Sharp R-415EW Service Manual Download Page 39

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R-415EW
R-515EK

PACKING AND ACCESSORIES

DOOR PROTECTION SHEET

PLASTIC BAG

PACKING CASE

TOP PAD ASSEMBLY

CAV

ITY

6-5 TURNTABLE TRAY

6-4 TURNTABLE SUPPORT

6-8 OPERATION MANUAL

TRAY PACK

BOTTOM PAD ASSEMBLY

TRAY HOLDER

None-Replaceable items

Summary of Contents for R-415EW

Page 1: ...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 COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE 22 PICTORIAL DIAGRAM 28 POWER UNIT CIRCUIT 29 C...

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: ...he center 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 P...

Page 5: ... D 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 Po...

Page 6: ... R 515EK 60 Hertz Single phase 3 wire grounded PowerOutput 1200 watts IEC 705 TEST PROCEDURE R 415EW R 515EK Operatingfrequencyof2450MHz CaseDimensions Width 21 21 32 R 415EW Width 24 R 515EK Height 12 3 8 R 415EW Height 13 3 8 R 515EK Depth 18 7 16 R 415EW Depth 19 1 8 R 515EK Cooking Cavity Dimensions Width 15 23 32 R 415EW 1 6 Cubic Feet R 415EW Height 9 21 32 R 415EW 2 0 Cubic Feet R 515EK Dep...

Page 7: ... 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 Power supply cord TOUCH CONTR...

Page 8: ... cooling fan motor and the high voltage components are de energized the oven lamp remains on and the digital read out displays the time still remaining in the cook cycle when the door was opened 7 The monitor switch electrically monitors the operation of the secondary interlock switch and primary interlock relayandismechanicallyassociatedwiththedoorsothat it will function in the following sequence...

Page 9: ... V RECTIFIER MAGNETRON SECONDARY INTERLOCK SWITCH TTM OL FM MONITOR FUSE 20A CAVITY TEMP FUSE MAGNETRON TEMP FUSE A1 A2 COM COM COM N O N C N O DOOR SENSING SWITCH RY 1 RY 2 CONTROL UNIT PRIMARY INTERLOCK RELAY B1 B2 GRN POWER TRANSFORMER CAPACITOR 1 0µF AC 2300V 120V AC 60 Hz OVEN LAMP TURN TABLE MOTOR FAN MOTOR MONITOR SWITCH H V RECTIFIER MAGNETRON SECONDARY INTERLOCK SWITCH TTM OL FM CAVITY TE...

Page 10: ...G A BLOWN MONITOR FUSE TEST THE DOOR SENSING SWITCH PRIMARY INTERLOCK RELAY RY2 RELAY RY1 SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH FOR PROPER OP ERATION REFERTOCHAPTER TESTPRO CEDURE NOTE MONITOR FUSE AND MONITOR SWITCH ARE REPLACED AS AN ASSEMBLY TURNTABLE MOTOR The turntable motor rotates the turntable located on the bottom of the oven cavity so that the foods on the turntable cook evenly d...

Page 11: ... BA016 KIT as an assembly 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 primar...

Page 12: ... 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 food is no...

Page 13: ...D 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 thermocouple type temperature tester For a...

Page 14: ...he 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 MAGNETRON TEMPERATURE FUSE 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 A c...

Page 15: ...terlock switch 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 PRIMARY INTERLOCK SYSTEM TEST DOOR SENSING SWITCH 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...

Page 16: ...rowave ovens proper maintenance cannot be performed with only a voltmeter and ohmmeter In this service manual the touch control panel assembly is divided into two units Control Unit and Key Unit and also the Control Unit is divided into two units LSI Unit and Power Unit and troubleshooting by unit replacement is described according to the symptoms indicated Before testing 1 Disconnect the power su...

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: ... 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 diode which is connected to the relay coil If diode is good control unit is defective RELAY SYMBOL OPERATIONAL VOLTAGE CONNECTED COMPONENTS RY1 Approx 11 8V D C Oven lamp Turntable motor Cooling fan motor RY2 Approx 10 7V D C Pow...

Page 19: ... case is installed 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 ...

Page 20: ...oltage Application VC 5V LSI IC1 4 Relay Circuit A circuit to drive the magnetron fan motor turntable motor and light the oven lamp 5 Buzzer Circuit The buzzer is responsive to signals from the LSI to emit audiblesounds keytouchsoundandcompletionsound 6 Synchronizing Signal Circuit The power source synchronizing signal is available in order to compose a basic standard time in the clock circuit It ...

Page 21: ... a corresponding signal will be input into P44 23 P43 IN Signal similar to P45 When either G10 line on key matrix is touched a corresponding signal will be input into P43 24 INT0 IN Signal synchronized with commercial power source frequency This is the basic timing for time processing of LSI 25 P41 IN Signal similar to P45 When either G9 line on key matrix is touched a corresponding signal will be...

Page 22: ...be signal Signal applied to touch key section A pulse signal is input to P41 P43 P44 and P45 terminal while one of G2 line keys on key matrix is touched 40 P20 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P41 P43 P44 and P45 terminal while one of G1 line keys on key matrix is touched 41 48 P17 P10 OUT Terminal not used 49 50 P07 P06 OUT Terminal not used 51 ...

Page 23: ... is equivalent to the oven door being closed Connect an external power source to the power input terminal of the touch control panel then it is possible to check and repair the controls of the touch control panel it is also possible to check the sensor related controls of the touch control panel by using the dummy resistor s 3 Servicing Tools Toolsrequiredtoservicethetouchcontrolpanelassembly 1 So...

Page 24: ... 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 25: ...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 26: ...h soft cloth not to scratch LSI UNIT NOTE Handle the LSI unit carefully so that there is no excessive force applied to the ribbon connection LSI unit 1 Disconnect the power supply cord 2 Removeturntableandturntablesupportfromovencavity 3 Lay the oven on it s backside Remove the turntable motor cover by snipping off the material in four corners 4 Where the corners have been snipped off bend corner ...

Page 27: ...he bracket 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 ...

Page 28: ...nt 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 face Both results play in the door should be less than 0 ...

Page 29: ...y meter should be used 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 Doorispositionedwithitsfacepres...

Page 30: ...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 RED WHT WHT ORG WHT RED BLK RED BLU PNK GRN GRN to Oven cavity WHT WHT RED BLK WHT WHT BLUE MARK WHT RED WHT CAVITY TEMP FUSE MAGNETRON TEMP FUSE FAN MOTOR MONITOR FUSE HOLDER RED RED WHT 1 WHT GRY WHT ORG GRN ORG ORG RY1 RY2 PRIMARY INTERLOCK RELAY CN A CN A...

Page 31: ...3 C 5 C 9 C 4 C 6 C 8 C 1 C 7 C 2 A 2 NO NO B 1 COM COM D1 S1NB10 T1 AC AC GND VR INT BUZZER MICRO BROWNER NC DOOR OVEN LAMP TURNTABLE MOTOR FAN MOTOR CN C 9PIN LEAD WIRE HARNESS OVEN LAMP TURNTABLE MOTOR FAN MOTOR MICRO DOOR SENSING SWITCH CN A RY1 RY2 a b c d J1 VRS1 SP1 PKM22EPT C1 2200µ 25v 10G471K B 2 CN B ...

Page 32: ...R1 82 R5 1k R6 15k R9 4 7k R8 4 7k R7 4 7k R10 15k R12 4 7k R41 15k R90 15k J17 4 7k J16 47k J15 4 7k J13 4 7k J11 4 7k 1 25 64 41 1 24 25 40 65 80 J14 J12 J10 12k Q1 2SA1037AK IC1 IXA096DR Q30 DTA143EKA Q20 DTA143EKA Q22 DTA123JKA D40 MA152WA Q21 DTD143EKA Q10 DTA143EKA Q2 2SA1037AK LD1 LD2 LD3 LD4 R4 560 1 2w VR INT BUZZER OVEN LAMP TURNTABLE MOTOR FAN MOTOR NC BROWNER MICRO NOTE IF NOT SPECIFIE...

Page 33: ...R1 82 R5 1k R6 15k R9 4 7k R8 4 7k R7 4 7k R10 15k R12 4 7k R41 15k R90 15k J17 4 7k J16 47k J15 4 7k J13 4 7k J11 4 7k 1 25 64 41 1 24 25 40 65 80 J14 J12 J10 12k Q1 2SA1037AK IC1 IXA096DR Q30 DTA143EKA Q20 DTA143EKA Q22 DTA123JKA D40 MA152WA Q21 DTD143EKA Q10 DTA143EKA Q2 2SA1037AK LD1 LD2 LD3 LD4 R4 560 1 2w VR INT BUZZER OVEN LAMP TURNTABLE MOTOR FAN MOTOR NC BROWNER MICRO NOTE IF NOT SPECIFIE...

Page 34: ... 2 3 6 4 5 1 2 3 A B C D E F G H A B C D E F G H Figure S 5 Printed Wiring Board of Power Unit FB034MR KPC M PP CN C QKITPB034MRE0 1 CN A AC 2 1 9 4 3 VRS1 SP1 D1 AC RY1 RY2 DU OM 1 7 P J1 T1 DIP DU OM 1 2 S MICRO CN B OL TTM FM ...

Page 35: ...B 3 1B QCNCMA275DRE0 J 2 pin connector CN B 1 AB 3 1C FW VZB169MRE0 M 9Pin wire harness CN C 1 AM C1 RC EZA333DRE0 J Capacitor 2200 uF 25V 1 AE D1 RSRCDA013DRE0 J Diode bridge S1NB10 1 AG RY1 2 RRLY A114DRE0 J Relay DU12D1 1PR M 2 AN SP1 RALM A014DRE0 J Buzzer PKM22EPT 1 AG T1 RTRNPB013MRE0 M Transformer 1 AK T1 RTRNPA110DRE0 J Transformer Interchangeable 1 AP VRS1 RH VZB002MRE0 M Varistor 470ND 1...

Page 36: ...topper 1 AK 5 8 PGLSPB027MRE0 M Door glass R 415EW 1 AQ 5 8 PGLSPB024MRE0 M Door glass R 515EK 1 AQ 5 9 XEPSD30P06XS0 M Door screw 1 AA 5 10 HDECQB029MRF0 M Door trim R 415EW 1 AE MISCELLANEOUS 6 1 FW VZB125MRE0 M Stop switch harness 1 AF 6 2 FW VZB168MRE0 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 A095WRE0 M Turntable tra...

Page 37: ... 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 12 4 10 7 2 7 2 7 4 4 3 1 13 1 10 7 3 7 5 7 5 1 9 7 7 7 7 4 2 7 4 1 11 1 3 1 4 7 1 1 8 1 8 4 4 7 1 4 1 1 1 1 2 2 2 2 2 2 2 2 2 7 4 7 4 4 11 7 4 6 6 1 7 1 6 4 5 1 14 7 8 7 6 7 8 7 6 7 9 7 9 4 12 ...

Page 38: ... C D E F G H CONTROL PANEL PARTS DOOR PARTS Actual wire harness may be different from illustration 6 9 6 2 6 1 5 5 5 6 5 4 5 7 5 2 5 9 5 1 5 3 5 8 3 4 3 3 3 7 3 8 3 9 3 9 3 9 3 1 3 2 3 6 3 5 5 5 5 6 5 4 5 7 5 2 5 9 5 1 5 3 5 8 R 415EW R 515EK R 415EW R 515EK 5 10 ...

Page 39: ... AND ACCESSORIES DOOR PROTECTION SHEET PLASTIC BAG PACKING CASE TOP PAD ASSEMBLY INTO THE OVEN CAVITY 6 5 TURNTABLE TRAY 6 4 TURNTABLE SUPPORT 6 8 OPERATION MANUAL TRAY PACK BOTTOM PAD ASSEMBLY TRAY HOLDER None Replaceable items ...

Page 40: ...001 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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