This is a supplemental Service Manual for Microwave Oven model R-509FW. This model is quite similar to the base
models; R-510FK/FW (S12M182R510FE).
This supplemental manual must be used in conjunction with the base model service manual for complete operation,
service, safety and replacement parts information.
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
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
GENERAL INFORMATION ...................................................................................................................................4
TEST PROCEDURE ..............................................................................................................................................8
TOUCH CONTROL PANEL..................................................................................................................................12
CPU UNIT CIRCUIT.............................................................................................................................................16
PARTS LIST........................................................................................................................................................17
PACKING AND ACCESSORIES .........................................................................................................................21
R-509FW
Page
SHARP ELECTRONICS CORPORATION
Service Headquarters: Sharp Plaza, Mahwah, New Jersey, 07430-2135
This document has been published to be used for after
sales service only.
The contents are subject to change without notice.
Page 2
R-509FW
PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE
EXPOSURE TO EXCESSIVE MICROWAVE
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.
(c) Before turning on microwave power for any service test or inspection within the microwave generating
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.
Page 3
WARNING TO SERVICE 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-509FW
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 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 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-509FW
MICROWAVE MEASUREMENT PROCEDURE
A. Requirements:
1) Microwave leakage limit (Power density limit): The power density of microwave radiation emitted by a microwave oven
should not exceed 1mW/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 switch shall prevent microwave radiation emission in excess of the requirement as above
mentioned. Secondary interlock relay and door sensing 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
O
C (68OF) 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 primary interlock switch/secondary interlock relay 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-509FW
MICROWAVE OVEN
R-509FW
FOREWORD
This Manual has been prepared to provide Sharp Electronics Corp.
Service Personnel with Operation and Service Information for the SHARP
MICROWAVE OVEN, R-509FW.
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.
PRODUCT DESCRIPTION
GENERAL INFORMATION
OPERATION
TROUBLESHOOTING GUIDE AND
TEST PROCEDURE
TOUCH CONTROL PANEL
WIRING DIAGRAM
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.
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.
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, Cook pads, Defrost center pads, Reheat pads, Number
selection pads, Power Level pad, Timer/Clock pad,Stop/Clear pad, START pad,
and Popcorn.
Complies with 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 contact
4
Page 7
a qualified electrician and have it replaced with a properly grounded
3-Pronged
Plug
Grounded
Receptacle Box
Grounding Pin
3-Pronged Receptacle
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. One touch door open button.
Push 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.
TOUCH CONTROL PANEL
10.Wave guide cover.
11.Power supply cord
6
2
3
R-509FW
5
10
4
7
11
9
8
1
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.
R-509FW
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R-509FW
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
primary 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)
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
secondary interlock relay (RY2) and primary 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 primary interlock switch and door sensing switch
close. And contacts of the relay (RY1) open.
If the primary interlock switch and secondary 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 C/T fuse, primary interlock switch, relay
(RY1) and secondary interlock relay (RY2), causing the C/T
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:
RELAYCONNECTED COMPONENTS
RY-1oven lamp/turntable motor/fan motor
RY-2power transformer
2. 120 volts A.C. is supplied to the primary winding of the
power transformer and is converted to about 3.3 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, primary interlock switch,
relay (RY1) and secondary 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 primary interlock switch and secondary interlock relay
VARI-MODEON TIMEOFF TIME
Power 10(P-HI)32 sec.0 sec.
(100% power)
Power 9(P-90)30 sec.2 sec.
(approx. 90% power)
Power 8(P-80)26 sec.6 sec.
(approx. 80% power)
Power 7(P-70)24 sec.8 sec.
(approx. 70% power)
Power 6(P-60)22 sec.10 sec.
(approx. 60% power)
Power 5(P-50)18 sec.14 sec.
(approx. 50% power)
Power 4(P-40)16 sec.16 sec.
(approx. 40% power)
Power 3(P-30)12 sec.20 sec.
(approx. 30% power)
Power 2(P-20) 8 sec.24 sec.
(approx. 20% power)
Power 1(P-10) 6 sec.26 sec.
(approx. 10% power)
Power 0(P-0) 0 sec.32 sec.
(0% power)
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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R-509FW
SCHEMATIC
NOTE: CONDITION OF OVEN
1. Door Closed
2. CLOCK APPEARS ON DISPLAY
RED
N.O.
C/T
FUSE
(RY1)
OVEN
LAMP
RELAY
ORG
ORG
N.O.
COM.
ORG
OL
GRY
120VAC
60Hz
CAVITY
TEMPERATURE
FUSE
RED
GRN
GND
WHT
Note:* Indicates component
BRN
WHT
WHT
GRY
ORG
OVEN
LAMP
COM.
(RY2)
SECONDARY
INTERLOCK
RELAY
CONTROL UNIT
N.O.
WHT
WHT
PRIMARY
INTERLOCK
SWITCH
BRN
TTM
WHT
COM.
TURN
TABLE
MOTOR
B2
B1
F3
F2
F1
ORG
RED
ORG
FM
WHT
DOOR
SENSING
SWITCH
HUMIDITY
SENSOR
FAN
MOTOR
MONITOR
SWITCH
WHT
N.C.
COM.
WHT
RED
RED
WHT
WHT
POWER
TRANSFORMER
HIGH
VOLTAGE
CAPACITOR
HIGH
VOLTAGE
RECTIFIER
MAGNETRON
Figure O-1 Oven Schematic - Off Condition
SCHEMATIC
NOTE: CONDITION OF OVEN
1. DOOR CLOSED
2. COOKING TIME PROGRAMMED
3. VARIABLE COOKING CONTROL "HIGH"
4. "START" PAD TOUCHED
RED
N.O.
C/T
FUSE
(RY1)
OVEN
LAMP
RELAY
ORG
ORG
BRN
ORG
N.O.
(RY2)
SECONDARY
INTERLOCK
RELAY
ORG
OL
WHT
WHT
CONTROL UNIT
OVEN
LAMP
COM.
GRY
PRIMARY
INTERLOCK
SWITCH
COM.
GRY
120VAC
60Hz
CAVITY
TEMPERATURE
FUSE
RED
GRN
GND
WHT
N.O.
WHT
WHT
TTM
BRN
WHT
COM.
TURN
TABLE
MOTOR
B2
B1
F3
F2
F1
ORG
RED
ORG
FM
WHT
DOOR
SENSING
SWITCH
HUMIDITY
SENSOR
FAN
MOTOR
MONITOR
SWITCH
WHT
N.C.
COM.
WHT
RED
RED
WHT
WHT
POWER
TRANSFORMER
HIGH
VOLTAGE
CAPACITOR
HIGH
VOLTAGE
RECTIFIER
MAGNETRON
Figure O-2 Oven Schematic - Cooking Condition
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R-509FW
TEST PROCEDURES
PROCEDURE
LETTER
GMONITOR 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 primary interlock switch and the secondary 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.
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.
Red
COMPONENT TEST
White/ White
Screw Driver
Primary
Interlock Switch
Monitor Switch
ITOUCH 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, LSI 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) Re-install the outer case (cabinet).
3) Reconnect the power supply cord after the outer case is installed.
4) 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.
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.
Ohmmeter
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TEST PROCEDURES
R-509FW
PROCEDURE
LETTER
COMPONENT 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) 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..
JKEY 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
connecter). 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.
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R-509FW
TEST PROCEDURES
PROCEDURE
LETTER
COMPONENT TEST
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.
8
91011121314
POPCORN
7654321
DEFROST
COOK
REHEAT
1
4
7
Key Unit
KRELAY 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 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 the normal open terminal of the relay RY1 and the
normal open terminal of the relay RY2 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,
RY1Approx. 12.0V D.C.Oven lamp / Turntable motor / Cooling fan motor
RY2Approx. 11.0V 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 functions.
LDEFROST 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 “ DEFROST “ pad once.
(3) Touch the number pad “ 2 “ and then touch the number pad “ 5 “.
(4) Touch the start pad.
WEIGHT 1ST STAGE 2ND STAGE
0.5lb LEVEL TIME LEVEL TIME
60% 57sec. 40% 22sec.
(5) The oven is in Defrost cooking condition.
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TEST PROCEDURES
R-509FW
PROCEDURE
LETTER
(6) The oven will operate as follows. (in case of Steak/Chops 0.5lb)
(7) If improper operation is indicated, the control unit is probably defective and should be checked.
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.
STEPSOCCURRENCECAUSE OR CORRECTION
1Only pattern at "a" is broken.*Insert jumper wire J1 and solder.
2Pattern 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 540 ohms ± 20%). If any
abnormal condition is detected, replace
the defective parts.
COMPONENT TEST
RY2
c
R
94V-
(J1)
M27A
a
b
MCR
T1
d
1
MR
7
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.
STEPSOCCURRENCECAUSE OR CORRECTION
1 The rated AC voltage is not present between Check supply voltage and oven power cord.
the normal open terminal of the relay RY1 and
the normal open terminal of the relay RY2
The rated AC voltage is present at primary Low voltage transformer or secondary circuit defective.
2
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.
11
Page 14
R-509FW
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 LSI 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,
P45, P47, P70 and AN2 to perform the function that was
requested.
Control Unit
Control unit consists of LSI, reset circuit, indicator circuit,
power source circuit, relay circuit, buzzer circuit,
synchronizing signal circuit and back light circuit.
1) Reset Circuit
This circuit generates a signal which resets the LSI to
the initial state when power is supplied.
2) Indicator Circuit
This circuit consists of 22 segments and 3 common
electrodes using a Liquid Crystal Display.
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.
SymbolVoltageApplication
VC-5VLSI(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.
8) Back Light Circuit
A circuit to drive the back light (Light emitting diodes
LD1- LD4).
12
Page 15
LSI
D
D
16.7 msec.
During cooking
H : GND
L : -5V
D
DESCRIPTION OF LSI
The I/O signal of the LSI is detailed in the following table.
Pin No.SignalI/ODescription
1-2VL2-VL1INPower source voltage input terminal.
Standard voltage for LCD.
3-6AN7-AN4IN
7P6 3OUTTerminal not used.
8AN2IN
9AN1INTo input signal which communicates the door open/close information to LSI.
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 according
to the power level.
Maximum
output
70% of maximum
output
OFF
ON
OFFOFF
ON
17-18P51-P50OUTTerminal not used.
19P47INSignal coming from touch key.
When either G12 line on key matrix is touched, a corresponding signal out of P20 -
P27 will be input into P47. When no key is touched, the signal is held at “H” level.
2 0P46OU TTerminal not used.
21P45INSignal similar to P47.
When either G11 line on key matrix is touched, a corresponding signal will be input
into P45.
22-23P44-P43INTerminal not used.
24INT0INSignal synchronized with commercial power source frequency.
This is the basic timing for time processing of LSI.
16.7 msec.
24 sec.
8 sec.
H : GND
L : -5V
H : GND
L : -5V
H : GN
L : -5V
25P41INSignal similar to P47.
When either G10 line on key matrix is touched, a corresponding signal will be input
2 6P40I NConnected to GND through the pull-down resistor R90.
into P41.
13
Page 16
R-509FW
Pin No.SignalI/ODescription
27RESETINAuto 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.
2 8P71OU TTerminal not used.
29P70INSignal similar to P47.
When either G9 line on key matrix is touched, a corresponding signal will be input into
P70.
30XININInternal clock oscillation frequency input setting.
The internal clock frequency is set by inserting the ceramic filter oscillation circuit with
respect to XOUT terminal.
31XOUTOUTInternal clock oscillation frequency control output.
Output to control oscillation input of XIN.
32VSSINPower source voltage: -5.0V.
VC voltage of power source circuit input.
33P27OUTKey strobe signal.
Signal applied to touch-key section. A pulse signal is input to P41, P45, P47 and P70
terminal while one of G8 line keys on key matrix is touched.
34P26OUTKey strobe signal.
Signal applied to touch-key section. A pulse signal is input to P41, P45, P47 and P70
terminal while one of G7 line keys on key matrix is touched.
35P25OUTKey strobe signal.
Signal applied to touch-key section. A pulse signal is input to P41, P45, P47 and P70
terminal while one of G6 line keys on key matrix is touched.
36P24OUTKey strobe signal.
Signal applied to touch-key section. A pulse signal is input to P41, P45, P47 and P70
terminal while one of G5 line keys on key matrix is touched.
37P23OUTKey strobe signal.
Signal applied to touch-key section. A pulse signal is input to P41, P45, P47 and P70
terminal while one of G4 line keys on key matrix is touched.
38P22OUTKey strobe signal.
Signal applied to touch-key section. A pulse signal is input to P41, P45, P47 and P70
terminal while one of G3 line keys on key matrix is touched.
39P21OUTKey strobe signal.
Signal applied to touch-key section. A pulse signal is input to P41, P45, P47 and P70
terminal while one of G2 line keys on key matrix is touched.
40P20OUTKey strobe signal.
Signal applied to touch-key section. A pulse signal is input to AN0, P41, P45, P47 and
P70 terminal while one of G1 line keys on key matrix is touched.
41-48P17-P10OUTTerminal not used.
49-50P07-P06OUTTerminal not used.
51-72SEG21-SEG0OUTSegment data signal.
Connected to LCD.
The relation between signals are as follows:
LSI signal (Pin No.)LCD segmentLSI signal (Pin No.)LCD segment
SEG 21 (51)
SEG 20 (52)
SEG 19 (53)
SEG 18 (54)
SEG 17 (55)
SEG 16 (56)
SEG 15 (57)
SEG 14 (58)
SEG 13 (59)
SEG 12 (60)
SEG 11 (61)
............................
............................
............................
............................
............................
............................
............................
............................
............................
............................
............................
SEG 22SEG 10 (62)
SEG 21SEG 9 (63)
SEG 20SEG 8 (64)
SEG 19SEG 7 (65)
SEG 18SEG 6 (66)
SEG 17SEG 5 (67)
SEG 16SEG 4 (68)
SEG 15SEG 3 (69)
SEG 14SEG 2 (70)
SEG 13SEG 1 (71)
SEG 12SEG 0 (72)
...........................
...........................
.............................
.............................
.............................
.............................
.............................
.............................
.............................
.............................
.............................
SEG 11
SEG 10
SEG 9
SEG 8
SEG 7
SEG 6
SEG 5
SEG 4
SEG 3
SEG 2
SEG 1
14
Page 17
Pin No.SignalI/ODescription
73/74VCC/VREFINConnected to GND.
75AVSSINConnected to VC.
76COM3OUTTerminal not used.
77COM2OUTCommon data signal.
3- 1CPWBFB063MRU0M Control unit 1 BA
3- 1AQCNCMA275DRE0J 2-pin connector (CN-B) 1 AB
3- 1BFW-VZB194MRE0M Lead wire harness (WH-1) 1 AG
C1RC-KZA087DRE0J Capacitor 0.1 uF 50V 1 AA
C2VCEA0A1EW108MM Capacitor 1000 uF 25V 1 AB
C3VCEA0A1AW227MM Capacitor 220 uF 10V 1 C21VCEAB31VW106MJ Capacitor 10 uF 35V 1 AA
D1-4RH-DZA006PRE0J Diode (1N4002) 4 AD
D20-22VHD1SS270A/-1J Diode (1SS270A) 3 AA
D40VHD1SS270A/-1J Diode (1SS270A) 1 AA
LD1-4RH-PXA002DRZZM Light emitting diode 4 Q21VSKRC243M//-3J Transistor (KRC243M) 1 AB
R1VRD-B12HF561JJ Resistor 560 ohm 1/2W 1 AA
RY1-2RRLY-A114DRE0J Relay (DU12D1-1PR(M)) 2 AN
SP1RALM-A019DRZZM Buzzer 1 T1RTRNPA110DRE0J Transformer 1 AP
VRS1RH-VZA032DRE0J Varistor (10G471K) 1 AE
ZD1VHEHZ4C3///-1J Zener diode (HZ4C3) 1 AA
3- 2FPNLCB404/KITM Control panel sub assembly 1 AY
3- 2-1FUNTKB349/KITM Key unit 1 AN
3- 2-2JBTN-B121MRF0M Open button 1 AF
3- 2-3MSPRTA050WRE0M Open button spring 1 AA
3- 3PSHEPA798WREZM LCD sheet 1 AG
3- 4QCNC-B001MRE0M Rubber connector 1 AD
3- 5RLCDSA107DRZZM Light crystal display 1 AG
3- 6XEPSD30P10XS0M Screw; 3mm x 10mm 3 AB
∆∆
∆” may cause undue microwave exposure.
∆∆
ELECTRIC PARTS
Monitor switch (V-16G-2C25), C/T fuse (20A 250V AC) & Inst.
Primary interlock switch and door sensing switch (V-5230Q)
O
C 1AE
O
C 1AF
CABINET PARTS
CONTROL PANEL PARTS
R-509FW
1AF
2AE
OVEN PARTS
4- 1LBNDKB007MRP0MH.V. Capacitor band 1AB
4- 2LANGTB059MRP0MChassis support 1AG
4- 3PHOK-B018MRF0MLatch hook 1AF
4- 4MLEVPB016MRF0MSwitch lever 1AD
4- 5PDUC-B120MRF0A MMagnetron duct 1AM
4- 6NFANPB006MRE0MFan blade 1AC
4- 7PDUC-B088MRF0MFan duct 1AC
4- 8-------------MOven cavity (Not a replaceable part) 1-4- 9PCOVPB085MRP0MWaveguide cover 1AH
4-10PPACGB014MRF0MTurntable motor packing 1AA
4-11PCUSGB037MRP0MCushion 1AB
4-12PCUSU0464MRE0MCushion 1AC
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.
18
Page 21
R-509FW
1
OVEN AND CABINET PARTS
A
B
C
D
4-8
2
3
45
7-8
6
A
7-8
7-6
2-3
B
7-9
4-7
7-6
7-5
6-7
C
1-9
1-5
7-9
4-6
1-13
7-7
7-3
1-8
7-6
D
1-6
4-2
7-1
1-10
7-4
E
1-3
1-4
4-5
F
E
4-9
6-3
6-5
7-2
7-2
7-4
4-10
F
6-4
2-1
1-11
7-5
1-12
4-11
4-3
6-6
7-1
1-7
1-6
1-7
4-4
4-1
G
1-1
G
1-2
7-4
2-2
7-4
2-2
H
1
2
2-2
2-2
3
7-4
45
4-12
H
6
19
Page 22
R-509FW
1
CONTROL PANEL PARTS
A
B
C
3-2-1
2
3 - 2
3 - 5
3-2-2
3 - 3
3
3-2-3
45
3 - 1
3 - 4
3 - 6
DOOR PARTS
6
A
B
C
D
E
5-4
5-7
D
E
5-6
5-5
F
F
MISCELLANEOUS
5-2
G
5-3
5-1
6-1
6-2
G
6-9
Actual wire harness may be different from illustration.
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.
22
2002 SHARP CORP. (2M2.20E) Printed in U.S.A
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