Sharp R-509fw Owner's manual

R-509FW

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.

WARNINGTOSERVICEPERSONNEL:Microwaveovenscontaincircuitrycapableofproducingveryhighvoltageandcurrent,

contactwithfollowingpartsmayresultinasevere,possiblyfatal,electricalshock.(HighVoltageCapacitor,HighVoltagePower

Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..)

S22M183R509FE

R-509FW

MICROWAVEOVEN

MODEL

SUPPLEMENTAL SERVICE MANUAL

SHARP ELECTRONICS CORPORATION This document has been published to be used for after

sales service only.

The contents are subject to change without notice.

Service Headquarters: Sharp Plaza, Mahwah, New Jersey, 07430-2135

R-509FW

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.

TABLE OF CONTENTS Page

PRECAUTIONSTOBEOBSERVEDBEFOREANDDURINGSERVICINGTO

AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY ................... INSIDEFRONTCOVER

BEFORESERVICING ...................................................................................................... INSIDEFRONTCOVER

WARNINGTOSERVICEPERSONNEL ................................................................................................................1

MICROWAVEMEASUREMENTPROCEDURE.....................................................................................................2

FOREWORDANDWARNING................................................................................................................................3

PRODUCTSPECIFICATIONS...............................................................................................................................4

GENERAL INFORMATION ...................................................................................................................................4

OPERATION .........................................................................................................................................................6

TESTPROCEDURE ..............................................................................................................................................8

TOUCHCONTROLPANEL..................................................................................................................................12

CPUUNITCIRCUIT.............................................................................................................................................16

PARTS LIST........................................................................................................................................................17

PACKINGANDACCESSORIES .........................................................................................................................21

R-509FW

PRECAUTIONS TO BE OBSERVED BEFORE AND

DURING SERVICING TO AVOID POSSIBLE

EXPOSURE TO EXCESSIVE MICROWAVE

ENERGY

(a) Do not operateor 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

microwavesource,andmakerepairsas necessary: (1) interlockoperation,(2)properdoorclosing,(3)

sealandsealingsurfaces(arcing,wear, and other damage),(4)damagetoorlooseningofhinges and

latches,(5)evidenceofdroppingorabuse.

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

integrity,andconnections.

(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

manualbefore the oven is released to the owner.

(e) A microwave leakage check to verify compliance with the Federal Performance Standard should be

performedoneachovenprior to release totheowner.

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

ELECTRONICSCORPORATIONimmediately @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.

R-509FW

WARNING TO SERVICE PERSONNEL

Microwave ovens contain circuitry capable of pro-

ducing very high voltage and current, contact with

following parts

may result in a severe, possibly

fatal, electrical shock.

(Example)

HighVoltageCapacitor,HighVoltagePowerTrans-

former,Magnetron,HighVoltageRectifierAssem-

bly, 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.

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

secondsaftertheovenhasbeenswitchedoff.Waitfor60

secondsandthenshort-circuittheconnectionofthehigh-

voltagecapacitor(thatis the connecting leadofthehigh-

voltage rectifier) against the chassis with the use of an

insulated screwdriver.

Whenever troubleshooting is performed the power supply

mustbedisconnected.Itmay,in somecases,benecessary

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. Reconnectthepowersupplycordaftertheouter 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. Reconnectthepowersupplycordaftertheouter case is

installed.

4. Run the oven and check all functions.

Microwaveovensshouldnotbeoperatedempty.Totestfor

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 re-

examine the connections to the component being tested.

When all service work is completed and the oven is fully

assembled,themicrowavepoweroutputshouldbechecked

and a microwave leakage test should be carried out.

Don't Touch !

Danger High Voltage

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

shouldnotexceed1mW/cm2atanypoint5cmormorefromtheexternalsurfaceoftheoven,measuredpriortoacquisition

byapurchaser, andthereafter(throughthe usefullifeofthe oven),5mW/cm2atany point5cmormorefromtheexternal

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±5O

C (68OF) in the center of the oven cavity.

Thewatercontainer shallbea lowformof600ml(20oz)beakerwithan insidediameterofapprox.8.5cm(3-1/2in.)and

made of an electrically nonconductive material such as glass or plastic.

Theplacingofthisstandardloadintheovenisimportantnotonlytoprotecttheoven,butalsotoinsurethatanyleakage

is measured accurately.

4) Set the cooking control on Full Power Cooking Mode.

5) Closethedoorandselectacookcycleofseveralminutes.Ifthewaterbeginstoboilbeforethesurveyiscompleted,replace

it with 275 ml of cool water.

C. Leakage test:

Closed-door leakage test (microwave measurement):

1) Grasptheprobeofthesurveyinstrumentandholditperpendiculartothegapbetweenthedoorandthebodyoftheoven.

2) Movetheprobeslowly,notfasterthan1in./sec.(2.5cm/sec.)alongthegap,watchingforthemaximumindicationonthe

meter.

3) Checkforleakageatthedoorscreen,sheetmetalseamsandotheraccessiblepositionswherethecontinuityofthemetal

has been breached (eg., around the switches, indicator, and vents).

Whiletestingforleakagearoundthedoor,pullthedoorawayfromthefrontoftheovenasfarasispermittedbytheclosed

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.

R-509FW

SHARP ELECTRONICS CORPORATION

SHARP PLAZA, MAHWAH,

NEW JERSEY 07430-2135

SERVICE MANUAL

MICROWAVE OVEN

R-509FW

FOREWORD

This Manual has been prepared to provide Sharp Electronics Corp.

ServicePersonnelwithOperationandServiceInformationfortheSHARP

MICROWAVEOVEN,R-509FW.

It is recommended that service personnel carefully study the entire text

ofthismanualsothattheywillbequalifiedtorendersatisfactorycustomer

service.

Checktheinterlockswitchesandthedoorsealcarefully.Specialattention

shouldbegiventoavoidelectricalshockandmicrowaveradiationhazard.

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.

(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 person-

nel - 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.

PRODUCTDESCRIPTION

GENERALINFORMATION

OPERATION

TROUBLESHOOTINGGUIDEAND

TESTPROCEDURE

TOUCHCONTROLPANEL

WIRINGDIAGRAM

PARTS LIST

R-509FW

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.

Intheeventofanelectricalshortcircuit,groundingreducestheriskofelectricshockbyprovidinganescapewirefortheelectric

current.

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

ElectricalRequirements

The electrical requirements are a 120 volt 60 Hz, AC only,

15or20amp.fusedelectricalsupply.Itisrecommendedthataseparatecircuitservingonlythisappliancebeprovided.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.

Whereatwo-prongedwall-receptacleisencountered,itisthepersonalresponsibilityandobligationofthecustomertocontact

SPECIFICATION

ITEM DESCRIPTION

PowerRequirements 120 Volts

13.3Amperes,1600watts

60Hertz

Singlephase,3wiregrounded

PowerOutput 1100watts(IEC705TEST PROCEDURE)

Operatingfrequencyof2450MHz

CaseDimensions Width 24"

Height 13-3/8"

Depth 19-1/8"

CookingCavityDimensions Width 17-3/8"

Height 10-1/2"

1.8 Cubic Feet Depth 18-5/8"

ControlComplement TouchControlSystem

Clock ( 1:00 - 12:59 )

Timer (0 - 99 min. 99 seconds)

MicrowavePowerforVariableCooking

Repetition Rate;

P-HI .................................................. Fullpower throughoutthecooking 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 ......................................................Nopowerthroughoutthecookingtime

MINUTEPLUSpad,Cookpads,Defrostcenterpads,Reheatpads,Number

selectionpads,Power Levelpad,Timer/Clockpad,Stop/Clear pad,START pad,

andPopcorn.

Oven Cavity Light Yes

SafetyStandard UL Listed FCC Authorized

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

R-509FW

a qualified electrician and have it replaced with a properly grounded

three-pronged wall receptacle or have a grounding adapter properly

groundedandpolarized.Iftheextensioncordmustbeused,itshouldbe

a 3-wire, 15 amp. or higher rated cord. Do not drape over a countertop

ortablewhereitcanbepulledonbychildrenortrippedoveraccidentally.

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.

10.Wave guide cover.

11.Power supply cord

TOUCH CONTROL PANEL

3-Pronged

Plug

Grounded

Receptacle Box

Grounding Pin

3-Pronged Receptacle

NOTE:

The directed features are disa-

bled 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

210

R-509FW

OPERATION

DESCRIPTION OF OPERATING SEQUENCE

Thefollowingisadescriptionofcomponentfunctionsduring

oven operation.

OFF CONDITION

Closing the door activates the door sensing switch and

primaryinterlockswitch.(Inthiscondition,themonitorswitch

contactsareopened.)

When oven is plugged in, 120 volts A.C. is supplied to the

control unit. (Figure O-1).

1. Thedisplaywillshowflashing"88:88".

Tosetanyprogramorsettheclock,youmustfirsttouch

theSTOP/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 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 3.3 volts

A.C. output on the filament winding, and approximately

2370 volts A.C. on the high voltage winding.

3. Thefilamentwindingvoltageheatsthemagnetronfilament

andtheH.V.windingvoltageissentto avoltagedoubler

circuit.

4. The microwave energy produced by the magnetron is

channelled through the waveguide into the cavity feed-

box, 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. Whenthedoorisopenedduringacookcycle,themonitor

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

componentsarede-energized,theovenlampremainson,

andthedigitalread-outdisplaysthetimestillremainingin

the cook cycle when the door was opened.

7. Themonitorswitchelectricallymonitorstheoperationof

theprimaryinterlockswitchandsecondaryinterlockrelay

andismechanicallyassociatedwiththedoorsothatitwill

functioninthefollowingsequence.

(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)remainsclosed.Thenthemonitorswitchcontacts

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.

Iftheprimaryinterlockswitchand secondaryinterlockrelay

(RY2)failwiththecontactsclosedwhenthedoorisopened,

the closing of the monitor switch contacts will form a short

circuit through the C/T fuse, primary interlock switch, relay

(RY1)andsecondaryinterlockrelay(RY2),causingtheC/T

fuse to blow.

POWER LEVEL P-0 TO P-90 COOKING

WhenVariableCookingPowerisprogrammed,the120volts

A.C. is supplied to the power transformer intermittently

throughthecontactsofrelay(RY-2)whichisoperatedbythe

controlunitwithina32secondtimebase.Microwavepower

operation is as follows:

VARI-MODE ON TIME OFF 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: TheON/OFFtimeratiodoesnotcorrespondwiththe

percentageofmicrowavepower,becauseapprox.2

seconds are needed for heating of the magnetron

filament.

R-509FW

Figure O-2 Oven Schematic - Cooking Condition

Figure O-1 Oven Schematic - Off Condition

SCHEMATIC

NOTE: CONDITION OF OVEN

1. Door Closed

2. CLOCK APPEARS ON DISPLAY

SCHEMATIC

3. VARIABLE COOKING CONTROL "HIGH"

2. COOKING TIME PROGRAMMED

1. DOOR CLOSED

NOTE: CONDITION OF OVEN

4. "START" PAD TOUCHED

Note:* Indicates component

CAVITY

TEMPERATURE

FUSE

120VAC

60Hz

COM.

RED

WHT

BRN

WHT

ORG

RED

WHT

GRN

N.O.

CONTROL UNIT

C/T

FUSE

N.O.

(RY2)

COM.

DOOR

SENSING

SWITCH

TTM FM

OL TURN

TABLE

MOTOR

FAN

MOTOR

OVEN

LAMP

MONITOR

SWITCH

PRIMARY

INTERLOCK

SWITCH

POWER

TRANSFORMER

MAGNETRON

HIGH

VOLTAGE

CAPACITOR

ORG

WHT

SECONDARY

INTERLOCK

RELAY

ORG

BRN

ORG

RED

GRY

GND

WHT

SENSOR

(RY1)

OVEN

LAMP

RELAY

COM. N.O.

HUMIDITY

COM.

N.C. HIGH

VOLTAGE

RECTIFIER

ORG

CAVITY

TEMPERATURE

FUSE

120VAC

60Hz

COM.

RED

WHT

BRN

WHT

ORG

RED

WHT

GRN

N.O.

CONTROL UNIT

N.O.

(RY2)

COM.

DOOR

SENSING

SWITCH

TTM FM

OL TURN

TABLE

MOTOR

FAN

MOTOR

OVEN

LAMP

MONITOR

SWITCH

PRIMARY

INTERLOCK

SWITCH

POWER

TRANSFORMER

MAGNETRON

HIGH

VOLTAGE

CAPACITOR

ORG

WHT

SECONDARY

INTERLOCK

RELAY

ORG

BRN

ORG

RED

GRY

GND

WHT

SENSOR

(RY1)

OVEN

LAMP

RELAY

COM. N.O.

HUMIDITY

COM.

N.C. HIGH

VOLTAGE

RECTIFIER

ORG

C/T

FUSE

RED

R-509FW

Primary

Interlock Switch Monitor Switch

Screw Driver

Ohmmeter

Red White/ White

TEST PROCEDURES

PROCEDURE

LETTER COMPONENT 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

andohmmeter.Inthisservicemanual,thetouchcontrolpanelassemblyisdividedintotwounits,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)CheckKeyunit ribbonconnectionbeforereplacement.

2)Re-installtheoutercase(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.

ITOUCH CONTROL PANEL ASSEMBLY TEST

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

2. Open the door and block it open.

3. Discharge high voltage capacitor.

4. Before performing this test, make sure that the primary interlock switch and the secondary interlock

relayareoperatingproperly,accordingtotheaboveSwitchTestProcedure.Disconnectthewirelead

fromthemonitorswitch(COM)terminal.Checkthemonitorswitch operation by using the ohmmeter

asfollows.Whenthedoorisopen,themetershouldindicateaclosedcircuit.Whenthemonitorswitch

actuatorispushedbyascrewdriverthroughthelowerlatchholeonthefrontplateoftheoven cavity

withthedooropened(inthisconditiontheplungerofthemonitorswitchispushedin),themetershould

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. Reconnectallleadsremoved from componentsduringtesting.

6. Reinstalltheoutercase(cabinet).

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

8. Run the oven and check all functions.

GMONITORSWITCHTEST

R-509FW

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

Thefollowingsymptomsindicateadefectivecontrolunit.Beforereplacingthecontrolunit,performthe

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..

TEST PROCEDURES

PROCEDURE

LETTER COMPONENT TEST

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

ismakinggoodcontact,verifythatthedoorsensingswitch(stopswitch)operatesproperly;thatisthe

contactsareclosedwhenthedoorisclosedandopenwhenthedoorisopen.Ifthedoorsensingswitch

(stopswitch)isgood,disconnecttheflatribboncablethatconnectsthekeyunittothecontrolunitand

make sure the door sensing switch is closed (either close the door or short the door sensing switch

connecter).UsetheKeyunitmatrixindicatedonthecontrolpanelschematicandplaceajumperwire

betweenthepinsthatcorrespondtotheSTOP/CLEARpadmakingmomentarycontact.Ifthecontrol

unitrespondsbyclearingwithabeepthekeyunitisfaultyandmustbereplaced.Ifthecontrolunitdoes

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.

R-509FW

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.

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.

TEST PROCEDURES

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. Disconnect the leads to the primary of the power transformer.

5. Ensurethattheseleadsremainisolatedfromothercomponentsandovenchassisbyusinginsulation

tape.

6. Afterthatprocedure, re-connect thepowersupplycord.

7.RemovetheoutercaseandcheckvoltagebetweenthenormalopenterminaloftherelayRY1andthe

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

Theserelaysareoperatedby 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. 12.0V D.C. Oven lamp / Turntable motor / Cooling fan motor

RY2 Approx. 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.

LDEFROSTTEST

Key Unit

KRELAY TEST

POPCORN

DEFROST

START

POWER

LEVEL

MINUTE

PLUS

TIMER

CLOCK

COOK

REHEAT

7 6 5 4 3 2 1

91011121314

STOP

CLEAR

R-509FW

(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.

TEST PROCEDURES

PROCEDURE

LETTER COMPONENT 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) Makeavisualinspectionofthe varistor.

Checkforburneddamageandexamine

the transformer with a tester for the

presence of layer short-circuit (check

the primary coil resistance which is

approximately540ohms ±20%).Ifany

abnormalconditionisdetected,replace

the defective parts.

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.Followthetroubleshootingguidegivenbelow,ifindicatordoesnotlightupafterabovecheckandrepairs

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

insulationtape.

6) After that procedure, re-connect the power supply cord.

7) Follow the troubleshooting guide given below for repair.

STEPS OCCURRENCE CAUSE 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

2 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.

M FOIL PATTERN ON THE PRINTED WIRING BOARD TEST

MCR

M27A

94V-

RY2

(J1)

R-509FW

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.

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

commercialfrequency.

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).

TOUCHCONTROLPANELASSEMBLY

OUTLINEOFTOUCHCONTROLPANEL

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

communicatedamongthemareexplainedbelow.

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

R-509FW

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

StandardvoltageforLCD.

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 Terminalnotused.

8 AN2 IN Input terminal to judge the model.

ConnectedtoGNDthroughthepull-downresistor.

9 AN1 IN To input signal which communicates the door open/close information to LSI.

Doorclose “H” level signal (0V). Door open “L” level signal (-5V).

10 AN0 IN Input terminal to judge the model.

The one of signals P20 - P27 will be input into AN0 through one of G1 - G8 lines on

key matrix.The LSI will judge the model by this signal.

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

12-13 P56-P55 OUT Terminalnotused.

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

A: key touch sound.

B:Completionsound.

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

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

square waveform voltage is delivered to the

RY1 driving circuit and RY2 control circuit.

16 P52 OUT Magnetron high-voltage circuit driving signal.

To turn on and off the cook relay (RY2).

Thesignals holds “L” level during

microwavecookingand “H”levelwhile

not cooking. In other cooking modes

(variablecooking) the signal turns to “H”

leveland“L”levelinrepetition according

to the power level.

17-18 P51-P50 OUT Terminalnotused.

19 P47 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 P47. When no key is touched, the signal is held at “H” level.

20 P46 OUT Terminal notused.

21 P45 IN Signal similar to P47.

When either G11 line on key matrix is touched, a corresponding signal will be input

into P45.

22-23 P44-P43 IN Terminalnotused.

24 INT0 IN Signal synchronized with commercial power source frequency.

This is the basic timing for time processing of LSI.

25 P41 IN Signal similar to P47.

When either G10 line on key matrix is touched, a corresponding signal will be input

into P41.

26 P40 IN ConnectedtoGNDthroughthepull-downresistorR90.

LSI

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

Pin No. Signal I/O Description

DESCRIPTION OF LSI

0.1 sec.

2.0 sec.

H : GN

L : -5V

H : GN

L : -5V

16.7 msec.

During cooking

H : GND

L : -5V

Maximum

output

70% of maximum

output

H : GND

L : -5V

H : GND

L : -5V

OFF

OFF OFF

24 sec.

8 sec.

16.7 msec.

H : GN

L : -5V

R-509FW

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 P71 OUT Terminal notused.

29 P70 IN Signal similar to P47.

When either G9 line on key matrix is touched, a corresponding signal will be input into

P70.

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 XOUT terminal.

31 XOUT OUT Internal clock oscillation frequency control output.

Output to control oscillation input of XIN.

32 VSS IN Power source voltage: -5.0V.

VC voltage of power source circuit input.

33 P27 OUT Key strobe signal.