Sharp R305dw Owner's Manual

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SERVICE MANUAL

S3006R305DPW/

MICROWA VE OVEN

R-305DW

COOK

DEFOST

TO ADJUST QUANTITY TOUCH PAD AGAIN

CASSEROLE

BEVERAGE

BAKED

FRESH

POTATOES

VEGETABLES

1 GROUND MEAT 2 STEAKS/CHOPS 3 CHICKEN PIECES

1 2 3 4 5 6 7 8

POWER LEVEL

STOP CLEAR

NO. LBS. CUPS.

OZ.

MINUTE PLUS

POPCORN

ROLLS & MUFFINS

COMPU DEFROST

TIMER CLOCK

START

MODEL

R-305DW

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 contain 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 Rectifier Assembly, High Voltage Harness etc..)

TABLE OF CONTENTS

Page 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 ..............................................................................................................................9

TEST PROCEDURE............................................................................................................................................ 10

TOUCH CONTROL PANEL .................................................................................................................................18

COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE ................................................................22

PICTORIAL DIAGRAM ........................................................................................................................................28

POWER UNIT CIRCUIT ......................................................................................................................................29

CPU UNIT CIRCUIT ............................................................................................................................................30

PRINTED WIRING BOARD .................................................................................................................................31

PARTS LIST ........................................................................................................................................................32

PACKING AND ACCESSORIES .........................................................................................................................36

SHARP CORPORATION

This document has been published to be used for after sales service only. The contents are subject to change without notice.

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R-3 05DW

PRECAUTIONS TO BE OBSER VED BEFORE AND DURING SER VICING TO A VOID POSSIBLE EXPOSURE TO EXCESSIVE MICROW A VE ENERGY

(a) Do not operate or allow the oven to be operated with the door open. (b) Make the following safety checks on all ovens to be serviced before activating the magnetron or other

microwave source, and make repairs as necessary: (1) interlock operation, (2) proper door closing, (3) seal and sealing surfaces (arcing, wear, and other damage), (4) damage to or loosening of hinges and latches, (5) evidence of dropping or abuse.

compartments, check the magnetron, wave guide or transmission line, and cavity for proper alignment, integrity, and connections.

(d) Any defective or misadjusted components in the interlock, monitor, door seal, and microwave

generation 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 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.

Service personnel should inform SHARP ELECTRONICS CORPORATION of any certified unit found with emissions in excess of 4mW/cm2. The owner of the unit should be instructed not to use the unit until the oven has been brought into compliance.

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W ARNING TO SER VICE PERSONNEL

Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts fatal, electrical shock.

(Example) High Voltage Capacitor, High Voltage Power Trans-

former, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..

Read the Service Manual carefully and follow all instructions.

may result in a severe, possibly

R-305DW

Don't Touch ! Danger High Voltage

Before Servicing

1. Disconnect the power supply cord ¬, and then remove outer case.

2. Open the door and block it open.

3. Discharge high voltage capacitor.

WARNING:RISK OF ELECTRIC SHOCK.

DISCHARGE THE HIGH-VOLTAGE CAPACITOR BEFORE SERVICING.

The high-voltage capacitor remains charged about 60 seconds after the oven has been switched off. Wait for 60 seconds and then short-circuit the connection of the highvoltage capacitor (that is the connecting lead of the highvoltage rectifier) against the chassis with the use of an insulated screwdriver.

Whenever troubleshooting is performed the power supply must be disconnected. It may, in some cases, be necessary to connect the power supply 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 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. Reconnect the leads to the primary of the power transformer.

5. Reinstall the outer case (cabinet).

6. Reconnect the power supply cord after the outer case is installed.

7. Run the oven and check all functions.

After repairing

1. Reconnect all leads removed from components during testing.

2. Reinstall the outer case (cabinet).

3. Reconnect the power supply cord after the outer case is installed.

4. Run the oven and check all functions.

Microwave ovens should not be run empty. To test for the presence of microwave energy within a cavity, place a cup of cold water on the oven turntable, close the door and set the power to HIGH and set the microwave timer for two (2) minutes. When the two minutes has elapsed (timer at zero) carefully check that the water is now hot. If the water remains cold carry out Before Servicing procedure and reexamine the connections to the component being tested.

When all service work is completed and the oven is fully assembled, the microwave power output should be checked and a microwave leakage test should be carried out.

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R-305DW

MICROW A VE 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/cm2 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/cm2 at any point 5cm or more from the external surface of the oven.

2) Safety interlock switches Primary interlock relay and door sensing switch shall prevent microwave radiation emission in excess of the requirement as above mentioned, secondary interlock switch shall prevent microwave radiation emission in excess of 5 mW/cm2 at any point 5cm or more from the external surface of the oven.

B. Preparation for testing: Before beginning the actual measurement of leakage, proceed as follows:

1) Make sure that the actual instrument is operating normally as specified in its instruction booklet.

Important: Survey instruments that comply with the requirement for instrumentation as prescribed by the performance standard for microwave ovens, 21 CFR 1030.10(c)(3)(i), must be used for testing.

2) Place the oven tray in the oven cavity.

3) Place the load of 275±15 ml (9.8 oz) of tap water initially at 20±5˚C (68˚F) in the 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 Power Cooking Mode.

5) Close the door and select a cook cycle of several minutes. If the water begins to boil before the survey is completed, replace it with 275 ml of cool water.

C. Leakage test:

Closed-door leakage test (microwave measurement)

1) Grasp the probe of the survey instrument and hold it perpendicular to the gap between the door and the body of the oven.

2) Move the probe slowly, not faster than 1 in./sec. (2.5 cm/sec.) along the gap, watching for the maximum indication on the meter.

3) Check for leakage at the door screen, sheet metal seams and other accessible positions where the continuity of the metal has been breached (eg., around the switches, indicator, and vents). While testing for leakage around the door pull the door away from the front of the oven as far as is permitted by the closed latch assembly.

4) Measure carefully at the point of highest leakage and make sure that the highest leakage is no greater than 4mW/cm2, and that the secondary interlock switch does turn the oven OFF before any door movement.

NOTE: After servicing, record data on service invoice and microwave leakage report.

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SERVICE MANUAL

R-305DW

MICROWAVE OVEN

R-305DW

FOREWORD

This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service Information for the SHARP MICROWAVE OVEN, R-305DW.

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.

Check the interlock switches and the door seal carefully. Special attention should be given to avoid electrical shock and microwave radiation hazard.

WARNING

Never operate the oven until the following points are ensured. (A) The door is tightly closed. (B) The door brackets and hinges are not defective. (C) The door packing 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

Certain initial parts are intentionally not grounded and present a risk of electrical shock only during servicing. Service personnel - Do not contact the following parts while the appliance is energized; High Voltage Capacitor, Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness; If provided, Vent Hood, Fan assembly, Cooling Fan Motor.

PRODUCT DESCRIPTION

GENERAL INFORMATION

OPERATION

TROUBLESHOOTING GUIDE AND TEST PROCEDURE

TOUCH CONTROL PANEL

COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE

WIRING DIAGRAM

PARTS LIST

All the parts marked “*” on parts list are used at voltages more than 250V.

Removal of the outer wrap gives access to voltage above 250V. All the parts marked “∆” on parts list may cause undue microwave

exposure, by themselves, or when they are damaged, loosened or removed.

SHARP ELECTRONICS CORPORATION

SHARP PLAZA, MAHWAH,

NEW JERSEY 07430-2135

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R-305DW

SPECIFICATION

ITEM DESCRIPTION

Power Requirements 120 Volts / 13 Amperes

60 Hertz Single phase, 3 wire grounded

Power Output 1100 watts (IEC TEST PROCEDURE)

Operating frequency of 2450MHz

Case Dimensions Width 20-1/2"

Height 11-7/8" Depth 17-1/8"

Cooking Cavity Dimensions Width 14-3/4"

Height 8-3/4"

1.2 Cubic Feet Depth 15-3/4" Control Complement Touch Control System

Clock ( 1:00 - 12:59 ) Timer (0 - 99 min. 99 seconds)

Microwave Power for Variable Cooking Repetition Rate;

P-HI..................................................Full power throughout the cooking time

P-90 .................................................................... approx. 90% of Full Power

P-80 .................................................................... approx. 80% of Full Power

P-70 .................................................................... approx. 70% of Full Power

P-60 .................................................................... approx. 60% of Full Power

P-50 .................................................................... approx. 50% of Full Power

P-40 .................................................................... approx. 40% of Full Power

P-30 .................................................................... approx. 30% of Full Power

P-20 .................................................................... approx. 20% of Full Power

P-10 .................................................................... approx. 10% of Full Power

P-0 .................................................... No power throughout the cooking time

MINUTE PLUS pad, INSTANT START pads COMPU DEFROST pads, Number selection pads POWER LEVEL pad, TIMER/CLOCK pad STOP/CLEAR pad, START pad

Oven Cavity Light Yes Safety Standard UL Listed FCC Authorized

DHHS Rules, CFR, Title 21, Chapter 1, Subchapter J

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 an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current.

WARNING: Improper use of the grounding plug can result in a risk of electric shock.

Electrical Requirements The electrical requirements are a 120 volt 60 Hz, AC only, 15 or 20 amp. fused electrical supply. It is recommended that a separate circuit serving only this appliance be provided. When installing this appliance, observe all applicable codes and ordinances. A short power-supply cord is provided to reduce risks of becoming entangled in or tripping over a longer cord. Where a two-pronged wall-receptacle is encountered, it is the personal responsibility and obligation of the customer to

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R-305DW

contact a qualified electrician and have it replaced with a properly grounded 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.

CAUTION: DO NOT UNDER ANY CIRCUMSTANCES CUT OR RE-

MOVE THE ROUND GROUNDING PRONG FROM THIS PLUG.

OVEN DIAGRAM

1. Door open handle. Pull to open door.

2. Door latches. The oven will not operate unless 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. Coupling.

3-Pronged Plug

Grounding Pin

3-Pronged Receptacle

Grounded Receptacle Box

11. Wave guide cover.

12. Power supply cord

TOUCH CONTROL PANEL

NO.

LBS.

CUPS.

DEFOST

COOK

TO ADJUST QUANTITY - TOUCH PAD AGAIN

CASSEROLE

BAKED

POTATOES

1 GROUND MEAT 2 STEAKS/CHOPS 3 CHICKEN PIECES

BEVERAGE

FRESH

VEGETABLES

OZ.

MINUTE PLUS

POPCORN

ROLLS &

MUFFINS

COMPU DEFROST

See note.

1 2 3

NOTE: The directed features are disabled after one minute when the oven is not in use. These features are automatically enabled when the door is opened and closed or the STOP/ CLEAR pad is pressed.

4 5 6 7 8

POWER

LEVEL

STOP

CLEAR

START

TIMER

CLOCK

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R-305DW

OPERATION

DESCRIPTION OF OPERATING SEQUENCE

The following is a description of component functions during oven operation.

OFF CONDITION

Closing the door activates the door sensing switch and secondary interlock switch. (In this condition, the monitor switch contacts are opened.) When oven is plugged in, 120 volts A.C. is supplied to the control unit. (Figure O-1).

1. The display will show flashing "88:88". To set any program or set the clock, you must first touch the STOP/CLEAR pad. The display will clear, and " : " will appear.

COOKING CONDITION

Program desired cooking time by touching the NUMBER pads. Program the power level by touching the POWER LEVEL pad and then a Number pad. When the START pad is touched, the following operations occur:

1. The contacts of relays are closed and components connected to the relays are turned on as follows. (For details, refer to Figure O-2)

relay and is mechanically associated with the door so that it will function in the following sequence.

(1) When the door opens from the closed position, the

primary interlock relay (RY2) and secondary interlock switch open their contacts. And contacts of the relay (RY1) remains closed. Then the monitor switch contacts close.

(2) When the door is closed from the open position, the

monitor switch contacts open first. Then the contacts of the secondary interlock switch and door sensing switch

close. And contacts of the relay (RY1) open. If the secondary interlock switch and primary interlock relay (RY2) fail with the contacts closed when the door is opened, the closing of the monitor switch contacts will form a short circuit through the monitor fuse, secondary interlock switch, relay (RY1) and primary interlock relay (RY2), causing the monitor fuse to blow.

POWER LEVEL P-0 TO P-90 COOKING

When Variable Cooking Power is programmed, the 120 volts A.C. is supplied to the power transformer intermittently through the contacts of relay (RY-2) which is operated by the control unit within a 32 second time base. Microwave power operation is as follows:

RELAY CONNECTED COMPONENTS RY-1 oven lamp/turntable motor/fan motor RY-2 power transformer

2. 120 volts A.C. is supplied to the primary winding of the power transformer and is converted to about 3.1 volts A.C. output on the filament winding, and approximately 2370 volts A.C. on the high voltage winding.

3. The filament winding voltage heats the magnetron filament and the H.V. winding voltage is sent to a voltage doubler circuit.

4. The microwave energy produced by the magnetron is channelled through the waveguide into the cavity feedbox, and then into the cavity where the food is placed to be cooked.

5. Upon completion of the cooking time, the power transformer, 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 monitor switch, door sensing switch, secondary interlock 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 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

VARI-MODE ON TIME OFF TIME P-HI (100% power) 32 sec. 0 sec. P-90 (approx. 90% power) 30 sec. 2 sec. P-80 (approx. 80% power) 26 sec. 6 sec. P-70 (approx. 70% power) 24 sec. 8 sec. P-60 (approx. 60% power) 22 sec. 10 sec. P-50 (approx. 50% power) 18 sec. 14 sec. P-40 (approx. 40% power) 16 sec. 16 sec. P-30 (approx. 30% power) 12 sec. 20 sec. P-20 (approx. 20% power) 8 sec. 24 sec. P-10 (approx. 10% power) 6 sec. 26 sec.

P-0 (approx. 0% power) 0 sec. 32 sec.

Note: The ON/OFF time ratio does not correspond with

the percentage of microwave power, because approx. 2 seconds are needed for heating of the magnetron filament.

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SCHEMATIC

120V AC 60 Hz

OVEN LAMP

TURNTABLE MOTOR

FAN MOTOR

POWER TRANSFORMER

CAPACITOR 0.94µF

AC 2200V

MONITOR SWITCH

RECTIFIER

MAGNETRON

SECONDARY INTERLOCK SWITCH

TTM

OL FM

MONITOR FUSE 20A

N.O.

COM.COM.

N.O.

DOOR SENSING SWITCH

(RY-1)

(RY-2)

CONTROL UNIT

PRIMARY INTERLOCK RELAY

THERMAL CUT-OUT (OVEN)

THERMAL CUT-OUT (MG.)

SH-B SH-A

GRN

OVEN LAMP

TURNTABLE MOTOR

FAN MOTOR

POWER TRANSFORMER

MONITOR SWITCH

RECTIFIER

SECONDARY INTERLOCK SWITCH

TTM

OL FM

N.O.

DOOR SENSING SWITCH

SH-B SH-A

(RY-1)

(RY-2)

CONTROL UNIT

PRIMARY INTERLOCK RELAY

120V AC 60 Hz

GRN

MONITOR FUSE 20A

THERMAL CUT-OUT (OVEN)

THERMAL CUT-OUT (MG.)

COM.

CAPACITOR 0.94µF

AC 2200V

COM

RECTIFIER

MAGNETRON

NOTE: CONDITION OF OVEN

1. DOOR CLOSED

2. CLOCK APPEARS ON DISPLAY

R-305DW

NOTE: Indicates components with potential above 250 V.

SCHEMATIC

NOTE: CONDITION OF OVEN

1. DOOR CLOSED

2. COOKING TIME PROGRAMMED

3. VARIABLE COOKING CONTROL "P-HI"

4. "START" PAD TOUCHED

Figure O-1. Oven Schematic-Off Condition

Figure O-2. Oven Schematic-Cooking Condition

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R-305DW

DESCRIPTION AND FUNCTION OF COMPONENTS

DOOR OPEN MECHANISM

The door is opened by pulling the door. Refer to the Figure D-1.

Door

Latch Heads

Latch Hook

Door Sensing Switch

Monitor Switch Secondary

Interlock Switch

Figure D-1. Door Open Mechanis

DOOR SENSING AND SECONDARY INTERLOCK SWITCHES

The secondary interlock switch is mounted in the lower position of the latch hook and the door sensing switch in the primary interlock system is mounted in the upper position of the latch hook. They are activated by the latch heads on the door. When the door is opened, the switches interrupt the power to all high voltage components. A cook cycle cannot take place until the door is firmly closed thereby activating both interlock switches. The primary interlock system consists of the door sensing switch and primary interlock relay located on the control circuit board.

MONITOR SWITCH

The monitor switch is activated (the contacts opened) by the latch head on the door while the door is closed. The switch is intended to render the oven inoperative, by means of blowing the monitor fuse, when the contacts of the primary interlock relay (RY2) and secondary interlock switch fail to open when the door is opened.

Functions:

1. When the door is opened, the monitor switch contact close (to the ON condition) due to their being normally closed. At this time the primary interlock relay (RY2) and secondary interlock switch are in the OFF condition (contacts open) due to their being normally open contact switches.

2. As the door goes to a closed position, the monitor switch contacts are first opened and then the door sensing switch and the secondary interlock switch contacts close. (On opening the door, each of these switches operate inversely.)

3. If the door is opened, and the primary interlock relay (RY2) and secondary interlock switch contacts fail to open, the monitor fuse blows simultaneously with closing of the monitor switch contacts.

CAUTION: BEFORE REPLACING A BLOWN MONITOR

FUSE TEST THE DOOR SENSING SWITCH, PRIMARY INTERLOCK RELAY (RY2), RELAY (RY1), SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH FOR PROPER OPERATION. (REFER TO CHAPTER "TEST PROCEDURE").

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 cooking. The turntable may turn in either direction.

COOLING FAN MOTOR

The cooling fan motor drives a blade which draws external cool air. This cool air is directed through the air vanes surrounding the magnetron and cools the magnetron. This air is channelled through the oven cavity to remove steam and vapors given off from the heating foods. It is then exhausted through the exhausting air vents at the oven cavity.

MONITOR FUSE

1. The monitor fuse blows when the contacts (COM-NO) of the primary interlock relay (RY2) and secondary interlock switch remain closed with the oven door open and when the monitor switch closes.

2. If the wire harness or electrical components are shortcircuited, this monitor fuse blows to prevent an electric shock or fire hazard.

OVEN THERMAL CUT-OUT

The thermal cut-out, located on the top of the oven cavity, is designed to prevent damage to the oven by fire. If the food load is overcooked, by either error in cook time or defect in the control unit, the thermal cut-out will open. Under normal operation, the oven thermal cut-out remains closed. However, when abnormally high temperatures are reached within the oven cavity, the oven thermal cut-out will open at 257˚F(125˚C), causing the oven to shut down.

MAGNETRON THERMAL CUT-OUT

The thermal cut-out located near the magnetron is designed to prevent damage to the magnetron if an over heated condition develops in the tube due to cooling fan failure, obstructed air guide, dirty or blocked air intake, etc. Under normal operation, the thermal cut-out remains closed. However, when abnormally high temperatures are reached within the magnetron, the thermal cut-out will open at 293˚F(145˚C) causing the oven to shut down.

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R-305DW

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. These tests are given a procedure letter which will be found in the "Test Procedure "section.

IMPORTANT: If the oven becomes inoperative because of a blown monitor fuse, check the monitor switch, relay (RY1)

primary interlock relay (RY2), door sensing switch and secondary interlock switch before replacing the monitor fuse. If the monitor fuse is replaced, the monitor switch must also be replaced. Use part FFSBA021WRK0 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 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. Reconnect all leads removed from components during testing.

5. Reinstall the outer case (cabinet).

6. Reconnect the power supply cord after the outer case is installed.

7. Run the oven and check all functions.

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R-305DW

CK = Check / RE = Replace

CONDITION

OFF CONDITION

COOKING CONDITION

TEST PROCEDURE

AND

POSSIBLE CAUSE

DEFECTIVE PARTS

PROBLEM

Home fuse or circuit breaker blows when power cord is plugged into wall receptacle

Monitor fuse blows when power cord is plugged into wall receptacle.

All letters and indicators do not appear in display when power cord is first plugged into wall outlet.

Display does not operate properly when STOP/CLEAR key is touched. (Buzzer should sound and ":" or time of day 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 cycle.)

Oven goes into a cook cycle but extremely uneven heating is produced in oven load (food).

Oven does not cook properly when programmed for Cooking Power P50 mode. (Operates properly on Cooking Power P-HI (100%) mode.)

Oven goes into COMPU DEFROST but food is not defrosted well.

RE RE

ABCDEFFGH

SHORT IN POWER CORD

SHORT OR OPENED WIRING

MAGNETRON

POWER TRANSFORMER

H.V. RECTIFIER ASSEMBLY

RERE

HIGH VOLTAGE CAPACITOR

THERMAL CUT-OUT

PRIMARY INTERLOCK SYSTEM

SECONDARY INTERLOCK SWITCH

MONITOR SWITCH

MONITOR FUSE

OVEN LAMP OR SOCKET

CKICK CKCK

COOLING FAN MOTOR

TURNTABLE MOTOR

TOUCH CONTROL PANEL

WRONG OPERATION

LOW VOLTAGE

DIRTY OVEN CAVITY

JKLM

KEY UNIT

RELAY (RY1)

COMPU DEFROST

FOIL PATTERN ON PWB.

PROCEDURE

LETTER

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.

TEST PROCEDURES

COMPONENT TEST

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TEST PROCEDURES

R-305DW

PROCEDURE

LETTER

COMPONENT TEST

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. This test should indicate an infinite resistance. If there is little or no resistance the magnetron is grounded and must be replaced.

6. Reconnect all leads removed from components during testing.

7. Reinstall the outer case (cabinet).

8. Reconnect the power supply cord after the outer case is installed.

9. Run the oven and check all functions.

MICROWAVE OUTPUT POWER

The following test procedure should be carried out with the microwave oven in a fully assembled condition (outer case fitted).

HIGH VOLTAGES ARE PRESENT DURING THE COOK CYCLE, SO EXTREME CAUTION SHOULD BE OBSERVED.

Power output of the magnetron can be measured by performing a water temperature rise test. This test should only be used if above tests do not indicate a faulty magnetron and there is no defect in the following components or wiring: silicon rectifier, high voltage capacitor and power transformer. This test will require a 16 ounce (453cc) measuring cup and an accurate mercury thermometer or thermocouple type temperature tester. For accurate results, the following procedure must be followed carefully:

1. Fill the measuring cup with 16 oz. (453cc) of tap water and measure the temperature of the water with a thermometer or thermocouple temperature tester. Stir the thermometer or thermocouple through the water until the temperature stabilizes. Record the temperature of the water.

2. Place the cup of water in the oven. Operate oven at power P-HI(100%) selecting more than 60 seconds cook time. Allow the water to heat for 60 seconds, measuring with a stop watch, second hand of a watch or the digital read-out countdown.

3. Remove the cup from the oven and again measure the temperature, making sure to stir the thermometer or thermocouple through the water until the maximum temperature is recorded.

4. Subtract the cold water temperature from the hot water temperature. The normal result should be 32.1 to 59.7˚F(17.9 to 33.2˚C) rise in temperature. If the water temperatures are accurately measured and tested for the required time period the test results will indicate if the magnetron tube has low power output (low rise in water temperature) which would extend cooking time or high power output (high rise in water temperature) which would reduce cooking time. Because cooking time can be adjusted to compensate for power output, the magnetron tube assembly should be replaced only if the water temperature rise test indicates a power output well beyond the normal limits. The test is only accurate if the power supply line voltage is 120 volts and the oven cavity is clean.

B POWER TRANSFORMER 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. Disconnect the primary input terminals and measure the resistance of the transformer with an ohmmeter. Check for continuity of the coils with an ohmmeter. On the R x 1 scale, the resistance of the primary coil should be less than 1 ohm and the resistance of the high voltage coil should be approximately 86.3 ohms; the resistance of the filament coil should be less than 1 ohm.

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.

(HIGH VOLTAGES ARE PRESENT AT THE HIGH VOLTAGE TERMINAL, SO DO NOT ATTEMPT TO MEASURE THE FILAMENT AND HIGH VOLTAGE.)

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LETTER

C 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. Isolate the rectifier from the circuit. Using the highest ohm scale of the meter, read the resistance across the terminals and observe, reverse the leads to the rectifier terminals and observe meter reading. If a short is indicated in both directions, or if an infinite resistance is read in both directions, the rectifier is probably defective and should be replaced.

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.

D HIGH VOLTAGE CAPACITOR 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 capacitor is open, no high voltage will be available to the magnetron. Disconnect input leads and check for short or open between the terminals using an ohmmeter. Checking with a high ohm scale, if the high voltage capacitor is normal, the meter will indicate continuity for a short time and should indicate an open circuit once the capacitor is charged. If the above is not the case, check the capacitor with an ohmmeter to see if it is shorted between either of the terminals and case. If it is shorted, replace the capacitor.

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.

COMPONENT TEST

E OVEN THERMAL CUT-OUT 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 continuity check across the thermal cut-out terminals should indicate a closed circuit unless the temperature of the thermal cut-out reaches approximately 257˚F(125˚C). An open thermal cut-out indicates overheating of the oven, exchange the oven thermal cut-out and check inside of oven cavity and for improper setting of cooking time or operation of control unit. Check for restricted air flow through the 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 THERMAL CUT-OUT 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 continuity check across the thermal cut-out terminals should indicate a closed circuit unless the temperature of the magnetron reaches approximately 293˚F(145˚C). An open thermal cut-out indicates overheating of the magnetron. Check for restricted air flow to the magnetron, especially the cooling fan 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.

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CAUTION: IF THE THERMAL CUT-OUT INDICATES AN OPEN CIRCUIT AT ROOM TEMPERATURE,

REPLACE THERMAL CUT-OUT.

F SECONDARY INTERLOCK 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. 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. If improper operation is indicated, replace the secondary interlock 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.

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: If the door sensing switch contacts fail in the open position and the door is closed, the cooling

fan, turntable and oven light will be activated by RY1.

COMPONENT TEST

PRIMARY INTERLOCK RELAY (RY2)

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 two (2) wire leads from the male tab terminals of the Primary Interlock Relay. Check the state of the relay contacts using a ohmmeter. The relay contacts should be open. If the relay contacts are closed, replace the circuit board entirely or the relay itself.

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.

G 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. Before performing this test, make sure that the secondary interlock switch and the primary interlock relay are operating properly, according to the above Switch Test Procedure. Disconnect the wire lead from the monitor switch (COM) terminal. Check the monitor switch operation by using the ohmmeter as follows. When the door is open, the meter should indicate a closed circuit. When the monitor switch actuator is pushed by a screw driver through the lower latch hole on the front plate of the oven cavity 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.

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TEST PROCEDURES

PROCEDURE

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. Run the oven and check all functions.

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 relay, secondary interlock switch and monitor switch according to the "TEST PROCEDURE" for those switches before replacing the blown monitor fuse.

CAUTION: BEFORE REPLACING A BLOWN MONITOR FUSE, TEST THE PRIMARY INTERLOCK

RELAY, SECONDARY INTERLOCK SWITCH, DOOR SENSING SWITCH AND MONITOR

SWITCH FOR PROPER OPERATION. If the monitor fuse is blown by improper switch operation, the monitor fuse and monitor switch must be replaced with "monitor fuse and monitor switch assembly" part number FFS-BA021WRK0, even if the monitor switch operates normally. The monitor fuse and monitor switch assembly is comprised of a 20 ampere fuse and 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.

COMPONENT TEST

Screw Driver

RED

WHT

Monitor Switch

Secondary Interlock Switch

Ohmmeter

I TOUCH CONTROL PANEL ASSEMBLY TEST

The touch control panel consists of circuits including semiconductors such as LSI, ICs, etc. Therefore, unlike conventional microwave 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, CPU Unit and Power Unit, and troubleshooting by unit replacement is described according to the symptoms indicated.

Before testing,

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.

1. Key Unit. NOTE ;

1) Check Key unit ribbon connection before replacement.

2) Reconnect all leads removed from components during testing.

3) Re-install the outer case (cabinet).

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.

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TEST PROCEDURES

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PROCEDURE

LETTER

COMPONENT TEST

b) When touching a number pad, two figures or more are displayed. c) When touching the pads, sometimes a pad produces no signal. If the Key unit is defective.

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) Replace the Key unit.

5) Reconnect all leads removed from components during testing.

6) Re-install the outer case (cabinet).

7) Reconnect the power supply cord after the outer case is installed.

8) Run the oven and check all functions.

2. Control Unit The following symptoms indicate a defective control unit. Before replacing the control unit, perform the Key unit test (Procedure J) to determine if control unit is faulty.

2-1 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.

2-2 In connection with indicators

a) At a certain digit, all or some segments do not light up. b) At a certain digit, brightness is low. c) Only one indicator does not light. d) The corresponding segments of all digits do not light up; or they continue to light up. e) Wrong figure appears. f) A certain group of indicators do not light up. g) The figure of all digits flicker.

2-3 Other possible problems caused by defective control unit.

a) Buzzer does not sound or continues to sound. b) Clock 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 check all functions.

J KEY UNIT 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 display fails to clear when the STOP/CLEAR pad is depressed, first verify the flat ribbon cable is making good contact, verify that the door sensing switch (stop switch) operates properly; that is the contacts are closed when the door is closed and open when the door is open. If the door sensing switch (stop switch) is good, disconnect the flat ribbon cable that connects the key unit to the control unit and make sure the door sensing switch is closed (either close the door or short the door sensing 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. If a specific pad does not respond, the above method may be used (after clearing the control unit) to determine if the control unit or key pad is at fault.

5. Reconnect all leads removed from components during testing.

6. Re-install the outer case (cabinet).

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TEST PROCEDURES

PROCEDURE

LETTER

K RELAY TEST

COMPONENT TEST

7. Reconnect the power supply cord after the outer case is installed.

8. Run the oven and check all functions.

G 9

G10

G11

G12

G13

G14

BEVERAGE

G 7 G 6 G 5 G 4 G 3 G 2 G 1

G 8

START

MINUTE

PLUS

FRESH

VEGETABLES

TIMER

CLOCK

09876

POWER

CASSEROLE

LEVEL STOP

CLEAR

POPCORN

BAKED

POTATOES

COMPU

DEFROST

ROLLS & MUFFINS

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, re-connect the power supply cord.

7. Remove the outer case and check voltage between Pin No. 1 of the 2 pin connector (A) and the normal open terminal 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 diode is good,

control unit is defective.

RELAY SYMBOL OPERATIONAL VOLTAGE CONNECTED COMPONENTS

RY1 Approx. -12.2V D.C. Oven lamp / Turntable motor / Cooling fan motor RY2 Approx. -11.1V D.C. Power transformer

8. Disconnect the power supply cord, and then remove outer case.

9. Open the door and block it open.

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 function.

L COMPU DEFROST TEST

WARNING : The oven should be fully assembled before following procedure.

(1) Place one cup of water in the center of the turntable tray in the oven cavity. (2) Close the door, touch the " COMPU DEFROST " pad twice. (3) Touch the Number pad " 5 " and then touch the " START " pad. (4) The oven is in Compu Defrost cooking condition. (5) The oven will operate as follows

WEIGHT 1ST STAGE 2ND STAGE

LEVEL TIME LEVEL TIME

0.5lb 70% 40sec. 40% 30sec.

(6) If improper operation is indicated, the control unit is probably defective and should be checked.

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TEST PROCEDURES

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LETTER

M 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.

1. Foil pattern check and repairs.

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) Follow the troubleshooting guide given below for repair.

STEPS OCCURRENCE CAUSE OR CORRECTION

1 Only pattern at "a" is broken. *Insert jumper wire J1 and solder. 2 Pattern at "a" and "b" are broken. *Insert the coil RCILF2003YAZZ between "c" and "d".

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 540Ω ± 20%). If any abnormal condition is detected, replace the defective parts.

COMPONENT TEST

(J1)

RY1

VRS1

6) Reconnect all leads removed from components during testing.

7) Re-install the outer case (cabinet).

8) Reconnect the power supply cord after the outer case is installed.

9) Run the oven and check all functions.

2. Follow the troubleshooting guide given below, if indicator does not light 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, re-connect the power supply cord.

7) Follow the troubleshooting guide given below for repair.

STEPS OCCURRENCE CAUSE OR CORRECTION

The rated AC voltage is not present between

1 Pin No. 1 of the 2-pin connector (A) and the Check supply voltage and oven power cord.

normal open terminal of the relay RY1. The rated AC voltage is present at primary Low voltage transformer or secondary circuit defective.

side of low voltage transformer. Check and repair.

8) Disconnect the power supply cord, and then remove outer case.

9) Open the door and block it open.

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.

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TOUCH CONTROL PANEL ASSEMBLY

OUTLINE OF TOUCH CONTROL PANEL The touch control section consists of the following units. (1) Key Unit

(2) Control Unit(The Control Unit consists of Power Unit

and CPU Unit).

The principal functions of these units and the signals communicated among them are explained below.

Key Unit

The key unit is composed of a matrix, signals generated in the LSI are sent to the key unit through P20, P21, P22, P23, P24, P25, P26 and P27. When a key pad is touched, a signal is completed through the key unit and passed back to the LSI through P41, P43, P44, P45 and AN0 to perform the function that was requested.

Control Unit

Control unit consists of LSI, ACL circuit, indicator circuit, power source circuit, relay circuit, buzzer circuit, synchronizing signal circuit and back light circuit.

1) ACL

This circuit generates a signal which resets the LSI to the initial state when power is supplied.

3) Power Source Circuit

This circuit generates voltages necessary in the control unit from the AC line voltage. In addition, the synchronizing signal is available in order to compose a basic standard time in the clock circuit.

Symbol Voltage 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 audible sounds (key touch sound and completion sound).

6) Synchronizing Signal Circuit

The power source synchronizing signal is available in order to compose a basic standard time in the clock circuit. It accompanies a very small error because it works on commercial frequency.

7) Door Sensing Switch

A switch to “tell” the LSI if the door is open or closed.

2) Indicator Circuit

This circuit consists of 22 segments and 3 common electrodes using a Liquid Crystal Display.

8) Back Light Circuit

A circuit to drive the back light (Light emitting diodes LD1- LD4).

LSI(IXA019DR)

The I/O signal of the LSI(IXA019DR) is detailed in the following table.

Pin No. Signal I/O Description

1-2 VL2-VL1 IN Power source voltage input terminal.

Standard voltage for LCD.

3-6 AN7-AN4 IN Terminal to change cooking input according to the Model.

By using the A/D converter contained in the LSI, DC voltage in accordance with the Model

in operation is applied to set up its cooking constant. 7 P63 OUT Terminal not used. 8 AN2 IN Input terminal to judge the model.

Connected to GND through the pull-down resistor R78. 9 AN1 IN To input signal which communicates the door open/close information to LSI.

Door close "H" level signal (0V). Door open "L" level signal (-5V).

10 AN0 IN Input terminal to judge the model.

The signal out of P20 will be input into AN0 through G1 line on key matrix. The LSI will

judge the model by this signal.

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Pin No. Signal I/O Description

11 P57 OUT Back light circuit (Light emitting diodes) driving signal.

12-13 P56-P55 OUT Terminal not used.

14 CNTR0 OUT Signal to sound buzzer (2.0 kHz).

A: Key touch sound.

0.1 sec.

B: Completion sound.

15 P53 OUT Oven lamp, fan motor and turntable motor driving signal

To turn on and off shut off relay (RY1). The

16.7 msec.

square waveform voltage is delivered to the RY1 driving circuit and RY2 control circuit.

2.0 sec.

During cooking

R-305DW

H : GND

L : -5V H : GND

L : -5V

H : GND

L : -5V

16 P52 OUT Magnetron high-voltage circuit driving sig-

nal.

To turn on and off the cook relay (RY2). The signals holds "L" level during microwave cooking and "H" level while not cooking. In other cooking modes (variable cooking) the signal turns to "H" level and "L" level in repetition

OFF

P-HI

OFF OFF

P-70

24 sec.

according to the power level.

(ON and OFF times for other power level.) 17-18 P51-P50 OUT Terminal not used. 19-20 P47-P46 OUT Terminal not used.

21 P45 IN Signal coming from touch key.

When either G12 line on key matrix is touched, a corresponding signal out of P20 - P27 will be input into P45. When no key is touched, the signal is held at "H" level.

22 P44 IN Signal similar to P45.

When either G11 line on key matrix is touched, 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.

16.7 msec.

8 sec.

H : GND

L : -5V H : GND

L : -5V

H : GND

L : -5V

25 P41 IN Signal similar to P45.

When either G9 line on key matrix is touched, a corresponding signal will be input into P41. 26 P40 IN Connected to GND through the pull-down resistor R90. 27 RESET IN 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"

level.

28-29 P71-P70 OUT Terminal not used.

30 XIN IN Internal clock oscillation frequency input setting.

The internal clock frequency is set by inserting the ceramic filter oscillation circuit with

respect to XIN terminal. 31 XOUT OUT Internal clock oscillation frequency control output.

Output to control oscillation input of XOUT. 32 VSS IN Power source voltage: -5.0V.

VC voltage of power source circuit input.

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Pin No. Signal I/O Description

33 P27 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 G8 line keys on key matrix is touched.

34 P26 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 G7 line keys on key matrix is touched.

35 P25 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 G6 line keys on key matrix is touched.

36 P24 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 G5 line keys on key matrix is touched.

37 P23 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 G4 line keys on key matrix is touched.

38 P22 OUT Key strobe signal.

Signal applied to touch-key section. A pulse signal is input to AN0, P41, P43, P44 and P45 terminal while one of G3 line keys on key matrix is touched.

39 P21 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 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. 51-72

SEG21-SEG0

OUT Segment data signal.

Connected to LCD.

The relation between signals are as follows:

LSI signal (Pin No.) LCD (Pin No.) LSI signal (Pin No.) LCD (Pin No.)

SEG 21 (51) .................................. SEG3 SEG 10 (62) ...............................SEG14

SEG 20 (52) .................................. SEG2 SEG 9 (63) ...............................SEG13

SEG 19 (53) .................................. SEG1 SEG 8 (64) ...............................SEG12

SEG 18 (54) ................................SEG22 SEG 7 (65) ...............................SEG11

SEG 17 (55) ................................SEG21 SEG 6 (66) ...............................SEG10

SEG 16 (56) ................................SEG20 SEG 5 (67) .................................SEG9

SEG 15 (57) ................................SEG19 SEG 4 (68) .................................SEG8

SEG 14 (58) ................................SEG18 SEG 3 (69) .................................SEG7

SEG 13 (59) ................................SEG17 SEG 2 (70) .................................SEG6

SEG 12 (60) ................................SEG16 SEG 1 (71) .................................SEG5

SEG 11 (61) ................................SEG15 SEG 0 (72) .................................SEG4

73/74 VCC/VREF IN Connected to GND.

75 AVSS IN Connected to VC. 76 COM3 OUT Terminal not used. 77 COM2 OUT Common data signal: COM1.

Connected to LCD signal C1.

78 COM1 OUT Common data signal: COM2.

Connected to LCD signal C2.

79 COM0 OUT Common data signal: COM3.

Connected to LCD signal C3.

80 VL3 IN Power source voltage input terminal.

Standard voltage for LCD.

Page 23

TOUCH CONTROL PANEL SERVICING

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1. Precautions for Handling Electronic Components

This unit uses CMOS LSI in the integral part of the circuits. When handling these parts, the following precautions should be strictly followed. CMOS LSI have extremely high impedance at its input and output terminals. For this reason, it is easily influenced by the surrounding high voltage power source, static electricity charge in clothes, etc. and sometimes it is not fully protected by the built-in protection circuit. In order to protect CMOS LSI.

1) When storing and transporting, thoroughly wrap them in aluminium foil. Also wrap all PW boards containing them in aluminium foil.

2) When soldering, ground the technician as shown in the figure and use grounded soldering iron and work table.

approx. 1M ohm

2. Servicing of Touch Control Panel

We describe the procedures to permit servicing of the touch control panel of the microwave oven and the precautions you must take when doing so. To perform the servicing, power to the touch control panel is available either from the power line of the oven itself or from an external power source.

(1) Servicing the touch control panel with power supply

of the oven:

CAUTION:

THE HIGH VOLTAGE TRANSFORMER OF THE MICROWAVE OVEN IS STILL LIVE DURING SERVICING AND PRESENTS A HAZARD.

Therefore, before checking the performance of the touch control panel,

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, re-connect the power supply

cord. After checking the performance of the touch control panel,

1) Disconnect the power supply cord.

2) Open the door and block it open.

3) Re-connect the leads to the primary of the power

transformer.

4) Re-install the outer case (cabinet).

5) Re-connect the power supply cord after the outer

case is installed.

6) Run the oven and check all functions.

A. On some models, the power supply cord between the

touch 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 possible to check and repair the controls of the touch control panel while keeping it apart from the oven proper; in this case you must short both ends of the door sensing switch (on PWB) of the touch control panel with a jumper, which activates an operational state that is equivalent to the oven door being closed. As for the sensor-related controls of the touch control panel, checking them is possible if dummy resistor(s) with resistance equal to that of the controls are used.

(2)Servicing the touch control panel with power supply

from an external power source:

Disconnect the touch control panel completely from the oven proper, and short both ends of the door sensing switch (on PWB) of the touch control panel, which activates an operational state that 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

Tools required to service the touch control panel assembly.

1) Soldering iron: 30W (It is recommended to use a soldering iron with a grounding terminal.)

2) Oscilloscope: Single beam, frequency range: DC10MHz type or more advanced model.

3) Others: Hand tools

4. Other Precautions

1) Before turning on the power source of the control unit, remove the aluminium foil applied for preventing static electricity.

2) Connect the connectors of the key unit to the control unit being sure that the lead wires are not twisted.

3) After aluminium foil is removed, be careful that abnormal voltage due to static electricity etc. is not applied to the input or output terminals.

4) Attach connectors, electrolytic capacitors, etc. to PWB, making sure that all connections are tight.

5) Be sure to use specified components where high precision is required.

Page 24

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)

COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE

W ARNING AGAINST HIGH VOL T AGE:

Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts may result in severe, possibly fatal, electric shock. (Example) High Voltage Capacitor, Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..

WARNING:

Avoid possible exposure to microwave energy. Please follow the instructions below before operating the oven.

1. Disconnect the power supply cord.

2. Visually check the door and cavity face plate for damage (dents, cracks, signs of arcing etc.).

Carry out any remedial work that is necessary before operating the oven. Do not operate the oven if any of the following conditions exist;

1. Door does not close firmly.

2. Door hinge, support or latch hook is damaged.

3. The door gasket or seal is damaged.

W ARNING FOR WIRING

To prevent an electric shock, take the following precautions.

1. Before wiring,

1) Disconnect the power supply cord.

2) Open the door block it open.

3) Discharge the high voltage capacitor and wait for 60 seconds.

2. Don’t let the wire leads touch to the following parts;

1) High voltage parts: Magnetron, High voltage transformer, High voltage capacitor and High voltage rectifier assembly.

2) Hot parts: Oven lamp, Magnetron, High voltage transformer

4. The door is bent or warped.

5. There are defective parts in the door interlock system.

6. There are defective parts in the microwave generating and transmission assembly.

7. There is visible damage to the oven.

Do not operate the oven:

1. Without the RF gasket (Magnetron).

2. If the wave guide or oven cavity are not intact.

3. If the door is not closed.

4. If the outer case (cabinet) is not fitted.

and Oven cavity.

3) Sharp edge:

Bottom plate, Oven cavity, Waveguide flange, Chassis support and other metallic plate.

4) Movable parts (to prevent a fault)

Fan blade, Fan motor, Switch.

3. Do not catch the wire leads in the outer case cabinet.

4. Insert the positive lock connector until its pin is locked and make sure that the wire leads do not come off even if the wire leads are pulled.

5. To prevent an error function, connect the wire leads correctly, referring to the Pictorial Diagram.

Please refer to ‘OVEN PARTS, CABINET PARTS, CONTROL PANEL PARTS, DOOR PARTS’, when carrying out any of the following removal procedures:

OUTER CASE REMOVAL

To remove the outer case, proceed as follows.

1. Disconnect the power supply cord.

2. Open the oven door and block it open.

3. Remove the two (2) screws from the lower portion of the rear cabinet using a T20H Torx type or GTXH20-100 screw driver.

4. Remove the remaining two (2) screws from rear and one (1) screw along the right side of outer case.

5. Slide the entire outer case back out about 1 inch (3 cm) to free it from retaining clips on the cavity face plate.

6. Lift entire outer case from the unit.

Special screw

Screw Driver (Type: TORX T20 H or GTXH20-100

Page 25

R-305DW

CAUTION: 1. DISCONNECT OVEN FROM POWER SUP

PLY BEFORE REMOVING OUTER CASE.

2. DISCHARGE THE HIGH VOLTAGE CAPACITOR BEFORE TOUCHING ANY OVEN COMPONENTS OR WIRING.

POWER TRANSFORMER REMOVAL

1. Disconnect the power supply cord and then remove outer case.

2. Open the oven door and block it open.

3. Discharge high voltage capacitor.

4. Disconnect wire leads (primary and high voltage) from power transformer and the filament leads from the magnetron and capacitor terminals.

5. Remove four (4) screws holding transformer to bottom plate.

6. Remove transformer from bottom plate.

TERMINAL INSULATOR REPLACEMENT

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. Open covers of the terminal insulator by using small flat type screw driver.

5. Remove the receptacle from the terminal insulator.

6. Now, the terminal insulator is free.

NOTE: When replacing the outer case, the 2 special

Torx screws must be reinstalled in the same locations.

Reinstallation

1. Rest transformer on the bottom plate with its primary terminals toward the oven face plate.

Secure transformer with four screws to bottom plate.

3. Re-connect wire leads (primary and high voltage) to power transformer and filament leads of transformer to magnetron and high voltage capacitor. Refer to "PICTORIAL DIAGRAM" on page 28.

4. Re-install outer case and check that oven is operating properly.

Installation

1. Insert the receptacle into terminal insulator.

2. Close covers of the terminal insulator, as shown below.

3. Reconnect all leads removed from components during testing.

4. Reinstall the outer case (cabinet).

5. Reconnect the power supply cord after the outer case is installed.

6. Run the oven and check all functions.

Terminal insulator

Flat type screw driver

HIGH VOLTAGE RECTIFIER AND HIGH VOLTAGE CAPACITOR REMOVAL

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 high voltage wire B from the power transformer.

5. Disconnect the high voltage wire of high voltage rectifier assembly from the magnetron.

6. Disconnect the filament lead (short one) of the power transformer from the high voltage capacitor.

7. Remove one (1) screw holding capacitor holder to oven cavity rear plate.

MAGNETRON REMOVAL

Removal

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 all wire leads from magnetron.

5. Remove the five (5) screws holding chassis support to

Covers

Receptacle

8. Remove one (1) screw holding high voltage rectifier assembly to capacitor holder.

9. Disconnect rectifier terminal from capacitor. High voltage rectifier assembly is now free.

10.Disconnect the high voltage wire B from the high voltage capacitor.

11.Remove capacitor holder. Capacitor is now free.

CAUTION: WHEN REPLACING HIGH VOLTAGE RECTI-

FIER AND HIGH VOLTAGE CAPACITOR, GROUND SIDE TERMINAL OF THE HIGH VOLTAGE RECTIFIER MUST BE SECURED FIRMLY WITH A GROUNDING SCREW.

magnetron, oven cavity back plate, oven cavity front flange and fan duct.

6. Remove the chassis support from oven.

7. Carefully remove the four (4) screws holding magnetron to waveguide flange.

8. Lift up magnetron with care so that magnetron antenna is not hit by any metal object around antenna.

Page 26

R-305DW

Terminal

Push

Pull down

Lever

Positive lock® connector

9. Now, the magnetron is free.

Reinstallation

1. Re-install the magnetron to waveguide flange with the four (4) screws.

2. Insert the two (2) tabs of the chassis support to the oven cavity front plate and the back plate.

3. Hold the chassis support to the oven cavity back plate, oven cavity front flang, magnetron and the fan duct with the five (5) screws.

OVEN LAMP AND LAMP SOCKET REMOVAL

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.

5. Pull the wire leads from the oven lamp socket by pushing the terminal hole of the oven lamp socket with the small flat type screw driver.

6. Bend the tab of the partition angle holding the lamp socket.

7. Lift up the oven lamp socket.

8. Now, the oven lamp socket is free.

4. Reconnect the wire leads to the magnetron and thermal cut-out (MG). Refer to "PICTORIAL DIAGRAM" on page

28.

5. Re-install outer case and check that the oven is operating properly.

CAUTION: WHEN REPLACING MAGNETRON, BE SURE

THE R.F. GASKET IS IN PLACE AND MOUNTING SCREWS ARE TIGHTENED SECURELY

Oven lamp socket

Terminal

Wire lead

Terminal hole

Flat type small screw driver

Figure C-1. Oven lamp socket

POSITIVE LOCK® CONNECTOR (NO-CASE TYPE) REMOVAL

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. Push the lever of positive lock® connector.

5. Pull down on the positive lock® connector.

CAUTION: WHEN CONNECTING THE POSITIVE LOCK

CONNECTORS TO THE TERMINALS, CONNECT THE POSITIVE LOCK® SO THAT THE LEVER FACES YOU

CONTROL PANEL ASSEMBLY REMOVAL

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 wire leads from the door sensing switch and the oven cavity front flange.

5. Disconnect the wire leads from panel components.

6. Make one (1) tab of the oven cavity front plate straight holding the control panel assembly to the oven flange.

7. Slide the control panel assembly upward and remove it.

8. Now, individual components can be removed.

NOTE: 1. Before attaching a new key unit, wipe off remaining

adhesive on the control panel frame surfaces completely with a soft cloth soaked in alcohol.

2. When attaching the key unit to the control panel frame, adjust the upper edge and right edge of the key unit to the correct position of control panel frame.

Figure C-2. Positive lock® connector

3. Stick the key unit firmly to the control panel frame by rubbing with soft cloth not to scratch.

CPU UNIT NOTE: Handle the CPU unit carefully so that the ribbon

cable does not come off. Because the ribbon cable is glued on the LCD and the printed wiring board only by heated paste.

Ribbon cable

Liquid Crystal

Display (LCD)

of CPU unit

Printed wiring board

CPU unit

Page 27

TURNTABLE MOTOR REMOVAL

R-305DW

1. Disconnect the power supply cord.

2. Remove turntable and turntable support from oven cavity.

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.

COOLING FAN MOTOR REMOVAL

REMOVAL

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 wire leads from the fan motor.

5. Remove the magnetron and chassis support from the waveguide flange, referring to "MAGNETRON REMOVAL".

Release the snap of the main wire harness from the fan duct.

7. Remove one (1) screw holding the fan duct assembly to oven cavity.

Release the main wire harness from the hole of the fan duct.

9. Release the fan duct from the waveguide flange.

10.Release the fan duct assembly from the oven cavity.

11.Remove the fan blade from the fan motor shaft according to the following procedure.

12.Hold the edge of the rotor of the fan motor by using a pair of groove joint pliers.

CAUTION: * Make sure that no metal pieces enter the gap between

the rotor and the stator of the fan motor because the rotor is easily shaven by pliers and metal pieces may be produced.

* Do not touch the pliers to the coil of the fan motor

because the coil may be cut or damaged.

* Do not disfigure the bracket by pinching with the

pliers.

13.Remove the fan blade from the shaft of the fan motor by pulling and rotating the fan blade with your hand.

14. Now, the fan blade will be free.

CAUTION: * Do not reuse the removed fan blade because the

hole (for shaft) may be larger than normal.

Coil

Groove joint pliers

5. Disconnect wire leads from turntable motor. (See "Positive lock connector removal")

6. Remove two (2) screws holding turntable motor to oven cavity.

7. Now the turntable motor is free.

8. After replacement use the one (1) screw to fit the turntable motor cover.

15.Remove the two (2) screws holding the fan motor to the fan duct.

16.Now, the fan motor is free.

INSTALLATION

1. Install the fan motor to the fan duct with the two (2) screws.

2. Install the fan blade to the fan motor shaft according to the following procedure.

3. Hold the center of the bracket which supports the shaft of the fan motor on the flat table.

4. Apply the screw lock tight into the hole (for shaft) of the fan blade.

5. Install the fan blade to the shaft of fan motor by pushing the fan blade with a small, light weight, ball peen hammer 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 smooth after

installation.

* Make sure that the axis of the shaft is not slanted.

6. Catch three holes of fan duct on three tabs of the waveguide flange.

7. Install the fan duct assembly to the oven cavity with the one (1) screw.

8. Insert the snap of the main wire harness to the hole of the fan duct and insert the main wire harness into the hole of the fan duct.

9. Install the magnetron and the chassis support to the oven cavity, referring to "Re-install of MAGNETRON REMOVAL".

10.Connect the wire leads to the fan motor, referring to the pictorial diagram.

Shaft

Stator

Gap Bracket

Rotor

Rear View

Axis

Shaft

Stator

Rotor

Side View

These are the positions that should be pinched with pliers

Table

Center of bracket

Page 28

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DOOR SENSING SWITCH/SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH REMOVAL

Disconnect 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.

Remove two (2) screws holding latch hook to oven flange.

6. Remove latch hook assembly from oven flange.

7. Push outward on the two (2) retaining tabs holding switch in place.

8. Switch is now free.

Reinstallation

1. Re-install each switch in its place. The secondary interlock/monitor switches are in the lower position and the door sensing switch is in the upper position.

2. Re-connect wire leads to each switch. Refer to pictorial diagram.

3. Secure latch hook (with two (2) mounting screws) to oven flange.

4. Make sure that the monitor switch is operating properly and check continuity of the monitor circuit. Refer to chapter "Test Procedure" and Adjustment procedure.

DOOR SENSING SWITCH/SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH ADJUSTMENT

1. Disconnect the power supply cord, and then remove outer case.

2. Open the door and block it open.

3. Discharge high voltage capacitor.

If the door sensing switch, secondary interlock switch and monitor switch do not operate properly due to a misadjustment, the following adjustment should be made.

4. Loosen the two (2) screws holding latch hook to the oven cavity front flange.

5. With door closed, adjust latch hook by moving it back and forth, and up and down. In and out play of the door allowed by the upper and lower position of the latch hook should be less than 0.5mm. The vertical position of the latch hook should be adjusted so that the door sensing switch and secondary interlock switch are activated with the door closed. The horizontal position of the latch hook should be adjusted so that the plunger of the monitor switch is pressed with the door closed.

6. Secure the screws with washers firmly.

7. Check the operation of all switches. If each switch has not activated with the door closed, loosen screw and adjust the latch hook position.

After adjustment, 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 hook, pushing and pulling lower portion of the door toward the oven face. Both results (play in the door) should be less than 0.5mm.

2. The contacts of door sensing switch and secondary interlock switch open within 0.9mm gap between right side of cavity face plate and door when door is open.

3. Monitor switch contacts close when door is opened.

4. Re-install outer case and check for microwave leakage around door with an approved microwave survey meter. (Refer to Microwave Measurement Procedure.)

Door

Latch Heads

Latch Hook

Door Sensing Switch

Monitor Switch Secondary

Interlock Switch

Figure C-3. Latch Switch Adjustments

DOOR REPLACEMENT

REMOVAL

1. Disconnect the power supply cord.

2. 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 cover from door panel.

6. Now choke cover is free.

7. Release two (2) pins of door panel from two (2) holes of upper and lower oven hinges by lifting up.

8. Now, door panel with door frame is free from oven cavity.

Door Frame

Putty Knife

Choke Cover

Figure C-4. Door Disassembly

9. Remove the four (4) screws holding the door panel to the door frame.

10.Release door panel from eight (8) tabs of door frame.

Page 29

R-305DW

11.Now, door panel with sealer film is free.

12.Tear sealer film from door panel.

13.Now, door panel is free.

14.Slide latch head upward and remove it from door frame with releasing latch spring from door frame and latch head.

15.Now, latch head and latch spring are free.

16.Remove door screen from door frame.

17.Now, door screen is free.

REINSTALLATION

1. Re-install door screen to door frame .

2. Re-install the latch spring to the latch head. Re-install the latch spring to the door frame. Re-install latch head to door frame.

3. Re-install door panel to door frame by fitting eight (8) tabs of door frame to eight (8) holes of door panel.

4. Hold the door panel to the door frame with the four (4) screws.

5. Put sealer film on door panel. Refer to “Sealer Film” about how to handle new one.

6. Catch two (2) pins of door panel on two (2) hole of upper and lower oven hinges.

7. Re-install choke cover to door panel by pushing.

Note: After any service to the door; (A) Make sure that door sensing switch and secondary

interlock switch are operating properly. (Refer to chapter “Test Procedures”.).

(B) An approved microwave survey 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. Door is positioned with its face pressed toward cavity face plate.

4. Check for microwave leakage around door with an approved microwave survey meter. (Refer to Microwave Measurement Procedure.)

Note: The door on a microwave oven is designed to act as

an electronic seal preventing the leakage of microwave energy from oven cavity during cook cycle. This function does not require that door be airtight, moisture (condensation)-tight or light-tight. Therefore, occasional appearance of moisture, light or sensing of gentle warm air movement around oven door is not abnormal and do not of themselves indicate a leakage of microwave energy from oven cavity.

Upper Oven Hinge

Lower Oven

Upper Oven Hinge

Lower Oven Hinge

Hinge

Choke Cover

Figure C-5. Door Replacement

SEALER FILM

Installation

1. Put the adhesive tape on the backing film of the sealer film as shown in Fig. C-6.

2. Tear the backing film by pulling the adhesive tape.

3. Put the pasted side of the sealer film on the door panel

Sealer film

Backing film

Adhesive tape

Figure C-6. Sealer film

Page 30

R-305DW

NOTE:

The grounding conductor of

the power supply cord has

been grounded by power

NOTE:

BLUE MARK

YLW

BLK

WHT

supply cord fixing screw.

The screw must allways be

kept tight.

Hot (YLW) wire must be

connected to the terminal

with blue mark on the

oven light socket.

WHT

OVEN LAMP

AND SOCKET

POWER SUPPLY

CORD 120V 60Hz

BLK

NOTE:

The neutral (WHT) wire must be

connected to the neutral (WHT)

wire of the power supply cord.

THERMAL

CUT-OUT (MG)

BLK

THERMAL

CUT-OUT (OVEN)

BLK

GRY

WHT

FAN MOTOR

RECTIFIER H.V.

HIGH VOLTAGE

CAPACITOR

HIGH VOLTAGE

WIRE B

POWER

MAGNETRON

HIGH VOLTAGE COMPONENTS

GRY

BLK

TURNTABLE

RED

WHT

MOTOR

GRY

TRANSFORMER

BLK

RED

GRN

N.O.

DOOR

SENSING

SWITCH

COM.

GRN

CONTROL UNIT

GRN

(To oven cavity front flange.)

CN-C

IC1

CN-G

(CPU UNIT)

GRN

RED

SH-B

CN-C

SH-A

WHT 1

CN-A

PRIMARY

INTERLOCK

RELAY

SP1

RED

YLW

WHT

RED

YLW

COM.

N.C.

BLK

RY2

RY1

MONITOR

SWITCH

YLW

BLK

FUSE

HOLDER

CN-A

BLK

GRY

SECONDARY

(POWER UNIT)

WHT

COM.

INTERLOCK

SWITCH

WHT

Figure S-1. Pictorial Diagram

Page 31

R-305DW

+ –

A 1

C 3

C 5

C 4

C 6

C 8

C 1

C 7

C 2

A 2

SH-A

COM

GND

D1 S1NB10

GND

INT

BUZZER

MICRO

DOOR SENSING SWITCH

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

(J1)

VRS1

SP1

C1 1000µ/25v

10G471K

SH-B

C 9

Figure S-2. Power Unit Circuit

Page 32

R-305DW

OZ.

NO.

LBS.

CUPS

LIQUID CRYSTAL DISPLAY

CPU UNIT

AUTO

DEFROST

COOK

GND

R7 4.7k

0.01µ/25v C4

R5 1k

–

125

COM1 COM2 COM3 SEG22 SEG21 SEG20 SEG19 SEG18 SEG17 SEG16 SEG15 SEG14 SEG13 SEG12 SEG11 SEG10 SEG 9 SEG 8 SEG 7 SEG 6 SEG 5 SEG 4 SEG 3 SEG 2 SEG 1

R8 4.7k

R6 15k

2SA1037AK

C3 0.01µ/25v

C2 220µ/10v

R9 4.7k

(J11) 4.7k

UDZ4.3B ZD1

(J10)

6580

SEG7 SEG6 SEG5 SEG4 SEG3 SEG2 SEG1 SEG0

VCC

VREF AVSS COM3 COM2 COM1 COM0

VL3

(J15) 4.7k

(J13) 4.7k

(J14)

(J12)

R10 15k

SEG8

SEG9

SEG10

VL2

VL1

AN7

(J17) 4.7k

(J16)

C11 0.01µ/25v

SEG11

AN6

SEG12

AN5

SEG13

AN4

SEG14

P63

SEG15

AN2

SEG16

AN1

SEG17

AN0

SEG18

P57

SEG19

IC1

P56

P06

P07

P10

P11

P12

SEG21

SEG20

IXA019DR

P55

P53

P52

P51

P50

P47

CNTR0

15k R60

ROLLS &

MUFFINS

15k R61

PLUS

FRESH

VEGETABLES

5 4 3 2 1

0 9 8 7 6

COMPU

DEFROST

TIMER

CLOCK

START

BAKED

POPCORN

POTATOES

CASSEROLE

STOP

LEVEL

CLEAR

POWER

BEVERAGE

15k R62

MINUTE

15k R63

15k

P13

P14

P15

P16

P17

P20 P21 P22 P23 P24 P25 P26 P27

VSS

XOUT XIN P70 P71

RESET P40 P41

P46

P45

25 40

P44

P43

INT0

R64

15k R65

15k R66

15k R67

G 7 G 6 G 5 G 4 G 3 G 2 G 1

G 8

KEY UNIT

R90 15k

G 9

G10

G11

G12

G13

G14

R80

CF1 CST4.00MGW

C60-65 330pF/50v

C60 C61 C62 C63 C64

C65

R74 270k R75 270k R76 270k R77 270k

/25v

0.01µ C40

R78 270k R79 270k

R68 15k

R69 15k

R70 15k

R71 15k

R72 15k

Figure S-3. CPU Unit Circuit

R73 15k

Q10

DTA143EKA

R12 4.7k

R2 4.7k

R1 82

2SA1037AK

/50v

0.1µ C10

R4 560 1/2w

Q30

DTA143EKA

Q21

C20 0.1µ/50v

Q20

DTA143EKA

–

C21

DTD143EKA

/35v 10µ

R41 15k

4.7k

R40

Q22

DTA123JKA

LD1 LD2 LD3 LD4

C1 0.1µ/50v

C-3

C-5

GND

R30 3.3k

C-9

C-4

C-2

C-6

D20

C-7

MA152WA

C-8

C-1

D40

MA152WA

: IF NOT SPECIFIED 1/10W ± 5%

NOTE

OVEN LAMP

TURNTABLE

MOTOR

FAN MOTOR

INT

BUZZER

DOOR

SENSING

MICRO

SWITCH

Page 33

R-305DW

SH - A

CN - B

SH - B

CN - C

D I P

SP1

(D2)

RY2

(D3)

RY1

(J1)

VRS1

CN - A

Figure S-4. Printed Wiring Board of Power Unit

Page 34

R-305DW

PARTS LIST

Note: The parts marked “∆” may cause undue microwave exposure.

The parts marked “*” are used in voltage more than 250V.

REF. NO. PART NO. DESCRIPTION Q'TY CODE

ELECTRIC PARTS

1- 1 QSW-MA147WRZZ 2nd interlock switch / door sensing switch 2 AG 1- 2 QFSHDA009WRE0 Fuse holder 1 AH 1- 3 FFS-BA021WRK0 1- 4 RTHM-A078WRE0 Thermal cut-out 125 deg. 1 AL 1- 5 FACCDA082WRE0 Power supply cord 1 AV 1- 5 FACCDA081WRE0 Power supply cord (Interchangeable) 1 AP 1- 6 FH-DZA088WRK0 High voltage rectifier assembly 1 AP

1- 7 RC-QZA173WRE0 High voltage capacitor 1 AX

1- 8 RV-MZA288WRE0 Magnetron 1 BK

∆

1- 9 RMOTEA383WRE0 Fan motor 1 AV 1- 9 RMOTEA355WRE0 Fan motor (Interchangeable) 1 AU 1-10 QSOCLA021WRE0 Oven lamp socket 1 AH 1-11 RLMPTA068WRE0 Oven lamp 1 AG 1-11 RLMPTA030WRE0 Oven lamp (Interchangeable) 1 AE 1-12 RMOTDA229WRE0 Turntable motor 1 AQ 1-12 RMOTDA211WRE0 Turntable motor (Interchangeable) 1 AS 1-13 RTHM-A080WRE0 Thermal cut-out 145 deg. 1 AP 1-14 RTRN-A576WRE0 Power transformer 1 BM

2- 1 GCABUA690WRP0 Outer case cabinet 1 AZ 2- 2 GDAI-A316WRW0 Bottom plate 1 AX 2- 3 GLEGPA074WRE0 Foot 2 AC 2- 4 GLEGPA077WRF0 Leg 1 AH

3- 1 DPWBFC021WRKZ Power unit 1 BA 3- 1A QCNCMA446DRE0 2-pin connector (CN-A) 1 AC 3- 1B FW-VZA250DRE0 9pin wire harness (CN-C) 1 AW 3- 1C FW-VZA195DRE0 Switch harness A (SH-A) 1 AD 3- 1D FW-VZA256DREZ Switch harness B (SH-B) 1 AF C1 VCEAB31EW108M Capacitor 1000 uF 25V 1 AE D1 RSRCDA013DRE0 Diode bridge (S1NB10) 1 AG RY1 RRLY-A094DRE0 Relay (OMIF-S-112LM) 1 AN RY2 RRLY-A114DRE0 Relay (DU12D1-1P(M)-R) 1 AN SP1 RALM-A014DRE0 Buzzer (PKM22EPT) 1 AG T1 RTRNPA110DRE0 Transformer 1 AP VRS1 RH-VZA032DRE0 Varistor (10G471K) 1 AE 3- 2 DPWBFC020WRKZ CPU unit 1 BA 3- 3 FPNLCB510WRKZ Control panel frame with key unit 1 BC 3- 3-1 FUNTKB005WREZ Key unit 1 AX 3- 4 PSHEPA588WRE0 LED sheet 1 AE 3- 5 LHLD-A205WRF0 LCD holder 1 AF 3- 6 XEPSD30P08XS0 Screw; 3mm x 8mm 4 AA

4- 1 PDUC-A724WRF0 Air separater 1 AU 4- 2 PPACGA084WRF0 TTM packing 1 AF 4- 3 PHOK-A116WRFZ Latch hook 1 AH

∆

4- 4 LBNDKA099WRW0 Capacitor holder 1 AD 4- 5 NFANJA029WRE0 Fan blade 1 AL 4- 6 PDUC-A728WRW0 Fan duct 1 AT 4- 7 ************* Oven cavity (Not a replaceable part) 1--

∆

4- 8 LANGFA194WRW0 Chassis support 1 AU 4- 9 PCUSGA321WRP0 Cushion 1 AH 4-10 LANG-A063WRPZ Air guide 1 AH 4-11 LANG-A064WRPZ Barrier 1 AK 4-12 NCPL-A053WRFZ Coupling 1 AE 4-13 PCUSUA511WRP0 Cushion 1 AC 4-14 PCOVPA349WRE0 Waveguide cover 1 AE 4-15 PCUSGA339WRP0 Cushion 2 AG 4-16 PCUSUA212WRP0 Cushion 1 AB 4-17 PCUSUA512WRP0 Cushion 1 AB 4-18 PCUSUA474WRP0 Cushion 2 AC 4-19 PCUSUA527WRP0 Cushion 1 AE 4-20 PCUSUA157WRP0 Cushion 2 AC 4-21 PCUSGA399WRE0 Cushion 1 AF

Monitor fuse 20A and monitor switch (V-16G-2C25) assembly

CABINET PARTS

CONTROL PANEL PARTS

OVEN PARTS

1AL

Page 35

REF. NO. PART NO. DESCRIPTION Q'TY CODE

DOOR PARTS

5- 1 FDORFA332WRT0 Door panel 1 BD

∆

5- 2 PSHEPA382WRE0 Sealer film 1 AH 5- 3 GWAKPA701WRRZ Door frame 1 AV

∆

5- 4 HPNL-A734WRRZ Door screen 1 AS 5- 5 LSTPPA193WRFZ Latch head 1 AE

∆

5- 6 MSPRTA187WRE0 Latch spring 1 AC 5- 7 XCPSD40P08000 Screw : 4mm x 8mm 4 AA 5- 8 PCUSUA461WRP0 Cushion 1 AB 5- 9 GCOVHA417WRFZ Choke cover 1 AG

MISCELLANEOUS

6- 1 FROLPA079WRK0 Turntable support 1 AQ 6- 2 NTNT-A079WRE0 Turntable tray 1 AR 6- 3 FW-VZB787WREZ Main wire harness 1 AU 6- 4 QW-QZA150WRE0 High voltage wire B 1 AF

6- 5 PZET-A012WRE0 Terminal insulator 1 AB 6- 6 TCAUAA166WRR0 DHHS caution label 1 AC 6- 7 TCAUAA254WRR0 Monitor caution label 1 AC 6- 8 TINSEA848WRRZ Instruction book 1 AK 6- 9 TCAUAA255WRR0 Screw caution 1 AC

SCREWS,NUTS AND WASHERS

7- 1 XHPSD40P08K00 Screw : 4mm x 8mm 9 AA 7- 2 XHPSD30P06000 Screw : 3mm x 6mm 1 AA 7- 3 XHTSD40P08RV0 Screw : 4mm x 8mm 4 AA 7- 4 XHTSD40P12RV0 Screw : 4mm x 12mm 1 AA 7- 5 XOTSD40P12RV0 Screw : 4mm x 12mm 3 AA 7- 6 XOTSD40P12000 Screw : 4mm x 12mm 16 AA 7- 7 XOTSE40P08000 Screw : 4mm x 8mm 1 AA 7- 8 LX-CZA070WRE0 Special screw (Torx tamper proof screw) 2 AC 7- 9 LX-CZ0052WRE0 Special screw 2 AA

R-305DW

HOW TO ORDER REPLACEMENT PARTS

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 36

R-305DW

OVEN AND CABINET PARTS

4-17

1-4

7-6

4-11

4-7

1-11

4-18

1-10

4-20

6-7

2-1

7-5

7-8

7-5

7-1

7-8

4-13

1-8

4-19

6-6

7-6

7-7

4-10

7-3

6-9

7-3

1-5

7-4

4-20

7-6

4-18

7-2

7-3

4-8

7-6

1-6

1-1

1-2

7-5

7-1

4-4

7-1

1-7

1-13

7-6

1-3

4-5

4-12

4-16

4-14

4-15

7-9

6-2

4-2

1-12

4-9

6-1

7-1

1-14

4-3

1-1

4-1

2-2

4-21

2-4

1-9

4-6

7-6

2-3

7-6

2-3

7-6

Page 37

R-305DW

3-2

CONTROL PANEL PARTS

3-5

3-6

3-3

3-4

3-6

3-1

3-3-1

DOOR PARTS

5-9

5-7

5-2

5-7

5-1

5-7

5-3

5-7

5-5

5-4

5-6

5-8

6-3

MISCELLANEOUS

(CAPACITOR)

6-4

6-5

Actual wire harness may be different from illustration.

Page 38

R-305DW

TOP PAD ASSEMBLY FPADBA416WRKZ

PACKING AND ACCESSORIES

DOOR PROTECTION SHEET SPADPA204WRE0

PLASTIC BAG

6- 8 INSTRUCTION BOOK & PRINTING MATTER

6- 2 TURNTABLE TRAY

INTO THE OVEN CAVITY

6- 1 TURNTABLE SUPPORT

TRAY PACK SPADFA451WRE0

SSAKHA034WRE0

BOTTOM PAD ASSEMBLY FPADBA417WRKZ

Not replaceable items.

PACKING CASE

SPAKCD410WREZ

Page 39

R-305DW

Page 40

R-305DW

No part of this publication may be reproduced, stored in retrieval systems, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher.

2000 SHARP CORP. (3S2.530E) Printed in U.S.A

Sharp R305dw Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual