Sharp R-402FW Service Manual
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Sharp R-402FW Service Manual

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R-402FW
R-404FK
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 .................................................................... 23
PICTORIAL DIAGRAM ........................................................................................................................................ 30
POWER UNIT CIRCUIT ....................................................................................................................................... 31
CPU UNIT CIRCUIT ............................................................................................................................................. 32
PRINTED WIRING BOARD ................................................................................................................................. 33
PARTS LIST ........................................................................................................................................................ 34
PACKING AND ACCESSORIES ......................................................................................................................... 38
SHARP ELECTRONCS CORPORATION
Service Headquarters: Sharp Plaza, Mahwah, New Jersey, 07430-2135
SERVICE MANUAL
MODELS
In the interest of user-safety the oven should be restored to its original
condition and only parts identical to those specified should be used.
WARNING TO SERVICE PERSONNEL: Microwave ovens con-
tain circuitry capable of producing very high voltage and
current, contact with following parts may result in a severe,
possibly fatal, electrical shock. (High Voltage Capacitor, High
Voltage Power Transformer, Magnetron, High Voltage Recti-
fier Assembly, High Voltage Harness etc..)

TABLE OF CONTENTS

This document has been published to be used for after
sales service only.
The contents are subject to change without notice.
S42M185R402FE
MICROWAVE OVEN
R-402FW
R-404FK
R- 402FW
R - 4 0 4 F K
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  • Page 1: Table Of Contents

    PARTS LIST ................................ 34 PACKING AND ACCESSORIES ......................... 38 This document has been published to be used for after sales service only. SHARP ELECTRONCS CORPORATION The contents are subject to change without notice. Service Headquarters: Sharp Plaza, Mahwah, New Jersey, 07430-2135...

  • Page 2: Precautions To Be Observed Before And During Servicing To Avoid Possible Exposure To Excessive Microwave Energy

    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-402FW R-404FK 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- 402FW R - 4 0 4 F K 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: Foreword And Warning

    MICROWAVE OVEN R-402FW/R-404FK GENERAL INFORMATION FOREWORD This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service Information for the SHARP OPERATION MICROWAVE OVENS, R-402FW, R-404FK. It is recommended that service personnel carefully study the entire text...

  • Page 6: Product Specifications

    14.0 Amperes, 1600 watts - (R-402FW) 13.0 Amperes, 1550 watts - (R-404FK) 60 Hertz Single phase, 3 wire grounded Power Output 1100 watts (IEC 705 TEST PROCEDURE) - (R-402FW) 1000 watts (IEC 705 TEST PROCEDURE) - (R-404FK) Operating frequency of 2450MHz Case Dimensions Width 21-21/32"...
  • Page 7 R-402FW R-404FK a qualified electrician and have it replaced with a properly grounded Grounded Receptacle Box three-pronged wall receptacle or have a grounding adapter properly grounded and polarized. If the extension 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- 402FW R - 4 0 4 F K OPERATION DESCRIPTION OF OPERATING SEQUENCE The following is a description of component functions during and is mechanically associated with the door so that it will oven operation. function in the following sequence. (1) When the door opens from the closed position, the OFF CONDITION secondary interlock relay (RY2) and primary interlock...
  • Page 9 R-402FW R-404FK Note:* Indicates component SCHEMATIC NOTE: CONDITION OF OVEN 1. Door Closed 2. CLOCK APPEARS ON DISPLAY CAVITY TEMPERATURE FUSE FUSE N.O. COM. DOOR SENSING POWER SWITCH TRANSFORMER HUMIDITY SENSOR (RY2) SECONDARY MAGNETRON INTERLOCK RELAY N.O. (RY1) COM. CONTROL UNIT...
  • Page 10 R- 402FW R - 4 0 4 F K DESCRIPTION AND FUNCTION OF COMPONENTS DOOR OPEN MECHANISM 3. If the door is opened, and the secondary interlock relay (RY2) and primary interlock switch contacts fail to open, The door is opened by pushing the open button on the control the C/T fuse blows simultaneously with closing of the panel, refer to the Figure D-1.

  • Page 11: Troubleshooting Guide

    R-402FW R-404FK 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 12: Test Procedure

    R- 402FW R - 4 0 4 F K CK = Check / RE = Replace RE RE A B C D E E F F G H RE RE CK I CK CK CK J K L M TEST PROCEDURE PROBLEM CONDITION Home fuse or circuit breaker blows...
  • Page 13 R-402FW R-404FK TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER 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. 5. To test for a shorted magnetron, connect the ohmmeter leads between the magnetron filament leads and chassis ground.
  • Page 14 R- 402FW R - 4 0 4 F K TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER HIGH VOLTAGE RECTIFIER 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-402FW R-404FK TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER 5. If the C/T fuse is blown when the door is opened, check the secondary interlock relay, primary interlock switch and monitor switch according to the "TEST PROCEDURE" for those switches before replacing the blown monitor fuse.
  • Page 16 R- 402FW R - 4 0 4 F K TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER MONITOR SWITCH 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 17 R-402FW R-404FK TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER 2) Open the door and block it open. 3) Discharge high voltage capacitor. 4) Replace the Key unit. 5) Reconnect all leads removed from components during testing. 6) Re-install the outer case (cabinet).
  • Page 18 R- 402FW TEST PROCEDURES R - 4 0 4 F K PROCEDURE COMPONENT TEST LETTER S T AR T T IME R DE F R OS T C LOC K S T OP C OOK C LE AR P OWE R MINUT E P OP C OR N R E HE AT...
  • Page 19 R-402FW R-404FK TEST PROCEDURES PROCEDURE COMPONENT TEST LETTER (7) If improper operation is indicated, the control unit is probably defective and should be checked. FOIL PATTERN ON THE PRINTED WIRING BOARD TEST To protect the electronic circuits, this model is provided with a fine foil pattern added to the primary on the PWB, this foil pattern acts as a fuse.

  • Page 20: Touch Control Panel

    R- 402FW R - 4 0 4 F K TOUCH CONTROL PANEL ASSEMBLY OUTLINE OF TOUCH CONTROL PANEL The touch control section consists of the following units. This circuit consists of 22 segments and 3 common electrodes using a Liquid Crystal Display. (1) Key Unit (2) Control Unit (The Control Unit consists of Power Unit 3) Power Source Circuit...
  • Page 21 R-402FW DESCRIPTION OF LSI R-404FK The I/O signal of the LSI is detailed in the following table. Pin No. Signal Description VL2-VL1 Power source voltage input terminal. Standard voltage for LCD. AN7-AN4 Terminal to change cooking input according to the Model.
  • Page 22 R- 402FW R - 4 0 4 F K Pin No. Signal Description RESET Auto clear terminal. Signal is input to reset the LSI to the initial state when power is applied. Temporarily set “L” level the moment power is applied, at this time the LSI is reset. Thereafter set at “H”...
  • Page 23 R-402FW R-404FK Pin No. Signal Description 73/74 Connected to GND. VCC/VREF AVSS Connected to VC. COM3 Terminal not used. COM2 Common data signal. Connected to LCD signal COM3. COM1 Common data signal. Connected to LCD signal COM2. COM0 Common data signal.
  • Page 24 R- 402FW TOUCH CONTROL PANEL SERVICING R - 4 0 4 F K 1. Precautions for Handling Electronic Components 1) Disconnect the power supply cord. This unit uses CMOS LSI in the integral part of the 2) Open the door and block it open. circuits.

  • Page 25: 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 26 R- 402FW R - 4 0 4 F K CAUTION: 1. DISCONNECT OVEN FROM POWER SUP- PLY BEFORE REMOVING OUTER CASE. 2. DISCHARGE THE HIGH VOLTAGE CA- PACITOR BEFORE TOUCHING ANY OVEN Special screw COMPONENTS OR WIRING. NOTE: When replacing the outer case, the 2 special Torx screws must be reinstalled in the same locations.
  • Page 27 R-402FW R-404FK OVEN LAMP AND LAMP SOCKET REMOVAL 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.
  • Page 28 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 turntable of the turntable motor cover.
  • Page 29 R-402FW R-404FK COOLING FAN MOTOR REMOVAL REMOVAL CAUTION: 1. Disconnect the power supply cord and then remove outer * Do not reuse the removed fan blade because the hole case. (for shaft) may be larger than normal. 2. Open the door and block it open.
  • Page 30 R- 402FW R - 4 0 4 F K 3. Secure latch hook (with two (2) mounting screws) to oven and check continuity of the monitor circuit. Refer to chapter flange. "Test Procedure" and Adjustment procedure. 4. Make sure that the monitor switch is operating properly DOOR SENSING SWITCH/PRIMARY INTERLOCK SWITCH AND MONITOR SWITCH ADJUSTMENT 1.
  • Page 31 R-402FW R-404FK 9. Release the door panel from twelve (12) tabs of door frame. 10.Remove the door panel from the door frame. 11.Now, door panel with sealer film is free. 12.Tear sealer film from door panel. 13.Now, door panel is free.

  • Page 32: Pictorial Diagram

    R- 402FW R - 4 0 4 F K...

  • Page 33: Power Unit Circuit

    R-402FW R-404FK...

  • Page 34: Cpu Unit Circuit

    LIQUID C R Y S T AL DIS P LAY R E S E T LB S . LS I UNIT C UP S LE D K G OZ. C OOK DE F R OS T S E NS OR AUT O G ND G ND...

  • Page 35: Printed Wiring Board

    R-402FW R-404FK WH-1 WH-1 QKITPB037MRE0 CN-B (J1) Figure S-5 . Printed Wiring Board of Power Unit...

  • Page 36: Parts List

    ELECTRIC PARTS 1- 1 RC-QZB018MRE0 High voltage capacitor [R-402FW] 1- 1 RC-QZA234WRE0 High voltage capacitor [R-404FK] 1- 2 FH-DZB013MRY0 High voltage rectifier assembly [R-402FW] 1- 2 FH-DZB018MRY0 High voltage rectifier assembly [R-404FK] 1- 3 QSOCLB006MRE0 Oven lamp socket 1- 4 RLMPTA068WRE0...
  • Page 37 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 38 R- 402FW R - 4 0 4 F K OVEN AND CABINET PARTS 1-13 1-10 4-10 1-11 1-12 4-11...
  • Page 39 R-402FW R-404FK CONTROL PANEL PARTS 3 - 1 3 - 2 3 - 4 3 - 6 3 - 3 3 - 5 3-2-1 3-2-3 DOOR PARTS 3-2-2 Actual wire harness may be different from illustration.

  • Page 40: Packing And Accessories

    R- 402FW R - 4 0 4 F K PACKING AND ACCESSORIES TOP PAD ASSEMBLY DOOR PROTECTION SHEET 6-5 TURNTABLE TRAY PLASTIC BAG TRAY HOLDER 6-8 OPERATION MANUAL BOTTOM PAD ASSEMBLY 6-4 TURNTABLE SUPPORT PACKING CASE...
  • Page 41 R-402FW R-404FK NOTES...
  • Page 42 R- 402FW R - 4 0 4 F K NOTES...
  • Page 43 R-402FW R-404FK NOTES...
  • 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, recording, or otherwise, without prior written permission of the publisher. 2002 SHARP CORP. (4M2.20E) Printed in U.S.A...

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