Sharp R-530BK User manual

R-530BK
R-530BW
SHARP@ SERVICE MANUAL
\
‘\
-i
I‘
_‘.
‘,,
S38Mi 08R530BE
MICROWAVE OVEN MODELS
R=530BK/R=530BW
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.
R-530BK
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 PAGE
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICE TO
AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY. ........... Inside Front Cover
Before Servicing ............................................................. Inside Front Cover
Warning to Service Personnel .. : .............................................................. 1
Foreword and Warning ....................................................................... 2
Specifications ............................................................................... 3
Generallnformation ......................................................................... 4
KeyUnitLayout ............................................................................. 5
Operation .................................................................................. 6
Servicing and Troubleshooting Guide .......................................................... 9
TestProcedures ............................................................................ 11
TouchControlOutline ....................................................................... 21
Component Replacement and Adjustment Procedure ........................................... 25
Microwave Measurement Procedure .......................................................... 35
Wiring/Schematic Diagram .................................................................. 36
Parts ..................................................................................... 41
Packing and Accessories .................................................................... 46
SHARP ELECTRONICS CORPORATION
Service Headquarters: Sharp Plaza, Mahwah, New Jersey, 07430-2135

R-530BK
R-530BW
( )
a
(b)
( )
C
cd)
( >
e
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
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.
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
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
should be performed on each oven prior to releasing the oven to the owner.
(RD21101U)
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.
Ifthe 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.
Service personnel should inform SHARP ELECTRONICS CORPORATION of any certified unit
found with emissions in excess of 4mWcm2. 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
SHARF?
Microwave Ovens
R-530BK/R=530BW
Foreword
This manual has been prepared to provide Sharp
Electronics Corporation personnel with complete
operation and service information for Sharp microwave
oven models R-530BWR-530BW.
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 en-
sured:
(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, Magne-
tron, High Voltage Rectifier Assembly and High volt-
age Harness.
If provided, Vent Hood, Fan Assembly and Cooling
Fan motor.
All of the parts marked “*” on parts list are used at volt-
ages more than 25OV.
Removal of the outer case cabinet gives access to 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.
,
Sharp Electronics Corporation
Sharp Plaza
Mahwah, New Jersey 0743012135
R-530BK
R-530BW
Specifications
General Information
Key Unit Layout
Operation
Troubleshootina /
Test Procedures
Touch Control Panel
Component Replacement
and Adjustment
Microwave Measurement
Wiring / Schematic Diagram

R-530BK
R-530BW
Microwave ovens contain circuitry capable of
producing very high voltage and current. Con-
tact 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.
oltage
L
Before Servicing
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.
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 se-
conds and then short-circuit the connection of the high volt-
age 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 sup-
ply must be disconnected. In some cases it may be nec-
essary to connect the power supply after the outer case
has been removed, in this event:
1.
2.
3.
4.
5.
6.
Disconnect the power supply cord, and then remove
outer case cabinet.
Open the door and block it open.
Discharge the high voltage capacitor.
Disconnect the leads to the primary of the power
transformer.
Ensure that the leads remain isolated from other
components and oven chassis by using insulation
tape.
After the above procedure, reconnect the power sup-
ply 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
1. 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. Totest
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 to see if the wa-
ter 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.

R-530BK
R-530BW
SPECIFICATIONS
Item Description
Power Requirements 120 Volts
14.0 Amperes
1650 Watts
60 Hertz
Single phase, 3 wire grounded
Power Output 1100 watts (IEC-705 Test Procedure)
Operating frequency of 2450 MHz
Case Dimensions Width 23.94”
Height 13.27” (including feet)
Depth 19”
Cooking Cavity
1.8 Cu.Ft. Width 17”
Height 9.96”
Depth 17.8”
Tray Size 16” Diameter
Control Complement Touch Control System
Clock (I:00 - 1259)
Timer (0 - 99 min. 99 sec.)
Microwave Power for variable cooking
Repetition Rate;
P-HI (HIGH) . . . . . . , . . Full power throughout the cooking time
P-90 . . . . . 1. . . . . . . 1. . . approx. 90% of full power
P-80 . . . . . . . . . . . . . . a. . approx. 80% of full power
P-70 (MED HIGH) . . . . approx. 70% of full power
P-60 . . . . . . . . . . . . . . . . . approx. 60% of full power
P-50 (MED) . . . . . . . . . . approx. 50% of full power
P-40 . . . , . . . . . . . . . . . . . approx. 40% of full power
P-30 (MED LOW) . . . . . approx. 30% of full power
P-20 . . . , . . . . . . . . . . rn. . approx. 20% of full power
P-IO , . . . . . . . . *.. . . . . . approx. 10% of full power
P-O................... No power throughout the cooking time
FEATURES
Custom Help
Sensor Cooking
Compu Defrost
Compu Cook
Minute Plus
Kitchen Timer
Sensor Popcorn
Sensor Reheat
Variable Power (10)
4 Stage Cooking Instant Action
Oven Cavity Light
Safety Standard
Yes
UL Listed
FCC Authorized
DHHS Rules, CFR, Title 21, Chapter 1, Subchapter J

R-530BK
R-530BW
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 rec-
ommended 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.
Grounded
Receptacle Box
3 Pronged Plug \
Grounding Pin
3 Pronged Receptacle
Grounded
Receptacle Box
Tab for
Grounding Screw
Where a two-pronged wall-receptacle is encountered, it
is the personal responsibility and obligation of the cus-
tomer to contact a qualified electrician and have it re-
placed with a properly polarized and grounded three-
pronged wall receptacle or use a grounding adaptor. If
an extension cord must be used, it should be a 3-wire,
15 ampere minimum cord. 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
IO. Power Cord
4

R-530BK
R-530BW
a.
b.
C.
d.
e.
f.
g*
h.
i.
i.
k.
I.
Key Unit Layout
Indicators.
Lighted digital display.
Custom Help.
Features user friendly communications during
cooking procedure.
SENSOR COOKING pads.
Cooking time is determined by AH Sensor
Minute Plus pad.
Touch to start oven or Touch to cook for 1
minute at 100% power or to increase cook-
ing time.
Compu Cook pad.
Touch to cook certain foods.
Compu Defrost pad.
Touch to defrost certain foods.
Number selection pads.
Power Level pad. Touch to select micro-
wave power setting.
Clock pad.
Touch to set clock.
Beverage Center pad.
Touch to Reheat certain beverages.
Stop/Clear pad.
Touch to erase during programming.
Touch once to stop operation of oven during
cooking.
Touch twice to cancel cooking program.
m. Kitchen Timer pad.
Touch to set minute function.
n. Start/Touch On pad.
Touch to start oven.
o-
k
o- f
o- j
o-
m
SENSOR COOKING- - d
0
- cl
0
- h
0
-
0
e
-
0
n
0
I
Compu
___ Cook
I
Beverage
Center Compu
Defrost
f 1 2 3 4 5.
6 7 8 9 0
Kitchen Minute -
_ Timer Clock Plus
!S

R-530BK
R-530BW
OPERATION
Description of Operating Sequence
The following is a description of component functions interlock relay and is mechanically associated with
during oven operation: 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 moni-
tor 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 88:88. 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 minute.
( 1
a.
(b).
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.
When the door is closed from the open position,
the monitor switch contacts first open and the
contacts of the secondary interlock switch close.
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:
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-Oto P-90 Cooking
1.
2.
3.
4.
5.
6.
7.
The relay contacts are closed and components con-
nected to the relays (RY-1 and RY-2) are turned on.
(For details, see table below.)
Relay Components
RY-1 Oven Lamp/Turntable Motor/Fan Motor
RY-2 Power Transformer
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 approxi-
mately 2400 volts AC on the high voltage winding.
The filament winding voltage heats the magnetron
filament and the high voltage is sent to a voltage dou-
bler circuit.
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
transformer, oven lamp and cooling fan are turned off
and the generation of microwave energy is termi-
nated.
When the door is opened during a cook cycle, the
monitor switch, door sensing switch, secondary in-
terlock switch and primary interlock relay are acti-
vated 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-
eration of the secondary interlock switch and primary
When Variable Cooking Power is programmed, 120
volts AC is supplied to the power transformer intermit-
tently 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)
P-IO
(approx. 10% power)
P-O
(0% power)
On Time
32 sec.
30 sec.
26 sec.
24 sec.
22 sec.
18 sec.
16 sec.
12 sec.
8 sec.
6 sec.
0 sec.
Off Time
0 sec.
2 sec.
6 sec.
8 sec.
IO sec.
14 sec.
16 sec.
20 sec.
24 sec.
26 sec.
32 sec.
The ON/OFF time ratio does not correspond with the
percentage of microwave power, because approximate-
ly 2 seconds are needed for heating the magnetron fila-
ment.

R-530BK
R-530BW
OPERATION
DESCRIPTION OF OPERATING SEQUENCE
The followin g is a descri
during oven operation. ption of corn
Sensor Cooking Condition
ponent functions
When using the REHEAT function, the foods are cooked
without figuring time, power level or quantity. When the
oven senses enough steam from the food, it relays the
information to its microprocessor which will calculate the
remaining cooking time and the power level needed for
best results.
When the food is cooked, water vapor is developed. The
sensor “senses” the vapor and its resistance increases
gradually. When the resistance reaches the value set
according to the menu, supplementary cooking is
started.
The time of supplementary cooking is determined by ex-
periment with each food category and is inputted into the
LSI.
The following is an example of how the AH Sensor
Works:
1. Potatoes at room temperature
Vapor is emitted very slowly.
2. Heated potatoes. Moisture and humidity is emitted
rapidly. You can smell the aroma as it cooks.
3. Sensor detects moisture and humidity and calcu-
lates cooking time and variable power level.
Cooking Sequence
1. Touch REHEAT pad.
Note: The oven should not be operated in either mode
2.
3.
immediately after plugging in the unit. Wait five
minutes before cooking in sensor mode.
The coil to the shut off relay (RY-1) is energized, the
oven lamp, turntable motor and cooling fan motor are
turned on and the power transformer remains off.
After about 16 seconds, the cook relay (RY-2) is en-
ergized. The power transformer is turned on, micro-
wave energy is produced and first stage cooking is
started.
Note: The 16 second delay is for cooling time required
4.
5.
6.
7
to remove any vapor from the oven cavity and
sensor. During this first stage, do not open the
oven door or touch the STOP/CLEAR pad.
When the sensor detects the vapor emitted from the
food, the display switches over the remaining cook-
ing time and the timer counts down to zero.
At this time, the door may be opened to stir food, turn
it or season, etc.
When the timer reaches zero, an audible signal
sounds. The shut-off relay and cook relay are de-en-
ergized and the power transformer, oven lamp, etc.
are turned off.
By opening the door or touching the STOP/CLEAR
pad, the time of day will re-appear on the display and
the oven will revert to an OFF condition.

R-530BK
R-530BW
DESCRIPTION AND FUNCTION OF COMPONENTS
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 magne-
tron. 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 temper-
atures are reached within the oven cavity, the fuse will
open at 152OC,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 121OC,causing the oven to shut down.
Note: This is a fuse and it does not reset.
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 lo-
cated on the control panel circuit board.
Monitor Switch
The monitor switch is activated (the contacts opened) by
the latch head on the door while the door is closed. The
switch is intended to render the oven inoperative by
means of blowing the monitor fuse when the contacts of
the primary interlock relay and secondary interlock
switch fail to open when the door is opened.
Monitor Switch Functions
1.
2.
3.
When the door is opened, the monitor switch con-
tacts 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.
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
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
ry interlock relay, door sensing switch, monitor switch
and secondary interlock switch for proper operation.
(Refer to section “Test Procedures”.)
7 -
1 I
Latch
Heads
!
=cl
-
II I-H I
Monitor
Switch
Secondal
Interlock
Switch
NOTE: MONITOR FUSE AND MONITOR SWITCH
ARE REPLACED AS AN ASSEMBLY.
8

R-530BK
R-530BW
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, sec-
ondary interlock switch and monitor switch for proper operation. (Refer to “Test Procedure” sec-
tion.)
Whenever troubleshooting is performed, the power supply must be disconnected. In some cases it may be neces-
sary 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.
Troubleshooting Guide
Off Condition I
Problem Possible Cause Test Procedure
Home fuse blows when power cord is Shorted power cord or wire harness Check or replace
plugged into the wall receptacle.
Monitor fuse blows when power is ap- Shorted power cord or wire harness Check or replace
plied. Secondary interlock or monitor Procedure E
switch
Display does not illuminate when Shorted or open wiring
power cord is plugged in. Monitor switch or monitor fuse
Oven temperature fuse
Control unit
Check or replace
Procedure E
Procedure F
Procedure G
Display does not operate properly Primary interlock relay or door sens- Procedure E
when STOP/CLEAR button is ing switch
touched. Control unit Procedure G
Key unit unit Procedure K
Oven lamp does not light with door Shorted or open wiring Check or replace
opened. Monitor fuse Procedure E
Oven temperature fuse Procedure F
Oven lamp or socket Check or replace
Control unit Procedure G
t
)Relay (RYI) /Procedure H
9

R-530BK
R-530BW
Troubleshooting Guide
Cook Condition
Problem Possible Cause
Oven lamp does not light at all. Shorted or open wiring
Oven lamp or socket
Control unit
Oven lamp lights, but fan motor and Shorted or open wiring
turntable motor do not operate. Cooling fan motor
Turntable motor
Oven does not go into cook cycle Shorted or open wiring
when START button is touched. Primary interlock system
Monitor fuse
Magnetron or oven temperature
fuse
Relay (RYI)
Oven seems to be operating but Shorted or open wiring
little or no heat is produced in oven
load. (incompletely cooked or not Magnetron
cooked at all at the end of cook Power transformer
cycle.) Rectifier assembly
H.V. capacitor
Primary interlock system
Oven goes into a cook cycle but ex- Shorted or open wiring
tremely uneven heating is produced Turntable motor
in oven load (food). Low voltage
Dirty oven cavity
Wrong operation
Oven does not cook properly when Shorted or open wiring
programmed for Cooking Power
P-50 (MED.) mode. (Operates
properly on Cooking Power P-HI Control unit
(HIGH) mode.)
Oven goes into COMPU DEFROST Magnetron
but food is not defrosted well Wrong operation
Low voltage
Dirty oven check
Compu Defrost
The oven is in the sensor cooking Control Unit
condition but AH sensor does not end
or AH sensor turns off about a maxi-
mum of 30 minutes after start.
When a cup of water is heated by AH Sensor
sensor, the oven does not shut off
when the water is boiling.
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
Procedure G
Procedure L
10

TEST PROCEDURES
Procedure Letter Component Test
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.
6. Reconnect all leads removed from components during testing.
7. Re-install the outercase cabinet.
8. Reconnect the power supply cord after installing the outer case cabinet.
9. Run the oven and check all functions.
MICROWAVE OUTPUT POWER
The following test procedure should be carried out with the microwave oven in a fully 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 trans-
former. 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:
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.
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-
mometer or thermocouple through the water until the maximum temperature is recorded.
Subtract the cold water temperature from the hot water temperature. The normal result should
be 38” to 78°F (21Oto 42.6OC) rise in temperature. If the water temperatures are accurately mea-
sured 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.
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 ohm-
meter. 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 1IRand the resistance of the high voltage coil should be approx-
imately IOOQ; the resistance of the filament coil should be less than 1Q.
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.
11

R-530BK
R-530BW
Procedure Letter Component Test
C. High Voltage Rectifier Test
1. Disconnect the power supply cord, and then remove outer case cabinet.
2. Open the door and block it open.
Discharge the high voltage capacitor.
Isolate the rectifier from the circuit. Using the highest ohm scale of the meter, read the resistance
across the terminals and observe, reverse the leads to the rectifier terminals and observe meter
reading. Ifa short is indicated in both directions, or if an infinite resistance is read in both directions,
the rectifier is probably defective and should be replaced.
Reconnect all leads removed from components during testing.
‘.
6. Re-install the outer case cabinet.
7. Reconnect the power supply cord after installing the outer case cabinet.
8. Run the oven and check all functions.
Note: Be sure to use an Ohm-Meter that will supply a forward bias voltage of more than 6.30 Volts.
D. High Voltage Capacitor Test
(Discharge the high voltage capacitor before touching any oven components or wiring.)
I. Disconnect the power supply cord, and then remove outercase.
2. Open the door and block it open.
3. Discharge the high voltage capacitor.
4 If the capacitor is open, no high voltage will be available to the magnetron. Disconnect input leads
and check for short or open between the terminal using an ohmmeter.
Checking with a high ohm scale, if the high voltage capacitor is normal, the meter will indicate conti-
nuity initially and once the capacitor is charged an open circuit.
If the above is not the case, check the capacitor with an ohmmeter to see if it is shorted between
each terminal and case. If it is shorted, replace the capacitor.
5. Reconnect all leads removed from components during testing.
6. Re-install the outercase (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
3
E. Secondary Interlock Switch Test
I. Disconnect the power supply cord, and then remove outercase.
2. Open the door and block it open.
3. Discharge the high voltage capacitor.
4 Isolate the switch and connect the ohmmeter to the common (COM) and normally open (NO) termi-
nal of the switch. The meter should indicate an open circuit with the door open and a closed circuit
with the door closed. If improper operation is indicated, replace the secondary interlock switch.
5. Reconnect all leads removed from components during testing.
6. Re-install the outercase (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
Primary Interlock System Test
Door Sensing Switch
1. Disconnect the power supply cord, and then remove outercase.
2. Open the door and block it open.
3. Discharge the high voltage capacitor.
4. Isolate the switch and connect the ohmmeter to the common (COM) and normally open (NO) termi-
nal of the switch. The meter should indicate an open circuit with the door open and a closed circuit
with the door closed. If improper operation is indicated, replace the door sensing switch.
5. Reconnect all leads removed from components during testing.
6. Re-install the outercase (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
12

R-530BK
R-530BW
Procedure Letter
E. Continued
Component Test
Primary Interlock Relay (RY-2)
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 two (2) wire leads from the relay on the printed circuit board in the control panel assem-
bly. The relay is located on the bottom portion of the circuit board on the backside of the control
panel assembly. Connect an ohmmeter to the male terminals and observe the meter reading. The
relay contacts should be open. If the relay contacts are closed, replace the primary interlock relay
or the circuit board.
5. Reconnect all leads removed from components during testing.
6. Re-install the outer case cabinet.
7. Reconnect the power supply cord after installing the outer case cabinet.
8. Run the oven and check all functions.
Monitor Switch Test
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 oven from the power supply.
Before performing this test, make sure that the secondary interlock switch and primary interlock
relay are operating properly referring to the above Switch Test Procedure.
Disconnect the wire lead from the monitor switch (NC) terminal.
Check the monitor switch operation by using the ohmmeter as follows:
When the door is open, the meter should indicate a closed circuit.
With the door open, take a screw driver and push in the monitor switch actuator located through
the lower latch hole on the faceplate of the cavity. The meter should indicate a open circuit.
If improper operation is indicated, the monitor switch may be defective and should be replaced.
After testing the monitor switch, re-connect the wire lead to the monitor switch (NC) terminal and
check continuity of the monitor circuit.
5. Reconnect all leads removed from components during testing.
6. Re-install the outer case cabinet.
7. Reconnect the power supply cord after installing the outer case cabinet.
8. Run the oven and check all functions.
Red Wire
Connected to
Normally Closed Terminal
Notel: Connect ohmmeter
probes here.
WhiteWires
Connected to
Common Terminal
Monitor Switch
13

R-530BK
R-530BW
Procedure Letter Component Test
E. Continued
Open Monitor Fuse
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 If the monitor fuse is open, perform the tests for the primary interlock system, secondary interlock
switch and the monitor switch according to the procedure outlined in this section. Adjust or replace
the secondary interlock and door sensing switches.
5. Reconnect all leads removed from components during testing.
6. Re-install the outer case cabinet.
7. Reconnect the power supply cord after installing the outer case cabinet.
8. Run the oven and check all functions.
F. Temperature Fuses
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. A continuity check across either of the temperature fuse terminals should indicate a closed circuit
unless the temperature of the magnetron temperature fuse reaches 121OCor the oven cavity fuse
reaches 152°C. An open magnetron temperature fuse indicates overheating of the magnetron as-
sembly while an open oven fuse indicates overheating of the oven cavity. If a temperature fuse
indicates an open circuit, exchange that temperature fuse and check for a restricted air duct, re-
stricted air flow to the magnetron and oven cavity through the vent holes of the oven cavity, espe-
cially the air duct and cooling fan assembly.
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.
G. Touch Control Panel Assembly Test
The touch control panel consists of circuits including semiconductors such as LSI, ICs, etc. There-
fore, unlike conventional microwave ovens, proper maintenance can not be performed with only a
voltmeter and ohmmeter. In this service manual, the touch control panel assembly is divided into two
control units, Control Unit and Key Unit. Troubleshooting by unit replacement is described according
to the symptoms indicated.
Before testing
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 these leads remain isolated from other components and oven chassis by using insu-
lated tape.
6. After that procedure, re-connect the power supply cord.
14

R-530BK
R-530BW
Procedure Letter Component Test
G. Continued
Touch Control Panel Assembly Test
1. Key Unit
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. Check unit ribbon connection before replacement.
5. Reconnect all leads removed from components during testing.
6. Re-install the outercase (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
The following symptoms indicate a defective key unit. Replace the 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.
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. Replace the key unit.
5. Reconnect all leads removed from components during testing.
6. Re-install the outercase 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 K) to determine if control unit is faulty.
2-I 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) All the segments of a digit 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 cabinet.
2. Open the door and block it open.
3. Discharge the high voltage capacitor.
4. Reconnect all leads removed from components during testing.
5. Re-install the outercase cabinet.
6. Reconnect the power supply cord after installing the outer case cabinet.
7. Run the oven and check all functions.
15

R-530BK
R-530BW
TEST PROCEDURES
Procedure Letter Component Test
H. Relay Test
1.
2.
3.
4.
5.
6.
7.
Disconnect the power supply cord, and then remove outer case cabinet.
Open the door and block it open.
Discharge the high voltage capacitor.
Disconnect the leads to the primary of the power transformer.
Ensure that the leads remain isolated from other components and oven chassis by using insulated
tape.
After the above procedure , reconnect the power supply cord.
Check voltage between Pin No. 1 of the 2 pin connector (A) and the common terminal of the relay
RYI on the control unit with A.C. voltmeter. The meter should indicate 120 volts. If not, check oven
circuit.
RY-1 and RY-2 Relay Test
These relays are operated by D.C. voltage.
Check voltage at the relay coil with a DC. 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.
1Relay Symbol 1Operational Voltage 1Connected Components
RY 1 1Approx. 24.3 V DC 1Oven lamp/Turntable motor/Cooling fan motor 1
RY2 Approx. 23.5 V DC Power transformer
8. Disconnect the power supply cord.
9. Open the door and block it open.
IO. Discharge the 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 installing the outer case cabinet.
14.Run the oven and check all functions.
I. 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, which acts as a fuse.
1 Foil Pattern check and repairs
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. Follow the troubleshooting guide given below for repair.
Steps Occurrence Cause or Correction
1 Only pattern at “a” is broken. * Insert jumper wire Jl and solder.
2 Pattern at “a” and “b” are broken * Insert the coil RCILF~ 0O~YAZZ between “c” and “d”.
16

R-530BK
R-530BW
Procedure Letter Component Test
I. Continued
Procedures to be taken when the foil pattern of the printed wiring board (PWB)
is open
5. Make a visual inspection of the varistor burn
damage and test the transformer with an ohm-
meter for the presence of layer short-circuit
(check the primary coil resistance which is
approximately 210 Q & 15%). If any abnormal
condition is detected, replace the defective
pan(s). m
0
6. Reconnect all leads removed from components during testing.
7. Re-install the outercase (cabinet).
8. Reconnect the power supply cord after installing the outer case cabinet.
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 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 insu-
lated tape.
6. After the above procedure, reconnect 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
Pin No.1 of the 2-pin connector (A) and the
common terminal of the relay RYI .
2 The rated AC voltage is present at primary Low voltage transformer or secondary circuit
side of low voltage transformer. defective. Check and repair.
8. Disconnect the power supply cord, and then remove the outer case.
9. Open the door and block it open.
IO. Discharge the 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 cabinet is installed.
14.Run the oven and check all functions.
17

R-530BK
R-530BW
Procedure Letter Component Test
J Compu Defrost Test
1. Place one cup of water in the center of the turntable tray in the oven cavity.
2. Close the door, touch the”COMPU DEFROST” pad twice and touch the number pad “I”, and touch
the number pad “5”. Then touch the “START” pad.
3. The oven is in “COMPU DEFROST” cooking mode.
4. The oven will operate as follows:
Weight 1st Stage
Level Time
2nd Stage
Level Time
3rd Stage
Level Time
4th Stage
Level Time
0.5 ( 70% ( 47 sec. ( 0% 1 52 sec. ( 50% ( 32 sec. ( 30% / 40 sec.
5. If improper operation is indicated, the control unit is probably defective and should be checked.
K. Key Unit Test
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. If the display fails to clear when the STOP/CLEAR pad is depressed, first verify the flat ribbon is
making good contact and verify that the door sensing switch operates properly (contacts are
closed when the door is closed and open when the door is open). Ifthe door sensing switch is good,
disconnect the flat ribbon cable that connects the key unit to the control unit and make sure the
door sensing switch is closed (either close the door or short the door sensing switch connector).
Use the key unit matrix indicated on the control panel schematic and place a jumper wire between
the pins that correspond to the STOP/CLEAR pad making momentary contact. If the control unit
responds by clearing with a beep the key unit is faulty and must be replaced. Ifthe control unit does
not respond, it is faulty and must be replaced.lf a specific pad does not respond, the above method
may be used (after clearing the control unit) to determine if the control unit or pad is at fault.
5. Reconnect all leads removed from components during testing.
6. Re-install the outer case cabinet.
7. Reconnect the power supply cord after installing the outer case cabinet
8. Run the oven and check all functions.
G8 G7 G6 G5 G4 G3 G2 Gl
Z! 5 4 3 2 1 Popcorn Custom
Reheat Help
0
i? 0 9 8 7 Fresh
6 Baked KITCHEN
potato vegetables TIMER
Minute Compu Fish/ Frozen Ground POWER
g Plus Defrost seafood vegetables Poultry meat LEVEL
cv Start Frozen Beverage Frozen stop
6 Touch Clock snacks center Rice Compu
Cook main dish Clear
KEY UNIT
18
.
.