5 Cu.ft. Accessories Owner’s Manual & Cooking Guide, Installation Manual,

Exhaust Adapter, Exhaust Damper, Mounting Kit and Two Filters, Rotating Ring Assembly, Metal Rack.

SPECIFICATIONS

2-1

CAUTIONS

• DO NOT operate on a 2-wire extension cord during repair and use.

• NEVER TOUCH any oven components or wiring during operation.

• BEFORE TOUCHING any parts of the oven, always remove the power plug from the outlet.

• For about 30 seconds after the oven stops, an electric charge remains in the high voltage capacitor. When replacing or checking, you must discharge the high voltage capacitor by shorting across the two terminals with an insulated screwdriver.

•

Remove your watches whenever working close to or

replacing the Magnetron.

• DO NOT touch any parts of the control panel circuit. A resulting static electric discharge may damage this P.C.B.

• NEVER operate the oven with no load.

• NEVER injure the door seal and front plate of the oven cavity.

• NEVER put iron tools on the magnetron.

• NEVER put anything into the latch hole and the interlock switches area.

• Proper operation of the microwave oven requires that the magnetron be assembled to the waveguide and cavity. Never operate the magnetron unless it is properly installed.

• Be sure that the magnetron gasket is properly installed around the dome of the tube whenever installing the magnetron.

Unlike other appliances, the microwave oven is high-voltage and high-current equipment. Though it is free from danger in ordinary use, extreme care should be taken during repair.

THE OVEN IS TO BE SERVICED ONLY BY PROPERLY QUALIFIED SERVICE PERSONNEL.

MICROWAVE RADIATION

Personnel should not be exposed to the microwave energy which may radiate from the magnetron or other microwave generating device if it is improperly used or connection. All input and output microwave connections, waveguide, flange, and gasket 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.

Gasket

ANTENNA

COOLING FIN

MAGNETRON CHASSIS GROUND

FILAMENT TERMINALS

MAGNETRON

3-1

INSTALLATIONS

PRECAUTIONS ON INSTALLATION

A. Plug the power supply cord into a 120V AC, 60Hz,

single-phase power source with a capacity of 15A or 20A.

B. Avoid placing the unit in a location where there is

direct heat or splashing water. C. Install the unit on the mounting plate firmly. D. Place the unit as far away as possible from TV,

radio, etc. to prevent interference.

GROUNDING INSTRUCTIONS

For personal safety, this appliance must be fully grounded at all times.

In the event of an electrical short circuit, grounding reduces the risk of electrical shock. The plug must be plugged into an outlet that is properly installed and grounded.

BEFORE YOU BEGIN, READ THE FOLLOWING INSTRUCTIONS COMPLETELY AND CAREFULLY.

WARNING

Improper use of the grounding plug can result in a risk of electric shock. Do not, under any circumstances, cut or remove the third ground prong from the power cord plug.

CAUTION

This unit is equipped with a 3-prong plug for your safety. If the wall outlet is a grounded 3-hole type, the unit will be grounded automatically.

Plug with Ground

Prong

Properly Polarized and Grounded Outlet

CONTROL PANEL

4-1

OPERA TING INSTRUCTIONS

CUSTOM

COOK

TURNTABLE

ON/OFF

FAN

HI/LO/OFF

LIGHT

HI/LO/OFF

KITCHEN

TIMER

CUSTOM

SET

CLOCK

AM/PM

LIGHT TIMER

AM/PM

POTATO

PIZZA

RICE

DINNER

PLATE

SOUP

SAUCE

FROZEN ENTREE

BACON

FRESH

VEGETABLE

FROZEN

VEGETABLE

POPCORN

BEVERAGE

CASSEROLE

POWER

HELP

HOLD

WARM

AUTO TOUCH

8 0

Ez OnEz On

DEFROST

MOREMORE

LESSLESS

STOP

CLEAR

START

CONTROL PANEL INSTRUCTIONS

4-2

The entire operation is done by simple touch control pads. (1) Display Window

Numbers and letters are shown in the display

window (Vacuum Fluorescent Tube). Each Indicator Light shows which function is set and involved in the course of cooking by turning itself on. Indicator Lights automatically go out upon completion of cooking.

(2) MORE, LESS Key

Used to add or subtract ten seconds of cooking

time each time pressing it.

(3) POWER Key

Used to select cooking power level.

(4) EZ on Key

Used to cook for one minute at 100% power level.

It can be used to extend cooking time in multiples

of one minute up to 99 minutes.

(5) CLOCK(TIME OF DAY) Key

Used in setting Time of Day.

(6) STOP/CLEAR Key

Used to stop the oven or clear all entries except

Time of Day.

(7) START Key

Touch the START key after setting the desired

cooking times etc. Also touch the START key to

resume cooking after the cooking is temporarily

stopped by opening the door. The key will not

function unless the door is closed.

(8) DEFROST Key

Used to defrost for frozen foods by weight.

(9) AUTO TOUCH

Used to cook the preprogrammed food

automatically.

(10) HELP Key

This HELP key display feature information and helpful hints.

(11) LIGHT TIMER

Used to set the cooktop light to turn on and off automatically at any time you want. The light comes on at the same time every day until reset.

(12) KITCHEN TIMER

Used to set the timer.

(13) TURNTABLE ON/OFF

Touch this pad to turn off the turntable. “T/TABLE OFF” will appear in the display.

(14) CUSTOM SET Key

Touch this pad to change the oven’s default setting for sound, clock, display speed, defrost weight, and demo mode operations.

(15) FAN HI/LO/OFF Key

Touch FAN once for HIGH fan speed, twice for low fan speed, or threetimes to turn the fan off.

(16) LIGHT HI/LO/OFF Key

Touch LIGHT once for bright light, twice for the night light, or three times to turn the light off.

5-1

RY 1

RY 3

RY 4

RY 5

PH 1

VR 2

(NO)

PRIMARY SWITCH (BOTTOM)

(C)

CN 1

RY6 RY2

123

CN 2

456

123456

6 uF CAPACITOR

S.M F.M

FAN MOTOR

TURNTABLE MOTOR

SECONDARY

SWITCH

(TOP)

RDBRBR

(NC)

H.V.TRANSFORMER

H.V.CAPACITOR

MAGNETRON

RECTIFIER

CONTROL MODULE

RESISTOR

15 PIN CONNECTOR(CN 1)

* NOTE

1. DOOR OPENED & COOK OFF MODE.

2. BLUE MARK ON LAMP SOCKET MUST BE CONNECTED TO LIVE PART(BLACK WIRE).

3. ONLY CERTAIN MODELS USE THE ABSOLUTE HUMIDITY SENSOR.

OVEN LAMP

COOK TOP LAMPS

O.L

SINGLE PHASE ONLY

AC 120V 60Hz

Low

WH WH

C.L C.L

STIRRER MOTOR

(C)

(NO)

SYMBOL COLOR

WHITE BLACK RED YELLOW PINK BLUE BROWN GREEN

BK RD YL PK BL BR GN

GREY

WIRE COLORS

13579111315

VENT MOTOR

V.M

FUSE 20A

MGT THERMAL FUSE (109 C/228 F)

MICRO COMPUTER BOARD

POWER TRANS

OVEN THERMOSTAT (110 C/230 F)

BASE

THERMOSTAT

(56 C/133 F)

3 PIN (CN 2)

(For not provided

Temp Probe)

T.M

SCHEMATIC DIAGRAM

OVERALL CIRCUIT DIAGRAM

MATRIX CIRCUIT FOR TOUCH KEY BOARD

7654321

FROZEN

VEGETABLE

POPCORN

FAN(VENT)

HI/LO/OFF

HELP N.C 5 0

POTATO

FROZEN ENTREE

LIGHT

HI/LO/OFF

CUSTOM

SET

DEFROST

BEVERAGE

DINNER

PLATE

EZ on CLOCK 7 2

RICE

HOLD

WARM

POWER

KITCHEN

TIMER

FRESH

VEGETABLE

LIGHT

TIMER

N.C 8 3

PIZZA

CASSEROLE

START

STOP/

CLEAR

SOUP/

SAUCE

BACON CUSTOM

COOK

LESS MORE N.C

TURNTABLE

ON/OFF

5-2

6-1

GENERAL PRECAUTIONS IN USE

A. Never operate the unit when it is empty.

Operating the oven with no load may shorten the life of the magnetron. Whenever cooking dry foods (dried fish, bread, etc.) or a small amount of food, be sure to put a glass of water into the cooking compartment. The glass turntable may become hot after operating, be careful when touching it.

B. Aluminum foil should be avoided because it will

disrupt cooking and may cause arcing. However, small pieces may be used to cover some parts of food to slow the cooking. Any aluminum foil used should never be closer than 2.5 cm to any side wall of the oven.

TRIAL OPERATION

After installation, the following sequences and results should be checked carefully.

A. Put a container filled with water (about 1 liter) into

the oven, and close the door tightly.

B. Set cooking time for 10 minutes by touching “1”

and then “0” three times. “1, 0, 0, 0” appears in the display window.

C. Touch the START key.

Make sure the cavity light comes on. The unit will begin cooking and the display window will show the time counting down by seconds.

D. After about 5 minutes, make sure the primary

interlock switch, the secondary interlock switch and the interlock monitor switch operate properly by opening and closing the door several times. Touch the START key each time the door is closed.

E. Continue operating the unit. Two short and a long

beep sound signal is heard when the time is up.

The unit will shut off automatically. F. Confirm the water is hot. G. Finally, measure the output power according to

“POWER OUTPUT MEASUREMENT” on

page 7-3.

FEATURES AND SPECIFICATIONS FEATURES

A. The safety systems incorporated in this model are:

(1) Primary interlock switch (2) Secondary interlock switch (3) Interlock monitor switch (4) Choke system (5) Magnetron thermal fuse (6) Oven cavity thermostat

(Note: This thermostat located on the oven cavity will open and stop the unit from operation only if a high temperature is reached, such as, a fire created by overcooking food.)

B. Any one of 10 power output levels ranging 100W to

1000W can be selected by the touch control and electronic computer system.

GENERAL INFORMATION FOR SERVICE

PRELIMINARY

A. SINCE NEARLY 2,100 VOLTS EXISTS IN SOME

CIRCUITS OF THIS UNIT REPAIRS SHOULD BE CARRIED OUT WITH GREAT CARE.

The filament leads of magnetron carry High Voltage with respect to ground. Extreme caution must be exercised. Never plug the unit into a power source to determine which component is defective in high voltage section.

B. TO AVOID POSSIBLE EXPOSURE TO

MICROWAVE ENERGY LEAKAGE, THE FOLLOWING PRECAUTIONS MUST BE TAKEN BEFORE SERVICING.

(1) Before the power is applied:

(a) Make sure the primary interlock switch, the

secondary interlock switch and the interlock monitor switch operate properly by opening and closing the door several by opening and closing the door several times.

(b) Make sure the perforated screen and the

dielectric choke of the door are correctly and firmly mounted.

(2) After power is applied:

(a) Make sure the interlock switch mechanism

is operating properly by opening and closing the door.

(b) Check microwave energy leakage must bebelow

the limit of 5 mW/cm

(All service adjustments should be made for minimum microwave energy leakage readings).

(3) Do not operate the unit until it is completely

repaired, if any of the following conditions exist.

The unit must not be operated. (a) The door does not close firmly. (b) The hinge is broken. (c) The door seal is damaged. (d) The door is bent or warped, or there is any

other visible damage on the unit that may

cause microwave energy leakage. NOTE: Always keep the seal clean. (e) Make sure that there are no defective parts

in the interlock mechanism. (f) Make sure that there are no detective parts

in the microwave generating and transmission

assembly (especially waveguide).

(4) The following items should be checked after the

unit is repaired:

(a) The interlock monitor switch is connected

correctly and firmly. (b) The magnetron gasket is properly positioned

and mounted. (c) The waveguide and the oven cavity are intact.

(no microwave energy leakage) (d) The door can be properly closed and the

safety switches work properly. (e) The unit must stop when the door is opened or

the time is up.

The unit must not be operated with any of the above components removed or by-passed.

7-1

PRECAUTIONS AND REPAIR SERVICE TIPS

SERVICE INFORMATION

7-2

CAUTIONS

• Be sure to check microwave leakage prior to servicing the oven if the oven is operative prior to servicing.

• The service personnel should inform the manufacture importer, or assembler of any certified oven unit found to have a microwave emission level in excess of 5 mW/cm2and should repair any unit

found to have excessive emission levels at no cost to the owner and should ascertain the cause of the excessive leakage. The service personnel should instruct the owner not to use the unit until the oven has been brought into compliance.

• If the oven operates with the door open, the service personnel should:

- Tell the user not to operate the oven.

- Contact the manufacturer and CDRH

(Center for Devices and Radiological Health)

immediately.

NOTE: Address on CDRH

Office of Compliance(HFZ-312) Center for Devices and Radiological Healthe 1390, Piccard Drive, Rockville. MD 20850

• The service personnel should check all surface and vent openings for microwave leakage.

• Check for microwave leakage after every servicing. The power density of the microwave radiation leakage emitted by the microwave oven should not exceed 4 mW/cm2. Always start measuring of an unknown field to assure safety for operating personnel from radiation leakage.

EQUIPMENT

• TESTER (VOLTS-DC, AC, Ohmmeter)

• Microwave survey meter

- Holaday HI-1500 HI-1501

- Narda 8100

8200

• 600 cc non conductive material beaker (glass or plastic), inside diameter: approx. 8.5 cm (3

in.)

• Glass thermometer: 100°C or 212°F (1 deg scale)

MEASURING MICROWAVE ENERGY LEAKAGE

• Pour 275±15cc of 20±5°C(68±9°F) water in a beaker which is graduated to 600 cc, and place the beaker on the center of the turntable.

• Set the energy leakage monitor to 2,450 MHz and use it following the manufacturer's recommended test procedure to assure correct result.

• When measuring the leakage, always use the 2-inch (5cm) spacer supplied with the probe.

• Operate the oven at its maximum output.

• Measure the microwave radiation using and

electromagnetic radiation monitor by holding the probe perpendicular to the surface being measured.

Move probe along shaded area.

Probe scanning speed Less than 2.5 cm/sec. ( 1 in/sec)

MICROWAVE LEAKAGE TEST

MEASUREMENT WITH THE OUTER CASE REMOVED

(1) When you replace the magnetron, measure for

microwave energy leakage before the outer case is installed and after all necessary components are replaced or adjusted. Special care should be taken in measuring the following parts.

- Around the magnetron

- The waveguide

WARNING: AVOID CONTACTING ANY HIGH

VOLTAGE PARTS.

MEASUREMENT WITH A FULLY ASSEMBLED OVEN

(1) After all components, including the outer

panels, are fully assembled, measure for microwave energy leakage around the door viewing window, the exhaust opening and air inlet openings.

(2) Microwave energy leakage must not exceed the

values prescribed below.

NOTES:

Leakage with the outer panels removed - less than 5 mW/cm

Leakage for a fully assembled oven (“Before the latch switch (primary) is interrupted”) with the door in a slightly opened position - less than 2 mW/cm

NOTE WHEN MEASURING

(1) Do not exceed meter full scale deflection. (2) The test probe must be removed no faster than

1 inch/sec (2.5cm/sec) along the shaded area, otherwise a false reading may result.

(3) The test probe must be held with the grip portion

of the handle. A false reading may result if the operator’s hand is between the handle and the probe.

(4) When testing near a corner of the door, keep

the probe perpendicular to the surface making sure the probe horizontally along the oven surface, this may possibly cause probe damage.

RECORD KEEPING AND NOTIFICATION AFTER MEASUREMENT

(1) After adjustment and repair of any microwave

energy interruption or microwave energy blocking device, record the measured values for future reference. Also enter the information on the service invoice.

(2) Should the microwave energy leakage not be

more than 2 mW/cm2after determining that all parts are in good condition, functioning properly and genuine replacement parts which are listed in this manual have been used.

(3) At least once a year, have the electromagnetic

energy leakage monitor checked for calibration by its manufacturer.

(1)

Microwave power output measurement is made with the microwave oven supplied at its rated voltage and operated at its maximum microwave power setting with a load of (1000±5) g of potable water.

(2)

The water is contained in a cylindrical borosilicate glass vessel having a maximum material thickness of

1/8” (3 mm) and an outside diameter of approximately 7.6” (190mm).

(3)

The oven and the empty vessel are at ambient temperature prior to the start of the test.

(4)

The initial temperature (T1) of the water is (10±2)°C (50°F) It is measured immediately before the water is added to the vessel. After addition of the water to the vessel, the load is immediately placed on the center of the turntable which is in the lowest position and the microwave power switched on.

(5)

The time T for the temperature of the water to rise by a value ∆ T of (10±2)°K is measured, where T is the time in seconds and ∆T is the temperature rise. The initial and final water temperatures are selected so that the maximum difference between the final water temperature and the ambient temperature is 5°K.

(6)

The microwave power output P in watts is calculated from the following formula :

4187 x (∆T)

is measured while the microwave generator is operating at full power. Magnetron filament heat-up time is not included. (about 3 sec)

(7)

The water is stirred to equalize temperature throughout the vessel, prior to measuring the final water temperature.

(8)

Stirring devices and measuring instruments are selected in order to minimize addition or removal of heat.

7-3

WATER LOAD

TURNTABLE

P =

POWER OUTPUT MEASUREMENT

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