SHARP R509BE, R-509BK Service Manual

SHARF?
R-509BK
S88M118R509BE
MICROWAVE OVEN
R-509BK
In the interest of user-safety the oven is to be restored to its original condition and only the 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 the 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

SECTION
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICE TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY.
Before Servicing .............................................................
Forewordand Warning
Warning to Service Personnel
Specifications ...............................................................................
General Information
KeyUnitLayout .............................................................................
Operation ..................................................................................
Servicing and Troubleshooting Guide ..........................................................
TestProcedures Touch Control Outline Component Replacement and Adjustment Procedure Microwave Measurement Procedure
Wiring/Schematic Diagram ..................................................................
Parts .....................................................................................
PackingandAccessories.. ...................................................................
............................................................................
............................................................
......................................................
.........................................................................
.......................................................................
...........................................
..........................................................
MODEL
cs
PAGE
........... Inside Front Cover
Inside Front Cover
1
2 3 4 5 6
8 10 18 22 28 29 34 38
SHARP ELECTRONICS CORPORATION
Service Headquarters: Sharp Plaza, Mahwah, New Jersey, 07430-2135
R-509BK
a
Do not operate or allow the oven to be operated with the door open.
( )
Make the following safety checks on all ovens to be serviced before activating the magnetron
(b)
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.
C
Before turning on microwave power for any service test or inspection within the microwave gen-
( )
erating compartments, check the magnetron, waveguide or transmission line, and cavity for proper alignment, integrity, and connections.
Any defective or misadjusted components in the interlock, monitor, door seal, and microwave
(co
generation and transmission systems shall be repaired, replaced, or adjusted by procedures described in this manual before the oven is released to the owner.
A microwave leakage check to verify compliance with the Federal Performance Standard
e
( )
should be performed on each oven prior to release to the owner.
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 @ I-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 DHHS immediately.
(RD21101U)
Service personnel should inform SHARP ELECTRONICS CORPORATION of any certified unit found with emissions in excess of 4mW/cm2m The owner of the unit should be instructed not to use the unit until the oven has been brought into compliance.
(RD81001 U)
SERVICE MANUAL
SHARR
R-509BK
Microwave Oven
R509BK

Foreword

This manual has been prepared to provide Sharp
Electronics Corporation personnel with complete operation and service information for Sharp microwave oven model R-509BK.
It is recommended that service personnel carefully study the entire text of this manual so they will be
qualified to render satisfactory customer service.
Check interlock switches and the door seal carefully.
Special attention must be given to avoid electrical shock
and microwave radiation hazards.
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 are no other visible signs of damage to the
oven.
DANGER
Certain initial parts are intentionally not grounded and present a risk of electrical shock only during servicing. Service personnel - Do not contact the fol-
lowing parts while the appliance is energized;
High Voltage Capacitor, Power Transformer, Magne­tron, High Voltage Rectifier Assembly and High volt­age Harness.
If provided, Vent Hood, Fan Assembly and Cooling
Fan motor.
All of the parts marked
ages more than 250V.
Removal of the outer case cabinet gives accessto volt=
age above 25OV.
All of the parts marked “A” on parts list may cause undue
microwave exposure, by themselves, or when they are
damaged, loosened or removed.
“*” on parts list are used at volt-
Specifications
General Information
Key Unit Layout
Operation
Troubleshooting / Test Procedures
Touch Control Panel
Component Replacement and Adjustment
/ Microwave Measurement
Wiring / Schematic Diagram
Sharp Electronics Corporation
Sharp Plaza
Mahwah, New Jersey 07430-2135
1
R-509BK

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.
(EXAMPLE) High Voltage Capacitor, High Voltage Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc.. Read the Service Manual carefully and follow all instructions.

Before Servicing

1. Disconnect the power supply cord and then remove outer case cabinet.
2. Open the door and block it open.
3. Discharge the high voltage capacitor.
WARNING:RlSK OF ELECTRICAL SHOCK. DISCHARGE THE HIGH VOLTAGE CAPACITOR BEFORE SERVICING.
The high-voltage capacitor remains charged about 60 se-
conds after the oven has been switched off. Wait for 60 se­conds and then short-circuit the connection of the high volt­age capacitor (that is the connecting lead of the high voltage rectifier) against the chassis with the use of an insulated screwdriver.
Whenever troubleshooting is performed, the power sup­ply must be disconnected. In some cases it may 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 cabinet.
2.
Open the door and block it open.
3.
Discharge the high voltage capacitor.
4.
Disconnect the leads to the primary of the power
transformer.
Ensure that the leads remain isolated from other
5. components and oven chassis by using insulation tape.
6.
After the above procedure, reconnect the power sup­ply cord.

When the testing is completed

1. Disconnect the power supply cord and then remove outer case cabinet.
2. Open the door and block it open.
3. Discharge the high voltage capacitor.
4. Reconnect the leads to the primary of the power
transformer.
5. Re-install the outer case cabinet.
6. Reconnect the power supply cord after the outer case cabinet is installed.
7. Start the oven and check all functions.

After repairing

I. Reconnect all leads removed from components dur-
ing testing.
2. Re-install the outer case (cabinet).
3. Reconnect the power supply cord after the outer case is installed.
4. Reconnect the power supply cord after the outer
case is installed.
5. Run the oven and check all functions.
Microwave ovens should not be operated 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 HfGH and set the miccowave timer for two (2) minutes. When the two minutes has elapsed (timer at zero), carefully check to see if the wa­ter is hot. If the water remains cold, carry out Before Servicing procedure and re-examine the connection 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 the microwave leakage test should be car-
ried out.

SPECIFICATIONS

R-509BK
Item
Power Requirements
Power Output
Case Dimensions
Cooking Cavity
1.8 Cu.Ft.
Control Complement
Description
120 Volts
14.0 Amperes 1650 Watts 60 Hertz Single phase, 3 wire grounded
1100 watts (IEC-705 Test Procedure)
Operating frequency of 2450 MHz
Width 23.94”
Height 13.27” (including feet) Depth 19”
Width 17”
Height 9.96”
. Depth 17.8”
Tray Size 16” Diameter
Touch Control System
Clock (I:00 - 1259) Timer (0 - 99 min. 99 sec.) Microwave Power for variable cooking
Repetition Rate;
P-HI (HIGH) . . , . . . . . .
P-90 . . . . . . . . , . . . . . . . . approx. 90% of full power
P-80 . . . . . . . . . . . . . . . . . approx. 80% of full power
P-70 (MED HIGH) . . . .
P-60 . . . . . . . . . . . . . . . . .
P-50 (MED) . . . . . . . a.. approx. 50% of full power
P-40 . , . . . . . . . . . . . . . . .
P-30 (MED LOW) . . . . .
P-20 . . , . . . . . . . . . , . . . .
P-IO . . * . , . . . . . . . . . . . .
P-O................... No power throughout the cooking time
Full power throughout the cooking time
approx. 70% of full power
approx. 60% of full power approx. 40% of full power
approx. 30% of full power approx. 20% of full power approx. 10% of full power
Oven Cavity Light Safety Standard
FEATURES
Instant Action Compu Defrost(3) Minute Plus
Timer/Clock
Popcorn Variable Power (10) 4 Stage Cooking
Yes
UL Listed FCC Authorized DHHS Rules, CFR, Title 21, Chapter 1, Subchapter J
R-509BK

GENERAL INFORMATION

Grounding Instructions

This oven must be fully grounded at all times. This appliance must be connected to a 120 volt, 60 Hz, AC only, 15 Ampere or more 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.
WARNING: Improper use of the grounding plug can
result in a risk of electric shock.
Where a two-pronged wall-receptacle is encountered, it is the personal responsibility and obligation of the cus­tomer to contact a qualified electrician and have it re­placed with a properly polarized and grounded three­pronged wall receptacle or use a grounding adaptor. If an extension cord must be used, it should be a 3-wire,
15 ampere minimum cord.
Grounded
Grounded
Grounding Pin
3 Pronged Receptacle
Receptacle Box
Grounding Screw
Do not under any circumstances cut or remove the
round grounding prong from this plug.
Oven
Diagram
1. Digital display
2. Auto-Touch control panel
3. Door open button
4. Door latches
5. Removable turntable support
6. Removable turntable
7. Oven lamp
8. Oven door with see through window
9. Waveguide cover
10. Power Cord
4

Key Unit Layout

a. Indicators. b. Lighted digital display. c. SNACKS/COOKING/REHEATING pad.
Touch to cook or reheat popluar items using a pre-set time constant.
d. COMPU DEFROST pad.
Touch to defrost certain foods. e. Number selection pads. f. TIMER/CLOCK pad.
Touch to set clock and minute timer function. g. START/MINUTE PLUS pad.
Touch to start oven or Touch to cook for 1 minute at 100% power or to increase cooking time.
h. STOP/CLEAR pad.
Touch to erase during programming. Touch once to stop operation of oven during cooking. Touch twice to cancel cooking program.
i. POWER LEVEL pad.
Touch to select microwave power setting.
R-509BK
1 Ground meat 2 Steaks/chops 3 Chicken pieces
f
1
4
COMPU
DEFROST
2 3 5 6
a
-0
b
-0
C
-0
\
i
o-
h
o-
5
7 '8
POWER
LEVEL
STOP
CLEAR
I
0 CLOCK
9
TIMER -.
START
MINUTE PLUS ,,
I
R-509BK

Description of Operating Sequence

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

OPERATION

interlock relay and is mechanically associated with
the door so that it functions as follows:

Off Condition

Closing the door activates the door sensing switch and secondary interlock switch. In this condition, the moni­tor switch contacts are opened. When the oven is plugged in, 120 volts AC is supplied to the control unit (see schematic diagram). The display flashes SHARP SIMPLY THE BEST. To set any program or set the clock, first touch the STOP/CLEAR pad. The display clears and “ : ”
appears and the control unit counts every min-
ute.

Cooking Condition

Program desired cooking time and Variable Cooking
Control by touching the NUMBER pads and the Power
Level pad of the Variable Cooking Control. When
START is touched, the following operations occur:
1.
The relay contacts are closed and components con­nected to the relays (RY-1 and RY-2) are turned on. (For details, see table below.)
Relay Components
RY-1 RY-2 Power Transformer
2.
120 volts AC is supplied to the primary winding of the
power transformer and is converted to approximate-
ly 3.4 volts AC on the filament winding and approxi­mately 2400 volts AC on the high voltage winding.
The filament winding voltage heats the magnetron
3. filament and the high voltage is sent to a voltage dou-
bler circuit.
4.
The microwave energy produced by the magnetron
is channeled through the waveguide into the cavity feed-box and into the cavity where the food is cooked.
Upon completion of the cooking cycle, the power
5. transformer, oven lamp and cooling fan are turned off
and the generation of microwave energy is termi­nated.
When the door is opened during a cook cycle, the
6.
monitor switch, door sensing switch, secondary in­terlock switch and primary interlock relay are acti­vated with the following results. The turntable motor,
cooling fan motor and the high voltage components
are de-energized. The oven lamp remains on and the digital readout displays the time still remaining in the cook cycle when the door was opened.
The monitor switch is electrically monitoring the op-
7. eration of the secondary interlock switch and primary
Oven Lamp/Turntable Motor/Fan Motor
a.
When the door opens from a closed position, the
( )
secondary interlock switch and primary interlock relay open their contacts, then the monitor switch contacts close.
.
- (W
When the door is closed from the open position, the monitor switch contacts first open and the contacts of the secondary interlock switch close.
If the secondary interlock switch and the primary inter-
lock relay contacts are closed when the door is opened, the monitor switch contacts form a short circuit through the monitor fuse, secondary interlock switch and prima-
ry interlock relay causing the monitor fuse to blow.
Power Level P-O to P-90 Cooking
When Variable Cooking Power is programmed, 120 volts AC is supplied to the power transformer intermit­tently through the contacts of relay RY-2 which is oper-
ated by the control unit within a 32 second time base. Mi-
crowave power operation is as follows:
Vari-Mode
P - HI (HIGH) (100% power)
P - 90 (approx. 90% power)
P - 80 (approx. 80% power)
P - 70 (MED, HIGH) (approx. 70% power)
P - 60 (approx. 60% power)
P - 50 (MED) (approx. 50% power)
P - 40 (approx. 40% power)
P - 30 (MED, LOW) (approx. 30 % power)
P - 20 (approx. 20% power) 8 sec.
P-IO
(approx. 10% power) 6 sec. 26 sec.
P-O
(0% power) 0 sec. 32 sec.
The ON/OFF time ratio does not correspond with the
percentage of microwave power, because approximate­ly 2 seconds are needed for heating the magnetron fila­ment.
On Time Off Time
32 sec.
30 sec.
26 sec.
24 sec.
22 sec.
18 sec.
16 sec.
12 sec.
0 sec.
2 sec.
6 sec.
8 sec.
IO sec.
14 sec.
16 sec.
20 sec.
24 sec.
6

DESCRIPTION AND FUNCTION OF COMPONENTS

R-509BK

Cooling Fan Motor

The cooling fan motor drives a blade which draws exter-
nal cool air. This cool air is directed through the air vanes surrounding the magnetron to cool the magne­tron. This air is channeled through the oven cavity to re-
move steam and vapors given off from the heating foods. It is then exhausted through exhaust vents in the
oven cavity.

Oven Temperature Fuse

The oven temperature fuse located on the top of the
oven cavity is designed to prevent damage to the unit if
the foods in the oven catch fire due to over heating pro-
duced by improper setting of cook time or failure of con-
trol unit.
Under normal operation, the oven temperature fuse re-
mains closed. However, when abnormally high temper­atures are reached within the oven cavity, the fuse will open at 150°C, causing the oven to shut down.
Note: This is a fuse and it does not reset.

Magnetron Temperature Fuse

The magnetron temperature fuse located on top of the
magnetron duct is designed to prevent damage to the
magnetron if an over heated condition develops in the
tube due to cooling fan failure, obstructed air ducts, dirty
or blocked air intake, etc.
Under normal operation, the magnetron temperature fuse remains closed. However, when abnormally high temperatures are reached within the magnetron the fuse will open at 1 50°C, causing the oven to shut down.
Note: This is a fuse and it does not reset.

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 and secondary interlock switch fail to open when the door is opened.

Monitor Switch Functions

1.
When the door is opened, the monitor switch con­tacts close (to the ON condition) due to their being
normally closed. At this time the primary interlock relay and secondary interlock switch are in the OFF condition (contacts open) due to their being normally open contacts.
2.
When the door is closed, the monitor switch contacts are first opened and then the door sensing switch and the secondary interlock switch contacts close.
Note: When opening the door, each of these
switches operate inversely.
If the door is opened and the primary interlock relay
3. and secondary interlock switch contacts fail to open, the monitor fuse blows simultaneously with closing
of the monitor switch contacts.
Before replacing a blown monitor fuse, test the prima­ry interlock relay, door sensing switch, monitor switch and secondary interlock switch for proper operation. (Refer to section “Test Procedures”.)

Door Open Mechanism

The door is opened by pushing the open button on the control panel. When the open button is pushed, the open button
pushes up the switch lever, and then the switch lever
pushes up the latch heads. The latch heads are moved upward and released from the latch hook. Now the door will open.
Door Sensing / 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 circuit to all components, except the oven lamp. 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 the primary interlock relay lo­cated on the control panel circuit board.
NOTE: MONITOR FUSE AND MONITOR SWITCH
ARE REPLACED AS AN ASSEMBLY.
7
R-509BK
SERVICING
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.
Before replacing a blown monitor fuse, test the door sensing switch, primary interlock relay, sec­ondary interlock switch and monitor switch for proper operation. tion.)
Whenever troubleshooting is performed, the power supply must be disconnected. In some cases it may be neces­sary to connect the power supply after the outer case cabinet has been removed. In this event,
1. Disconnect the power supply cord, and then remove outer case cabinet.
2. Open the door and block it open.
3. Discharge the 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 insulated tape.
6. After the above procedure, install the outer case cabinet and 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 the high voltage capacitor.
4. Reconnect the leads to the primary of the power transformer.
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.
(Refer to “Test Procedure” sec-

Troubleshooting Guide

Off Condition

Problem
Home fuse blows when power cord is plugged into the wall receptacle.
Monitorfuse blows when power is ap­plied.
Display does not illuminate when Shorted or open wiring power cord is plugged in.
Display does not operate properly Primary interlock relay or door sens- Procedure E when STOP/CLEAR button is ing switch touched.
Oven lamp does not light with door Shorted or open wiring
opened.
Shorted power cord or wire harness
Shorted power cord or wire harness Secondary interlock or monitor
switch
Monitor switch or monitor fuse
Oven temperature fuse
Control unit
Control unit Key unit unit
Monitor fuse Oven temperature fuse Oven lamp or socket Control unit
Relay (RYI)
Possible Cause
Check or replace
Check or replace
Procedure E
Check or replace
Procedure E Procedure F Procedure G
Procedure G Procedure K Check or replace
Procedure E Procedure F
Check or replace
Procedure G Procedure H
Test Procedure
8
Troubleshooting Guide
R-509BK
Problem
Oven lamp does not light at all.
Oven lamp lights, but fan motor and turntable motor do not operate.
Oven does not go into cook cycle when START button is touched.
Oven seems to be operating but
little or no heat is produced in oven
load. (incompletely cooked or not cooked at all at the 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
P-50 (MED.) mode. (Operates
properly on Cooking Power P-HI
(HIGH) mode.)
Oven goes into COMPU DEFROST
but food is not defrosted well
r
Shorted or open wiring Oven lamp or socket Control unit Shorted or open wiring Cooling fan motor Turntable motor
Shorted or open wiring Primary interlock system Monitor fuse Magnetron or oven temperature
fuse
Relay (RYI) Shorted or open wiring Magnetron
Power transformer Rectifier assembly H .V. capacitor Primary interlock system Shorted or open wiring
Turntable motor
Low voltage Dirty oven cavity
Wrong operation
Shorted or open wiring
Control unit
Magnetron
Wrong operation
Low voltage Dirty oven check
Compu Defrost
Possible Cause

Cook Condition

Test Procedure
Check or replace Check or replace Procedure G Check or replace Check or replace Check or replace Check or replace
Procedure E Procedure E Procedure F
Procedure H Check or replace Procedure A Procedure B
Procedure C Procedure D
Procedure E Check or replace Check or replace Check Check
Check
Check or replace
Procedure G
Procedure A
Check
Check
Check
Procedure J

TEST PROCEDURES

Procedure Letter

A . Magnetron Assembly Test

1. Disconnect the power supply cord, and then remove outercase cabinet.
2. Open the door and block it open.
3. Discharge the high voltage capacitor.
4. To test for an open filament, isolate the magnetron from the high voltage circuit. A continuity check across the magnetron filament leads should indicate less than IQ.
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 (shorted) and must be replaced.
Reconnect all leads removed from components during testing. Re-install the outercase cabinet. Reconnect the power supply cord after installing the outer case cabinet.
‘.
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 assembeled 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: high voltage rectifier, high voltage capacitor and power trans­former. This test will require a 16 oz. (453~~) measuring cup and an accurate mercury thermometer
or thermocouple type temperature tester. For accurate results, the following procedure must be fol-
lowed:
1.
Fill the measuring cup with 16 oz. (453~~) 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 on HIGH selecting 62 seconds cook time. Allow the water to heat.
Remove the cup from the oven and again measure the temperature, making sure to stir the ther-
3. mometer 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 38” to 78°F (21 O to 42.6OC) rise in temperature. If the water temperatures are accurately mea­sured and are 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 cook 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.
Component Test
B .
Power Transformer
1. Disconnect the power supply cord, and then remove outer case cabinet.
2. Open the door and block it open.
3. Discharge the 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 Q and the resistance of the high voltage coil should be approx-
imately IOOQ; the resistance of the filament coil should be less than IQ.
5. Reconnect all leads removed from components during testing.
6. Re-install the outercase cabinet.
7. Reconnect the power supply cord after installing the outer case cabinet.
8. Run the oven and check all functions.
Note: High voltages are present at the high voltage terminal, so do not attempt to measure the fila-
ment and high voltage.
10
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