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R-305KS SERVICE MANUAL

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2. PARTS CODE No PRICE NEW PART PARTS CODE No PRICE NEW PART D RLCDSA108DRZZ 2 3 7 AU DPWBFC414WRUZ 2 3 1 BH RLMPTA082WRZZ 1 8 AL F RLMPTA085WRZZ 1 8 AH FACCDA098WREZ 1 3 RLMPTA087WRZZ 1 8 AL FACCDA099WREZ 1 3 RMOTDA186WRF0 21 59 AW FACCDA109WREZ 1253 AU RMOTDA252WRZZ 1 9 FACCDA110WREZ RMOTDA264WRZZ 1 9 AT FDORFA364WRTZ 2 5 1 AS RMOTEA346WREO 716 FFS BA037WRKZ 1 2 AN RMOTEA35 6WREO 1 6 FH DZA075WRK0 1 4 RMOTEA433WRZZ 1 6 AX FH DZA109WRKZ 1 4 RTHM A119WREO 1 7 AK FH DZA112WRKZ 1 4 AR Pha Le AK FPNLCB8 60WRKZ 2 3 2 RTRN A729WRZZ 1 10 BG FPWBFA385WRKZ 1 13 AV RTRN A730WRZZ 1 10 FROLPA101WRKZ 6 1 RV MZA288WRE0 1 11 BK FW VZC048WREZ 2 6 6 AS RV MZA321WRZZ b 1l BH G RV MZA340WRZZ 1 11 GCABUA935WRPZ 2 1 T GCOVHA450WRFZ 2 5 7 AG TCAUAA268WRRZ 6 3 GDAI A360WRWZ 2 2 AS TCAUAA292WRRZ 6 4 GLEGPA074WREO TINSEB081WRRZ 2 6 7 GMADIA142WRRZ 2 3 3 AG TLABMB052WRRZ 6 5 GWAKPA998WRFZ 2 5 3 AX x 1 LH 5730 08 50 2 3 8 HDECQA285WRPZ 2 3 2 1 XEPS740P08000 2 5 8 HDECQA286WRPZ 2 3 2 3 5730 06000 1 7 6 HDECQA287WRRZ 2 5 9 AT XHPS740P08000 1 7 7 HPNL A841WRRZ 2 5 4 AU XHPS740P08K00 ick J XHTS740P08000 1 7
3. Actual wire harness may be different from illustration R305KS PRICE NEW PART NO PARTS CODE RANK MARK RANK DESCRIPTION 2 DOOR AND CONTROL PANEL PARTS CONTROL PANEL PARTS 3l DPWBFC414WRUZ BH Control unit 3 2 FPNLCB860WRKZ Panel sub assy cde HDECQA285WRPZ Button decoration 3 222 JBIN B316WRFZ Open button 3 2 3 HDECQA286WRPZ Panel decoration 3 2 4 Button spring 3 2 5 PSHEPB114WREZ Graphic sheet 3 2 6 QSW KA055DRZZ Membrane switch 3 3 GMADIA142WRRZ AG Display window 3 4 LHLD A262WRFZ AF LCD holder 3 5 PSHEPBO21WREZ AQ LED SHEET 3 6 QCNC A019WRZZ AG Rubber connector 3 4 RLCDSA108DRZZ AU Liquid crystal display 3 8 5730 08 50 Screw 3mm x 8mm DOOR PARTS ocu FDORFA364WRTZ AS Door panel 5 2 PSHEPA382WREO AH Sealer film gem GWAKPA998WRFZ AX Door frame 5 4 HPNL A841WRRZ AU Door screen 0 5 LSTPPA188WRFO AG Latch head 5 6 MSPRTA187WREO AC Spring pc GCOVHA450WRFZ AG Choke cover 5 8 XEPS740P08000 Screw 4mm x 8mm 579 HDECQA287WRRZ AT Door decoration MISCELLANEOUS 6 6 FW VZCOA8WREZ AS Main wire harness 6 7 TINSEBO81WRRZ AM Instruction book R305KS mINDEX
4. Monitor Switch Secondary Interlock Switch Figure D 1 Door Open Mechanism 2 DOOR SENSING AND 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 power to all high voltage components cook cycle can not take place until the door is firmly closed thereby activating both interlock switches The primary interlock system consists of the door sensing switch and primary interlock relay located on the control circuit board 3 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 RY2 and secondary interlock switch fail to open when the door is opened Functions 1 When the door is opened the monitor switch contacts close to the ON condition due to their being normally closed At this time the primary interlock relay RY2 and secondary interlock switch are in the OFF condition contacts open due to its being normally open contact switches As the door goes to a closed position the monitor switch contacts are first opened a
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6. approx 20 of FULL Power 10 approx 10 of FULL Power power throughout the cooking time pad MINUTE PLUS pad SHORT CUTS pads REHEAT pad COOK pad DEFROST pad Number selection pads POWER LEVELK pad TIMER CLOCL pad STOP CLEAR pad START pad Oven Light Yes Safety Standard UL Listed FCC Authorized DHHS Rules CFR Title 21 Chapter 1 Subchapter J R305KS R305KS CHAPTER 5 GENERAL INFORMATION 1 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 accor dance with the National Electrical Code and local codes and ordinances In the event of an electrical short circuit grounding reduces the risk of electric shock by providing an escape wire for the electric current WARNING Improper use of the grounding plug can result in a risk of electric shock Electrical Requirements Grounded The electrical requirements are a 120 volt 60 Hz AC only 15 or 20 amp fused electrical supply It Receptacle Box is recommended that a separate circuit serving only this appliance be provided When installing this appliance observe all applicable codes and ordinances A short power supply cord is provided to reduce risks of becoming entangled in or tripping over a longer cord Where a two pronged wall _ 3 Pronged receptacle is encounte
7. THERMAL CUT OUT TEMPERATURE LINE BYPASS CAPACITOR 0 0033yF AC 125V NOISE FILTER 120V AC 60 Hz o LINE CROSS CAPACITOR 0 22yF AC 250V NOISE SUPPRESSION COIL gt aed 95 go lt F 9 icu ER 258 145 C MAGNETRON OR TEMPERATURE FUSE 150 C MAGNETRON FUSE 150 C OVEN n n 1 THERMAL CUT OUT 1 145 C OVEN NO OVEN LAMP RELAY RY1 PRIMARY INTERLOCK RELAY RY2 CONTROL UNIT DOOR SENSING SWITCH SECONDARY INTERLOCK SWITCH COM Figure O 2 Oven Schematic Cooking Condition MONITOR SWITCH POWER TRANSFORMER gt POWER TRANSFORMER CAPACITOR 0 19 AC 21007 RECTIFIER CAPACITOR 19 AC 2100V R305KS NOTE indicates components with potentials above 250V L I MAGNETRON MAGNETRON R305KS 3 DESCRIPTION AND FUNCTION OF COMPONENTS 1 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 Door Latch Hook Door Sensing Latch Switch Heads
8. 12 Re install the outer case cabinet 13 Reconnect the sli cord after the outer case is installed 14 Run the oven and check all functions 14 Procedure M DEFROST TEST WARNING The oven should be fully assembled before following procedure 1 Place one cup of water in the center of the turntable tray in the oven cavity 2 Close the door touch the DEFROST pad once And then touch the number pad 2 3 Touch the number pad 5 and then touch the start pad 4 The oven is in Defrost cooking condition 5 The oven will operate as follows MENU 1ST STAGE 2ND STAGE 3RD STAGE Steaks Chops LEVEL TIME LEVEL TIME LEVEL TIME 0 5Ib 70 175 60 275 30 40sec 6 If improper operation is indicated the control unit is probably defective and should be checked 8 6 Check diode which is connected to the relay coil If diode is good control unit is defective R305KS 15 Procedure N 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 2 3 4 Disconnect the power supply cord and then remove outer case Open the door and block it open Discharge high voltage capacitor Follow the troubleshooting guide given below for repair STEPS OCCURRENCE CAUSE OR CORRECTION 1 Only pattern at
9. Release two 2 pins of door panel from two 2 holes of upper and lower oven hinges by lifting up 8 Now door panel is free from oven cavity 11 6 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 The door sensing switch and secondary interlock switch interrupt the circuit before the door can be opened 3 Monitor switch contacts close when door is opened 4 Re install outer case and check for microwave leakage around door with an approved microwave survey meter Refer to Micro wave Measurement Procedure Latch Hook Door Sensing Latch Switch Heads Monitor Switch Secondary Interlock Switch Figure C 4 Latch Switch Adjustments Figure C 5 Door Disassembly 9 Release door panel from ten 10 tabs of door frame 10 Now door panel with sealer film is free 11 Tear sealer film from door panel 12 Now door panel is free 13 Slide latch head upward and remove it from door frame with releas ing latch spring from door frame and latch head 14 Now latch head and latch spring are free 15 Remove door screen from door frame 16 door screen is free 17 Remove the door decoration from the door frame by straightening all tabs of the door decoration 18 Now the door decoration is free 2 1 2 REINSTALL Re install t
10. This function does not require that door be air tight moisture conden sation tight or light tight Therefore occasional appear ance of moisture light or sensing of gentle warm air movement around oven door is not abnormal and do not of themselves indicate a leakage of microwave energy from oven cavity 11 7 R305KS Upper Oven Oven Hinge Hinge Lower Oven Hinge Figure C 6 Door Replacement SEALER FILM Put the adhesive tape on the backing film of the sealer film as shown in Fig C 7 2 Tear the backing film by pulling the adhesive tape 3 Putthe pasted side of the sealer film on the door panel Sealer film Backing film Adhesive tape Figure C 7 Sealer film 12 1 5 IHM 3 AWD woo Z HOLIMS aay 1HM YOO THSLNI 0 5 LHM 2 HOIH d 621 OLON al
11. referring to the Pictorial Diagram Please refer to OVEN PARTS CABINET PARTS CONTROL PANEL PARTS DOOR PARTS when carrying out any of the following removal proce dures 11 1 R305KS 2 OUTER CASE REMOVAL To remove the outer case procedure as follows 1 2 3 6 Disconnect the power supply cord Open the oven door and block it open Remove the two 2 screws from the lower portion of the rear cabinet using a T20H Torx type or GTXH20 100 screw driver Remove the remaining three 3 screws from rear and one 1 screw along the right side of outer case Slide the entire outer case back out about 1 inch 3 cm to free it from retaining clips on the cavity face plate Lift entire outer case from the unit CAUTION DISCONNECT OVEN FROM POWER SUPPLY BEFORE REMOVING OUTER CASE 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 3 POWER TRANSFORMER REMOVAL E Omm REMOVAL Disconnect the power supply cord and remove outer case Open the oven door and block it open Discharge high voltage capacitor Disconnect wire leads primary from power transformer and the fil ament leads and high voltage wire from the magnetron and capaci tor terminals Remove four 4 screws two 2 screws from the upper side and two 2 screws from bottom side holding
12. 3 screws holding the control unit to the control panel frame And remove the control unit Remove the LCD holder and the rubber connector from the control panel frame 7 Tear away the graphic sheet from the control panel frame Tear away the membrane switch from the control panel frame REINSTALLATION Remove remaining adhesive on the control panel frame surfaces with a soft cloth soaked in alcohol 2 Tear the backing paper from the new membrane switch 3 Insert the ribbon cable of the membrane switch into the slit of the control panel frame Adjust the upper edge and right edge of the membrane switch to the small depression on the surface of the control panel frame Attach the membrane switch to the control panel frame by rubbing with a soft cloth not to scratch 11 3 6 Tear the backing paper from new graphic sheet 7 Adjust the upper edge and left edge of the graphic sheet to the large depression on the surface of the control panel frame Attach the graphic sheet to the control panel frame by rubbing with a soft cloth not to scratch Make sure that the liquid crystal display and the LED sheet are installed in position 10 Tear the small backing paper from the ribbon cable of the mem brane switch 11 Attach the ribbon cable to the control panel frame rear side 12 Place the edge of the membrane switch s ribbon cable on the lower portion of the liquid crystal display 13 Reinstall the L
13. 9 AC JBTN B316WRFZ 2 3 2 2 XHTS740P08RVO 1 7 8 L XOTS740P08000 1 7 10 LBNDKA163WRPZ 4 2 LHLD A262WRFZ 3 4 LSTPPA188WRFO 5 5 LX CZ0052WRE0 7 4 LX CZA070WREO 7 2 AC LX CZA073WREO 7 3 LX EZA042WREO 7 5 M MLEVPA233WRFO 4 5 MROD A019WREZ 4 16 AN MSPRCA050WRE0 2 3 2 4 AB MSPRTA187WRE0 2 5 6 N NFANJA053WRFZ 4 3 NTNT A117WREZ 6 2 5 EI PCOVPA394WREZ 4 7 PCUSGA399WRE0 4 11 AF PCUSGA614WRPZ 4 14 AF PCUSGA615WRPZ 4 15 PCUSGA616WRPZ 4 17 AK PCUSGA620WRPZ 4 6 PCUSUA235WRP0 4 13 AF PCUSUA278WRP0 4 PDUC A832WRWZ 4 9 PDUC A833WRPZ 4 8 AM PHOK A131WRFZ 4 AL PPACGA176WREZ 4 10 AC PSHEPA382WREO 2 5 2 AH PSHEPBO21WREZ 2 3 5 AQ PSHEPB114WREZ 2 3 2 5 Lo QCNC A019WRZZ 2 3 6 AG QFS TA014WREO 1 1 7 AG 1 1 12 QSW KAO55DRZZ 2 3 2 6 QSW MA147WRZZ 1 1 1 AG R RC QZA218WRE0 1 1 5 AW RC QZA295WRZZ 1 1 5 AV
14. Do not re use the removed fan blade because the hole for shaft may be larger than normal 10 Now the fan motor is free 2 1 INSTALLATION Install the fan blade to the fan motor shaft according to the following procedure Hold the center of the bracket which supports the shaft of the fan motor on the flat table 3 Apply screw lock tight into the hole for shaft of the fan blade 4 Install the fan blade to the shaft of fan motor by pushing the fan blade with a small light weight ball peen hammer or rubber mallet CAUTION Do not hit the fan blade strongly when installed Install the fan motor assembly to the oven cavity back plate with two 2 screws because the bracket may be disfigured R305KS Make sure that the fan blade rotates smooth after installation Make sure that the axis of the shaft is not slanted 6 Connect the wire leads to the magnetron and fan motor referring to the pictorial diagram L shaft These are the positions y Coi Groove joint pliers 9 N Stator z Axis Gap Bracket Rotor Rear View 11 POWER SUPPLY CORD REPLACEMENT REMOVAL Disconnect the power supply cord and remove outer case Open the door and block it open Discharge high voltage capacitor Remove the single 1 screw holding the
15. Noise filter assembly CABINET PARTS 2 1 GCABUA935WRPZ BD Outer case cabinet 2 2 GDAI A360WRWZ AS Bottom plate 2 3 GLEGPA074WREO AC Foot OVEN PARTS 4 1 PHOK A131WRFZ AL Latch hook 4 2 LBNDKA163WRPZ A Capacitor holder 4 3 NFANJA053WRFEZ AG Fan blade 4 4 SOR ROR REOR ene ee e Oven cavity Not a replacement part 4 5 MLEVPA233WRFO AG Switch lever 4 6 PCUSGA620WRPZ AF Cushion 4 7 PCOVPA3 94WREZ AK Waveguide cover 4 8 PDUC A833WRPZ AM Air duct 4 9 PDUC A832WRWZ AP Fan duct 4 10 PPACGA176WREZ AC TTM packing 4 11 PCUSGA399WRE AF Cushion 4 12 PCUSUA278WRP0 AB Cushion 4 13 PCUSUA235WRPO AE Cushion 4 14 PCUSGA614WRPZ AE Cushion 4 15 PCUSGA615WRPZ AE Cushion 4 16 MROD A019WREZ AN Chassis support 4 17 PCUSGA616WRPZ AK Cushion MISCELLANEOUS 6 1 FROLPA101WRKZ AR Turntable support 6 2 NTNT A117WREZ AS Turntable 6 3 TCAUAA268WRRZ AF DHHS caution label 6 4 TCAUAA292WRRZ AE Monitor caution 6 5 TLABMB052WRRZ Menu label SCREWS NUTS AND WASHERS qe 5740 08 00 Screw 4mm x 8mm 7 2 LX CZA070WREO AC Special screw 1 3 LX CZA073WREO AC Special screw 7 4 LX CZ0052WREO AA Special screw 19 LX EZA042WREO AB Special screw 7 6 XHPS730P06000 Screw 3mm x 6mm 1 7 5740 08000 Screw 4mm x 8mm 7 8 XHTS740P08RVO Screw 4mm x 8mm 5740 08000 Screw 4mm x 8mm 7 10 XOTS740P08000 AA Screw 4mm x 8mm R305KS 2 DOOR AND CONTROL PANEL PARTS
16. Remove the one 1 screw holding the chassis support to the mag netron Release the chassis support from the hole of the oven cavity front flange 11 2 7 Remove the one 1 screw holding capacitor holder to bottom plate 8 Remove one 1 screw holding high voltage rectifier assembly to capacitor holder Disconnect rectifier terminal from capacitor High voltage rectifier assembly is now free 10 Remove capacitor holder Capacitor is now free CAUTION WHEN REPLACING HIGH VOLTAGE RECTIFIER AND HIGH VOLTAGE CAPACITOR GROUND SIDE TERMI NAL OF THE HIGH VOLTAGE RECTIFIER MUST BE SECURED FIRMLY WITH A GROUNDING SCREW MAGNETRON REMOVAL Remove the two 2 screws holding air duct to magnetron and oven cavity top plate 8 Remove the air duct from oven 9 Carefully remove the four 4 screws holding magnetron to waveguide flange 10 Remove magnetron with care so that magnetron antenna is not hit by any metal object around antenna 11 Now the magnetron is free REINSTALLATION Reinstall the magnetron to waveguide flange with the four 4 Screws Reinstall the air duct to the oven cavity top plate and the magnetron with two 2 screws Insert the end of the chassis support into the hole of the oven cavity front flange 6 R305KS Hold the other end of the chassis support to the magnetron with the one 1 screw Reconnect the wire leads to the magnetron Refer to PICTORIAL DIAGRAM Reinst
17. When all service work is completed and the oven is fully assembled the microwave power output should be checked and microwave leak age test should be carried out R305KS CHAPTER 2 MICROWAVE MEASUREMENT PROCEDURE 1 Requirements 1 Microwave leakage limit Power density limit The power density of microwave radiation emitted by a microwave oven should not exceed 1mW cm at any point 5cm or more from the external surface of the oven measured prior to acquisition by a purchaser and thereafter through the use ful life of the oven 5 mW cm at any point 5cm or more from the external surface of the oven 2 Safety interlock switches Primary interlock relay and door sensing switch shall prevent microwave radiation emission in excess of the requirement as above mentioned secondary interlock switch shall prevent microwave radiation emission in excess of 5 mW cm at any point 5cm or more from the external surface of the oven 2 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 5 ml 9 8 oz of tap water initially at 20 5 6
18. 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 Make a visual inspection of the varistor Check for burned damage and examine the trans former with a tester for the presence of layer short circuit check the primary coil resis tance which is approximately 5630 10 any abnormal condition is detected replace the control unit assembly Reconnect all leads removed from components during testing Re install the outer case cabinet d Reconnect the power supply cord after the outer case is installed Run the oven and check all functions 2 Follow the troubleshooting guide given below if indicator does not light up after above a b check and repairs are finished VRS1 Ji Disconnect the power supply cord and then remove outer case Open the door block open 3 4 Discharge high voltage capacitor Disconnect the leads to the primary of the power transformer 22 YS a 5 that these leads remain isolated from other components and oven chassis by using insulation tape 6 After that procedure re connect the power supply cord 7 Follow the troubleshooting guide given below for repair STEPS OCCURRENCE CAUSE OR CORRECTION The rated AC voltage is not present between the normal open terminal of the relay RY1 and the normal open t
19. at voltages more than 250 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 CHAPTER 4 PRODUCT DESCRIPTION 1 SPECIFICATIONS ITEM DESCRIPTION Power Requirements 120 Volts 60 Hertz Single phase 3 wire grounded Power Consumption 1530W Approx 13 Amperes Power Output 1100 W nominal of RF microwave energy IEC Test procedure Operating frequency 2450 MHz Case Dimensions Width 20 1 2 520mm Height 12 1 4 310mm Depth 17 1 8 436mm Cooking Cavity Dimensions 1 0 Cubic feet Width 14 3 4 375mm NOTE Internal capacity is calculated by measuring Height 8 1 8 206mm maximum width depth and hight Depth 15 1 4 387mm Actual capacity for holding food is less Control Complement Touch Control System Clock 1 00 12 59 Timer 0 99 minutes 99 seconds Microwave Power for Variable Cooking Repetition Rate P HI Full power throughout the cooking time P 90 approx 90 of FULL Power 80 approx 80 of FULL Power 70 approx 70 of FULL Power 60 approx 60 of FULL Power 50 approx 50 of FULL Power 40 approx 30 of FULL Power 30 approx 40 of FULL Power 20
20. for improper setting of cooking time or operation of control unit Check for restricted air flow through the vent holes of the oven cavity especially the cooling fan and air guide Reconnect all leads removed from components during testing Reinstall the outer case cabinet Reconnect the power supply cord after the outer case is installed Run the oven and check all functions CAUTION IF THE TEMPERATURE FUSE OR THERMAL CUT OUT INDICATES AN OPEN CIRCUIT AT ROOM TEMPERATURE REPLACE IT 6 Procedure F SECONDARY INTERLOCK SWITCH 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 switch and connect ohmmeter to the common COM and normally open NO terminal 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 Reinstall the outer case cabinet 7 8 Run the oven and check all functions Reconnect the power supply cord after the outer case is installed 7 Procedure INTERLOCK SYSTEM TEST 1 1 DOOR SENSING SWITCH Disconnect the power supply cord and then remove outer case R305KS 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Isolate the switch and co
21. integral part of the circuits When han dling these parts the following precautions should be strictly followed CMOS LSI have extremely high impedance at its input and output ter minals 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 In order to protect CMOS LSI 1 When storing and transporting thoroughly wrap them in aluminium foil Also wrap PW boards containing them in aluminium foil 2 When soldering ground the technician as shown in the figure and use grounded soldering iron and work table approx 1M ohm 2 Servicing of Touch Control Panel We describe the procedures to permit servicing of the touch control panel of the microwave oven and the precautions you must take when doing so To perform the servicing power to the touch control panel is available either from the power line of the oven itself or from an exter nal power source 1 Servicing the touch control panel with power supply of the oven CAUTION THE HIGH VOLTAGE TRANSFORMER OF THE MICRO WAVE OVEN IS STILL LIVE DURING SERVICING AND PRESENTS A HAZARD Therefore before checking the performance of the touch control panel 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 4 5 Discharge high voltage capacitor Disconnect the leads to t
22. 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 6 7 Re install the outer case cabinet Reconnect the e cord after the outer case is installed Run the oven and ch II functions 12 Procedure K KEY 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 Using an ohmmeter and referring to the key unit matrix indicated on the control unit circuit check the circuit between the pins of the key unit that correspond to the STOP CLEAR pad When the pad is pressed the ohmmeter should indicate short circuit When the pad is released the ohmme ter should indicate open circuit If incorrect readings are obtained the key unit is faulty and must be replaced About the other pads the above method may be used Reconnect all leads removed from components during testing Reinstall the outer case cabinet Reconnect the power supply cord after the outer case is installed oven check all functions LANE e START 2 WARM REHEAT i 9 9 JHR 5 1 COOK aus 3 8 4 Sp POPC
23. require that a specific test be performed These tests are given a procedure letter which will be found in the Test Procedure section IMPORTANT If the oven becomes inoperative because of a blown monitor fuse check the monitor switch primary interlock relay RY2 door sensing switch and secondary interlock switch before replacing the monitor fuse If monitor fuse is replaced the monitor switch must also be replaced Use part FFS BA037WRKZ as an assembly IMPORTANT Whenever troubleshooting is performed with the power supply cord disconnected It may in some cases be necessary to connect the power supply cord 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 1 TROUBLESHOOTING CHART TTEST PROCEDURE A 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 6 7 Reinstall the outer case cabinet Reconnect the power supply cord after the outer case is installed
24. should inform SHARP ELECTRONICS CORPORATION of any certified unit found with emissions in excess of 4mW cm The owner of the unit should be instructed not to use the unit until the oven has been brought into compliance R305KS CHAPTER 1 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 1 Before Servicing 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor WARNING RISK OF ELECTRIC SHOCK DISCHARGE THE HIGH VOLTAGE CAPACITOR BEFORE SERVICING The high voltage capacitor remains charged about 60 seconds after the oven has been switched off Wait for 60 seconds and then short circuit the connection of the high voltage 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 supply must be disconnected It may in some cases be necessary to connect the power supply after the outer case has been removed in this event 1 Disconnect the power supply cord and
25. signal Connected to LCD signal 1 23 1 OUT Common data signal Connected to LCD signal 2 R305KS Pin No Signal 1 0 Description 24 COM2 OUT Common data signal Connected to LCD signal COM3 25 OUT Terminal not used 26 39 SEG0 SEG13 OUT Segment data signal Connected to LCD The relation between signals are as follows LSI signal Pin No LCD segment LSI signal Pin No SEG 0 26 1 SEG 0 33 SEG 0 27 27 28 SEG 0 29 30 31 32 LCD segment SEG 8 SEG 0 30 SEG 0 31 SEG 0 G2 40 SEG14 OUT Terminal not used 41 P70 OUT Oven lamp fan motor and turntable motor driving signal To turn on and off shut off relay RY1 The square wave form voltage is delivered to the RY1 driving circuit and RY2 control circuit 16 7 msec 2 L 5V During cooking 42 P71 OUT Terminal not used 43 P72 OUT Magnetron high voltage circuit driving signal To turn on and off the cook relay RY2 The signals holds L level during microwave cooking and H level while not cooking In other cooking modes variable cooking the sig nal turns to H level and L level in repetition according to the power level Maximum output OFF H GND 70 of maximum 24 sec outpu
26. then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 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 Don t Touch Danger High Voltage 2 When the testing is completed 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 Reconnect the leads to the primary of the power transformer 5 Reinstall the outer case cabinet 6 Reconnect the power supply cord after the outer case is installed 7 Run the oven and check all functions 3 After repairing 1 Reconnect all leads removed from components during testing 2 Reinstall the outer case cabinet 3 Reconnect the power supply cord after the outer case is installed 4 Run the oven and check all functions Microwave ovens should not be run empty To test for the presence of microwave energy within a cavity place a cup of cold water on the oven turntable close the door and set the power to HIGH and set the microwave timer for two 2 minutes When the two minutes has elapsed timer at zero carefully check that the water is now hot If the water remains cold carry out Before Servicing procedure and re examine the connections to the component being tested
27. 8 F in the center of the oven cavity The water container shall be a low form of 600 ml 20 oz beaker with an inside diameter of approx 8 5 cm 3 1 2 in and made of an electrically nonconductive material such as glass or plastic The placing of this standard load in the oven is important not only to protect the oven but also to insure that any leakage is measured accurately 4 the cooking control Full Power Cooking Mode 5 Close the door and select a cook cycle of several minutes If the water begins to boil before the survey is completed replace it with 275 ml of cool water 3 Leakage test Closed door leakage test microwave measurement 1 Grasp the probe of the survey instrument and hold it perpendicular to the gap between the door and the body of the oven 2 Move the probe slowly not faster than 1 in sec 2 5 cm sec along the gap watching for the maximum indication on the meter 3 Check for leakage at the door screen sheet metal seams and other accessible positions where the continuity of the metal has been breached eg around the switches indicator and vents While testing for leakage around the door pull the door away from the front of the oven as far as is permitted by the closed latch assembly 4 Measure carefully at the point of highest leakage and make sure that the highest leakage is no greater than 4mW cm and that the secondary interlock switch and the primary interlock relay do turn the oven O
28. 8 sec r s OFF 44 AVDD A D converter power source voltage The power source voltage to drive the A D converter in the LSI Connected to GND 45 48 5 2 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 49 AIN1 This is the terminal to detect the voltage of the signal coming from the touch key 50 AIN0 Signal similar to AIN1 51 AVSS A D converter power source voltage The power source voltage to drive the A D converter in the LSI 52 P11 To input signal which communicates the door open close information to LSI Door close H level signal Door open L level signal 5V 53 P10 OUT Terminal not used 54 P33 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P50 P51 P52 and P53 terminal while one of G1 line keys on key matrix is touched 55 P32 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P50 P51 P52 and P53 terminal while one of G2 line keys on key matrix is touched 56 P31 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P50 P51 P52 and P53 terminal while one of G3 line keys on key matrix is touched 57 INTPO Signal synch
29. CD holder to the control panel frame 14 Insert the rubber connector into the long slit of the LCD holder 15 Reinstall the control unit to the control panel frame with the three 3 screws NOTE Do not contact the contact surface of the ribbon cable edge and the rubber connector directly with your fin gers This is to avoid oxidized If display digits are miss ing or scrambled remove control unit and clean contact surface with alcohol After cleaning do not attach the rub ber connector until alcohol dries up Do not use alcohol or solution to clean the rubber connector Make sure that there is no trash or foreign substance on contact surface of the rubber connector R305KS Display window gt b p Figure Graphic Sheet and Membrane Switch Replacement 9 TURNTABLE MOTOR REMOVAL 1 2 3 Disconnect the power supply cord Remove turntable and turntable support from oven cavity Lay the oven on it s backside Remove the turntable motor cover by snipping off the material in four corners Where the corners have been snipped off bend corner areas flat No sharp edges must be evident after removal of the turntable motor cover 10 COOLING FAN MOTOR REMOVAL oN REMOVAL Disconnect the power supply cord then remove outer case Open the door and block it open Discharge high voltage capacito
30. Discharge high voltage capacitor 4 Before performing this test make sure that the secondary interlock switch and the primary interlock relay are operating properly according to the above Switch Test Procedure Disconnect the wire lead from the monitor switch COM terminal Check the monitor switch operation by using the ohmmeter as follows When the door is open the meter should indicate a closed circuit When the monitor switch actuator is pushed by a screw driver through the lower latch hole on the front plate of the oven cavity with the door opened in this condition the plunger of the monitor switch is pushed in the meter should indicate an open circuit If improper operation is indicated the switch 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 Reinstall the outer case cabinet Reconnect the power supply cord after the outer case is installed Run oven check all functions Secondary Ohmmeter Interlock Switch 9 Procedure BLOWN FUSE 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 monitor fuse is blown when the door is opened check the primary interlock relay secondary interlock switch and monitor
31. FF before any door movement NOTE After servicing record data on service invoice and microwave leakage report R305KS CHAPTER 3 FOREWORD AND WARNING 1 FOREWORD This Manual has been prepared to provide Sharp Electronics Corp Service Personnel with Operation and Service Information for the SHARP MICROWAVE OVENS R 305KS It is recommended that service personnel carefully study the entire text of this manual so that they will be qualified to render satisfactory customer service Check the interlock switches and the door seal carefully Special attention should be given to avoid electrical shock and microwave radiation hazard 2 WARNING Never operate the oven until the following points are ensured A The door is tightly closed B The door brackets and hinges are not defective C The door packing is not damaged D The door is not deformed or warped E There is not any other visible damage with the oven Servicing and repair work must be carried out only by trained service personnel 3 DANGER Certain initial parts are intentionally not grounded and present a risk of electrical shock only during servicing Service personnel Do not contact the following parts while the appliance is energized High Voltage Capacitor Power Transformer Magnetron High Voltage Rectifier Assembly High Voltage Harness If provided Vent Hood Fan assembly Cooling Fan Motor All the parts marked 4 on parts list used
32. H VOLTAGE RECTIFIER TEST 1 Disconnect the power ly cord and then remove outer case 2 Open the door and block it open 3 Discharge high voltage capacitor 4 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 If a short is indicated in both directions or if an infinite resistance is read in both direc tions the rectifier is probably defective and should be replaced 5 Reconnect all leads removed from components during testing 6 7 8 R305KS Reinstall the outer case cabinet Reconnect the power supply cord after the outer case is installed Run the oven and check all functions NOTE Be sure to use an ohmmeter that will supply a forward bias voltage of more than 6 3 volts 4 Procedure D HIGH VOLTAGE CAPACITOR TEST 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 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 termi Discharge high voltage capacitor nals using an ohmmeter Checking with a high ohm scale if the high voltage capacitor is normal the meter will indicate continuity for a short time and should indicate an open circuit once the capacitor is charged If the above is not the case check the
33. ORN 6 PED 0 7 MELT SOFTEN DEFROST 1 012 Pin NO G12 Pin NO G1 Key unit ribbon cable Key unit Membrane Switch front view 13 Procedure L RELAY TEST 1 Disconnect the power supply cord and then remove outer case Open the door and block it open Discharge high voltage capacitor Ensure that these leads remain isolated from other components and oven chassis by using insulation tape 2 3 4 Disconnect the leads to the primary of the power transformer 5 6 After that procedure re connect the power supply cord 7 R305KS Remove the outer case and check voltage between the normal open terminal of the relay RY1 and the normal open terminal of the relay RY2 on the control unit with an A C voltmeter The meter should indicate 120 volts if not check oven circuit RY1 and RY2 Relay Test These relays are operate b 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 RELAY SYMBOL OPERATIONAL VOLTAGE CONNECTED COMPONENTS RY1 Approx 12V D C Oven lamp Turntable motor Cooling fan motor RY2 Approx 11V 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
34. PWB making sure that all connections are tight 5 Be sure to use specified components where high precision is required R305KS CHAPTER 10 PRECAUTIONS FOR USING LEAD FREE SOLDER 1 Employing lead free solder The Main PWB of this model employs lead free solder This is indicated by the LF symbol printed on the PWB and in the service manual The suf fix letter indicates the alloy type of the solder Sn Ag Cu Indicates lead free solder of tin silver and copper Example 2 Using lead free wire solder When repairing a PWB with the LF symbol only lead free solder should be used Using normal tin lead alloy solder may result in cold soldered joints and damage to printed patterns As the melting point of lead free solder is approximately 40 C higher than tin lead alloy solder it is recommend that a dedicated bit is used and that the iron temperature is adjusted accordingly 3 Soldering As the melting point of lead free solder Sn Ag Cu is higher and has poorer wettability flow to prevent damage to the land of the PWB extreme care should be taken not to leave the bit in contact with the PWB for an extended period of time Remove the bit as soon as a good flow is achieved The high content of tin in lead free solder will cause premature corrosion of the bit To reduce wear on the bit reduce the temperature or turn off the iron when it is not required Leaving different types of solder on the bit will cause conta
35. R305KS SHARP SERVICE MANUAL No S4504R305KPST MICROWAVE OVEN MODEL R 305KS In the interest of user safety the oven should be restored to its original condition and only parts identical to those specified should be used WARNING TO SERVICE PERSONNEL Microwave ovens contain circuitry capable of producing very high voltage and current contact with following parts may result in a severe possibly fatal electrical shock High Voltage Capacitor High Voltage Power Transformer Magnetron High Voltage Rectifier Assembly High Voltage Harness etc CONTENTS PRECAUTIONS TO BE OBSERVED BEFORE AND CHAPTER 7 TROUBLESHOOTING GUIDE DURING SERVICING TO AVOID POSSIBLE EXPO SURE TO EXCESSIVE MICROWAVE ENERGY CHAPTER 8 TEST PROCEDURES BEFORE SERVICING CHAPTER 9 TOUCH CONTROL PANEL ASSEMBLY CHAPTER 1 WARNING TO SERVICE PERSONNEL CHAPTER 10 PRECAUTIONS FOR USING LEAD FREE SOLDER CHAPTER 2 MICROWAVE MEASUREMENT PRO CEDURE CHAPTER 11 COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE CHAPTER 3 FOREWORD AND WARNING CHAPTER 12 CIRCUIT DIAGRAMS CHAPTER 4 PRODUCT DESCRIPTION Parts Guide CHAPTER 5 GENERAL INFORMATION CHAPTER 6 OPERATION FSS a a ee Dec ae ae a ee p This document has been published to be used SHAR P CORPO RATION for after sales service only The contents are subject to change without notice 5 PRECAUTIONS BE OBSERVED BEFORE AND DURING SERVICING TO A
36. RECTIFIER AS SEMBEYI Um ee 11 2 b MAGNETRON 11 2 6 POSITIVE LOCK CONNECTOR NO CASE TYPE 11 3 7 CONTROL PANEL ASSEMBLY REMOV 11 3 8 GRAPHIC MEMBRANE SWITCH 11 3 9 TURNTABLE MOTOR REMOVAL 11 4 10 COOLING FAN MOTOR REMOVAL 11 4 111 POWER SUPPLY CORD REPLACE 12 DOOR SENSING SWITCH SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH 11 5 13 DOOR SENSING SWITCH SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH ADJUSTMENT 11 6 14 DOOR 11 6 CHAPTER 12 CIRCUIT DIAGRAMS 1 Pictorial Diagram Figure S 1 12 1 2 Control Unit Circuit Figure S 2 12 2 3 Printed Wiring Board of Power Unit Figure S 9 a esiste hee te 12 3 Parts Guide R305KS PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY a Do not operate or allow the oven to be operated with the door open b Make the following safety checks on all ovens to be serviced before activating the magnetron or other micr
37. REMOVAL Boo gt REMOVAL Disconnect the power supply cord and remove outer case Open the door and block it open Discharge high voltage capacitor Disconnect wire leads from the switches 11 5 m gv cow Remove two 2 screws holding latch hook to oven flange Remove latch hook assembly from oven flange Push outward on the two 2 retaining tabs holding switch in place Switch is now free At this time switch lever will be free do not lose it R305KS 2 REINSTALL 1 Reinstall each switch in its place The secondary interlock monitor switches are in the lower position and the door sensing switch is in the upper position 2 Reconnect wire leads to each switch Refer to pictorial diagram 3 Secure latch hook with two 2 mounting screws to oven flange Make sure that the monitor switch is operating properly and check continuity of the monitor circuit Refer to chapter Test Procedure and Adjustment procedure 13 DOOR SENSING SWITCH SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH ADJUSTMENT 1 1 2 Open the door and block it open 3 If the door sensing switch secondary interlock switch and monitor switch do not operate properly due to a misadjustment the following adjustment should be made 4 Adjustment Disconnect the power supply cord and then remove outer case Discharge high voltage capacitor Loosen the two 2 screws holding latch hook to the oven cavity front flange W
38. Run the oven and check all functions POSSIBLE AND DEFECTIVE PARTS MAGNETRON CONDITION PROBLEM Home fuse or circuit breaker blows when power cord is plugged into wall receptacle O SHORT IN POWER CORD POWER TRANSFORMER H V RECTIFIER ASSEMBLY HIGH VOLTAGE CAPACITOR TEMPERATURE FUSE SECONDARY INTERLOCK SWIT KEY UNIT MEMBRAINE SWITCH MONITOR SWITCH MONITOR FUSE PRIMARY INTERLOCK SYSTEM OVEN LAMP TOUCH CONTROL PANEL WRONG OPERATION LOW VOLTAGE FOIL PATTERN ON PWB or THERMAL CUT OUT COOLING FAN MOTOR TURNTABLE MOTOR DIRTY OVEN CAVITY NOISE FILTER DEFROST Monitor fuse blows when power cord is plug ged into wall receptacle OFF CONDITION All letters and indicators do not appear in dis play 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 Oven lamp does not go out when door is closed O SHORT OPENED WIRING Oven lamp lights but fan motor and turntable motor do not operate Oven does not go into cook cycle when START pad is touched Oven seems to be operating but little or no heat is produced in oven load Food incom pletely cooked or not cooked at all at end of cook cycle COOKING CONDITION Oven goes into a cook cycle
39. TEST su amas Sum a pa 8 1 4 Procedure D HIGH VOLTAGE TORTES niit eem teinte d 8 2 5 Procedure E TEMPERATURE FUSE OR THERMAL CUT OUT TEST 8 2 6 Procedure F SECONDARY INTERLOCK SWITCH TEST iiie ee 8 2 7 Procedure F PRIMARY INTERLOCK SYSTEM TESTA iori ethos 8 2 8 Procedure G MONITOR SWITCH TEST 8 3 9 Procedure H BLOWN MINITOR FUSE 11 Procedure J TOUCH CONTROL PANEL ASSEMBLY 8 4 12 Procedure K KEY UNIT 8 5 13 Procedure L RELAY 5 8 6 14 Procedure M DEFROST TEST 8 6 15 Procedure N FOIL PATTERN ON THE PRINTED WIRING BOARD TESTT 8 6 CHAPTER 9 TOUCH CONTROL PANEL ASSEM BLY 1 OUTLINE OF TOUCH CONTROL PANEL 9 1 2 DESCRIPTION OF LSI 9 1 3 SERVICING FOR TOUCH CONTROL PANE iiie en ttt e tates 9 3 CHAPTER 10 PRECAUTIONS FOR USING LEAD FREE SOLDER 1 Employing lead free solder 10 1 2 Using lead free wire solder 10 1 BI inse 10 1 CHAPTER 11 COMPONENT REPLACEMENT ADJUSTMENT PROCEDURE 1 8 2 4 4440 4 1 11 1 2 OUTER CASE 11 2 3 POWER TRANSFORMER REMOVAL 11 2 4 HIGH VOLTAGE COMPONENTS RE MOVAL HIGH VOLTAGE CAPACITOR AND HIGH VOLTAGE
40. VOID POSSIBLE EXPO SURE TO EXCESSIVE MICROWAVE ENERGY BEFORE SERVICING CHAPTER 1 WARNING TO SERVICE PERSONNEL 1 Before Servicing 1 1 2 When the testing is completed 1 1 3 After repairing 1 1 CHAPTER 2 MICROWAVE MEASUREMENT PRO CEDURE 1 Requirements 2 1 2 Preparation for testing 2 1 3 Leakage test 2 1 CHAPTER 3 FOREWORD AND WARNING 1 FOREWORD seen 3 1 2 WARNING i retinere 3 1 23 DANGER nint 3 1 CHAPTER 4 PRODUCT DESCRIPTION 1 4 1 CHAPTER 5 GENERAL INFORMATION 1 GROUNDING INSTRUCTIONS 5 1 2 OVEN DIAGRAVM 5 1 CHAPTER 6 OPERATION 1 DESCRIPTION OF OPERATING SE QUENCE MRNA UEM 6 1 2 OVEN 6 2 3 DESCRIPTION AND FUNCTION OF COMPONENTS 6 3 CHAPTER 7 TROUBLESHOOTING GUIDE 1 TROUBLESHOOTING CHART 7 1 CHAPTER 8 TEST PROCEDURES 1 Procedure A MAGNETRON ASSEMBLY TEST inis eee tam dotted tend 8 1 2 Procedure B POWER TRANSFORMER TEST ascia ties 8 1 3 Procedure C HIGH VOLTAGE RECTIFI ER
41. all outer case and check that the oven is operating properly CAUTION WHEN REPLACING MAGNETRON BE SURE THE R F GASKET IS IN PLACE AND MOUNTING SCREWS ARE TIGHTENED SECURELY 6 POSITIVE LOCK CONNECTOR NO CASE TYPE REMOVAL 1 Disconnect the power supply cord and remove outer case 2 Open the door and block it open 3 4 5 Discharge high voltage capacitor Push the lever of positive lock connector Pull down on the positive lock amp connector CAUTION WHEN CONNECTING THE POSITIVE LOCK CONNECTORS TO THE TERMINALS CON THE POSITIVE LOCK SO THAT THE LEVER FACES YOU 7 CONTROL PANEL ASSEMBLY REMOVAL 1 2 Open the door and block it open 3 4 Disconnect the wire leads from the control unit Disconnect the power supply cord and then remove outer case Discharge high voltage capacitor Terminal Positive lock connector Lever Figure C 1 Positive lock amp connector Remove the one 1 screw holding the control panel assembly to the oven flange 6 Slide the control panel assembly upward and remove it 7 Now individual components can be removed 8 GRAPHIC SHEET AND MEMBRANE SWITCH REPLACEMENT REMOVAL Disconnect the power supply cord and then remove outer case Open the door and block it open Discharge high voltage capacitor Remove the control panel assembly referring to chapter of CON TROL PANEL ASSEMBLY REMOVAL Remove the three
42. but extremely uneven heating is produced in oven load food Oven does not cook properly when program med for Cooking Power P 50 mode Oper ates properly on Cooking Power P HI HIGH mode Oven goes into DEFROST but food is not defrosted well R305KS CHAPTER 8 TEST PROCEDURES 1 Procedure 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 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 To test for a shorted magnetron connect 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 Reconnect all leads removed from components during testing 7 Reinstall the outer case cabinet 8 Reconnect the power supply cord after the outer case is installed 9 Run the oven and check all functions 1 MICROWAVE OUTPUT POWER The following test procedure should be carried out with the microwave oven in a fully assembled condition outer case fitted HIGH VOLTAGES ARE PRESENT DURING THE COOK CYCLE SO EXTREME CAUTION SHOULD BE OBSERVED Power outp
43. capacitor with an ohmmeter to see if it is shorted between either of the terminals and case If it is shorted replace the capacitor 5 Reconnect all leads removed from components during testing 6 Reinstall the outer case cabinet 7 8 Run the oven and check all functions Reconnect the power supply cord after the outer case is installed 5 Procedure E TEMPERATURE FUSE OR THERMAL CUT OUT TEST 1 Disconnect the power supply cord and then remove outer case 2 Open the door and block it open 3 4 Check a continuity across the temperature fuse or thermal cut out terminals in the table below Discharge high voltage capacitor Table Temperature Fuse and Thermal Cut out Test Temperature of ON condition Temperature of OFF condition Indication of onmmeter When room Parts Name NE closed circuit open circuit temperature is approx 20 C Temperature fuse 150 G This is not resetable type Above 150 302 Closed circuit Thermal cut out 145 This is not resetable type Above 145 293 F Closed circuit 5 An open temperature fuse indicates overheating of the magnetron Check for restricted air flow to the magnetron especially the cooling fan and air 9 2002420 An open temperature fuse oven thermal cut out magnetron indicates overheating of the oven exchange the temperature fuse or thermal cut out and check inside of oven cavity and
44. cause approx 3 seconds are needed for heating of the magnetron filament 4 POWER OUTPUT REDUCTION If the oven is set for more than 20 minutes at 80 90 or 100 power level after the first 20 minutes the power level will automatically adjust itself to 70 power to avoid overcooking 2 OVEN SCHENATIC 1 Off Condition SCHEMATIC NOTE CONDITION OF OVEN 1 DOOR CLOSED 2 CLOCK APPEARS ON DISPLAY i THERMAL CUT OUT THE TEMPERATURE 145 C FUSE 150 C OVEN LINE BYPASS CAPACITOR 0 0033 AC 125V NOISE FILTER o 2 N 120V AC 60 Hz LINE CROSS CAPACITOR 0 22yF AC 250V NOISE SUPPRESSION COIL LINE BYPASS CAPACITOR 0 0033pF 125V 2 Cooking Condition SCHEMATIC NOTE CONDITION OF OVEN 1 DOOR CLOSED 2 COOKING TIME PROGRAMMED 3 VARIABLE COOKING CONTROL P HI 4 START PAD TOUCHED NO MAGNETRON i n 1 i OR TEMPERATURE 1 1 FUSE 150 C 1 THERMAL CUT OUT 1 n n 145 C OVEN PRIMARY INTERLOCK RELAY RY2 CONTROL UNIT DOOR SWITCH OVEN LAMP RELAY RY1 m sEcoNDARY TURN TAN a INTERLOCK T SWITCH MOTOR o SWITCH SENSING 777 Figure O 1 Oven Schematic Off Condition
45. cuit 1 Reset Circuit This circuit generates a signal which resets the LSI to the initial state when power is supplied 2 Indicator Circuit 2 DESCRIPTION OF LSI The I O signal of the LSI are deiled in the following table This circuit consists of 14 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 avail able in order to compose a basic standard time in the clock circuit Symbol Voltage Application vss 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 com pose basic standard time in the clock circuit It accompanies very small error because it works on commercial frequency 7 Door Sensing Switch A switch to tell the LSI if the door is open or closed 8 Back Light Circuit A circuit to drive the back light Light emitting diodes LD1 LD3 Pin No Signal yo Description 1 P50 IN Signal coming from touch key When either G9 line on key matrix is touched a corresponding sig
46. d R305KS 2 TOUCH CONTROL PANEL COOK DEF POPCORN DEFROST COOK REHEAT NOTE Some one touch cooking features such as MINUTE PLUS are disabled after three minutes when the oven is not in use These fea tures are automatically enabled when the door is opened and closed or the STOP CLEAR pad is pressed R305KS CHAPTER 6 OPERATION 1 DESCRIPTION OF OPERATING SEQUENCE The following is a description of component functions during oven operation 1 OFF CONDITION Closing the door activates door sensing switch and secondary inter lock switch In this condition the monitor switch contacts are opened When oven is plugged in 120 volts A C is supplied to the noise filter and the control unit Figure O 1 1 The display will show flashing 88 88 To set any program or set the clock you must first touch the STOP CLEAR pad The display will clear and will appear 2 COOKING CONDITION Program desired cooking time by touching the NUMBER pads Pro gram the power level by touching the POWER LEVEL 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 trans former and is converted to abo
47. ent an electric shock take the following precau tions 1 Before wiring 1 Disconnect the power supply cord 2 Open the door block it open 3 Discharge the high voltage capacitor and wait for 60 seconds 2 Don t let the wire leads touch to the following parts 1 High voltage parts Magnetron High voltage transformer High voltage capacitor and High voltage rectifier assembly 2 Hot parts Oven lamp Magnetron Power transformer and Oven cavity WARNING FOR WIRING Door hinge support or latch hook is damaged The door gasket or seal is damaged The door is bent or warped There are defective parts in the door interlock system There are defective parts in the microwave generating and transmission assembly 7 There is visible damage to the oven F sN Do not operate the oven 1 Without the RF gasket Magnetron 2 If the wave guide or oven cavity are not intact 3 If the door is not closed 4 If the outer case cabinet is not fitted 3 Sharp edge Bottom plate Oven cavity Waveguide flange and other metallic plate 4 Movable parts to prevent a fault Fan blade Fan motor Turntable motor Switch Switch lever Open button 3 Do not catch the wire leads in the outer case cabinet 4 Insert the positive lock connector until its pin is locked and make sure that the wire leads do not come off even if the wire leads are pulled 5 To prevent an error function connect the wire leads correctly
48. erminal of the relay RY2 Check supply voltage and oven power cord The rated AC voltage is present at primary side of low voltage trans Low voltage transformer or secondary circuit defective 2 former Check and replace control unit 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 R305KS CHAPTER 9 TOUCH CONTROL PANEL ASSEMBLY 1 OUTLINE OF TOUCH CONTROL PANEL The touch control section consists of the following units 1 Key Unit 2 Control Unit The Control Unit consists of Power Unit and CPU Unit The principal functions of these units and the signals communicated among them are explained below 1 Key Unit The key unit is composed of a matrix signals generated in the LSI are sent to the key unit through P22 P23 P24 P25 P26 P31 P32 and P33 When a key pad is touched a signal is completed through the key unit and passed back to the LSI through P50 P51 P52 and P53 to perform the function that was requested 2 Control Unit Control unit consists of LSI reset circuit indicator circuit power source circuit relay circuit buzzer circuit synchronizing signal circuit and back light cir
49. green wire to the oven cavity back plate Disconnect the leads of the power supply cord from the noise filter referring to the Figure C 3 a Release the moulding cord stopper of the power supply cord from the square hole of the oven cavity back plate referring to the Fig ure C 3 b Power Supply Cord Screw Oven Cavity Back Plate Fuse Green Wire Noise Filter r Tm c r38 2 e gt m s Gray Wires Connect the wire lead which has the black case to the terminal L of the noise filter Figure C 3 a Power Supply Cord Replacement Side View that should be pinched with pliers Table er s the power supply cord is free INSTALL Insert the moulding cord stopper of power supply cord into the square hole of the rear cabinet referring to the Figure C 3 b Install the earth wire lead of power supply cord to the oven cavity back plate with one 1 screw and tight the screw Connect the gray wire leads of power supply cord to the noise filter correctly referring to the Pictorial Diagram Re install outer case and check that the oven is operating properly Power Supply Cord Moulding Cord Stopper Oven Cavity Back Plate Square Hole Figure C 3 b Power Supply Cord Replacement 12 DOOR SENSING SWITCH SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH
50. he door screen and the door decoration to door frame Reinstall the latch spring to the latch head Reinstall the latch spring to the door frame Reinstall latch head to door frame Reinstall door panel to door frame by fitting ten 10 tabs of door frame to ten 10 holes of door panel Put sealer film on door panel Refer to Sealer Film about how to handle new one Catch two 2 pins of door panel on two 2 hole of upper and lower oven hinges 6 NOTE Atter any service to the door Re install choke cover to door panel by pushing 1 Make sure that door sensing switch and secondary interlock switch are operating properly Refer to chapter Test Proce dures An approved microwave survey meter should be used to assure compliance with proper microwave radiation emission limitation standards After any service make sure of the following Door latch heads smoothly catch latch hook through latch holes and that latch head goes through center of latch hole Deviation of door alignment from horizontal line of cavity face plate is to be less than 1 0mm 3 Door is positioned with its face pressed toward cavity face plate 4 Check for microwave leakage around door with an approved micro wave survey meter Refer to Microwave Measurement Procedure NOTE The door on a microwave oven is designed to act as an electronic seal preventing the leakage of microwave energy from oven cavity during cook cycle
51. he 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 cooking 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 2 Procedure B POWER TRANSFORMER 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 primary input terminals and measure the resistance of the transformer with ohmmeter Check for continuity of the coils with ohmmeter On the R x 1 scale the resistance of the primary coil should be less than 1 ohm and the resistance of the high voltage coil should be approximately 150 ohms RTRN A729WRZZ 125 ohms RTRN A730WRZZ the resistance of the filament coil should be less than 1 ohm 5 Reconnect all leads removed from components during testing 6 Reinstall the outer case cabinet 7 Reconnect the power supply cord after the outer case is installed 8 Run the oven and check all functions HIGH VOLTAGES ARE PRESENT AT THE HIGH VOLTAGE TERMINAL SO DO NOT ATTEMPT TO MEASURE THE FILAMENT AND HIGH VOLTAGE 3 Procedure G HIG
52. he primary of the power transformer Ensure that these leads remain isolated from other components and oven chassis by using insulation tape 6 After that procedure re connect the power supply cord After checking the performance of the touch control panel 1 Disconnect the power supply cord 2 3 4 5 Open the door and block it open Re connect the leads to the primary of the power transformer Re install the outer case cabinet lt gt Re connect the power supply cord after the outer case is installed 6 Run the oven and check all functions a On some models the power supply cord between the touch control panel and the oven itself is so short that the two can t be separated For those models check and repair all the controls sensor related ones included of the touch control panel while keeping it connected to the oven On some models the power supply cord between the touch control panel and the oven proper is so long enough that they may be separated from each other For those models therefore it is possible to check and repair the controls of the touch control panel while keeping it apart from the oven proper in this case you must short both ends of the door sensing switch on PWB of the touch control panel with a jumper which brings about an operational state that is equiv alent to the oven door being closed As for the sensor related controls of the touch control panel checking them is poss
53. ible if the dummy resistor s with resistance equal to that of the controls are used 2 Servicing the touch control panel with power supply from an external power source Disconnect the touch control panel completely from the oven proper and short both ends of the door sensing switch on PWB of the touch control panel which brings about an operational state that is equivalent to the oven door being closed Connect an exter nal power source to the power input terminal of the touch control panel then it is possible to check and repair the controls of the touch control panel it is also possible to check the sensor related controls of the touch control panel by using the dummy resistor s 3 Servicing Tools Tools required to service the touch control panel assembly 1 Soldering iron 30W It is recommended to use a soldering iron with a grounding termi nal 2 Oscilloscope Single beam frequency range DC 10MHz type or more advanced model 3 Others Hand tools 4 Other Precautions 1 Before turning on the power source of the control unit remove the aluminium foil applied for preventing static electricity 2 Connect the connector of the key unit to the control unit being sure that the lead wires are not twisted 3 After aluminium foil is removed be careful that abnormal voltage due to static electricity etc is not applied to the input or output ter minals 4 Attach connectors electrolytic capacitors etc to
54. ith door closed adjust latch hook by moving it back and forth and up and down In and out play of the door allowed by the upper and lower position of the latch hook should be less than 0 5mm The vertical position of the latch hook should be adjusted so that the door sensing switch and secondary interlock switch are acti vated with the door closed The horizontal position of the latch hook should be adjusted so that the plunger of the monitor switch is pressed with the door closed 6 Secure the screws with washers firmly 7 Check the operation of all switches If each switch has not activated with the door closed loosen screw and adjust the latch hook posi tion After adjustment check the following 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 14 DOOR REPLACEMENT REMOVAL Disconnect the power supply cord 2 Open the door slightly 3 Insert a putty knife thickness of about 0 5mm into the gap between the choke cover and door frame as shown in Figure C 5 to free engaging parts 4 5 6 NOTE When carrying repair to the door not bend warp the slit choke tabs on the door panel assembly to prevent microwave leakage Pry the choke cover by inserting a putty knife as shown Figure C 5 Release choke cover from door panel Now choke cover is free 7
55. leys o q 6 STaVLNYNL milalal falls AYO Q AYO ZAM HOLIMS ANO ON ON YOLINOW WOO WOO M9O TH3INI WOO LHM m ANO Lp zn LII LHM ANd AMO 249 qas L PSIOU OU JO 7 EulUJe hs yoejq eui Seu uoiuM peaj 99 JOOUUOD LINN TOH LNOO 1 3SION L LNO LND z AYO IYWYJHL gt ANO gt 3 c Woo ANd aay 2 1 CHAPTER 12 CIRCUIT DIAGRAMS 1 Pictorial Diagram Figure S 1 R305KS HOLIMS NYS mi ONISNSS Hood IHM NYS 2 weio RINES USA 5 Ajddns Figure 5 1 Pictorial Diagram R305KS 2 Control Unit Circuit Figure S 2
56. mination of the different alloys which will alter their characteristics making good soldering more difficult It will be necessary to clean and replace bits more often when using lead free solder To reduce bit wear care should be taken to clean the bit thoroughly after each use 10 1 R305KS CHAPTER 11 COMPONENT REPLACEMENT AND ADJUSTMENT PROCE DURE 1 WARNINGS 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 N Avoid possible exposure to microwave energy Please follow the instructions below before WARNING operating the oven 1 Disconnect the power supply cord 2 Make sure that a definite click can be heard when the microwave oven door is unlatched Hold the door in a closed position with one hand then push the door open button with the other this causes the latch leads to rise it is then possible to hear a click as the door switches operate 3 Visually check the door and cavity face plate for damage dents cracks signs of arcing etc Carry out any remedial work that is necessary before operat ing the oven Do not operate the oven if any of the following conditions exist 1 Door does not close firmly To prev
57. n the monitor switch contacts close When the door is closed from the open position the monitor switch contacts open first Then the contacts of the secondary interlock switch and door sensing switch close And contacts of the relay RY1 open If the secondary interlock switch and primary interlock relay RY2 fail with the contacts closed when the door is opened the closing of the monitor switch contacts will form a short circuit through the monitor fuse secondary interlock switch relay RY1 and primary interlock relay RY2 causing the monitor fuse to blow 3 POWER LEVEL P 0 TO P 90 COOKING When Variable Cooking Power is programmed the 120 volts A C is supplied to the power transformer intermittently through the contacts of relay RY 2 which is operated by the control unit within a 32 second time base Microwave power operation is as follows VARI MODE ONTIME OFF TIME P HI 100 power 32 sec 0 sec P 90 approx 90 power 30 sec 2 sec P 80 approx 80 power 26 sec 6 sec P 70 approx 70 power 24 sec 8 sec P 60 approx 60 power 22 sec 10 sec P 50 approx 50 power 18 sec 14 sec P 40 approx 40 power 16 sec 16 sec P 30 approx 30 power 12 sec 20 sec P 20 approx 20 power 8 sec 24 sec P 10 approx 10 power 6 sec 26 sec P 0 0 power 0 sec 32 sec NOTE The ON OFF time ratio does not correspond with the per centage of microwave power be
58. nal out of P22 P26 and P31 P33 will be input into P50 When no key is touched the signal is held at H level 2 P51 IN Signal similar to P50 When either G10 line on key matrix is touched a corresponding signal will be input into P51 3 52 IN Signal similar to 50 When either G11 line on key matrix is touched a corresponding signal will be input into P52 4 P53 IN Signal similar to P50 When either G12 line on key matrix is touched a corresponding signal will be input into P53 5 IC IN Connected to VSS 6 XT1 IN Connected to VSS 7 XT2 Terminal not used 8 VDD IN Power source voltage input terminal The power source voltage to drive the LSI Connected to GND 9 VSS IN Power source voltage input terminal The power source voltage to drive the LSI 10 X1 IN Internal clock oscillation frequency input setting The internal clock frequency is set by inserting the resistor capacitor oscillation circuit with respect to X2 termi nal 11 X2 OUT Internal clock oscillation frequency control output Output to control oscillation input of X1 12 RESET IN Auto clear terminal Signal is input to reset the LSI to the initial state when power is applied 13 15 P00 P02 OUT Terminal not used 16 OUT Back light circuit Light emitting diodes driving signal 17 CAPH Terminal not used 18 CAPL Terminal not used 19 21 VLCO VLC2 IN Power source voltage input terminal Standard voltage for LCD 22 COMO OUT Common data
59. nd then the door sensing switch and secondary interlock switch contacts close 9 If the door is opened and the primary interlock relay RY2 and the secondary interlock switch contact 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 PRIMARY INTERLOCK RELAY RY2 SECONDARY INTERLOCK SWITCH AND MONITOR SWITCH FOR PROPER OPERATION REFER TO CHAPTER TEST PROCEDURE NOTE MONITOR FUSE AND MONITOR SWITCH ARE REPLACED AS AN ASSEMBLY 4 TURNTABLE MOTOR The turntable motor rotates the turntable located on the bottom of the oven cavity so that the food on the turntable is cooked evenly The turntable may turn in either direction 5 COOLING FAN MOTOR The cooling fan motor drives a blade which draws external cool air This cool air is directed through the air vents surrounding the magne tron and cools the magnetron This air is channelled through the oven cavity to remove steam and vapours given off from the heating foods It is then exhausted through the exhausting air vents at the oven cav ity 6 MAGNETRON TEMPERATURE FUSE The temperature fuse located near the magnetron is designed to pre vent damage to the magnetron if an over heated condition develops in the tube due to cooling fan failure obstructed air guide dirty or blocked air intake etc Under normal operation the temperature fuse remain
60. nnect the ohmmeter to the common COM and normally open NO terminal 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 all leads removed from components during testing Reinstall the outer case cabinet Reconnect the power supply cord after the outer case is installed Run oven check all functions NOTE If the door sensing switch contacts fail in the open position and the door is closed the cooling fan turntable and oven light will be activated by RY1 2 PRIMARY INTERLOCK RELAY RY2 Disconnect the power supply cord and then remove outer case Open the door and block it open Discharge high voltage capacitor Disconnect two 2 wire leads the male tab terminals of the Primary Interlock Relay Check the state of the relay contacts using ohmmeter The relay contacts should be open If the relay contacts are closed replace the circuit board entirely or the relay itself Reconnect all leads removed from components during testing Reinstall the outer case cabinet Reconnect the power supply cord after the outer case is installed Run oven check all functions 8 Procedure SWITCH TEST 1 Disconnect the power ly cord and then remove outer case 2 Open the door and block it open 3
61. owave source and make repairs as necessary 1 interlock operation 2 proper door closing 3 seal and sealing surfaces arcing wear and other damage 4 damage to or loosening of hinges and latches 5 evidence of dropping or abuse c Before turning on microwave power for any service test or inspection within the microwave generating compartments check the magnetron wave guide or transmission line and cavity for proper alignment integrity and connections d Any defective or misadjusted components in the interlock monitor door seal and microwave generation and transmission systems shall be repaired replaced or adjusted by procedures described in this manual before the oven is released to the owner e A microwave leakage check to verify compliance with the Federal Performance Standard should be performed on each oven prior to release to the owner BEFOR SERVICING BEFORE SERVICING Before servicing an operative unit perform a microwave emission check as per the Microwave Measurement Procedure outlined in this service manual If microwave emissions level is in excess of the specified limit contact SHARP ELECTRONICS CORPORATION immediately 1 800 237 4277 If the unit operates with the door open service person should 1 tell the user not to operate the oven and 2 contact SHARP ELECTRONICS CORPORATION and Food and Drug Administration s Center for Devices and Radiological Health immediately Service personnel
62. ower supply cord Interchangeable for production use 1 3 FACCDA099WREZ AI Power supply cord Interchangeable for production use 1 3 FACCDA110WREZ a Power supply cord Interchangeable for production use 1 4 FH DZA109WRKZ AR High voltage rectifier assmebly 1 4 FH DZA075WRKO AR High voltage rectifier assembly Interchangeable 1 4 FH DZA112WRKZ AR High voltage rectifier assembly Interchangeable 1 5 RC QZA295WRZZ AV High voltage capacitor 1 5 RC QZA218WRE AW High voltage capacitor Interchangeable 1 6 RMOTEA433WRZZ AX Fan motor l6 RMOTEA346WREO AV Fan motor Interchangeable 1 6 RMOTEA356WRE Fan motor Interchangeable for production use lex RTHM A119WREO A Thermal cut out 145C oven 1 7 OFS TAO14WRE AG Temperature fuse 150deg C oven Interchangeable 1 8 RLMPTA087WRZZ AL Oven lamp 1 8 RLMPTA082WRZZ AL Oven lamp Interchangeable 1 8 RLMPTA085WRZZ AH Oven lamp Interchangeable 1 9 RMOTDA264WRZZ AT Turntable motor 1 9 RMOTDA252WRZZ AN Turntable motor Interchangeable 19 RMOTDA186WRE AW Turntable motor Interchangeable 1 10 RTRN A729WRZZ BG Power transformer 1 10 RTRN A730WRZZ Power transformer Interchangeable for production RV MZA288WREO B Magnetron 154 RV MZA321WRZZ BH Magnetron Interchangeable 155121 RV MZA340WRZZ E Magnetron Interchangeable for production use 12 5 014 Temperature fuse 150deg C Magnetron 12 RTHM A119WRE A Thermal cut out 145C Magnetron Interchangeable 13 FPWBFA385WRKZ AV
63. r Disconnect the wire leads from the fan motor Remove the two 2 screws holding the fan motor to the oven cavity back plate Remove the fan blade from the fan motor shaft according to the fol lowing procedure Hold the edge of the rotor of the fan motor by using a pair of groove joint pliers CAUTION Make sure that no metal pieces enter the gap between the rotor and the stator of the fan motor because the rotor is easily shaven by pliers and metal pieces may be produced 11 4 5 6 7 8 8 9 Control unit Liquid crystal display sub assembly Control panel frame Control panel frame Slit Ribbon cable of membrane switch Figure C 2b Ribbon Cable of Membrane Switch Disconnect wire leads from turntable motor See Positive lock connector removal Remove one 1 screw holding turntable motor to oven cavity the turntable motor is free After replacement use the one 1 screw to fit the turntable motor cover Do not touch the pliers to the coil of the fan motor because the coil may be cut or injured Do not disfigure the bracket by touching with the pli ers Remove the fan blade assembly from the shaft of the fan motor by pulling and rotating the fan blade with your hand Now the fan blade will be free CAUTION
64. red it is the personal responsibility and obligation of the customer to contact Plug a qualified electrician and have it replaced with a properly grounded three pronged wall receptacle or have a grounding adapter properly grounded and polarized If the extension cord must be used it should be a 3 wire 15 amp or higher rated cord Do not drape over a countertop or table where it can be pulled on by children or tripped over accidentally CAUTION DO NOT UNDER ANY CIRCUMSTANCES CUT OR REMOVE THE ROUND GROUNDING PRONG FROM THIS PLUG Grounding Pin 3 Pronged Receptacle 2 OVEN DIAGRAM 1 OVEN 1 Door opening button Push to open door 2 Oven door with see through win dow 3 Safety door latches The oven will not operate unless the door is securely closed Door hinges Door seals and sealing surfaces Turntable motor shaft m P Removable turntable support Carefully place the turntable sup port in the center of the oven floor 8 Removable turntable Place the turntable securely on the turntable support securely The turntable will rotate clockwise or counterclockwise Only remove for cleaning 9 Ventilation openings Rear 10 Oven light It will light when oven is operating or when the door is open 11 Waveguide cover DO NOT REMOVE 12 Auto Touch control panel 13 Time display 99 minutes 99 seconds 14 Power supply cor
65. ronized with commercial power source frequency This is the basic timing for time processing of LSI 16 7 58 26 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P50 P51 P52 and P53 terminal while one of G4 line keys on key matrix is touched 59 P25 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P50 P51 P52 and P53 terminal while one of G5 line keys on key matrix is touched 60 P24 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P50 P51 P52 and P53 terminal while one of G6 line keys on key matrix is touched 61 P23 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P50 P51 P52 and P53 terminal while one of G7 line on key matrix is touched 9 2 R305KS Pin No Signal y o Description 62 P22 OUT Key strobe signal Signal applied to touch key section A pulse signal is input to P50 P51 P52 and P53 terminal while one of G8 line keys on key matrix is touched 63 BZO90 OUT Signal to sound buzzer 2 0 kHz A key touch sound B Completion sound 0 1 sec GND 5 GND B 5 64 20 OUT Terminal used 3 SERVICING FOR TOUCH CONTROL PANEL 1 Precautions for Handling Electronic Components This unit uses CMOS LSI in the
66. s closed However when abnormally high temperatures are reached within the magnetron the temperature fuse will open at 302 F 150 C causing the oven to shut down 7 THERMAL CUT OUT OVEN The thermal cut out located on the top of the oven cavity is designed to prevent damage to the oven by fire If the food load is overcooked by either error in cook time or defect in the control unit the thermal cut out will open Under normal operation the oven thermal cut out remains closed However when abnormally high temperatures are reached within the oven cavity the oven thermal cut out will open at 293 F 145 C causing the oven to shut down 8 MONITOR FUSE 1 The monitor fuse blows when the contacts COM NO of the pri mary interlock relay RY2 and the secondary interlock switch remain closed with the oven door open and when the monitor switch closes 2 If the wire harness or electrical components are short circuited this monitor fuse blows to prevent an electric shock or fire hazard 9 NOISE FILER The noise filter prevents the radio frequency interference that might flow back in the power circuit R305KS CHAPTER 7 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
67. switch according to the TEST PROCEDURE for those switches before replacing the blown monitor fuse R305KS CAUTION BEFORE REPLACING A BLOWN MONITOR FUSE TEST THE PRIMARY INTERLOCK RELAY SECONDARY INTERLOCK SWITCH DOOR SENSING SWITCH AND MONITOR SWITCH FOR PROPER OPERATION If the monitor fuse is blown by improper switch operation the monitor fuse and monitor switch must be replaced with monitor fuse and monitor switch assembly part number FFS BA037WRKZ even if the monitor switch operates normally The monitor fuse and monitor switch assembly is comprised of a 20 ampere fuse and switch 5 Reconnect all leads removed from components during testing 6 Reinstall the outer case cabinet 7 Reconnect the power supply cord after the outer case is installed 8 Run the oven and functions 10 Procedure NOISE FILTER TEST 1 Disconnect the power supply then remove outer case 2 Open the door and block it open NOISE FILTER 3 Discharge high voltage capacitor r 05 4 Disconnect the lead wires from the terminal the noise filter Using an ohmmeter check between FUSE ue the terminals as described in the following table If incorrect reading are obtained replace the ODE PAG OS On noise filter e 5 Reconnect all leads removed from components during testing NOISE SUPPRESSION COIL 6 Reinstall the outer case cabinet Hm 7 Reconnect the power s
68. tion R 305KS 1 MODEL NUMBER 2 REF NO 1 3 PART Parts marked may cause undue microwave exposure 4 DESCRIPTION Parts marked 1 are used in voltage more than 250 CONTENTS 1 OVEN PARTS PANEL PARTS 2 DOOR AND CONTROL m INDEX PAD ASSEMBLY FPADBA593WRKZ DOOR PROTECTION SHEET SPADPA204WRE0 FOAM SHEET PLASTIC SSAKHA034WREO SPAKHA012WREZ INTO THE G OVEN CAVITY Z PACKING CASE FPAK A541WRKZ Not replaceable items TRAY ASSY CPADBA317WRKZ _ SHARP CORPO RATION This document has been published to be used for after sales service only The contents are subject to change without notice R305KS 1 OVEN PARTS gt R305KS PRICE NEW PART NO PARTS CODE RANK MARK RANK DESCRIPTION 1 OVEN PARTS ELECTRIC PARTS 1 1 QSW MA147WRZZ AG Secondary interlock switch door sensing switch T 2 FFS BA037WRKZ AN Monitor fuse 20 and monitor switch assembly switch D3V 1G 2C25 1 3 FACCDA109WREZ AU Power supply cord 1 3 FACCDA098WREZ P
69. transformer to bottom plate gt 2 S E Screw Driver Type TORX T20 H or GTXH20 100 Remove transformer from bottom plate REINSTALLATION Rest transformer on the bottom plate with its primary terminals toward the oven face plate Secure transformer with four 4 screws two 2 screws from the upper side and two 2 screws from bottom side to bottom plate wire leads primary to power transformer and filament leads and high voltage wire of transformer to magnetron and high voltage capacitor Refer to PICTORIAL DIAGRAM Reinstall outer case and check that oven is operating properly 4 HIGH VOLTAGE COMPONENTS REMOVAL HIGH VOLTAGE CAPACITOR AND HIGH VOLT AGE RECTIFIER ASSEMBLY To remove the components proceed as follows 1 Disconnect the power supply cord and remove outer case 2 Open the oven door and block it open 3 4 Disconnect the high voltage wire of the power transformer from the Discharge high voltage capacitor high voltage capacitor Disconnect the high voltage wire of high voltage rectifier assembly from the magnetron Disconnect the filament lead short one of the power transformer from the high voltage capacitor 5 MAGNETRON REMOVAL P o9 m ct REMOVAL Disconnect the power supply cord and then remove outer case Open the oven door and block it open Discharge high voltage capacitor Disconnect all wire leads from magnetron
70. uching 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 2 Control Unit The following symptoms indicate a defective control unit 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 In connection with indicators a Ata certain digit all or some segments do not light up R305KS 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 certain group of indicators do not light up g The figure of all digits flicker 99 Other possible problems caused defective control unit a Buzzer does not sound or continues to sound b Clock does not operate properly c Cooking is not possible 3 If the Key unit or control unit is defective 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 control unit assembly 5 6 7 8 Reconnect all leads removed from components during testing Re install the outer case cabinet Reconnect the power supply cord after the outer case is installed Run the oven and check all functions 4 When testing
71. upply cord after the outer case is installed 8 Run the oven and check all functions LINE BYPASS LINE BYPASS CAPACITOR CAPACITOR MEASURING POINT INDICATION OF OHMMETER Between N and L Open circuit c Between terminal N and WHITE Short circuit WHITE RED Between terminal L Short circuit 11 Procedure J 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 In this service manual the touch control panel assembly is divided into two units Control Unit and Key Unit and also the Control Unit is divided into two units CPU 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 4 5 3 Discharge high voltage capacitor Disconnect the leads to the primary of the power transformer Ensure that these leads remain isolated from other components and oven chassis by using insulation tape 1 Key Unit NOTE 1 Re install the outer case cabinet 2 Reconnect the power supply cord after the outer case is installed 3 Run the oven and check all functions The following symptoms indicate a defective key unit a When to
72. ut 3 3 volts A C output on the fila ment winding and approximately 2360 volts A C on the high voltage winding 3 The filament winding voltage heats the magnetron filament and the winding voltage is sent to a voltage doubler circuit 4 The microwave energy produced by the magnetron is channelled through the waveguide into the cavity feed box and then into the cavity where the food is placed to be cooked S39 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 When the door is opened during a cook cycle the monitor switch door sensing switch secondary interlock switch relay RY1 and primary interlock relay are activated with the following results The circuits to the turntable motor the cooling fan motor and the high voltage components are de energized the oven lamp remains on and the digital read out displays the time still remaining in the cook cycle when the door was opened The monitor switch electrically monitors the operation of the sec ondary interlock switch and primary interlock relay and is mechani cally associated with the door so that it will function in the following sequence a When the door opens from the closed position the primary interlock relay RY2 and secondary interlock switch open their contacts And contacts of the relay RY1 remains closed The
73. ut of the magnetron can be measured by performing a water temperature rise test This test should only be used if above tests do not indi cate a faulty magnetron and there is no defect in the following components or wiring silicon rectifier high voltage capacitor and power transformer This test will require a 16 ounce 453cc measuring cup and an accurate mercury thermometer or thermocouple type temperature tester For accurate results the following procedure must be followed carefully 1 Fill the measuring cup with 16 02 453cc of tap water and measure the temperature of the water with a thermometer or thermocouple tempera ture tester Stir the thermometer or thermocouple through the water until the temperature stabilizes Record the temperature of the water 2 Place the cup of water in the oven Operate oven at P HI 100 Power selecting more than 60 seconds cook time Allow the water to heat for 60 seconds measuring with a stop watch second hand of a watch or the digital read out countdown 3 Remove the cup from the oven and again measure the temperature making sure to stir the thermometer or thermocouple through the water until the maximum temperature is recorded 4 Subtract the cold water temperature from the hot water temperature The normal result should be32 1 to 59 7 F 17 9 to 33 2 C rise in tempera ture If the water temperatures are accurately measured and tested for the required time period the test results will indicate if t

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