R-1405 R-1406 SERVICE MANUAL S92M198R1405E OVER THE RANGE MICROWAVE OVEN MODELS R-1405 R-1406 R-1405 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 the following parts may result in a severe, possibly fatal, electrical shock.
R-1405 R-1406 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.
R-1405 R-1406 WARNING TO SERVICE PERSONNEL Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts may result in a severe, possibly fatal, electrical shock. (Example) High Voltage Capacitor, High Voltage Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc.. Read the Service Manual carefully and follow all instructions. Don't Touch ! Danger High Voltage When the testing is completed, 1.
R-1405 R-1406 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.
R-1405 R-1406 SERVICE MANUAL PRODUCT DESCRIPTION OVER THE RANGE MICROWAVE OVEN R-1405/ R-1406 GENERAL INFORMATION FOREWORD This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service Information for the SHARP OVER THE RANGE MICROWAVE OVEN, R-1405 and R1406. 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.
R-1405 R-1406 PRODUCT SPECIFICATION ITEM DESCRIPTION Power Requirements 120 Volts / 13.5 Amperes 60 Hertz Single phase, 3 wire grounded Power Output 950 watts (IEC TEST PROCEDURE) Operating frequency of 2450MHz Case Dimensions Width 29-15/16" Height 15- 9/16" Depth 16-1/4" Cooking Cavity Dimensions Width 17-1/2" Height 14-15/16" Depth 9-7/8" 1.5 Cubic Feet Hood lamp 2 bulbs, 20W x 2, Incandescent light bulbs Hood fan Approx. 300 C.F.M.
R-1405 R-1406 Electrical Requirements The oven is equipped with a 3-prong grounding plug. DO NOT UNDER ANY CIRCUMSTANCES CUT OR REMOVE THE GROUNDING PIN FROM THE PLUG. The power supply cord and plug must be connected to a separate 120 Volt AC, 60 Hz, 15 Amp. or more dedicated line, using a grounded receptacle. The receptacle should be located inside the cabinet directly above the Microwave Oven/Hood system mounting location.
R-1405 R-1406 CONTROL PANEL NOTE: Some one-touch cooking features such as "MINUTE PLUS" are disabled after three minutes when the oven is not used. These features are automatically enabled when the door is opened and closed or STOP/CLEAR button is pressed.
R-1405 R-1406 OPERATION DESCRIPTION OF OPERATING SEQUENCE The following is a description of component functions during oven operation. relay (RY2) and is mechanically associated with the door so that it will function in the following sequence. (1) When the door opens from a 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.
R-1405 R-1406 VENTILATION METHODS HOT AIR EXHAUST 1. VERTICAL VENTING For this venting method, hot air rising from the conventional range below is drawn in by the hood fan motor through the grease filters at the right and left sides of the base cover, up through the right and left sides of the oven cavity, then discharged vertically at rear center top of the oven, into the customer's vent system. To Duct To Duct Hood Fan Motor Hood Intake Duct R Grease Filter 2.
R-1405 R-1406 NOTE: " CAVITY THERMAL CUTOUT MAGNETRON TEMPERATURE FUSE RED ORG RED BLK BLK ORG RED RED CONTROL UNIT COM. E2 RY5 (RY1) HOOD CAPACITOR E1 (RY2) SECONDARY INTERLOCK RELAY OVEN LAMP RELAY F1 WHT RED BRN WHT WHT WHT WHT WHT MONITOR SWITCH FM FAN MOTOR WHT YLW RED HOOD LAMP TURN TTM TABLE MOTOR OL OVEN LAMP GRY HL HL WHT WHT WHT HIGH VOLTAGE CAPACITOR xx uF ORG GRY GRY BRN COM. WHT WHT BRN RED WHT BLU N.O.
R-1405 R-1406 DESCRIPTION AND FUNCTION OF COMPONENTS 3. If the door is opened, and the secondary interlock relay (RY2) and primary interlock switch contacts fail to open, the monitor fuse blows simultaneously with closing of the monitor switch contacts. CAUTION: BEFORE REPLACING A BLOWN MONITOR FUSE TEST THE DOOR SENSING SWITCH, SECONDARY INTERLOCK RELAY (RY2), RELAY (RY1), PRIMARY INTERLOCK SWITCH AND MONITOR SWITCH FOR PROPER OPERATION. (REFER TO CHAPTER "TEST PROCEDURE").
R-1405 R-1406 vapors given off from the heating foods. It is then exhausted through the exhausting air vents at the oven cavity. supplied duct system, or discharged back into the kitchen. HOOD LAMP HOOD FAN MOTOR The hood lamps are mounted at the hood lamp angle on the base cover. The hood lamps can be turned off and on by touching the LIGHT button. The hood fan motor is a one-speed, single-phase, double pole induction type, requiring a hood fan capacitor.
R-1405 R-1406 I CK CK RE CK CK RE RE RE RE P O N N N N N M L K J MONITOR FUSE LOW VOLTAGE NO POWER AT OUTLET SHORT IN POWER CORD OPENED OR SHORTED WIRING HOOD MOTOR CAPACITOR HOOD LAMP OR SOCKET TURNTABLE MOTOR FAN MOTOR OVEN LAMP OR SOCKET FOIL PATERN ON P.W.B. DEFROST CENTER RELAYS (RY-5), (TY6) RELAY (RY-4) RELAY (RY-3) RELAY (RY-2) RELAY (RY-1) KEY UNIT CONTROL UNIT HOOD FAN MOTOR HOOD HERMAL CUT-OUT Home fuse blows when power cord is plugged into wall receptacle.
R-1405 R-1406 TEST PROCEDURES PROCEDURE LETTER A COMPONENT TEST MAGNETRON ASSEMBLY TEST 1. 2. 3. 4. 5. 6. 7. 8. 9. Disconnect the power supply cord, and then remove outer case. Open the door and block it open. Discharge high voltage capacitor. To test for an open filament, isolate the magnetron from the high voltage circuit. A continuity check across the magnetron filament leads should indicate less than 1 ohm.
R-1405 R-1406 TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST (HIGH VOLTAGES ARE PRESENT AT THE HIGH VOLTAGE TERMINAL, SO DO NOT ATTEMPT TO MEASURE THE FILAMENT AND HIGH VOLTAGE.) C HIGH VOLTAGE RECTIFIER TEST 1. 2. 3. 4. Disconnect the power supply cord, and then remove outer case. Open the door and block it open. Discharge high voltage capacitor. Isolate the rectifier from the circuit.
R-1405 R-1406 TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST 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. CAUTION: IF THE THERMAL CUT-OUT OR TEMPERATURE FUSE INDICATES AN OPEN CIRCUIT AT ROOM TEMPERATURE, REPLACE THERMAL CUT-OUT OR TEMPERATURE FUSE. F PRIMARY INTERLOCK SWITCH TEST 1. 2. 3. 4. 5. 6. 7. 8. G Disconnect the power supply cord, and then remove outer case.
R-1405 R-1406 TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST 5. 6. 7. 8. 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. Reconnect all leads removed from components during testing.
R-1405 R-1406 TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST YLW Resistance between; BLU 1 4 HOOD FAN CAPACITOR MAIN SUB 5 120 v 60 Hz 60 Ω 5. 6. 7. 8. AND AND AND AND AND AND YLW (4) = YLW (4) = BLK (2) = BLU (1) = BLK (2) = RED (5) = 0 Ω (Shorted) 60Ω 60Ω 162Ω 102Ω 162Ω 2 BLK 102 Ω RED BLU (1) BLK (2) BLU (1) RED(5) RED(5) YLW(4) 6-PIN CONNECTOR OF HOOD FAN MOTOR Reconnect all leads removed from components during testing. Reinstall the outer case (cabinet).
R-1405 R-1406 TEST PROCEDURES PROCEDURE LETTER L COMPONENT TEST TOUCH CONTROL PANEL ASSEMBLY TEST The touch control panel consists of circuits including semiconductors such as LSI, ICs, etc. Therefore, unlike conventional microwave ovens, proper maintenance cannot be performed with only a voltmeter and ohmmeter.
R-1405 R-1406 TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST When testing is completed, 1) Disconnect the power supply cord. 2) Open the door and block it open. 3) To discharge high voltage capacitor, wait for 60 seconds. 4) Reconnect all leads removed from components during testing. 5) Re-install the hood intake duct R. 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. M KEY UNIT TEST 1. 2. 3. 4. 5.
R-1405 R-1406 TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST 7. After that procedure, re-connect the power supply cord. 8. Check voltage between normal open terminal of the relay RY2 and the normal open terminal of the relay RY1 on the control unit with an A.C. voltmeter. The meter should indicate 120 volts, if not check oven circuit. RY1, RY2, RY4, and RY5 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.
R-1405 R-1406 TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST 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". 1 VRS1 d J1 P S b a 3 T1 c RY2 QKITPB035 6) Make a visual inspection of the varistor.
R-1405 R-1406 TOUCH CONTROL PANEL ASSEMBLY OUTLINE OF TOUCH CONTROL PANEL The touch control section consists of the following units as shown in the touch control panel circuit. Symbol VC (1) Key Unit (2) Control Unit (The Control unit consists of LSI Unit and Power U nit) Voltage -5.3V Application LSI(IC1) 3) Synchronizing Signal Circuit The power source synchronizing signal is available in order to compose a basic standard time in the clock circuit.
R-1405 R-1406 Pin No. 7 8 9-10 11-13 14 Signal I/O AN3 AN2 OUT IN AN1-AN0 P57-P55 CNTR0 OUT OUT OUT Description Back light circuit (Light emitting diodes) driving signal. To input signal which communicates the door open/close information to LSI. Door close "H" level signal (0V). Door open "L" level signal (-5V). Terminal not used. Terminal not used. 0.1 sec. Signal to sound buzzer (2.0 kHz). H : GND A: key touch sound. A L : -5V B: Completion sound. 2.0 sec.
R-1405 R-1406 Pin No. Signal I/O 34 P26 OUT 35 P25 OUT 36 37 38 P24 P23 P22 OUT OUT OUT 39 P21 OUT 40 P20 OUT 41 42 P17 P16 OUT OUT 43 44 P15 P14 OUT OUT 45-47 48-50 51-72 73/74 75 76 77 P13-P11 OUT SEG24-SEG22 OUT SEG21-SEG0 OUT VCC/VREF AVSS COM3 COM2 IN IN OUT OUT 78 COM1 OUT 79 COM0 OUT 80 VL3 IN Description Key strobe signal. Signal applied to touch-key section. A pulse signal is input to P43-P46 terminal while one of G7 line keys on key matrix is touched.
R-1405 R-1406 SERVICING 1. Precautions for Handling Electronic Components This unit uses CMOS LSI in the integral part of the circuits. When handling these parts, the following precautions should be strictly followed. CMOS LSI have extremely high impedance at its input and output terminals. For this reason, it is easily influenced by the surrounding high voltage power source, static electricity charge in clothes, etc. and sometimes it is not fully protected by the built-in protection circuit.
R-1405 R-1406 COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE WARNING AGAINST HIGH VOLTAGE: Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts may result in severe, possibly fatal, electric shock. (Example) High Voltage Capacitor, Power Transformer, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc.. WARNING: Avoid possible exposure to microwave energy. Please follow the instructions below before operating the oven. 1.
R-1405 R-1406 5. Pull the hood exhaust louver from the oven cavity by pushing the right and left tabs of the hood exhaust louver to remove. 6. Now, the hood exhaust louver is free. Left tab Hood exhaust louver Screw Screw Right tab Screw REMOVAL OF OVEN FROM WALL (Two persons recommended to remove the oven) 1. Disconnect the power supply cord, and uncoil the power supply cord. 2. To discharge the high voltage capacitor, wait for 60 seconds. 3. Remove the turntable tray and support from the oven cavity.
R-1405 R-1406 4. Disconnect the 6-pin connector of the hood fan motor from the main wire harness located at the right edge of the oven cavity top plate and release the snap band from the hood duct. 5. Remove the hood fan motor from the oven cavity top plate by lifting it up. 6. Now, the hood fan motor is free. MAGNETRON REMOVAL 1. Disconnect the power supply cord , remove the oven from wall and remove outer case (Refer to procedure of "Removal of Oven from Wall" and "Outer case Removal".) 2.
R-1405 R-1406 TEMPERATURE FUSE (MAGNETRON) REMOVAL 1. Disconnect the power supply cord and remove the oven from wall and remove outer case. (Refer to procedure of "Removal of Oven from Wall" and "Outer case Removal") 2. Open the door and block it open. 3. To discharge the high voltage capacitor, wait for 60 seconds. 4. Remove the fan duct assembly from the oven cavity, referring to the procedure of " COOLING FAN MOTOR REMOVAL". 5. Disconnect the wire leads from the temperature fuse (Magnetron). 6.
R-1405 R-1406 TURNTABLE MOTOR AND FOOD LAMP SOCKETS REMOVAL 1. Disconnect the power supply cord. 2. Open the door and block it open. 3. To discharge the high voltage capacitor, wait for 60 seconds. 4. Remove the one (1) screw holding the base cover to the oven cavity back plate. 5. Remove the three (3) screws holding the base cover to the oven cavity front face plate. 6. Open the base cover. 7. Release the two hood lamp sockets from the base cover. 8.
R-1405 R-1406 13.Remove the two (2) screws holding the LCD holder to the key fixing plate. 14.Remove two (2) screws holding the power unit to the key fixing plate. 15.Release the two (2) tabs holding the power unit to the key fixing plate. 16.Release the three (3) tabs holding the LCD to the LCD holder. 17.Release the two (2) tabs holding the LSI unit to the LCD holder. 18.Remove the LCD holder and the LED sheet. 19.Now, the control unit is free. 20.
R-1405 R-1406 After adjustment, check the following. 1. In and out play of door remains less than 0.5mm when in the latched position. First check upper position of latch hook, pushing and pulling upper portion of door toward the oven face. Then check lower portion of the latch hook, pushing and pulling lower portion of the door toward the oven face. Both results (play in the door) should be less than 0.5mm. 2.
R-1405 R-1406 DOOR DISASSEMBLY 1. Disconnect the power supply cord. 2. Open the door and block it open. 3. To discharge the high voltage capacitor, wait for 60 seconds. 4. Remove the three (3) screws holding the hood exhaust louver to the oven cavity front face plate. 5. Remove the hood exhaust louver from the oven cavity by pushing the right and left tabs of the hood exhaust louver. (Refer to the procedure of "HOOD EXHAUST LOUVER REMOVAL".) 6. Remove door assembly, referring to "DOOR REPLACEMENT".
1 GRY 2 WHT R E D RED ORG COM. T1 1 2 CN-E 1 C100 CN-B 9 1 3 34 CN-A 5 1 RY2: SECONDARY INTERLOCK RELAY RY2: N.O. N.O. COM. CN-C CN-B F 4 N.O. COM.
R-1405 R-1406 2 1 4 3 6 5 A A B B D1-D4 1N4002 D4 5 D2 (J1) C 1 D1 + – C2 1000µ/35v D3 d a 8 JVR-10S471J VRS1 3 C1 0.1µ/50v T1 R1 390 2w R2 750 1w b – c D21 1SS270A OVEN LAMP TURNTABLE MOTOR FAN MOTOR COM SP1 PKM22EPT COM MICRO. B3 HOOD MOTOR COM.
R-1405 R-1406 R13 4.7k R14 4.7k COOK 1 COM0(LCD) COM1(LCD) COM2(LCD) 26 DEFROST COM0 COM1 COM2 NC SEG0 SEG1 SEG2 SEG3 SEG4 SEG5 SEG6 SEG7 SEG8 SEG9 SEG10 SEG11 SEG12 SEG13 SEG14 SEG15 SEG16 SEG17 SEG18 SEG19 SEG20 SEG21 3.6k 4.7k GND R15 4.7k 10k (J16) 4.7k 10k (J14) (J15) (J17) (J12) C12 0.1µ/50v R5 4.7k R4 82 C11 0.1µ/50v C10 47µ/16v 4.7k C4 (J13) BUZZER (J10) C6 4.7k N.C. (J11) C3 C14 0.01µ /25v VA R11 15k C8 UDZ4.3B R10 1k HOOD LAMP ZD10 C9 C13 0.01µ/25v H.
R-1405 R-1406 2 1 4 3 6 5 A A CN-C 14 D40 D20 B D21 1 DIP 2 R2 E R CN-E Q1 B ZD1 R3 R30 C 2 SP1 RY1 0 RM 5 3 0 B F 0 V 4 9 A 7 2 M SCM 1 B R1 C2 C C21 B C3 1 C1 D1 D3 D4 D2 1 VRS1 D Q21 T1 BFB E D 5 J1 P S RY2 E 3 8 RY5 D25 D26 D22 F F D24 D23 RY4 RY3 9 1 RY6 LOT NO. G C100 QKITPB035MRE0 E 5 1 G CN-A CN-B H H Figure S-4.
R-1405 R-1406 PARTS LIST ∆” may cause undue microwave exposure. Note: The parts marked “∆ The parts marked “*” are used in voltage more than 250V. REF. NO. PART NO.
R-1405 R-1406 REF. NO. 3- 2-2 3- 2-3 3- 2-3 3- 2-4 3- 3 PART NO.
R-1405 R-1406 REF. NO. PART NO.
R-1405 R-1406 2 1 4 3 6 5 OVEN AND CABINET PARTS A A 6-1-5 6-11 4-10 7-3 2-1 7-3 7-5 B 7-3 2-5 7-3 7-5 4-12 1-12 7-5 4-19 7-5 1-14 C C 2-6 7-3 7-3 4-17 7-3 4-16 4-18 4-13 D B 4-17 D 2-4 2-2 7-3 4-7 6-8 7-7 4-16 1-3 7-1 4-15 6-7 E 7-6 4-8 6-6 4-3 1-9 1-4 7-9 4-5 1-16 4-6 F 2-8 1-16 1-10 7-7 7-8 E 7-8 1-13 4-21 1-7 1-11 1-5 4-4 1-1 1-10 1-11 1-2 7-4 4-11 1-8 4-9 1-15 4-20 4-13 4-14 4-22 1-6 F 1-13 7-3 4-2 2-3 7-3 7-3 7-2 7-3 7-3 G
R-1405 R-1406 2 1 4 3 CONTROL PANEL PARTS 5 6 3-3 3-1-2 3-1-1 A A 3-1 3-2 3-2-1 3-3 3-3 B B 7-3 DOOR PARTS 3-2-3 3-2-2 3-2-4 C C 5-3 5 5-1 D D 5-5 5-6 5-4 E E 5-2-1 5-2-2 5-2 F F MISCELLANEOUS G G 6-4 6-1 6-1-1 6-1-4 6-5 6-1-5 6-1-2 6-1-6 6-9 6-1-7 6-1-3 H Actual wire harness may be different from illustration.
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R-1405 R-1406 NOTES 45
R-1405 R-1406 COPYRIGHT © 2002 BY SHARP CORPORATION ALL RIGHTS RESERVED. 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. '02 SHARP CORP. (9S2.420E) Printed in U.S.