Sharp R-405KS-T Service Manual
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Sharp R-405KS-T Service Manual

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See also: Operating Manual
PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE EXPO-
SURE TO EXCESSIVE MICROWAVE ENERGY
CHAPTER 1. WARNING TO SERVICE PERSONNEL
CHAPTER 2. MICROWAVE MEASUREMENT PRO-
CEDURE
CHAPTER 3. FOREWORD AND WARNING
CHAPTER 4. PRODUCT DESCRIPTION
CHAPTER 5. GENERAL INFORMATION
CHAPTER 6. OPERATION
CHAPTER 7. TROUBLESHOOTING GUIDE

SHARP CORPORATION

SERVICE MANUAL
MODEL
NIGHT LIGHT
POPCORN
In the interest of user-safety the oven should be restored to its origi-
1
2
3
4
5
6
7
8
9
nal condition and only parts identical to those specified should be
0
TIMER
POWER
LEVEL
CLOCK
STOP
MINUTE
START
CLEAR
PLUS
used.
DEFROST
COOK
REHEAT
WARNING TO SERVICE PERSONNEL: Microwave ovens con-
SOFTEN
MELT
WARM
tain circuitry capable of producing very high voltage and cur-
rent, contact with following parts may result in a severe,
possibly fatal, electrical shock. (High Voltage Capacitor, High
Voltage Power Transformer, Magnetron, High Voltage Rectifier
Assembly, High Voltage Harness etc..)
CONTENTS
CHAPTER 8. TEST PROCEDURES
CHAPTER 9. TOUCH CONTROL PANEL ASSEMBLY
CHAPTER 10. PRECAUTIONS FOR USING LEAD-
FREE SOLDER
CHAPTER 11. COMPONENT REPLACEMENT AND
ADJUSTMENT PROCEDURE
CHAPTER 12. CIRCUIT DIAGRAMS
Parts List

MICROWAVE OVEN

R-405KS-T
This document has been published to be used
for after sales service only.
The contents are subject to change without notice.
R405KST

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  • Page 1: Microwave Oven

    R405KST SERVICE MANUAL MICROWAVE OVEN R-405KS-T MODEL NIGHT LIGHT POPCORN In the interest of user-safety the oven should be restored to its origi- nal condition and only parts identical to those specified should be TIMER POWER LEVEL CLOCK STOP MINUTE...

  • Page 2: Table Of Contents

    CONTENTS PRECAUTIONS TO BE OBSERVED BEFORE AND [10] Procedure I: NOISE FILTER TEST..... 8-4 DURING SERVICING TO AVOID POSSIBLE EXPO- [11] Procedure J: TOUCH CONTROL PANEL SURE TO EXCESSIVE MICROWAVE ENERGY ASSEMBLY TEST........8-4 [12] Procedure K: KEY UNIT TEST ....8-5 CHAPTER 1.

  • Page 3: Precautions To Be Observed Before And During Servicing To Avoid Possible Expo

    Before servicing an operative unit, perform a microwave emission check as per the Microwave Measurement Procedure outlined in this service manual. If microwave emissions level is in excess of the specified limit, contact SHARP ELECTRONICS CORPORATION immediately @1-800-237-4277. If the unit operates with the door open, service person should 1) tell the user not to operate the oven and 2) contact SHARP ELECTRONICS CORPORATION and Food and Drug Administration's Center for Devices and Radiological Health immediately.

  • Page 4: Before Servicing

    R405KST CHAPTER 1. R405KST WARNING TO SERVICE PERSONNEL Service Manual Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts may result in a severe, possibly fatal, electrical shock. (Example) High Voltage Capacitor, High Voltage Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc.. Read the Service Manual carefully and follow all instructions.

  • Page 5: Chapter 2. Microwave Measurement Pro

    R405KST CHAPTER 2. R405KST MICROWAVE MEASUREMENT PROCEDURE Service Manual [1] Requirements: 1. Microwave leakage limit (Power density limit): The power density of microwave radiation emitted by a microwave oven should not exceed 1mW/ at any point 5cm or more from the external surface of the oven, measured prior to acquisition by a purchaser, and thereafter (through the use- ful life of the oven), 5 mW/cm at any point 5cm or more from the external surface of the oven.

  • Page 6: Chapter 3. Foreword And Warning

    Service Manual [1] FOREWORD This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service Information for the SHARP MICROWAVE OVEN, R-405KS-T. It is recommended that service personnel carefully study the entire text of this manual so that they will be qualified to render satisfactory customer service.

  • Page 7: Chapter 4. Product Description

    R405KST CHAPTER 4. R405KST PRODUCT DESCRIPTION Service Manual [1] SPECIFICATIONS ITEM DESCRIPTION 120 Volts Power Requirements 60 Hertz Single phase, 3 wire grounded Power Consumption 1600W / Approx. 13.5 Amperes 1100 W nominal of RF microwave energy (IEC Test procedure) Power Output Operating frequency 2450 MHz Width 21-5/8"...

  • Page 8: Chapter 5. General Information

    R405KST CHAPTER 5. R405KST GENERAL INFORMATION Service Manual [1] 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 accor- dance with the National Electrical Code and local codes and ordinances. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current.
  • Page 9 R405KST 2. TOUCH CONTROL PANEL NIGHT LIGHT POPCORN TIMER POWER LEVEL CLOCK STOP MINUTE START PLUS CLEAR DEFROST COOK REHEAT SOFTEN MELT WARM NOTE: Some one-touch cooking features such as “MINUTE PLUS” are disabled after three minutes when the oven is not in use. These fea- tures are automatically enabled when the door is opened and closed or the STOP/ CLEAR pad is pressed.

  • Page 10: Chapter 6. Operation Description Of Operating Se- Quence

    R405KST CHAPTER 6. R405KST OPERATION Service Manual [1] DESCRIPTION OF OPERATING SEQUENCE The following is a description of component functions during oven operation. 1. OFF CONDITION 3. POWER LEVEL P-0 TO P-90 COOKING Closing the door activates the door sensing switch and primary inter- When Variable Cooking Power is programmed, the 120 volts A.C.

  • Page 11: Oven Schematic

    R405KST [2] OVEN SCHEMATIC 1. Off Condition SCHEMATIC NOTE: CONDITION OF OVEN 1. DOOR CLOSED 2. CLOCK APPEARS ON DISPLAY NOTE: " " indicates components with potentials above 250V DOOR SENSING SWITCH POWER TRANSFORMER (RY2) SECONDARY INTERLOCK RELAY 120VAC 60Hz CONTROL UNIT (RY1) HIGH...

  • Page 12: Description And Function Of Components

    R405KST [3] DESCRIPTION AND FUNCTION OF COMPONENTS 1. DOOR OPEN MECHANISM 4. TURNTABLE MOTOR The door is opened by pushing the open button on the control panel, The turntable motor rotates the turntable located on the bottom of the refer to the Figure D-1. When the open button is pushed, the open but- oven cavity, so that the foods on the turntable cook evenly during ton pushes up the switch lever, and then the switch lever pushes up cooking.

  • Page 13: Chapter 7. Troubleshooting Guide

    R405KST CHAPTER 7. R405KST TROUBLESHOOTING GUIDE Service Manual Never touch any part in the circuit with your hand or an uninsulated tool while the power supply is connected. When troubleshooting the microwave oven, it is helpful to follow the Sequence of Operation in performing the checks. Many of the possible causes of trouble will require that a specific test be performed.

  • Page 14: Procedure A: Magnetron Assembly Test

    R405KST CHAPTER 8. R405KST TEST PROCEDURES Service Manual [1] Procedure A: MAGNETRON 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. To test for an open filament, isolate the magnetron from the high voltage circuit. A continuity check across the magnetron filament leads should indicate less than 1 ohm.

  • Page 15: Procedure D: High Voltage Capacitor Test

    R405KST 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. NOTE: Be sure to use an ohmmeter that will supply a forward bias voltage of more than 6.3 volts. [4] Procedure D: HIGH VOLTAGE CAPACITOR TEST 1.

  • Page 16: Procedure F: Secondary Interlock System Test

    R405KST [7] Procedure F: SECONDARY INTERLOCK SYSTEM TEST 1. 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. Isolate the switch and connect the ohmmeter to the common (COM.) and normally open (NO) terminal of the switch. The meter should indicate an open circuit with the door open and a closed circuit with the door closed.

  • Page 17: Procedure H: Blown Monitor Fuse Test

    R405KST [9] Procedure H: BLOWN MONITOR 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. If the monitor fuse is blown when the door is opened, check the primary interlock switch, secondary interlock relay (RY2), relay (RY1) and monitor switch according to the “TEST PROCEDURE”...

  • Page 18: Procedure K: Key Unit Test

    R405KST 2. Control Unit. The following symptoms indicate a defective control unit. 1) In connection with pads. a) When touching the pads, a certain group of pads do not produce a signal. b) When touching the pads, no pads produce a signal. 2) In connection with indicators a) At a certain digit, all or some segments do not light up.

  • Page 19: Procedure M: Defrost Test

    R405KST 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.
  • Page 20 R405KST 5) Make a visual inspection of the varistor. Check for burned damage and examine the transformer with a tester for the presence of layer short-circuit (check the primary coil resistance which is approximately 563Ω±10%). If any abnormal condition is detected, replace the control unit.

  • Page 21: Chapter 9. Touch Control Panel Assem

    R405KST CHAPTER 9. R405KST TOUCH CONTROL PANEL ASSEMBLY Service Manual [1] OUTLINE OF TOUCH CONTROL PANEL 3) Power Source Circuit This circuit generates voltage necessary in the control unit from the The touch control section consists of the following units. AC line voltage.
  • Page 22 R405KST Pin No. Signal Description 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 H : GND while not cooking. In other cooking modes (variable Maximum output cooking) the signal turns to “H”...
  • Page 23 R405KST Pin No. Signal Description Segment data signal. Connected to LCD. The relation between signals are as follows: LSI signal (Pin No.) LCD (segment) LSI signal (Pin No.) LCD (segment) SEG 0 (72) ----------------- SEG 0 SEG 9 (63) ----------------- SEG 9 SEG 1 (71) ----------------- SEG 1 SEG 10(62) ----------------- SEG 10 56-72...

  • Page 24: Servicing For Touch Control Panel

    R405KST [3] SERVICING FOR TOUCH CONTROL PANEL 1. Precautions for Handling Electronic Components b) On some models, the power supply cord between the touch control panel and the oven proper is so long enough that This unit uses CMOS LSI in the integral part of the circuits. When han- they may be separated from each other.

  • Page 25: Chapter 10. Precautions For Using Lead-Free Solder

    R405KST CHAPTER 10. R405KST PRECAUTIONS FOR USING LEAD-FREE SOLDER Service Manual [1] Employing lead-free solder The “Main PWB” of this model employs lead-free solder. This is indicated by the “LF” symbol printed on the PWB and in the service manual. The suffix letter indicates the alloy type of the solder.

  • Page 26: Adjustment Procedure 1] Warnings

    1. Door does not close firmly. 4. If the outer case (cabinet) is not fitted. WARNING FOR WIRING To prevent an electric shock, take the following precau- 3) Sharp edge: tions. Bottom plate, Oven cavity, Waveguide flange, 1. Before wiring, Chassis support and other metallic plate.

  • Page 27: Outer Case Removal

    R405KST [2] OUTER CASE REMOVAL To remove the outer case, procedure as follows. NOTE: When replacing the outer case, the 2 special Torx screws must be reinstalled in the same locations. 1. Disconnect the power supply cord. 2. Open the oven door and block it open. 3.

  • Page 28: Oven Lamp Removal

    R405KST 3. Hold the chassis support to the oven cavity front plate and the mag- 5. Reinstall outer case and check that the oven is operating properly. netron with the two (2) screws. CAUTION: WHEN REPLACING MAGNETRON, BE SURE THE R.F. 4.

  • Page 29: Turntable Motor Removal

    4. Where the corners have been snipped off bend corner areas flat. 8. After replacement use the one (1) screw XOTS740P10000 to fit the No sharp edges must be evident after removal of the turntable turntable motor cover. motor cover.

  • Page 30: Door Sensing Switch/Primary Interlock Switch And Monitor Switch Removal

    R405KST Coil Shaft Groove joint pliers Shaft These are the positions Axis that should be pinched Stator with pliers. Stator Table Center of bracket Rotor Bracket Rotor Side View Rear View [12] DOOR SENSING SWITCH/PRIMARY INTERLOCK SWITCH AND MONITOR SWITCH REMOVAL 1.
  • Page 31 R405KST 3. Insert a putty knife (thickness of about 0.5mm) into the gap NOTE: After any service to the door; between the door stopper and the choke cover to free engaging 1) Make sure that door sensing switch and primary interlock parts as shown in Figure C-4.

  • Page 32: Chapter 12. Circuit Diagrams

    R405KST CHAPTER 12. R405KST CIRCUIT DIAGRAMS Service Manual [1] Pictorial Diagram (Figure S-1) Figure S-1. Pictorial Diagram 12 – 1...

  • Page 33: Control Panel Circuit (Figure S-2)

    R405KST [2] Control Panel Circuit (Figure S-2) Figure S-2. Control Panel Circuit 12 – 2...

  • Page 34: Printed Wiring Board (Figure S-3)

    R405KST [3] Printed Wiring Board (Figure S-3) Figure S-3. Printed Wiring Board 12 – 3...

  • Page 35: Parts List

    R405KST PARTS LIST MICROWAVE OVEN HOW TO ORDER REPLACEMENT PARTS To have your order filled promptly and correctly, please R-405KS-T MODEL furnish the following information. 1. MODEL NUMBER 2. REF. NO. 3. PART NO. Parts marked "*" may cause undue microwave exposure.
  • Page 36 R405KST [1] OVEN PARTS 7-10 7-10 4-13 4-11 1-10 4-15 7-10 4-12 7-10 1-11 4-10 1-12 4-14 1-13 7-10 7-10...
  • Page 37 R405KST PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK [1] OVEN PARTS ELECTRIC PARTS FPWBFA417WRKZ Noise filter assembly FPWBFA389WRKZ Noise filter assembly (Interchangeable) FFS-BA033WRKZ Monitor fuse 20A and monitor switch FFS-BA037WRKZ Monitor fuse 20A and monitor switch (Interchangeable) QFS-TA013WRE0 Temp. fuse 150C (Magnetron) QSW-MA085WRE0 Primary interlock switch/ door sensing switch QSW-MA147WRZZ...
  • Page 38 R405KST [2] DOOR AND CONTROL PANEL PARTS 5-3-1 5-3-2 3-1-2 3-1-4 3-1-1-1 3-1-1 3-1-3 3-1-5 3-1-1-2 Actual wire harness may be different from illustration. 3-1-6...
  • Page 39 R405KST PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK [2] DOOR AND CONTROL PANEL PARTS CONTROL PANEL PARTS DPNLCB972WRKZ Panel med assembly 3-1-1 FBTN-A158WRKZ Open button assembly 3-1-1-1 JBTN-B358WRFZ Open button 3-1-1-2 HDECQA299WRPZ Button decoration 3-1-2 HDECQA300WRPZ Panel decoration 3-1-3 MSPRCA157WREZ Open button spring 3-1-4...
  • Page 40 R405KST INDEX PRICE PART PRICE PART PARTS CODE PARTS CODE RANK MARK RANK RANK MARK RANK [ D ] [ P ] DPNLCB972WRKZ 2-3-1 PCOVPA311WRE0 1-4-7 DPWBFC531WRKZ 2-3-2 PCUSGA532WRP0 1-4-8 PCUSUA191WRP0 1-4-9 [ F ] PCUSUA410WRP0 1-4-11 FACCDA083WRE0 1-1-7 PCUSUA455WRP0 1-4-12 FACCDA085WREZ 1-1-7...
  • Page 41 COPYRIGHT © 2006 BY SHARP CORPORATION ALL RIGHTS RESERVED. © COPYRIGHT XXXX BYSHARP CORPORATION No part of this publication may be reproduced, stored in retrieval systems, or transmitted in anyform or by ALL RIGHTS RESERVED. any means, electronic, mechanical, photocopying, re- cording, or other wise, without prior written permission of the publisher.

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