Sharp R-540DK Service Manual

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Operation manual (41 pages)

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PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO

AVOID POSSIBLE 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 ............................................................................................................................ 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

SHARP CORPORATION

SERVICE MANUAL

MODELS

12 : 30 PM

Minute

Kitchen

Plus +

Timer

T O U C H . S C R E E N

MINUTE

STOP

PLUS

START

CLEAR

ONE TOUCH SENSOR

Reheat

Baked

Popcorn

Potatoes

6x6 NO GUESS COOKING

6 Categories + 36 Foods

Vegetables

Meat

Poultry

Fish/

Frozen

Pasta

Seafood

Food

Grains

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Summary of Contents for Sharp R-540DK

Page 1: Table Of Contents
LSI UNIT CIRCUIT ............................... 37 PRINTED WIRING BOARD ..........................40 PARTS LIST ................................ 41 PACKING AND ACCESSORIES ......................... 43 This document has been published to be used for after SHARP CORPORATION sales service only. The contents are subject to change without notice.
Page 2: Precautions To Be Observed Before And During Servicing To Avoid Possible Exposure To Excessive Microwave Energy
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 3: Warning To Service Personnel
R -540DK R-540DW WARNING TO SERVICE PERSONNEL Microwave ovens contain circuitry capable of pro- ducing 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 Trans- former, Magnetron, High Voltage Rectifier Assem- bly, High Voltage Harness etc..
Page 4: Microwave Measurement Procedure
R - 5 4 0 D K R -540DW MICROWAVE MEASUREMENT PROCEDURE A. Requirements: 1) Microwave leakage limit (Power density limit): The power density of microwave radiation emitted by a microwave oven should not exceed 1mW/cm at any point 5cm or more from the external surface of the oven, measured prior to acquisition by a purchaser, and thereafter (through the useful life of the oven), 5 mW/cm at any point 5cm or more from the external surface of the oven.
Page 5 MICROWAVE OVEN R-540DK/R-540DW GENERAL INFORMATION FOREWORD This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service Information for the SHARP MICROWAVE OVEN, R-540DK, R-540DW. OPERATION 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 6: General Information
R - 5 4 0 D K R -540DW SPECIFICATION ITEM DESCRIPTION Power Requirements 120 Volts / 13.8 Amperes 60 Hertz Single phase, 3 wire grounded Power Output 1200 watts (IEC TEST PROCEDURE) Operating frequency of 2450MHz Case Dimensions Width 24"...
Page 7 R -540DK R-540DW grounding adapter properly grounded and polarized. If the extension Grounded Receptacle Box cord must be used, it should be a 3-wire, 15 amp. or higher rated cord. Do not drape over a countertop or table where it can be pulled on by children or tripped over accidentally.
Page 8: Operation
R - 5 4 0 D K R -540DW OPERATION DESCRIPTION OF OPERATING SEQUENCE The following is a description of component functions during box, and then into the cavity where the food is placed to oven operation. be cooked. 5. Upon completion of the cooking time, the power OFF CONDITION transformer, oven lamp, etc.
Page 9 R -540DK R-540DW Note: The ON/OFF time ratio does not correspond with 3. After about 16 seconds, the cook relay (RY-2) is the percentage of microwave power, because energized. The power transformer is turned on, approx. 2 seconds are needed for heating of the microwave energy is produced and first stage is started.
Page 10 R - 5 4 0 D K R -540DW SCHEMATIC NOTE: CONDITION OF OVEN 1. DOOR CLOSED. NOTE: Indicates components with potential above 250 V. 2. CLOCK APPEARS ON DISPLAY. MAGNETRON MONITOR TEMP. FUSE 20A FUSE COM. N.O. CAPACITOR 1.0µF AC 2300V (RY-2) (RY-1)
Page 11 R -540DK R-540DW DESCRIPTION AND FUNCTION OF COMPONENTS DOOR OPEN MECHANISM open, the monitor fuse blows simultaneously with closing of the monitor switch contacts. The door is opened by pushing the open button on the CAUTION: BEFORE REPLACING A BLOWN MONITOR control panel, refer to the Figure D-1.
Page 12: Troubleshooting Guide
R - 5 4 0 D K R -540DW TROUBLESHOOTING GUIDE 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 13 R -540DK R-540DW CK = Check / RE = Replace TEST PROCEDURE A B C D E E F F G H J K L M N RE RE RE RE CK CK CK CK POSSIBLE CAUSE DEFECTIVE PARTS PROBLEM CONDITION Home fuse or circuit breaker blows when power cord is plugged into wall receptacle.
Page 14: Test Procedure
R - 5 4 0 D K R -540DW TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER 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.
Page 15 R -540DK R-540DW TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER (HIGH VOLTAGES ARE PRESENT AT THE HIGH VOLTAGE TERMINAL, SO DO NOT ATTEMPT TO MEASURE THE FILAMENT AND HIGH VOLTAGE.) HIGH VOLTAGE RECTIFIER TEST 1. Disconnect the power supply cord, and then remove outer case. 2.
Page 16 R - 5 4 0 D K R -540DW TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER 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.
Page 17 R -540DK R-540DW TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER with the door opened (in this condition the plunger of the monitor switch is pushed in), the meter should indicate an open circuit. If improper operation is indicated, the switch may be defective. After testing the monitor switch, reconnect the wire lead to the monitor switch (COM) terminal and check the continuity of the monitor circuit.
Page 18 R - 5 4 0 D K R -540DW TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER 4) Reconnect the power supply cord after the outer case is installed. 5) Run the oven and check all functions. The following symptoms indicate a defective key unit. a) When touching the pads, a certain pad produces no signal at all.
Page 19 R -540DK R-540DW TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER switch connector). Use the Key unit matrix indicated on the control panel schematic and place a jumper wire between the pins that correspond to the STOP/CLEAR pad making momentary contact. If the control unit responds by clearing with a beep the key unit is faulty and must be replaced. If the control unit does not respond, it is faulty and must be replaced.
Page 20 R - 5 4 0 D K R -540DW TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER (Now, weight 0.5lb is set.) And then touch the start pad. (3) The oven is in Compu Defrost cooking condition. (4) The oven will operate as follows WEIGHT 1ST STAGE 2ND STAGE...
Page 21 R -540DK R-540DW TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER 10) Discharge high voltage capacitor. 11) Reconnect all leads removed from components during testing. 12) Re-install the outer case (cabinet). 13) Reconnect the power supply cord after the outer case is installed. 14) Run the oven and check all functions.
Page 22 R - 5 4 0 D K R -540DW TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER 9-4. Touch Reheat pad. 9-5 The control panel is in automatic Sensor operation. 9-6. The display will start to count down the remaining cooking time, and the oven will turn off automatically after the water is boiling (bubbling).
Page 23: Touch Control Panel
R -540DK R-540DW TOUCH CONTROL PANEL ASSEMBLY OUTLINE OF TOUCH CONTROL PANEL 8) Power Source Circuit The touch control section consists of the following units. This circuit generates voltages necessary in the control unit from the AC line voltage. (1) Key Unit In addition, the synchronizing signal is available in (2) Control Unit (The Control Unit consists of Power Unit order to compose a basic standard time in the clock...
Page 24 R - 5 4 0 D K R -540DW LSI(IXA029DR) The I/O signal of the LSI(IXA029DR) is detailed in the following table. Pin No. Signal Description TIOCA2 Terminal not used. Terminal not used. Power source voltage : +5.0V. The power source voltage to drive LSI is input to Vcc terminal. Connected to Vcc. TMO0 Signal to sound buzzer.
Page 25 R -540DK R-540DW Pin No. Signal Description Key strobe signal. Signal applied to touch screen section. A pulse signal is input to PB1-PB5 terminal while one of G10 line keys on key matrix is touched. Oven lamp, fan motor and turntable motor driving signal To turn on and off shut off relay (RY1).
Page 26 R - 5 4 0 D K R -540DW Pin No. Signal Description 75-76 MD0-MD1 Connected to VCC. Connected to GND. Avcc A/D converter power source voltage : +5V. The power source voltage to drive the A/D converter. Connected to VCC. Vref A/D converter power source voltage : +5V.
Page 27 R -540DK R-540DW ABSOLUTE HUMIDITY SENSOR CIRCUIT resistance balance of the bridge circuit is deviated to (1) Structure of Absolute Humidity Sensor increase the voltage available at AN6 terminal of the The absolute humidity sensor includes two thermistors LSI. as shown in the illustration. One thermistor is housed in Then the LSI observes that voltage at AN6 terminal and the closed vessel filled with dry air while another in the compares it with its initial value, and when the...
Page 28 R - 5 4 0 D K R -540DW TOUCH CONTROL PANEL SERVICING transformer. 1. Precautions for Handling Electronic Components 4) Re-install the outer case (cabinet). This unit uses CMOS LSI in the integral part of the 5) Re-connect the power supply cord after the outer circuits.
Page 29: Component Replacement And Adjustment Procedure
4. If the outer case (cabinet) is not fitted. WARNING FOR WIRING To prevent an electric shock, take the following pre- 3) Sharp edge: cautions. Bottom plate, Oven cavity, Waveguide flange, 1. Before wiring, Chassis support and other metallic plate.
Page 30: Pictorial Diagram
R - 5 4 0 D K R -540DW CAUTION: 1. DISCONNECT OVEN FROM POWER SUP PLY BEFORE REMOVING OUTER CASE. 2. DISCHARGE THE HIGH VOLTAGE CA- PACITOR BEFORE TOUCHING ANY OVEN COMPONENTS OR WIRING. Special screw NOTE: When replacing the outer case, the 2 special Torx screws must be reinstalled in the same locations.
Page 31 4. Where the corners have been snipped off bend corner 7. Now the turntable motor is free. areas flat. No sharp edges must be evident after removal 8. After replacement use the one (1) screw to fit the of the turntable motor cover.
Page 32 R - 5 4 0 D K R -540DW 6. Remove the fan blade from the fan motor shaft according INSTALLATION to the following procedure. 1. Install the fan blade to the fan motor shaft according to 7. Hold the edge of the rotor of the fan motor by using a pair the following procedure.
Page 33 R -540DK R-540DW DOOR SENSING SWITCH/SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH ADJUSTMENT 1. Disconnect the power supply cord, and then remove hook, pushing and pulling lower portion of the door outer case. toward the oven face. Both results (play in the door) 2.
Page 34 R - 5 4 0 D K R -540DW (B) An approved microwave survey meter should be SEALER FILM used to assure compliance with proper microwave Installation radiation emission limitation standards. 1. Put the adhesive tape on the backing film of the sealer After any service, make sure of the following : film as shown in Fig.
Page 35 R -540DK R-540DW...
Page 36 R - 5 4 0 D K R -540DW R2 91 1w R3 91 1w CN-A Q1 2SD1859 S1NB10 – AC120V 60Hz BZ/EN SP30 BUZZR OVEN LAMP OVEN LAMP FAN MOTOR FAN MOTOR TURNTABLE TURNTABLE MOTOR MOTOR MICRO MICRO DOOR SENSING DOOR SWITCH...
Page 37 R -540DK R-540DW...
Page 38 R - 5 4 0 D K R -540DW CN - C VRS1 (J1) CN - A QKITPB031MREO Figure S-4. Printed Wiring Board of Power Unit...
Page 39: Parts List
Transformer VRS1 RH-VZA032DRE0 Varistor (10G471K) VHEHZ161///-1 Zener diode (HZ16-1) 3- 2 FPNLCB303MRK0 Control panel frame with key unit [R-540DK] 3- 2 FPNLCB304MRK0 Control panel frame with key unit [R-540DW] 3- 2- 1 FUNTKB248MRE0 Key unit [R-540DK] 3- 2- 1 FUNTKB249MRE0...
Page 40 To have your order filled promptly and correctly, please furnish the following information. 1. MODEL NUMBER 2. REF. NO. 3. PART NO. 4. DESCRIPTION Order Parts from the authorized SHARP parts Distributor for your area. Defective parts requiring return should be returned as indicated in the Service Policy.
Page 41 R -540DK R-540DW 7-10 OVEN AND CABINET PARTS 7-10 1-10 1-15 7-11 4-11 1-14 1-11 4-10 1-12 1-13 7-11 4-13 4-12...
Page 42 R - 5 4 0 D K R -540DW CONTROL PANEL PARTS 3-2-1 3-2-2 3-2-3 DOOR PARTS 5-1-1 5-1-2 MISCELLANEOUS Actual wire harness may be different from illustration.
Page 43: Packing And Accessories
R-540DW TOP PAD ASSEMBLY PACKING AND ACCESSORIES FPADBB038MRE0 DOOR PROTECTION SHEET SPADP0221MRE0 PLASTIC BAG SSAKHB007MRE0 TRAY HOLDER SPADFB051MRE0 6-5 TURNTABLE TRAY 6-8 OPERATION MANUAL 6-4 TURNTABLE SUPPORT BOTTOM PAD ASSEMBLY FPADBB039MRE0 TRAY PACK SPADPB042MRE0 PACKING CASE SPAKCB285MRR3 (R-540DK) SPAKCB285MRR4 (R-540DW)
Page 44 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. 2000 SHARP CORP. (5S2.530E) Printed in U.S.A...

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