WINCHESTER ENGINEERING ANO ANALYTICAL CENTER PROCEDURES FOR LABORATORY TESTING OF MICROWAVE OVENS OCTOBER 1981FOOD AND DRUG ADMINISTRATION WINCHESTER ENGINEERING ANO ANALYTICAL CENTER PROCEDURES FOR LABORATORY TESTING OF MICROWAVE OVENS OCTOBER 1981 INTRODUCTION a The purpose of this document is to establish procedures for laboratory testing of microwave ovens that are certified by the manufacturer as being in compliance with the DHHS Performance Standard for Microwave Ovens published in 21 CFR 1010 and 21 CFR 1030.10, The procedures described in this document ere applicabie to both domestic and imported microwave ovens manufactured for use in homes, restaurants, food vending or service establishments, on interstate carriers, and in similar facilities. Definitions of terms used in this document are identical to definitions published in 21 CFR Parts 1000 through 1030. GEN! NSTRUCTIONS 1. Laboratory control of microwave ovens shal! be maintained as specified in tne FOA Regulatory Procedures Manual, the Analyst Operations Manual, Compliance Program 7393.804 "Compliance Testing of Electronic Products et WEAC", and Compliance Program Circular 7397.804A "Compliance Testing of Microwave Ovens at WEAC". * 2. Upon notification of assignment of an oven for analysis the Analyst shall: 1 for the assigned oven 3. brain a copy of the service man cit sor); and, not available, consult Super b. arrange with the Sample Custodian to transfer the oven to the testing laboratory. 3. All test data shall be recorded on Analyst Worksheets (FDA-431 anc 4319} and/or the preprinted data sheets con- tained in Appendix A. When recording test date on tne peeprintec worksheets, ail boxes shall be filled in (use N/A # item is not applicable).The sample number shali be acquired from the "Collection Report" (Form F0-454) for the sample and verified with the “Official Seal" (Form FO-415a), and shall be cleerly printed on all worksheets and preprinted date sheets. !f no seal is present on the sample, consult Supervisor. Before breaking the seal and removing the oven trom its shipping carton, the Analyst shall initiate: a. an Analyst Worksheet (FD-431) in accordance with Chapter 9 of the Analyst Operations Manual; and, b. 2 preprinted data sheet set (see Appendix A). Caution shail be taken unpacking the oven. The original shipping carton and packing material shall be saved and the packing material shall be returned to the carton for later use in repacking the oven for storage or shipment. All microwave leakage measurements shall be carried out according to the procedures outlined in Appendix 8 "Test Procedures for Measurement of Microwave Energy Leakage from Microwave Ovens". All accompanying materials (user and service manuals and other materials) shall be read and understood before any testing procedures are Initiated. Consult Supervisor if any problems are encountered with these materials. Consult Supervisor if at any time du failure occurs in the oven. g testing component crowave and electrical hazards ere inherent with these tests. Perform all operations with extreme care. CAUTION: If ar any time during the testing the, measured microwave radiation leakage reecnes 5 mwW/cm*, STOP. Immediately notify Supervisor.PART A - COMPLIANCE LASORATORY TESTING The compliance tests delineated in Part A are pertormed on all microwave ovens selected for analysis at WEAC under Compliance Program Circular 7393.804A. Endurance Testing (Part 3) is performed on specially designated samples. If eny of the following labels are found to be missing, have this finding verified by another Analyst. I. Labeling a Label A. User Precautio: Visually examine the label specified in 21 CFR 1030.10 part (c)(6)(i) for the following: 1. Presence 2. Permanence 3. Legibility 4. Proper location Document any Inadequa 8. Service Caution Label Visually examine the label specified in 21 CFR 1030.10 part (c)(6)(Ti) for the following: Presence Permanence + legibility + Proper location Document eny inadequacies. ° Certificotion Label examine the certification label (21 CFR for the following: Legidility 4. Accessibility Bocument any inadequacies.D. Identification Label ually examine the identification label (21 CFR 1010.3) for the following: Presence Permanence Legibility Accessibility Verify that the month and year of manufacture are clear and legible without abbreviation and with the year shown as 2 four-digit number. If the date is not on the identification label, indicate its location on the worksheet. Document any inadequacies. 11. Performance Tests A. Door Open Start Test Verity that the oven will not operate under any of the following conditions. ie Open the oven door. With no time on the timer, try to start the oven by pushing the “ON”, "START, "COOK" or other buttons which have the same function. Open the oven door. Set the timer. (Some push button or programmable timers cannot be set when the oven door is open, If this is the case, skip to #3.) Try to start the oven by pushing the button specified in #1 above. Close the oven door. Set the timer. Open the oven door, Try to start the oven by pusning the button specified in #1 above. Examine tne oven cavity, waveguide, or other micro- wave energy containing spaces for ail entrances which allow access to them with the oven door closed, and all lamp and vent covers in place. The possible entrances include, but are not restricted to, ventilation slots, holes in the corners of the oven aoor, or gaps in tne corners of the oven cavity. Describe any insertion paths found and document these paths photographically. Have the insertion path verified by another analyst.1, Ovens shall be tested at their rated line voltage as shown on the microwave oven unit, + 5%. 2. The same microwave power density measuring instru- ments should be used for all tests on a given sample. Record the manufacturer, mode! number, and serial number of the probe and survey meter. Record the calibration factor for the power density measuring unit. 3. Due to calibration schedules, ovens that are endurance tested may not have the final compliance tests performed using the same ‘instrument; this should be noted on the data sheets. 4. Record manufacturer, model number, and serial number of the line voltage monitor or other instrumentation used in the determination of compliance status. 5. Microwave leakage measurements shail be performed according to procedures described in Appendix 8. CAUTIOL Microwave and electrical hazards are present. Leakage Measurements-Door Clo: 4 1, Study Appendix 8 and survey the following oven surfaces for microwave leakage: a. The circumterence of the door/cavity seal. Should be performed while pulling on the door or door handle in order to pull the door snug against the door latcn(es). b. The area of the docr screen. c. The area of the contro! panel. d. The line cord at the point where it entérs the oven. 2. All vent openings. Ali cabinet seams. Any other suspected openings. 2. Record the value and location of the maximum leakage. Use codes as shown in the location identification guide in Appendix C. 3. Record the line voltage under, which the performed. asurements-Door Fixed Leakage Me This test applies to any oven = positive latch interlock (one that turnbefore door movement can begin) If an oven does fot have a positive latch interlock, tne following procedure shall be followed: + Turn the oven on, slowly open the door, and determine the distance the door must open before the primary interlock interrupts the oven operation. Make as many measurements as required to determine the location of the maximum leakage using the fast response position on the microwave power density measuring Instrument. Using the slow response position, of the microwave power density measuring instrument, determine the maximum leakage. Record the value and location of the maximum leakage using the codes on the location guide in Appendix C. 4. Record the line voltage at which the test was perforaned. Secondary Interlock Leakage Measurements This test Is intended to determine the leakage contro! limit of non-positive (those which allow door motion before actuating) secondary interlocks. If It is deter- mined that the secondary interlock is a positive inter- lock, the portion of the preprinted data sheet for the secondary interlock leakage measurement will indicate that this test is not applicable (N/A). 1. Defeat the primary and other interlocks as necessary so that microwave power is controlled by the action of the secondary interlock only. 2. \t may be necessary to defeat the interlock monitor before this test can be performed. “ 3. Proceed as described previously in Section 11.0. 4, Record the value and location of the maximum leakage. 1, Verify that there is @ minimum of interlocks. wo functional Test ali interlocks for defeatability by: a. Any part of the doay, and/or b. A rod with useful length of 10 centimeters, and/or A test magnet, for magne erlocks. Eco 1Only the force necessary to activate the interlock switch itself shall be used. Verify tnat the interlock actuators are not removable without disassembly of the oven or its door. Review the electrical and mechanical design of the interlocks to determine if any single electrical or mechanical failure could cause all safety interlocks to become inoperative. Perform individual function tests for all interlocks whose function has not been determined by previous tests. This will include tertiary and higher orcer interlocks. If necessary, a high impedance neon lamp may be placed in sertes with the power transformer to indicate interlock function and prevent possible door open operation. In some cases other interlocks and the monitor may have to be defeated to perform this test. If appropriate the procedure of G.2.a. may be used. Record the following information for all safety ta- terlocks: a. Whether or not it is monitored (see G below) b. Whether or not S concealed (see #2 above) c. Whether or not it is positive. itor Function Test Review the schematic diagram as well as the physical components of the monitored safety interlock(s) Circuit and determine whether the monitor would caus. the oven to become inoperable and remain so unti repaired if the required sefety interlock(s) should fail to perform required functions. Determine if interlock failures would disrupt the monitoring function. Comment on inadequate operation. The following techniques may be used to determine whether the monitor will perform its function if the monitored interiock(s) should fail. 2. Neon indicator method - for monitors using the “crow-ber" techniques or using tuses and/or thermal elements. (1) insure that the oven is not connected to the power line and that the capacitor is dis- charged. (2) Disconn the two leads of the primary side(3s) “a (3) (6) am Alt a (2) a a os (6) of the magnetron high voltage transformer (required only if completion of this test would cause current to flow in the trans- former primary). Place a neon test light having a high resistance in series with one of the two leads of the monitor switch. An electrical or electronic circuit that will Indicate current flow may be used in place of the neon test light. Short the monitored intertock(s). als to avoid electri- Tape all exposed termi cal shorts. Close the oven door, connect the power line, activate the oven, and then open the oven door. The neon test light should tight and remain so indicating proper operation of the monitor. Consult with your Supervisor if the neon light does not indicate proper monitor operation. Restore all components to their original condition. other monitors not covered by a. above. Insure that the oven is not connected to the power line and that the capacitor is dis- charged. Disconnact the two leads of the primary side of the magnetron high voltage transformer {required only if completion of this test would cause current to tlow in the: trans- former primary). Short the monitored interlock(s). Tape all exposed terminals to avoid electri- cal shorts. Close the oven door, activate the oven, and then open the door. The monitor should der the oven inoperable. Restore al! components to theic original condition.Manual 1. Identity the menual(s) by title and/or part number. Verify that the user manual(s) contain(s) the instructions as specified in 21 CFR 1030.10(c)(4). 3. Document inadequate or improper instructions. Service Manual The only manuals which are to be evaluated are those directly applicable to the unit being tested (limited to the microwave portion of a Hi/Lo unit). 1. Evaluate the ‘instructions including adjustment and replacement procedures to see that adherence te. them would result in proper operation of the oven. Document any inadequate or improper instructions. Verify that service instructions (including diagrams and schematics) correctly identify the primary and secondary interlocks. Document discrepancies. 3. Verify that the service manual(s) conta'n(s) the instructions as specified in 21 CFR 1030.10(c)(5). 4. Identify the manual(s) by title and/or part number. Include the manual publication date If shown on the manual(s}. Also include information about how and when the manual(s) was/were received at WEAC.B_- ENDURANCE LABORATORY TESTING Introduction The DHHS Performance Standard for microwave ovens requires that the plane wave power density of the microyave radiation emitted by a microwave oven not exceed 5 ma/cm* at any point 5 cm or more from the external surface of the oven after acquisition by a purchaser (21 CFR 1030.10(c)). This statement has been interpreted to require that this limit shall apply throughout the useful life of the oven. in order to evaluate the potential for leskage of the oven as a function of use, the oven door and interlocks shall be cycled at least 100,000 cycles of operation for household ovens and 200,000 cycles for commercial appliances. A cycle consists of closing door, energizing power and allowing the microwave energy source to operate and stabilize, shutting off the power by opening the door, and closing the oven door to restart the cycle. Preperatory Procedures A. Test Stand Preparation Endurance testing is performed on special test stands. These test stands provide the means of operating the door and its latching mechanisms as well as any operator con- trols that are necessary to place the oven in the cook mode. Controls are provided to adjust the sequence, speed of operation, and the pneumatic devices required to operate the particular model of oven being tested. Electro- mechanical registers are provided to: display the total number of door closings, display the total number of operating cycles, automatically terminate tne door cycling atter 10,000 cycles, and indicate the number of cycles since the last 10,000 cycle termination. en Preparati A 1, Remove tne oven wrapper and disconnect the timer drive mechanism if it cannot be operated oy the endurance test stand mechanism. Make connections ro both sides of the high voltage transformer primary (or equivalent) to drive the operating cycle counting register. Replace the wrapper. Mount the oven on the endurance test stand and adjust the operation of fhe endurance test stand so that the door closure force simulates normal operation. The aoor shail swing, where appiicable, from the closec -ld-te. position to 90 + 10 degrees. Make connection to the operating cycle register. 3. Place the carbon loaded, synthetic rubber endurance load supplied by 8RH, or other suitable microwave energy absorbing heat dissipating load in the oven cavity. (The 8RH load shall be placed with the sol'd side up 4. Adjust the test stand controls so that the power Source operates and stabilizes without causing the load to overheat. Endurance Tests CAUTION: If at any time during testing the microwave radiation leakage exceeds 5 mW/cm*, STOP and notify Supervisor. ial Set-up 1, Disconnect the door from the test stand and perform a microwave leakage survey following procedures de- scribed in Appendix 8. The microwave leakage survey in the compliance testing report may be used as the initial survey. . 2. Record the value of the maximum microwave leakage and the location of the maximum leakage and your initials on the preprinted worksheet. 3. Install the BRH endurance test load and connect endurance test stand oven operating mechanisms. Set the counters to zero. Daily Operational Procedure Check toad placement. 2. Check registers for previous days counter readings. 3. Periodically throughout the day the stands and ovens should be checked for proper operation. The test loads should be warm but not hot. A cool test load usually indicates oven malfunction. At the end of each day record the following: (a) accumulated number of cycles, (b) the date, and (c) your initials on the preprinted worksheet. Ao10,000 cycle Test ie rn Disconnect the door from the endurance test stand at the completion of every 10,000 cycles of operation. Follow the instructions of "A. Initial Set-up", 1 through 3, Resetting only the 10,G00 cycle register. al Test Disconnect the dsor from the endurance test stand at the completion of the scheduled number of cycles (at least 100,000 for household end at least 200,000 for commercial ovens). Perform microwave energy leakage survey as prescribed in Attachment 8. Determine if the interlocks are still functioning by making voltage or resistance checks at the end of the test. In some cases there will be test stand monitors to indicate interlock operation. Test the interlock monitor to see that it is capable of disabling the microwave generator. If completion of this test would cause current to flow in the transtormer the two leads on the primary may be dis- connected. (See Part A, Section G of this document.) Enter the results obtained above and the date accun- ulated from each 10,000 cycle test on the endurance test data sheet. -12-APPENDIX A DATA SHEETSAPPENDIX A PREPR:NTED DATA SHEETS FOR COMPLIANCE TESTINGSEALS tac {Clnone _ Clanoxen SCRIPTION OF SAMPLE One_cardboard carton CER Te 3 HECENED FROw 7 GHTRET OR UABORATORT| WEAC ER)ner apeuicasce oncuame/omir Omer cerenuines amount rouno, Te SUMMARY OF ANALYSIS Labeling: See page 2 and below Code (Found on Identification Label): Manufacturer Tywone (Photographic) BAH USE ONLY Brand Model # __ — Serial # Oate Manufactured Location of Identification Label Product: Microwave Oven Rated Line Voltage: VAC Analysi Method: Procedures for Laboratory Testing of Performance Standards: 21 CFR 1010.2 21 CFR 1010.3 21 CFR 1030.10 Certification : Identification: Performance Winchester Engineering and Analytical Center Microwave Ovens - Part A Oriainai cardboard carton officially sealed TE a RRC SY TRATORE Tira Saat CT cuece | Foau FO a nan Dacvious Corio 7 OBsOLeT ETICENERAL CONTINUATION SHEET MICROWAVE OVEN RESULTS & SUMMARY OF ANALYSIS Date [Not Adequate | Adequate Question able Labeling Requirements a.__User Precautions Label b. Service Caution Label c. Certification Label d. Identification Label Performance Requirements e. Door Open Start Test fF. Insertion g._Nicrowave Leakage h. Secondary Leakage Tntertock Microwave T_Safety Interlocks = Minimum of Two 2. At Teast One 1S Concealed J._Non-Removal of Actuators 4.Failure of Single Component Will Not Cause Interlocks to Become Inoperative Monitor Function Manuals (Instructions & Warnings} k User Manual (User Precautions Statement Present) ervice Manual T. Service Adjustments or Service Procedures Do Not Cause Safety interlocks to Become Inoperative or Allow the Microwave Radia- tion Eniission to Exceed Power Sensity Limits Primary and Secondary interlocks Proverly Identified in Manual Service Precoutions State- went Present |._ ==— | GENERAL CONTINUATION SHEET NICROWAVE ovEN PERFORMANCE TEST DATA OATE: Monitored Concealed Positive A. Safety Interlocks Yes No Yes No Yes No 1. Primary Interlock a | 2. Secondary Interlock = aE 2a =a : 3. Other = == -= 4, Moni tor a =a at 8. Instrumentation for Microwave Survey Microwave Survey Inst. Mfr. Meter Model # Meter Serial # Probe Serial # Calibration Factor Line Voltage Meter Mfr. Neter Nodel # Heter Serial # LEAKAGE IN 21 CFR LINE *SUR- *LOCATION | mi/en? = LIMIT VOLTAGE FACE GN SURFACH C. Door Closed 7] 1.0 atten Ol 0. Door Fixed Leakage: LE] 1.0 sivsone (To be filled in only if primary interlock is non-positive.) E. Secondary Leakage: CAL T.E] 5.0 ttrent (To be filled in only if secondary interlock is non-positive.) X C OF HEAC PROCEDURES FOR ORATORY TESTING OF MICROWAVE OVENS - Fo rome ale aT SEBURCEE FSa FS BIT SmES WAYGENERAL CONTI:IUATION SHEET WAVE OVEN aWELE NO. MANUAL IDENTIFICATION USER MANUAL(S): SERVICE MANUAL(S) :APPENDIX A PREPRINTED DATA SHEETS FOR ENDURANCE TESTINGANALYST WORKSHEET MICROWAVE. OVEN tence TOATE RECS [u, REC TED FROM Cyntact Divorce Cl enonen DESCRIPTION OF SAMPLE One cardboard carton [RINT arpuicasue orcuanesomir Onveiwacia Sue TED Kner cerenmmes suounr roune. sumer Ter SUMMARY OF ANALYSIS Labeling: See Compliance Testing Report Dated Code: (Found on Identification Label, See Compliance Testing Report for Location of Label) Brand Yodel F Serial # Date Manufactured Manufacturer | i Product: Microwave Oven Rated Line Voltage: vac Analysis: Fethod: Winchester Engineering & Analytical Center Procedures for Laboratory Testing of Microwave Ovens - October 1981 Part 8 Performance Standards: 21 CFR 1030.10 MOTE: This oven was put on the endurance test stand to avait set-up. NOTE: The compliance tests for this unit have been previously reported. Thr RESERVE SAMPLE | c TIRRRCTEY ERATURE ioe Seat IT es cane " cuecx | Ta OTE REPORTED Foun Fo a7 Paevious COviOn 1S OasOLETES ee| |GENERAL CONTINUATION SHEET MICROWAVE OVEN ENDURANCE TEST SUMMARY A. Leakage vs. Number of Cycles # of Leakage Flocation | Line Voltage tiyem) | Surface_| an Surface VAC) Date __| Initials *See Appendix C of WEAC Procedures for Laboratory Testing of Microwave Ovens - October 1981. B. Interlocks functional at end of test: Yes No C. Monitor function test at end of cycling: Passed Failed 0. Condition of monitor switch at end of test: Normal Other If "Other", speci fy €. Instrumencation 1. Line Voltage Monitor - The instrument listed below was used throughout the encire enaurance testing unless otherwise noted. Manufacturer Model # Serial @ Microwave Survey Instrument - The following instruzents were used for the measurement cf microwave energy for the indicated 10,000 cycle cks: 10.00 Meter Mate Prove Calibration i Cyeie Check Manufacturer ModeT seri & Factor i 4 oiosursie sia TEauaTe Fore PSTHICRONAYE OVEN Endurance Test Continuation Sheet Nunber of Cycles Completed Analyst; Date | Transforner Door Operation* “*Cyeration Coder 1-Datly Check, 2- 10,000 Cycle Check, 3- Repair, &- Other (Specify) PAGE___oF.APPENDIX 8 TEST PROCEDURES FOR MEASUREMENT OF MICROWAVE ENERGY LEAKAGE FROM MICROWAVE OVENS. AAPPENDIX 8 TEST PROCEDURES FOR MEASUREMENT OF MICROWAVE ENERGY LEAKAGE FROM MICROWAVE OVENS Purpose To obtain the microwave radi 1 characteristics of a microwave oven in order to devermine whether the oven is in compliance with the requirements of 21 CFR 1030.10. Apparatus A, Microwave Survey Meter The microwave survey meter shall comply with the requirements of 21 CFR 1030.10(c}(3I( 1). The instrument shall reach 90% of its steady-state reading hin 3 seconds when it is subjected to a stepped input signal. The instrument shall have a radiation detector with an effective aperture of 25 cm* or less as measured in @ plane wave, said aperture having no dimension exceeding 10 cm. This aperture shall be determined at the fundamental frequency of the oven. The instrument shall be capable of measuring the power density limits of 21 CFR 1030.10 with an accuracy of plus 25% and minus 20% (plus or minus 1 decibel). Examples of instruments which fulfill tnese requirements are the Narda modal 8110 modified such that when the Response Switch is in’ the Slow position, reaches 90% of the steady-state value in approximately 3 seconds; and the Holaday mode! 1501, Ling Voltage Meter The instrument shall measure tne AC line voltage within + 1% of the reading. q_Procedu for Microwave Leakage Obtain 2 standard 600 mi glass deaker having an inside diameter of approximately 8.5 cm filled with -81-tap water to a level of 275 + 15 ml, the water being at a temperature of 20°C + 5°. Place the beaker in the center of the load carrying surface of the oven. If there is an adjustable shelf, place it so that the center of the water volume is as near the center of the cavity as possible. Set the microwave survey instrument up to measure 2,450 MHz signals. If the oven operates at any other frequency, consult Supervisor. Select the appropriate range on the meter. Turn on and zero the meter. Re-zero the meter any time the range is changed. Check the battery and probe with their respective "Test" switches. Check to fake sure that movement of the probe cable will not cause errat readings on the meter. If the power output of the oven is adjustable (Hi-Low Power Switch or multiple magnetrons), set the oven controls so that the maximum microwave power output is obtained. Close the oven door normally and activate any latching mechanisms. Turn the oven on, setting the timer for sufficient operating time to complete the survey. Set the line voltage with a Variac to the rated line voltage. Should the water load begin to boil during the leakage survey, it shal! be replaced witn water at the specified initial temperature before continuing with the survey. Survey the oven using the microwave survey meter in the following manner: 1. Set the response switch to the fast position. At alf times the probe shal! be held in such a manner as to be perpendicular to the surface being surveyed. The probe shall be held only by the handle portion of the probe. Survey around the door seal and note locations of all nigh leakage points. The maximum probe survey speed shall not exceed one inch per second. At several locations in the vicinity of each high leakage point, hold the probe stationary until a steady state value is reached on the microwave survey meter, Observe the maxinun leakage at each location. e304]Set the Response Switch to the Slow position; remeasure the leakage at tho point of maximum leakage located in step G.4. above. Record the value and location of the maximum leakage measurement with the meter response on Slow.APPENDIX C SURFACE AND LOCATION IDENTIFICATION~ —y 6 APPENDIX ¢ SURFACE AND LOCATION IDENTIFICATION SURFACE IDENTIFICATION If leakage is less than 1.0 mi/cm? everywhere, use surface - A designation. Tf leakage occurs around the door, use the surface - 0 designation. D ieee Door t Top E L nL) Back | Left | Front | Right End 8 Bottom 1-2-3 1 i a 6 1 I 7—8--9 __ Visio srs