Sharp R-402FW Service Manual Download Page 9

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R-402FW
R-404FK

Figure O-2 Oven Schematic - Cooking Condition

Figure O-1 Oven Schematic - Off Condition

SCHEMATIC

NOTE: CONDITION OF OVEN

1. Door Closed

2. CLOCK APPEARS ON DISPLAY

SCHEMATIC

3. VARIABLE COOKING CONTROL "HIGH"

2. COOKING TIME PROGRAMMED

1. DOOR CLOSED

NOTE: CONDITION OF OVEN

4. "START" PAD TOUCHED

Note:* Indicates component

CAVITY

TEMPERATURE

FUSE

120VAC

60Hz

COM.

RED

WHT

BRN

WHT

ORG

RED

WHT

GRN

N.O.

CONTROL UNIT

C/T

FUSE

N.O.

(RY2)

COM.

DOOR

SENSING

SWITCH

TTM

TURN

TABLE

MOTOR

FAN

MOTOR

OVEN

LAMP

MONITOR

SWITCH

PRIMARY

INTERLOCK

SWITCH

POWER

TRANSFORMER

MAGNETRON

HIGH

VOLTAGE

CAPACITOR

ORG

WHT

SECONDARY

INTERLOCK

RELAY

ORG

BRN

ORG

RED

GRY

GND

WHT

SENSOR

(RY1)

OVEN

LAMP

RELAY

COM.

N.O.

HUMIDITY

COM.

N.C.

HIGH

VOLTAGE

RECTIFIER

ORG

CAVITY

TEMPERATURE

FUSE

120VAC

60Hz

COM.

RED

WHT

BRN

WHT

ORG

RED

WHT

GRN

N.O.

CONTROL UNIT

N.O.

(RY2)

COM.

DOOR

SENSING

SWITCH

TTM

TURN

TABLE

MOTOR

FAN

MOTOR

OVEN

LAMP

MONITOR

SWITCH

PRIMARY

INTERLOCK

SWITCH

POWER

TRANSFORMER

MAGNETRON

HIGH

VOLTAGE

CAPACITOR

ORG

WHT

SECONDARY

INTERLOCK

RELAY

ORG

BRN

ORG

RED

GRY

GND

WHT

SENSOR

(RY1)

OVEN

LAMP

RELAY

COM.

N.O.

HUMIDITY

COM.

N.C.

HIGH

VOLTAGE

RECTIFIER

ORG

C/T

FUSE

RED

Summary of Contents for R-402FW

Page 1: ...IBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY INSIDE FRONT COVER BEFORE SERVICING INSIDE FRONT COVER WARNING TO SERVICE PERSONNEL 1 MICROWAVE MEASUREMENT PROCEDURE 2 FOREWORD AND WARNING 3 PRODUCT SPECIFICATIONS 4 GENERAL INFORMATION 4 OPERATION 6 TROUBLESHOOTING GUIDE 9 TEST PROCEDURE 10 TOUCH CONTROL PANEL 18 COMPONENTREPLACEMENTANDADJUSTMENTPROCEDURE 23 PICTORIALDIAGRAM 30 POWERUNITCIRCUIT 31 CPU...

Page 2: ...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 BEFORE SERVICING Before servicing an operative unit perform a microwave emission check as per the Microwav...

Page 3: ...pacitor 4 Disconnect the leads to the primary of the power transformer 5 Ensure that the leads remain isolated from other components and oven chassis by using insulation tape 6 After that procedure reconnect the power supply cord When the testing is completed 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Reconne...

Page 4: ... of the oven cavity The water container shall be a low form of 600 ml 20 oz beaker with an inside diameter of approx 8 5 cm 3 1 2 in and made of an electrically nonconductive material such as glass or plastic The placing of this standard load in the oven is important not only to protect the oven but also to insure that any leakage is measured accurately 4 Set the cooking control on Full Power Cook...

Page 5: ...The door is not deformed or warped E There is no other visible damage with the oven Servicing and repair work must be carried out only by trained service personnel DANGER Certain initial parts are intentionally not grounded and present a risk of electrical shock only during servicing Service person nel Do not contact the following parts while the appliance is energized High Voltage Capacitor Power...

Page 6: ...FICATION ITEM DESCRIPTION PowerRequirements 120 Volts 14 0 Amperes 1600 watts R 402FW 13 0 Amperes 1550 watts R 404FK 60 Hertz Single phase 3 wire grounded PowerOutput 1100 watts IEC 705 TEST PROCEDURE R 402FW 1000 watts IEC 705 TEST PROCEDURE R 404FK Operating frequency of 2450MHz CaseDimensions Width 21 21 32 Height 12 3 8 Depth 18 7 16 Cooking Cavity Dimensions Width 15 23 32 1 6 Cubic Feet Hei...

Page 7: ...oven will not operate unless the door is securely closed 3 Removable turntable support 4 Removable turntable The turntable will rotate clockwise or counterclockwise 5 Oven lamp It will light when oven is operating or door is opened 6 Oven door with see through window 7 Ventilation openings Rear 8 Auto Touch control panel 9 Time display Digital display 99 minutes 99 seconds 10 Wave guide cover 11 P...

Page 8: ...turntable motor the cooling fan motor and the high voltage componentsarede energized theovenlampremainson andthedigitalread outdisplaysthetimestillremainingin the cook cycle when the door was opened 7 The monitor switch electrically monitors the operation of theprimaryinterlockswitchandsecondaryinterlockrelay andismechanicallyassociatedwiththedoorsothatitwill function in the following sequence 1 W...

Page 9: ... OVEN LAMP MONITOR SWITCH PRIMARY INTERLOCK SWITCH POWER TRANSFORMER MAGNETRON HIGH VOLTAGE CAPACITOR ORG WHT SECONDARY INTERLOCK RELAY ORG BRN ORG ORG RED RED GRY GRY GND WHT F3 F2 F1 SENSOR RY1 OVEN LAMP RELAY COM N O HUMIDITY COM N C HIGH VOLTAGE RECTIFIER ORG CAVITY TEMPERATURE FUSE 120VAC 60Hz COM RED RED WHT WHT WHT WHT BRN WHT WHT WHT ORG RED WHT WHT GRN N O B2 B1 CONTROL UNIT N O RY2 COM D...

Page 10: ...o open the C T fuse blows simultaneously with closing of the monitor switch contacts CAUTION BEFORE REPLACING A BLOWN C T FUSE TEST THE DOOR SENSING SWITCH SEC ONDARY INTERLOCK RELAY RY2 RELAY RY1 PRIMARY INTERLOCK SWITCH AND MONITOR SWITCH FOR PROPER OPERA TION REFER TO CHAPTER TEST PROCE DURE NOTE C T FUSE AND MONITOR SWITCH ARE REPLACED AS AN ASSEMBLY TURNTABLE MOTOR The turntable motor rotates...

Page 11: ...bly IMPORTANT Whenever troubleshooting is performed with the power supply cord disconnected It may in some cases be necessary to connect the power supply cord after the outer case has been removed in this event 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Disconnect the leads to the primary of the power transfo...

Page 12: ...START pad is touched Oven seems to be operating but little or no heat is produced in oven load Food incompletely cooked or not cooked at all at end of cook cycle Oven goes into a cook cycle but extremely uneven heating is pro duced in oven load food Oven does not cook properly when programmed for Cooking Power P 50 mode Operates properly on Cooking P HI HIGH mode Oven goes into COMPU DEFROST but f...

Page 13: ...TREME CAUTION SHOULD BE OBSERVED Power output of the magnetron can be measured by performing a water temperature rise test This test shouldonlybeusedifabovetestsdonotindicateafaultymagnetronandthereisnodefectinthefollowing componentsorwiring siliconrectifier highvoltagecapacitorandpowertransformer Thistestwillrequire a 16 ounce 453cc measuring cup and an accurate mercury thermometer or thermocoupl...

Page 14: ...ow through the vent holes of the oven cavity especially the cooling fan and air guide 5 Reconnect all leads removed from components during testing 6 Reinstall the outer case cabinet 7 Reconnect the power supply cord after the outer case is installed 8 Run the oven and check all functions C T FUSE TEST 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3...

Page 15: ...nd the door is closed the cooling fan turntable and oven light will be activated by RY1 SECONDARYINTERLOCKRELAY RY2 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Disconnecttwo 2 wireleadsfromthemaletabterminalsoftheSecondaryInterlockRelay Checkthe state of the relay contacts using a ohmmeter The relay contacts s...

Page 16: ... touching the pads a certain pad produces no signal at all b When touching a number pad two figures or more are displayed c When touching the pads sometimes a pad produces no signal If the Key unit is defective I TOUCH CONTROL PANEL ASSEMBLY TEST 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Before performing th...

Page 17: ...ck does not operate properly c Cooking is not possible When testing is completed 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Reconnect all leads removed from components during testing 5 Re install the outer case cabinet 6 Reconnect the power supply cord after the outer case is installed 7 Run the oven and chec...

Page 18: ...minal of the relay RY1 and the normal open terminal of the relay RY2 on the control unit with an A C voltmeter The meter should indicate 120 volts if not check oven circuit RY1 and RY2 Relay Test These relays are operated by D C voltage Check voltage at the relay coil with a D C voltmeter during the microwave cooking operation DC voltage indicated Defective relay DC voltage not indicated Check dio...

Page 19: ...led 9 Run the oven and check all functions 2 Followthetroubleshootingguidegivenbelow ifindicatordoesnotlightupafterabovecheckandrepairs are finished 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Disconnect the leads to the primary of the power transformer 5 Ensure that these leads remain isolated from other comp...

Page 20: ...witch to tell the LSI if the door is open or closed 8 Back Light Circuit A circuit to drive the back light Light emitting diodes LD1 LD4 TOUCHCONTROLPANELASSEMBLY OUTLINEOFTOUCHCONTROLPANEL The touch control section consists of the following units 1 Key Unit 2 Control Unit The Control Unit consists of Power Unit and LSI Unit The principal functions of these units and the signals communicated among...

Page 21: ...6 P52 OUT Magnetron high voltage circuit driving signal To turn on and off the cook relay RY2 The signals holds L level during microwave cooking and H level while not cooking In other cooking modes variable cooking the signal turns to H level and L level in repetition according to the power level 17 18 P51 P50 OUT Terminal not used 19 P47 IN Signal coming from touch key When either G12 line on key...

Page 22: ...UT Key strobe signal Signal applied to touch key section A pulse signal is input to P41 P45 P47 and P70 terminal while one of G5 line keys on key matrix is touched 37 P23 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P41 P45 P47 and P70 terminal while one of G4 line keys on key matrix is touched 38 P22 OUT Key strobe signal Signal applied to touch key section...

Page 23: ...Connected to VC 76 COM3 OUT Terminal not used 77 COM2 OUT Common data signal Connected to LCD signal COM3 78 COM1 OUT Common data signal Connected to LCD signal COM2 79 COM0 OUT Common data signal Connected to LCD signal COM1 80 VL3 IN Power source voltage input terminal Standard voltage for LCD ...

Page 24: ...ch control panel and the oven itself is so short that the two can t be separated For those models check and repair all the controls sensor related ones included of the touch control panel while keeping it connected to the oven B On some models the power supply cord between the touch control panel and the oven proper is long enough that they may be separated from each other For those models it is p...

Page 25: ... power supply cord 2 Make sure that a definite click can be heard when the microwave oven door is unlatched Hold the door in a closed position with one hand then push the door open button with the other this causes the latch leads to rise it is then possible to hear a click as the door switches operate 3 Visuallycheckthedoorandcavityfaceplatefordamage dents cracks signs of arcing etc Carry out any...

Page 26: ...ead short one of the power transformer from the high voltage capacitor 7 Remove one 1 screw holding capacitor holder with the high voltage rectifier to the base plate 8 Disconnect rectifier terminal from capacitor High voltage rectifier assembly is now free 9 Remove capacitor holder Capacitor is now free CAUTION WHEN REPLACING HIGH VOLTAGE RECTI FIER AND HIGH VOLTAGE CAPACITOR GROUND SIDE TERMINAL...

Page 27: ...anel frame 3 Placethekeyunitfirmlytothecontrolpanelframe by rubbing with soft cloth not to scratch 1 Disconnect the power supply cord and remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Remove the oven lamp from the oven lamp socket 5 Pullthewireleadsfromtheovenlampsocketby pushing the terminal hole of the oven lamp socket with the small flat type screw dri...

Page 28: ...ch to the control panel frame by rubbing with a soft cloth not to scratch 7 Remove the backing paper from the new graphic sheet 8 Adjust the upper edge and right edge of the graphic sheet to the large depression on the surface of the control panel frame 9 Attach the graphic sheet to the control panel frame by rubbing with a soft cloth not to scratch 10 Attach the ribbon cable to the control panel ...

Page 29: ...ket which supports the shaft of the fan motor on the flat table 3 Apply the screw lock tight into the hole for shaft of the fan blade 4 Install the fan blade to the shaft of fan motor by pushing thefanbladewithasmall lightweight ballpeenhammer or rubber mallet CAUTION Do not hit the fan blade strongly when installed because the bracket may be disfigured Make sure that the fan blade rotates smooth ...

Page 30: ...n screw and adjust the latch hook position After adjustment check the following 1 In and out play of door remains less than 0 5mm when in the latched position First check upper position of latch hook pushing and pulling upper portion of door toward the oven face Then check lower portion of the latch Figure C 3 Latch Switch Adjustments hook pushing and pulling upper portion of door toward the oven ...

Page 31: ... to assure compliance with proper microwave radiation emission limitation standards After any service make sure of the following 1 Door latch heads smoothly catch latch hook through latch holes and that latch head goes through center of latch hole 2 Deviation of door alignment from horizontal line of cavity face plate is to be less than 1 0mm 3 Doorispositionedwithitsfacepressedtowardcavityface pl...

Page 32: ...d to the terminal with blue mark on the oven light socket POWER TRANSFORMER COM NO NOTE The neutral WHT GRY wire must be connected to the terminal with N mark on the power supply cord RED WHT BRN RED WHT WHT ORG WHT RED RED PNK GRN GRN to Oven cavity WHT WHT WHT WHT BLUE MARK RED WHT CAVITY TEMP FUSE FAN MOTOR C T FUSE RED RED WHT GRY WHT GRN ORG ORG RY2 RY1 SECONDARY INTERLOCK RELAY T1 1 2 POWER ...

Page 33: ...15 40 16 39 17 38 18 37 19 36 20 35 21 34 22 33 23 32 24 31 25 30 26 29 27 28 B1 COM N O COM B2 N O VRS1 J1 10G471K C1 0 1µ 50v C2 1000µ 25v C21 10µ 35v AC OVEN LAMP TURNTABLE MOTOR FAN MOTOR AC H MICRO DOOR SENSING SWITCH C3 220µ 10v ZD1 HZ4C3 J11 D21 1SS270A SP1 KEY UNIT LSI UNIT D22 1SS270A J10 a c RY1 RY2 D20 1SS270A D40 1SS270A d 1 3 D3 D4 D1 LD1 LD4 LD3 LD2 D2 R1 560 1 2W Q21 KRC243M 2 4 T1 ...

Page 34: ...10 S E G11 S E G12 S E G13 S E G14 S E G15 S E G16 S E G17 S E G18 S E G19 S E G20 S E G21 S E G22 COM3 COM2 C0M1 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 S TOP CLE AR 53 52 51 50 41 R E S E T LE D GND VC INT AN7 AN6 AN5 AN4 BUZZE R VR MICR O D20 OVE N LAMP FAN MOTOR TUR NTABLE MOTOR DOOR S E NS ING S WITCH NOTE IF NOT S PCIFIE D 1 16W 5 C 4 0 1µ 50v C 11 0 01µ 25v C...

Page 35: ...Printed Wiring Board of Power Unit M R F B 0 3 7 M C R M 2 7 A 9 4 V 0 R 1 1 WH 1 WH 1 LOT BFB QKITPB037MRE0 DIP NO LD4 LD3 LD2 LD1 2 2 D40 D20 1 2 CN B ZD1 R1 C2 C21 D21 Q21 JP3 JP5 JP4 T1 VRS1 2 3 4 1 P S C3 D1 D3 D4 D2 B E J17 J15 J13 J11 J16 J14 J12 J10 JP1 JP2 D22 RY1 RY2 J1 SP1 C1 ...

Page 36: ... C1 RC KZA087DRE0 J Capacitor 0 1 uF 50V 1 AA C2 VCEA0A1EW108M M Capacitor 1000 uF 25V 1 AB C3 VCEA0A1AW227M M Capacitor 220 uF 10V 1 C21 VCEAB31VW106M J Capacitor 10 uF 35V 1 AA D1 4 RH DZA006PRE0 J Diode 1N4002 4 AD D20 22 VHD1SS270A 1 J Diode 1SS270A 3 AA D40 VHD1SS270A 1 J Diode 1SS270A 1 AA LD1 4 RH PXA002DRZZ M Light emitting diode 4 Q21 VSKRC243M 3 J Transistor KRC243M 1 AB R1 VRD B12HF561J...

Page 37: ...MRE0 M Door screen R 404FK 1 AK 5 7 GCOVHB042MRF0 M Choke cover 1 AG MISCELLANEOUS 6 1 FW VZB125MRE0 M Stop switch harness 1 AF 6 2 FW VZB192MRE0 M Main wire harnes 1 AU 6 3 TLABBB007MRE0 M Cavity hole cover 1 AA 6 4 FROLPB025MRK0 M Turntable support 1 AN 6 5 NTNT A108WRE0 M Turntable tray 1 AN 6 6 TCAUAB045MRR0 M Monitor caution label 1 AA 6 7 TCAUAB038MRR0 M DHHS Screw caution label 1 AB 6 8 TIN...

Page 38: ...B C D E F G H OVEN AND CABINET PARTS 2 3 4 7 6 7 1 5 4 6 4 8 4 9 6 3 6 5 6 4 2 1 7 5 1 11 4 10 7 2 7 2 7 4 4 3 1 12 1 9 7 3 7 6 7 5 1 8 7 7 4 2 7 4 1 10 1 3 1 4 7 1 1 7 1 7 4 4 7 1 4 1 1 1 1 2 2 2 2 2 2 2 2 2 7 4 7 4 7 4 6 6 1 6 4 5 1 13 7 8 7 6 7 8 7 6 1 6 4 11 ...

Page 39: ... 4 5 1 2 3 6 4 5 1 2 3 A B C D E F G H A B C D E F G H Actual wire harness may be different from illustration 6 9 6 2 6 1 3 2 3 2 1 3 5 3 3 3 4 3 2 3 3 2 2 3 1 3 6 5 1 5 3 5 2 5 5 5 7 5 6 5 4 DOOR PARTS CONTROL PANEL PARTS ...

Page 40: ... ACCESSORIES DOOR PROTECTION SHEET PLASTIC BAG PACKING CASE TOP PAD ASSEMBLY INTO THE OVEN CAVITY 6 5 TURNTABLE TRAY 6 8 OPERATION MANUAL BOTTOM PAD ASSEMBLY TRAY HOLDER 6 4 TURNTABLE SUPPORT ON TOP OF THE OVEN Non replaceable items ...

Page 41: ...39 R 402FW R 404FK NOTES ...

Page 42: ...40 R 402FW R 404FK NOTES ...

Page 43: ...41 R 402FW R 404FK NOTES ...

Page 44: ...002 BY SHARP CORPORATION ALL RIGHTS RESERVED No part of this publication may be repro duced stored in retrieval systems or trans mitted in any form or by any means elec tronic mechanical photocopying recording orotherwise withoutpriorwrittenpermission of the publisher ...

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