Sharp R-540DK Service Manual Download Page 10

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R - 5 4 0 D K
R -540DW

Figure O-1. Oven Schematic-Off Condition

SCHEMATIC

NOTE: CONDITION OF OVEN
1. DOOR CLOSED.
2. CLOCK APPEARS ON DISPLAY.

Figure O-2. Oven Schematic-Cooking Condition

120V AC
60 Hz

OVEN
LAMP

TURN-
TABLE
MOTOR

FAN
MOTOR

MONITOR
SWITCH

H.V. RECTIFIER

MAGNETRON

SECONDARY
INTERLOCK
SWITCH

TTM

MONITOR
FUSE 20A

CAVITY
TEMP.
FUSE

MAGNETRON
TEMP.
FUSE

COM.

N.O.

N.C.

N.O.

DOOR
SENSING
SWITCH

(RY-1)

(RY-2)

CONTROL UNIT

PRIMARY
INTERLOCK
RELAY

GRN

POWER
TRANSFORMER

CAPACITOR 1.0

AC 2300V

AH SENSOR

120V AC
60 Hz

OVEN
LAMP

TURN-
TABLE
MOTOR

FAN
MOTOR

MONITOR
SWITCH

H.V. RECTIFIER

MAGNETRON

SECONDARY
INTERLOCK
SWITCH

TTM

CAVITY
TEMP.
FUSE

COM.

N.O.

N.C.

N.O.

DOOR
SENSING
SWITCH

(RY-1)

(RY-2)

CONTROL UNIT

PRIMARY
INTERLOCK
RELAY

GRN

POWER
TRANSFORMER

CAPACITOR 1.0

AC 2300V

MONITOR
FUSE 20A

MAGNETRON
TEMP.
FUSE

NOTE: Indicates components with potential above 250 V.

SCHEMATIC

NOTE: CONDITION OF OVEN
1. DOOR CLOSED.
2. COOKING TIME PROGRAMMED.
3. VARIABLE COOKING CONTROL "POWER 100 %

PROGRAMMED".

4. "START" PAD TOUCHED.

Summary of Contents for R-540DK

Page 1: ...EL 1 MICROWAVE MEASUREMENT PROCEDURE 2 FOREWORD AND WARNING 3 PRODUCT SPECIFICATIONS 4 GENERAL INFORMATION 4 OPERATION 6 TROUBLESHOOTING GUIDE 10 TEST PROCEDURE 12 TOUCH CONTROL PANEL 21 COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE 29 PICTORIAL DIAGRAM 35 POWER UNIT CIRCUIT 36 LSI UNIT CIRCUIT 37 PRINTED WIRING BOARD 40 PARTS LIST 41 PACKING AND ACCESSORIES 43 S5010R540DUW R 540DK R 540DW MICROW...

Page 2: ...tion 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 Mic...

Page 3: ...acitor 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 Reconnec...

Page 4: ...f 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 Cookin...

Page 5: ...ing is not damaged 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 Certaininitialpartsareintentionallynotgroundedandpresent a risk of electrical shock only during servicing Service personnel Do not contact the following parts while the appliance is energized HighVoltageCapac...

Page 6: ...ven Cavity Light Yes Safety Standard UL Listed FCC Authorized DHHS Rules CFR Title 21 Chapter 1 Subchapter J SPECIFICATION GENERAL INFORMATION GROUNDING INSTRUCTIONS This oven is equipped with a three prong grounding plug It must be plugged into a wall receptacle that is properly installed and grounded in accordance with the National Electrical Code and local codes and ordinances In the event of a...

Page 7: ... operating or door is opened 6 Oven door with see through window 7 Ventilation openings Rear 8 Auto Touch control panel 9 Touch screen 10 Coupling 11 Wave guide cover 12 Power supply cord 3 Pronged Plug Grounded Receptacle Box Grounding Pin 3 Pronged Receptacle NOTE The directed features are disabled after three minutes when the oven is not in use These features are automatically enabled when the ...

Page 8: ...er oven lamp etc are turned off and the generation of microwave energy is stopped The oven will revert to the OFF condition 6 When the door is opened during a cook cycle the monitorswitch doorsensingswitch secondaryinterlock switch relay RY1 and primary interlock relay are activated with the following results The circuits to the turntable motor the cooling fan motor and the high voltage components...

Page 9: ...in the unit Wait two minutes before cooking on SENSOR 2 Thecoilofshut offrelay RY 1 isenergized theturntable motor oven lamp and cooling fan motor are turned on but the power transformer is not turned on 3 After about 16 seconds the cook relay RY 2 is energized The power transformer is turned on microwave energy is produced and first stage is started The 16 seconds is the cooling time required to ...

Page 10: ... PRIMARY INTERLOCK RELAY B1 B2 GRN POWER TRANSFORMER CAPACITOR 1 0µF AC 2300V F3 F1 F2 AH SENSOR 120V AC 60 Hz OVEN LAMP TURN TABLE MOTOR FAN MOTOR MONITOR SWITCH H V RECTIFIER MAGNETRON SECONDARY INTERLOCK SWITCH TTM OL FM CAVITY 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 MONITOR F...

Page 11: ...NITOR 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 during cookin...

Page 12: ...S 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 prima...

Page 13: ...sound and Home Page should appear in display Oven lamp does not light when door is opened Oven lamp does not go out when door is closed Oven lamp lights but fan motor and turntable motor do not operate Oven does not go into cook cycle when 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 cycl...

Page 14: ...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 thermocouple type...

Page 15: ...he 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 MAGNETRON TEMPERATURE FUSE TEST 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it ...

Page 16: ...ents 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 Isolatetheswitchandconnecttheohmmetertothecommon COM an...

Page 17: ...owave 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 Also the Control Unit is divided into two units LSI Unit and Power Unit Troubleshooting by unit replacement is described according to the symptoms indicated Before testing 1 Disconnect the power supply cord...

Page 18: ...f indicators do not light up g The figure of all digits flicker h The following symptoms indicate a defective LSI unit When touching the keys on the touch screen a certain key produces no signal at all When touching a number key on the touch screen two figures or more are displayed When touching the keys on the touch screen sometimes a key produces no signal 2 3 Other possible problems caused by d...

Page 19: ...erminal of the relay RY1 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 diode which is connected to the relay coil If d...

Page 20: ...up after above check and repairs 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 components and oven chassis by using insulation tape 6 After that procedure reconnect the power supply cord...

Page 21: ...cooking test WARNING The oven should be fully assembled before following procedure Make sure the oven has been plugged in at least two minutes before checking sensor cook operation The cabinet should be installed and screws tightened 1 Fill approximately 200 milliliters 7 2 oz of tap water in a 1000 milliliter measuring cup 2 Place the container on the center of tray in the oven cavity 3 Close the...

Page 22: ...h Reheat pad 9 2 The control panel is in the sensor cooking operation 9 3 After approximately 50 seconds push plunger of select switch for more than 3 seconds This condition is same as judgement by AH sensor 9 4 After approximately 3 seconds the display shows X X X X which is the remaining cooking time and the display counts down If the above is not the case the control unit is probably defective ...

Page 23: ... passed back to the LSI through PB1 PB2 PB3 PB4 and PB5 to perform the function that was requested 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 com municated among them are explained below Key Unit The key unit is composed of a matrix signals generated ...

Page 24: ...voltage to drive LSI is input to Vss terminal 14 TxD0 OUT Data signal is output to a memory IC IC4 15 P91 OUT Clock signal is output to a memory IC IC4 16 RxD0 OUT Terminal not used 17 P93 OUT Key strobe signal Signal applied to key unit section A pulse signal is input to PB1 PB5 terminal while one of G1 line keys on key matrix is touched 18 P94 OUT Key strobe signal Signal applied to key unit sec...

Page 25: ...5 59 Vss IN Power source voltage GND 0V The power source voltage to drive LSI is input to Vss terminal 60 WATT IN Connected to VCC 61 P61 OUT Envelope signal to sound buzzer A key touch sound short beep B Completion sound melody or long beep 62 P62 OUT Reset signal is output to IC5 63 P67 OUT Terminal not used 64 STBY IN Connected to VCC 65 RES IN Auto clear terminal Signal is input to reset the L...

Page 26: ...pen close information to LSI Door close H level signal 5V Door open L level signal GND 85 AN5 IN Used for initial balancing of the bridge circuit absolute humidity sensor This input is an analog input terminal from the AH sensor circuit and connected to the A D converter built into the LSI 86 AN6 IN AH sensor input This input is an analog input terminal from the AH sensor circuit and connected to ...

Page 27: ...rned on in such a way as to change the resistance values in parallel with R47 R52 Changing the resistance values results in that there is the same potential at both F 3 terminal of the absolute humidity sensor and AN5 terminal of the LSI The voltage of AN6 terminal will indicate about 2 5V This initial balancing is set up about 16 seconds after the unit is put in the SensorCookingmode Asthesensorc...

Page 28: ...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 poss...

Page 29: ...OR WIRING 1 Disconnect the 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 o...

Page 30: ... lead 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 TERMIN...

Page 31: ...l Push Pull down 1 2 Lever Positive lock connector 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 areas flat No sharp edges must be evident after removal of the turntable motor cover TURNTABLE MOTO...

Page 32: ...ct the power supply cord and remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Disconnect wire leads from the switches 5 Remove two 2 screws holding latch hook to oven flange 6 Remove latch hook assembly from oven flange 7 Pushoutwardonthetwo 2 retainingtabsholdingswitch in place 8 Switch is now free At this time switch lever will be free do not lose it Reins...

Page 33: ...efer to Microwave Measurement Procedure Figure C 3 Latch Switch Adjustments REMOVAL 1 Disconnect the power supply cord 2 Push the open button and open the door slightly 3 Insert a putty knife thickness of about 0 5mm into the gap between the choke cover and door frame as shown in Figure C 4 to free engaging parts 4 Pry the choke cover by inserting a putty knife as shown Figure C 4 5 Release choke ...

Page 34: ... microwave oven is designed to act as an electronic seal preventing the leakage of microwave energy from oven cavity during cook cycle Thisfunctiondoesnotrequirethatdoorbeair tight moisture condensation tight or light tight Therefore occasionalappearanceofmoisture light or sensing of gentle warm air movement around oven door is not abnormal and do not of themselves indicate a leakage of microwave ...

Page 35: ...ral WHT GRY wire must be connected to the terminal with N mark on the power supply cord RED WHT RED WHT WHT ORG WHT 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 GRN ORG ORG CN A H N NOTE The grounding conductor of the power supply cord has been grounded by power supply cord fixi...

Page 36: ...ZR MICRO N C N C AC MICRO OVEN LAMP FAN MOTOR TURNTABLE MOTOR OVEN LAMP FAN MOTOR TURNTABLE MOTOR DOOR SENSING SWITCH NOTE IF NOT SPECIFIED 0 1µF 50V DOOR SENSING SWITCH AC120V 60Hz CN A CN C 11P LEAD WIRE HARNESS SP30 RY1 GND RY2 a b c d D1 D1 S1NB10 R2 91 1w Q1 2SD1859 R3 91 1w ZD1 HZ 16 1 R1 VRS1 J1 10G471K 2 4k 1 4w C2 1000µ 35v C1 C 4 C11 C10 C 9 C 7 C 8 C 2 C 1 B 2 ...

Page 37: ...C9 C7 C8 C2 C1 C5 VR VA GND INT AH SENSOR BUZZER ENV BUZZER OVEN LAMP TURNTABLE MOTOR FAN MOTOR MICROR NC NC DOOR SENSING SWITCH CN C G 5 G 1 Set UP Pasta Grains Defrost 3 6 Frozen Food MINUTE PLUS START TOUCH SCREEN CPU UNIT KEY UNIT Popcorn Meat STOP CLEAR More from Your microwave Fish Seafood Reheat Beverage Center Vegetables Baked Potatoes Poultry G 2 G 3 G14 G 7 G 8 G 9 G10 G14 G6 G13 G12 G11...

Page 38: ...d of Power Unit 6 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 R3 CN C Q1 SH A GREEN E B R2 D20 RY3 XA VH QKITPB031MREO J1 VRS1 CN A R1 ZD1 C2 C1 VH CN B SH B SP30 D22 RY1 RY2 D21 T1 P S 7 1 3 5 D U D U D U O M O M O M DIP D1 11 1 1 1 2 2 1 2 ...

Page 39: ...A087DRE0 J Capacitor 0 1 uF 50V 1 AA C2 VCEAB31VW108M J Capacitor 1000 uF 35V 1 AF D1 RSRCDA013DRE0 J Diode bridge S1NB10 1 AG Q1 VS2SD1859 3 J Transistor 2SD1859R 1 AC R1 VRD B12EF242J J Resistor 2 4k ohm 1 4W 1 AA R2 3 VRS B13AA910J J Resistor 91 ohm 1W 2 AA RY1 2 RRLY A113DRE0 J Relay DU24D1 1P M R 2 AM SP1 RALM A014DRE0 J Buzzer PKM22EPT 1 AG T1 RTRNPA113DRE0 J Transformer 1 AT VRS1 RH VZA032D...

Page 40: ...1 AF 6 2 FW VZB168MRE0 M Main wire harness 1 AU 6 3 TLABBB007MRE0 M Cavity hole cover 1 AA 6 4 FROLPB025MRK0 M Turntable support 1 AN 6 5 NTNT A099WRE0 M Turntable tray 1 AT 6 6 TCAUAB037MRR0 M Monitor caution label 1 AA 6 7 TCAUAB038MRR0 M DHHS Screw caution label 1 AB 6 8 TINSEB224MRR0 M Operation manual 1 AF 6 9 QW QZB016MRE0 M High voltage wire A 1 AC SCREWS NUTS AND WASHERS 7 1 LX BZA041WRE0 ...

Page 41: ...ND CABINET PARTS 2 3 4 7 6 7 1 5 4 6 4 8 4 11 7 11 7 2 1 15 4 9 6 3 6 5 6 4 2 1 7 11 1 12 4 10 4 13 7 2 7 2 7 5 4 3 1 13 1 10 7 3 7 6 7 6 1 9 7 8 7 8 4 2 7 5 1 11 1 3 1 4 7 4 1 8 1 8 4 4 7 1 4 1 1 1 1 2 2 2 2 2 2 2 2 2 7 5 7 5 4 12 7 5 6 6 1 7 1 6 4 5 1 14 7 10 7 7 7 10 7 9 7 9 7 7 ...

Page 42: ...2 3 6 4 5 1 2 3 A B C D E F G H A B C D E F G H CONTROL PANEL PARTS MISCELLANEOUS DOOR PARTS 3 2 1 3 2 3 2 2 3 2 3 3 1 3 3 3 3 Actual wire harness may be different from illustration 6 9 6 2 5 1 5 1 2 5 1 1 5 3 5 4 5 5 5 2 5 6 6 1 ...

Page 43: ...PLASTIC BAG SSAKHB007MRE0 PACKING CASE SPAKCB285MRR3 R 540DK SPAKCB285MRR4 R 540DW TOP PAD ASSEMBLY FPADBB038MRE0 INTO THE OVEN CAVITY 6 5 TURNTABLE TRAY 6 4 TURNTABLE SUPPORT 6 8 OPERATION MANUAL TRAY PACK SPADPB042MRE0 BOTTOM PAD ASSEMBLY FPADBB039MRE0 TRAY HOLDER SPADFB051MRE0 ...

Page 44: ...000 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 record ing or otherwise without prior written per mission of the publisher ...

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