Microwave Technical Bulletin Sharp Electronics Corporation Services and Solutions Group 1300 Naperville Drive Romeoville, IL 60446 Number: MW-290 Date: November 2006 Model(s): R520KS SUBJECT: Correction to the service manual. Please correct the part number in the service manual for the key sheet assembly, reference number 3-3 for the model listed above.
Microwave Technical Bulletin Sharp Electronics Corporation Services and Solutions Group 1300 Naperville Drive Romeoville, IL 60446 Number: MW-298 Date: June 2007 Model(s): R530EKF / R530EWF / R530ESF / R520KS / R520LK / R520LW SUBJECT: Waveguide cover information.
Parts Tip Parts Tip Number: PT321 Model (s) Affected : Subject: Symptom or Problem: Cause: Solution or action to resolve issue: Date: February 20, 2007 R520KS, R520LK, R520LW, R530EKF, R530EWF, R530ESF Change to wave guide covers Please use the information below SVC251 Description Waveguide Cover Waveguide Cover Part Code PCOVPB085MRP0 PCOVPB172MRP0 When Ending Jan 2007 Starting Jan 2007 Pricing AH AC
R - 520KS SERVICE MANUAL S45M251R520KE MICROWAVE OVEN MODEL R-520KS In the interest of user-safety the oven should be restored to its original condition and only parts identical to those specified should be used. WARNING TO SERVICE PERSONNEL: Microwave ovens contain circuitry capable of producing very high voltage and current, contact with following parts may result in a severe, possibly fatal, electrical shock.
R- 520KS 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-520KS 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-520KS 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-520KS SERVICE MANUAL PRODUCT DESCRIPTION MICROWAVE OVEN R-520KS GENERAL INFORMATION FOREWORD This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service Information for the SHARP MICROWAVE OVEN R-520KS. 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.
SPECIFICATION R-520KS ITEM DESCRIPTION PowerRequirements 120 Volts 14.3 Amperes, 1700 watts 60 Hertz Single phase, 3 wire grounded Power Output 1200 watts (IEC TEST PROCEDURE) Operating frequency of 2450MHz Case Dimensions Width 24" Height 13-3/8" Depth 19-1/8" Cooking Cavity Dimensions Width 17-3/8" Height 10-1/2" Depth 18-5/8" 2.0 Cubic Feet Control Complement Touch Control System Clock ( 1:00 - 12:59 ) Timer (0 - 99 min.
R-520KS 15 or 20 amp. fused electrical supply. It is recommended that a separate circuit serving only this appliance be provided. When installing this appliance, observe all applicable codes and ordinances. A short power-supply cord is provided to reduce risks of becoming entangled in or tripping over a longer cord.
R-520KS OPERATION DESCRIPTION OF OPERATING SEQUENCE The following is a description of component functions during oven operation. and is mechanically associated with the door so that it will function in the following sequence. (1) When the door opens from the closed position, the secondary interlock relay (RY2) and primary interlock switch open their contacts. And contacts of the relay (RY1) remains closed. Then the monitor switch contacts close.
R-520KS SENSOR COOKING CONDITION 2. The coil of shut-off relay (RY-1) is energized, the turntable motor are turned on, but the power transformer is not turned on. 3. After about 16 seconds, the cook relay (RY-2) is energized. The power transformer is turned on, microwave energy is produced and first stage is started. The 16 seconds is the cooling time required to remove any vapor from the oven cavity and sensor. Using the SENSOR function, food is cooked without figuring time, power level or quantity.
R-520KS Note:* Indicates component SCHEMATIC NOTE: CONDITION OF OVEN 1. Door Closed 2. CLOCK APPEARS ON DISPLAY CAVITY TEMPERATURE FUSE MAGNETRON TEMPERATURE FUSE ORG ORG RED RED BRN ORG RED N.O. GRN GRN COM. GRN B2 GRN (RY1) MAGNETRON RED RED CONTROL UNIT COM. ORG ORG BRN GRY COM. GRY MONITOR SWITCH N.C. FM FAN MOTOR WHT WHT WHT "TO LOAD" "TO SOURCE" TURN TTM TABLE MOTOR OVEN LAMP OL HIGH VOLTAGE RECTIFIER COM.
R-520KS DESCRIPTION AND FUNCTION OF COMPONENTS DOOR OPEN MECHANISM The door is opened by pushing the open button on the control panel, refer to the Figure D-1. When the open button is pushed, the open button pushes up the switch lever, and then the switch lever pushes up the latch head. The latch heads are moved upward and released from latch hook. Now the door will open. Latch Heads Door Door S ens ing S witch 3.
R-520KS TROUBLESHOOTING GUIDE Never touch any part in the circuit with your hand or an uninsulated tool while the power supply is connected. 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.
R-520KS CK = Check / RE = Replace Home fuse or circuit breaker blows when power cord is plugged into wall receptacle C/T fuse blows when power cord is plugged into wall receptacle. OFF CONDITION All letters and indicators do not appear in display when power cord is first plugged into wall outlet. Display does not operate properly when STOP/CLEAR key is touched. (Buzzer should sound and ":" or time of day should appear in display.) Oven lamp does not light when door is opened.
R-520KS TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST 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 1 ohm. 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 and must be replaced. 6.
R-520KS TEST PROCEDURES PROCEDURE LETTER C COMPONENT TEST 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. 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.
R-520KS TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST CAUTION: IF THE TEMPERATURE FUSE INDICATES AN OPEN CIRCUIT AT ROOM TEMPERATURE, REPLACE TEMPERATURE FUSE. F PRIMARY INTERLOCK SWITCH TEST 1. 2. 3. 4. 5. 6. 7. 8. Disconnect the power supply cord, and then remove outer case. Open the door and block it open. Discharge high voltage capacitor. Isolate the switch and connect the ohmmeter to the common (COM.) and normally open (NO) terminal of the switch.
R-520KS TEST PROCEDURES PROCEDURE LETTER G MONITOR SWITCH TEST 1. 2. 3. 4. 5. 6. 7. 8. COMPONENT TEST Disconnect the power supply cord, and then remove outer case. Open the door and block it open. Discharge high voltage capacitor. Before performing this test, make sure that the primary interlock switch and the secondary interlock relay are operating properly, according to the above Switch Test Procedure. Disconnect the wire lead from the monitor switch (COM) terminal.
R-520KS TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST 2. Control Unit The following symptoms indicate a defective control unit. 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.
R-520KS TEST PROCEDURES PROCEDURE LETTER G7 G6 G9 G8 COMPONENT TEST G10 G11 KEEP WARM G12 FRESH VEGETABLES STEAKS/ CHOPS FROZEN ENTREES G13 FROZEN ROLLS/ MUFFINS GROUND MEAT (DEFROST) POWER LEVEL FISH SEAFOOD SENSOR REHEAT BONELESS POULTRY PLUS BONE-IN POULTRY FRESH ROLLS/ MUFFINS G5 G4 G3 G2 G1 5 3 8 2 1 0 4 9 7 6 STOP CLEAR CUSTOM HELP RICE POPCORN NIGHT LIGHT FROZEN VEGETABLES CHICKEN BREAST Pin NO. G1 Pin NO.
R-520KS TEST PROCEDURES PROCEDURE LETTER L COMPONENT TEST FOIL PATTERN ON THE PRINTED WIRING BOARD TEST To protect the electronic circuits, this model is provided with a fine foil pattern added to the primary on the PWB, this foil pattern acts as a fuse. 1. Foil pattern check and repairs. 1) Disconnect the power supply cord, and then remove outer case. 2) Open the door and block it open. 3) Discharge high voltage capacitor. 4) Follow the troubleshooting guide given below for repair.
R-520KS N AH SENSOR TEST Checking the initial sensor cooking condition WARNING : The oven should be fully assembled before following procedure. (1) The oven should be plugged in at least two minutes before sensor cooking. (2) Room temperature should not exceed 95½F (35½C). (3) The unit should not be installed in any area where heat and steam are generated. The unit should not be installed, for example, next to a conventional surface unit. Refer to the “INSTALLATION INSTRUCTIONS” of the operation manual.
R-520KS If new sensor dose not operate properly, the problem is with the control unit, and refer to explanation below. CHECKING CONTROL UNIT (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. Disconnect the sensor connector that is mounted to control panel. Then connect the dummy resistor circuit (see fig.) to the sensor connector of control panel.
R-520KS TOUCH CONTROL PANEL ASSEMBLY OUTLINE OF TOUCH CONTROL PANEL 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. 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).
R-520KS DESCRIPTION OF LSI LSI The I/O signal of the LSI is detailed in the following table. Pin No. Signal I/O Description 1-2 VL2-VL1 IN Power source voltage input terminal. Standard voltage for LCD. 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 AN3 IN Signal coming from touch key.
R-520KS Pin No. Signal I/O 25 P41 IN Signal similar to AN3. When either G11 line on key matrix is touched, a corresponding signal will be input into P41. 26 P40 IN Connected to GND through the pull-down resistor. 27 RESET IN Auto clear terminal. Signal is input to reset the LSI to the initial state when power is applied. 28 P71 IN Signal similar to AN3. When either G10 line on key matrix is touched, a corresponding signal will be input into P71. 29 P70 IN Signal similar to ANI3.
R-520KS Pin No. Signal I/O Description Connected to LCD. The relation between signals are as follows: LSI signal (Pin No.) LCD (Pin No.) SEG0 (72) ................................ SEG 0 SEG1 (71) ................................ SEG 1 SEG2 (70) ................................ SEG 2 SEG3 (69) ................................ SEG 3 SEG4 (68) ................................ SEG 4 SEG5 (67) ................................ SEG 5 SEG6 (66) ................................ SEG 6 SEG7 (65) .................
R-520KS ABSOLUTE HUMIDITY SENSOR CIRCUIT (1) Structure of Absolute Humidity Sensor The absolute humidity sensor includes two thermistors as shown in the illustration. One thermistor is housed in the closed vessel filled with dry air while another in the open vessel. Each sensor is provided with the protective cover made of metal mesh to be protected from the external airflow. Thermistors Sensing part (Closed vessel) R1 S R3 R2 R98 620k 11 R99 300k 12 R100 150k 13 R101 75k 17 R102 37.
R-520KS TOUCH CONTROL PANEL 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-520KS COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE WARNING AGAINST HIGH VOLTAGE: Microwave ovens contain circuitry capable of producing very high voltage and current. Contact with the 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: To Avoid possible exposure to microwave energy, please follow the instructions below before operating the oven. 1.
R-520KS CAUTION: 1. DISCONNECT OVEN FROM POWER SUPPLY BEFORE REMOVING OUTER CASE. 2. DISCHARGE THE HIGH VOLTAGE CAPACITOR BEFORE TOUCHING ANY OVEN COMPONENTS OR WIRING. NOTE: When replacing the outer case, the 2 special Torx screws must be reinstalled in the same locations. Special screw Screw Driver (Type: TORX T20 H or GTXH20-100) POWER TRANSFORMER REMOVAL Re-install 1. Rest transformer on the bottom plate with its primary terminals toward the oven face plate. 2.
R-520KS OVEN LAMP AND LAMP SOCKET REMOVAL 1. 2. 3. 4. 5. Disconnect the power supply cord and remove outer case. Open the door and block it open. Discharge high voltage capacitor. Remove the oven lamp from the oven lamp socket. Pull the wire leads from the oven lamp socket by pushing the terminal hole of the oven lamp socket with the small flat type screw driver. 6. Remove the oven lamp socket from the magnetron duct by turning the socket counterclockwise. 7.
R-520KS Installation 1. Remove remaining adhesive on the control panel frame surfaces with a soft cloth soaked in alcohol. 2. Make sure that the LCD sheet and the liquid crystal display is installed in position. 3. Remove the backing paper from the new membrane switch and ribbon cable. 4. Insert the ribbon cable of the membrane switch into the slit of the control panel frame. 5. Adjust the upper edge and right edge of the membrane switch to the small depression on the surface of the control panel frame. 6.
R-520KS COOLING FAN MOTOR REMOVAL REMOVAL 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 wire leads from the fan motor. 5. Remove the two (2) screws holding the fan motor to the oven cavity back plate. 6. Remove the fan blade from the fan motor shaft according to the following procedure. 7. Hold the edge of the rotor of the fan motor by using a pair of groove joint pliers.
R-520KS 3. Secure latch hook (with two (2) mounting screws) to oven flange. 4. Make sure that the monitor switch is operating properly and check continuity of the monitor circuit. Refer to chapter "Test Procedure" and Adjustment procedure. DOORSENSINGSWITCH/PRIMARY INTERLOCKSWITCHANDMONITORSWITCHADJUSTMENT 1. Disconnect the power supply cord, and then remove outer case. 2. Open the door and block it open. 3. Discharge high voltage capacitor.
R-520KS 9. Release the door panel from twelve (12) tabs of door frame. 10.Remove the door panel from the door frame. 11.Now, door panel with sealer film is free. 12.Tear sealer film from door panel. 13.Now, door panel is free. 14.Slide latch head upward and remove it from door frame with releasing latch spring from door frame and latch head. 15.Now, latch head and latch spring are free. 16.Remove door screen from door frame 17.Now, door frame is free. RE-INSTALL 1. Re-install door screen to door frame. 2.
1 2 3 34 4 2 GRY RY1 COM. SECONDARY INTERLOCK RELAY WHT N.O. N.O. COM. BRN RY2 ORG G WHT T1 ORG GRY OVEN LAMP AND SOCKET WHT WHT WHT 5 GRY COM. NO WHT RED RED WHT WHT WHT ORG CN-B 1 PNK 2 GRN WHT TURNTABLE MOTOR BRN MAGNETRON POWER TRANSFORMER H.V. RECTIFIER HIGH VOLTAGE WIRE A N.O. HIGH VOLTAGE CAPACITOR HIGH VOLTAGE COMPONENTS FAN MOTOR ORG NOTE: The neutral (WHT/GRY) wire must be connected to the terminal with "N" mark on the power supply cord.
R-520KS 1 2 4 3 5 6 A B B C C Figure S-3.
R-520KS 1 2 4 3 5 6 A A B B DIP CHIP SIDE C C J3 CN-F C10 R90 C4 1 2 3 LED D31 CN-B D D R3 R5 C5 R6 WH-2 B1 2 E Q1 Q4 SP1 Q3 DZ1 E C B E C B J1 E Q2 E C B D30 2 1 J5 J6 2 1 WH-2 D5 D8 T1 J2 R4 E D6 R2 R7 RY2 C1 R8 F F D1 D2 P S L1 D3 D4 VRS1 G G C2 D7 RY1 H H Figure S-5 .
R-520KS PARTS LIST ∆” may cause undue microwave exposure. Note: The parts marked “∆ The parts marked “*” are used in voltage more than 250V. "§" MARK: PARTS DELIVERY SECTION. REF. NO. PART NO.
R-520KS REF. NO. PART NO.
R-520KS 2 1 4 3 6 5 OVEN AND CABINET PARTS 7-4 A A 7-4 7-7 2-3 7-8 B B 4-7 7-7 6-5 7-5 7-2 C 7-8 1-7 C 1-14 1-4 1-5 7-4 7-5 4-6 7-3 4-13 1-11 1-13 7-6 4-12 1-12 D D 4-8 7-6 4-2 7-4 E 1-8 4-9 6-4 E 7-4 7-2 7-2 6-3 1-3 7-4 7-1 1-6 4-3 4-10 4-5 1-9 1-10 F 7-5 2-1 6-2 F 1-5 1-6 7-1 4-4 4-1 1-1 1-2 G G 7-4 7-4 2-2 2-2 4-11 7-4 2-2 2-2 H H 1 2 4 3 39 5 6
R-520KS 2 1 4 3 6 5 CONTROL PANEL PARTS 3-11 3-1 A 3-2 A 3-8 3-9 3-10 3-6 3-7 3-3 B B 3-5 C C 3-4 DOOR PARTS 5-7 D 5-6 D 5 5-4 E E 5-8 5-10 5-5 5-11 5-9 F F 5-2 MISCELLANEOUS 5-3 G G 5-1 6-1 6-7 Actual wire harness may be different from illustration.
R-520KS PACKING AND ACCESSORIES TOP PAD ASSEMBLY DOOR PROTECTION SHEET 6-3 TURNTABLE TRAY PLASTIC BAG ON TOP OF THE OVEN TRAY HOLDER 6-6 OPERATION MANUAL IN TO TH EO NC VE AV ITY BOTTOM PAD ASSEMBLY 6-2 TURNTABLE SUPPORT PACKING CASE Non-replaceable items 41
R-520KS COPYRIGHT © 2005 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. 2005 SHARP CORP. (5M2.00E) Printed in U.S.
