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Sharp R1481 Manual

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    							R-1480
    R-1481
    R-1482
    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 con-
    tain 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 Recti-
    fier Assembly,  High Voltage Harness etc..)
    TABLE OF CONTENTS
    Page
    PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO
    AVOID POSSIBLE  EXPOSURE TO EXCESSIVE MICROWAVE ENERGY ................... INSIDE FRONT COVER
    BEFORE SERVICING ...................................................................................................... INSIDE FRONT COVER
    WARNING TO SERVICE PERSONNEL ................................................................................................................ 1
    MICROWAVE MEASUREMENT PROCEDURE ................................................................................................... 2
    FOREWORD AND WARNING ............................................................................................................................... 3
    PRODUCT SPECIFICATIONS .............................................................................................................................. 4
    GENERAL  INFORMATION ................................................................................................................................... 4
    OPERATION .......................................................................................................................................................... 6
    TROUBLESHOOTING GUIDE ............................................................................................................................ 11
    TEST PROCEDURE ............................................................................................................................................ 12
    TOUCH CONTROL PANEL ASSEMBLY ............................................................................................................ 21
    COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE ................................................................ 26
    PICTORIAL DIAGRAM ........................................................................................................................................ 34
    CONTROL PANEL CIRCUIT ............................................................................................................................... 35
    PRINTED WIRING BOARD ................................................................................................................................. 36
    PARTS LIST ........................................................................................................................................................ 37
    PACKING AND ACCESSORIES ......................................................................................................................... 42S3807R1480X//
    R-1480
    R-1481
    R-1482
    OVER THE  RANGE
    MICROWAVE OVEN
    MODELS
     SERVICE MANUAL
    SHARP CORPORATION
    This document has been published to be used for after
    sales service only.
    The contents are subject to change without notice.
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    CUSTOM HELP1 Coffee/tea
    2 Roll/muffin, fresh
    3 Roll/muffin, frozen
    4 Hot cereal
    5 Scrambled eggs
    
    1 Dinner plate
    2 Pasta/casserole
    3 Frozen entree
    4 Frozen snack
    5 Pizza, slice
    1 Baked potatoes
    2 Fresh vegetables
    3 Frozen vegetables
    4 Rice
    5 Ground meatPOPCORN
    COMPU DEFROST
    POWER
    LEVELKITCHEN TIMER
    CLOCKMINUTE
    PLUS
    TURNTABLE
    ON/OFFSTOP
    CLEARSTART
    TOUCH ONWORK
    LIGHTNIGHT
    LIGHTFAN
    HI/LO
    BREAKFAST
    COMPU COOK SNACKS &
    REHEAT 
    						
    							R-1480
    R-1481
    R-1482
    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
    microwave source, and make repairs as necessary: (1) interlock operation, (2) proper door closing, (3)
    seal and sealing surfaces (arcing, wear, and other damage), (4) damage to or loosening of hinges and
    latches, (5) evidence of dropping or abuse.
    (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 releasing oven to the owner.
    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 Administrations
    Center for Devices and Radiological Health immediately.
    Service personnel should inform SHARP ELECTRONICS CORPORATION of any certified unit found
    with emissions in excess of 4mW/cm
    2. The owner of the unit should be instructed not to use the unit
    until the oven has been brought into compliance. 
    						
    							1
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    R-1481
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    WARNING TO SERVICE PERSONNEL
    Microwave ovens contain circuitry capable of pro-
    ducing very high voltage and current, contact with
    following parts 
     may result in a severe, possibly
    fatal, electrical shock.
    (Example)
    High Voltage Capacitor, High Voltage Power Trans-
    former, Magnetron, High Voltage Rectifier Assem-
    bly,  High Voltage Harness etc..
    Read the Service Manual carefully and follow all
    instructions.
    Before Servicing
    1. Disconnect the power supply cord ,  and  then
    remove outer case.
    2. Open the door and block it open.
    3. Discharge high voltage capacitor.
    WARNING: RISK OF ELECTRIC SHOCK.
    DISCHARGE THE HIGH-VOLTAGE
    CAPACITOR BEFORE SERVICING.
    The high-voltage capacitor remains charged about 60
    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 then remove
    outer case.
    2. Open the door and block it open.
    3. Discharge high voltage capacitor.
    4. Disconnect the leads to the primary of the power
    transformer.
    5. Ensure that these leads remain isolated from other
    components and oven chassis by using insulation tape.
    6. After that procedure, reconnect the power supply cord.
    When the testing is completed,
    1. Disconnect the power supply cord, and then remove
    outer case.
    2. Open the door and block it open.
    3. Discharge high voltage capacitor.
    4. Reconnect the leads to the primary of the power
    transformer.
    5. Reinstall the outer case (cabinet).
    6. Reconnect the power supply cord after the outer case is
    installed.
    7. Run the oven and check all functions.
    After repairing
    1. Reconnect all leads removed from components during
    testing.
    2. Reinstall the outer case (cabinet).
    3. 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.
    When all service work is completed and the oven is fully
    assembled, the microwave power output should be checked
    and microwave leakage test should be  carried out.
    Dont Touch !
    Danger High Voltage 
    						
    							2
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    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/cm
    2 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.
    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
    2 at any point 5cm or more from the external surface of the oven.
    B. Preparation for testing:
    Before beginning the actual measurement of leakage, proceed as follows:
    1) Make sure that the actual instrument is operating normally as specified in its instruction booklet.
    Important:
    Survey instruments that comply with the requirement for instrumentation as prescribed by the performance standard
    for microwave ovens, 21 CFR 1030.10(c)(3)(i), must be used for testing.
    2) Place the oven tray in the oven cavity.
    3) Place the load of 275±15 ml (9.8 oz) of tap water initially at 20±5ûC (68ûF) 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) Set the cooking control on 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.
    C. 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
    2,
    and that the secondary interlock switch does turn the oven OFF before any door movement.
    NOTE:  After servicing, record data on service invoice and microwave leakage report. 
    						
    							3
    R-1480
    R-1481
    R-1482
    SHARP ELECTRONICS CORPORATION
    SHARP PLAZA, MAHWAH,
    NEW JERSEY 07430-2135
    SERVICE MANUAL
    OVER THE RANGE
    MICROWAVE OVEN
    R-1480 / R-1481 / R-1482
    FOREWORD
    This Manual has been prepared to provide Sharp Electronics Corp.
    Service Personnel with Operation and Service Information for the
    SHARP OVER THE RANGE  MICROWAVE OVEN, R-1480, R-1481,
    R-1482.
    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.
    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.
    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 Ò*Ó on parts list are used at voltages more than
    250V.
    Removal of the outer wrap gives access to voltage above 250V.
    All the parts marked ÒDÓ on parts list may cause undue microwave
    exposure, by themselves, or when they are damaged, loosened
    or removed.PRODUCT DESCRIPTION
    GENERAL INFORMATION
    OPERATION
    TROUBLESHOOTING GUIDE AND
    TEST PROCEDURE
    TOUCH CONTROL PANEL
    COMPONENT REPLACEMENT
    AND ADJUSTMENT PROCEDURE
    WIRING DIAGRAM
    PARTS LIST 
    						
    							4
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    ITEM DESCRIPTION
    Power Requirements 120 Volts / 14.3 Amperes
    60 Hertz
    Single phase, 3 wire grounded
    Power Output 950 watts (IEC-705 TEST PROCEDURE)
    Operating frequency of 2450MHz
    Convection Power Output 1700 watts
    Case Dimensions Width 29-15/16
    Height 16-3/8
    Depth  15- 1/4 (Not including the door handle)
    Cooking Cavity Dimensions Width 20-1/4
    Height 8-3/16
    1.4 Cubic Feet Depth  14-1/2
    Hood lamp 2 bulbs, 30W x 2,  Incandescent light bulbs
    Hood fan Approx. 300 C.F.M.
    Control Complement Touch Control System
    Clock ( 1:00 - 12:59 )
    Timer (0 - 99 min. 99 seconds)
    Microwave Power for Variable Cooking
      Repetition Rate;
    P-HI .................................................. Full power throughout the cooking time
    P-90 .................................................................... approx. 90% of Full Power
    P-80 .................................................................... approx. 80% of Full Power
    P-70 .................................................................... approx. 70% of Full Power
    P-60 .................................................................... approx. 60% of Full Power
    P-50 .................................................................... approx. 50% of Full Power
    P-40 .................................................................... approx. 40% of Full Power
    P-30 .................................................................... approx. 30% of Full Power
    P-20 .................................................................... approx. 20% of Full Power
    P-10 .................................................................... approx. 10% of Full Power
    P-0 .................................................... No power throughout the cooking time
    CUSTOM HELP pad, BREAKFAST pad, POPCORN pad,
    SNACKS & REHEAT pad, COMPU DEFROST pad, COMPU COOK pad,
    Number selection pads, POWER LEVEL pad, KITCHEN TIMER / CLOCK pad
    MINUTE PLUS pad, TURNTABLE ON / OFF pad, START / TOUCH ON pad
    WORK LIGHT pad, NIGHT LIGHT pad, FAN HI / LO pad
    Oven Cavity Light 30W x 1 Incandescent light bulb
    Safety Standard UL Listed                FCC Authorized
    DHHS Rules, CFR, Title 21, Chapter 1, Subchapter J
    Weight Approx. 55 lbs.
    PRODUCT SPECIFICATION
    GENERAL INFORMATION
    GROUNDING INSTRUCTIONS
    This oven is equipped with a three prong grounding plug. It must be plugged into a wall receptacle that is properly installed
    and grounded in accordance with the National Electrical Code and local codes and ordinances.
    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. 
    						
    							5
    R-1480
    R-1481
    R-1482
    Electrical Requirements
    The oven is equipped with a 3-prong grounding plug. DO NOT UNDER ANY CIRCUMSTANCES CUT OR REMOVE THE
    GROUNDING PIN FROM THE PLUG.
    The power supply cord and plug must be connected to a separate 120 Volt AC, 60 Hz, 15 Amp. or more branch circuit, using
    a grounded receptacle. The receptacle should be located inside the cabinet directly above the Microwave Oven/Hood
    system mounting location.
    OVEN DIAGRAM
    1. Oven door with see-through window.
    2. Door hinges.
    3. Stirrer cover.
    4. Turntable motor shaft.
    5. Oven lamp.
    It will light when oven is operating or door is open.
    6. Door latches.
    The oven will not operate unless the door is securely closed.
    7. Auto-Touch control panel.8. Time display: Digital display, 99 minutes 99 seconds.
    9. Ventilation openings.
    10. Light Cover.
    11. Grease filters.
    12. Removable turntable.
    The turntable will rotate clockwise or counterclockwise.
    Only remove for cleaning.
    13. Removable turntable support.
    14. Power supply cord
    10
    11 12
    8
    7
    14
    6
    9
    3
    4
    5
    1
    9
    13
    2
    3-Pronged Plug
    Grounded
    Receptacle Box
    Grounding Pin
    3-Pronged Receptacle 
    						
    							6
    R-1480
    R-1481
    R-1482
    MIX CONV COOK LBS KGTURNTABLEOFF HELP
     CONTROL PANEL
    OPERATION
    DESCRIPTION OF OPERATING SEQUENCE
    The following is a description of component functions during
    oven operation.
    OFF CONDITION
    Closing the door activates the door sensing switch and
    secondary interlock switch. (In this condition, the monitor
    switch contacts are opened.)
    When oven is plugged in, 120 volts A.C. is supplied to the
    control unit. (Figure O-1).
    1. The display will show , , ,
    ,, , ,
      and                .To set any program or set the clock, you must first touch
    the STOP/CLEAR pad. The display will clear, and    :   
    will appear .COOKING CONDITION
    Program desired cooking time touching the NUMBER pads.
    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)
    12345
    67890
    CUSTOM HELP
    1 Coffee/tea
    2 Roll/muffin, fresh
    3 Roll/muffin, frozen
    4 Hot cereal
    5 Scrambled eggs
    
    1 Dinner plate
    2 Pasta/casserole
    3 Frozen entree
    4 Frozen snack
    5 Pizza, slice
    1 Baked potatoes
    2 Fresh vegetables
    3 Frozen vegetables
    4 Rice
    5 Ground meat
    POPCORN
    COMPU DEFROST
    POWER
    LEVELKITCHEN TIMER
    CLOCKMINUTE
    PLUS
    TURNTABLE
    ON/OFFSTOP
    CLEARSTART
    TOUCH ON
    WORK
    LIGHTNIGHT
    LIGHTFAN
    HI/LO
    BREAKFAST
    COMPU COOK SNACKS &
    
    REHEAT 
    						
    							7
    R-1480
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    RELAY CONNECTED COMPONENTS
    RY1 Oven lamp / Fan motor / Stirrer motor
    RY2 Power transformer
    RY3 Turntable motor
    RY4 Hood fan motor
    2. 120 volts A.C. is supplied to the primary winding of the
    power transformer and is converted to about 3.3 volts
    A.C. output on the filament winding, and approximately
    2000 volts A.C. on the high voltage winding.
    3. The filament winding voltage heats the magnetron
    filament and the H.V. 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.
    5. Upon completion of the cooking time, the power
    transformer, oven lamp, etc. are turned off, and the
    generation of microwave energy is stopped. The oven
    will revert to the OFF condition.
    6. When the door is opened during a cook cycle, monitor
    switch, door sensing switch, secondary interlock switch
    and primary interlock relay are activated with the following
    results. The circuits to the stirrer motor, the cooling fan
    motor, the turntable motor, and the high voltage
    components are de-energized, and the digital read-out
    displays the time still remaining in the cook cycle when
    the door was opened.
    7. The monitor switch is electrically monitoring the operation
    of the secondary interlock switch and primary interlock
    relay (RY2) and is mechanically associated with the door
    so that it will function in the following sequence.
    (1) When the door opens from a closed position, the
    primary interlock relay and secondary interlock switch
    open their contacts, and then the monitor switch
    contacts close.
    (2) When the door is closed from the open position, the
    monitor switch contacts first open, and then the
    contacts of the secondary interlock switch and door
    sensing switch close.
    If the secondary interlock switch and primary interlock relay
    (RY2) fail with their 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 and primary interlock relay (RY2), causing the moni-
    tor fuse to blow.
    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 (RY2) which is operated by the
    control unit within an interval second time base. Microwave
    power operation is as follows:
    VARI-MODE ON TIME OFF TIME
    Power 10(P-HI) 32 sec. 0 sec.
    (100% power)
    Power 9(P-90) 30 sec. 2 sec.
    (approx. 90% power)
    Power 8(P-80) 26 sec. 6 sec.
    (approx. 80% power)
    Power 7(P-70) 24 sec. 8 sec.
    (approx. 70% power)
    Power 6(P-60) 22 sec. 10 sec.
    (approx. 60% power)
    Power 5(P-50) 18 sec. 14 sec.
    (approx. 50% power)
     Power 4(P-40) 16 sec. 16 sec.
    (approx. 40% power)
    Power 3(P-30) 12 sec. 20 sec.
    (approx. 30% power)
    Power 2(P-20)  8 sec. 24 sec.
    (approx. 20% power)
    Power 1(P-10)  6 sec. 26 sec.
    (approx. 10% power)
    Power 0(P-0)  0 sec. 32 sec.
    (0% power)
     Note: The ON/OFF time ratio does not correspond with
    the percentage of microwave power, because
    approx. 2 seconds are needed for heating of the
    magnetron filament.
    COMPU COOK
    COMPU COOK will automatically compute the microwave
    power and cooking time. Set the desired program by touch-
    ing one of the COMPU COOK pad, and number pad to
    select menu. Enter the weight or quantity by touching the
    Number pads. When the START pad is touched, the follow-
    ing operations occur:
    1. The COOK indicator will light.
    2. The cooking time will appear on the display and start
    counting down to zero. The cooking time is adjusted
    automatically according to the weight of the food.
    3. The shut-off relays (RY1, RY2 and RY3) are energized,
    turning on the oven lamp, turntable motor, cooling fan
    motor and convection motor. The power supply voltage
    is applied to the heating element.
    4. Now, the oven is in the microwave cooking mode.
    COMPU DEFROST COOKING
    The COMPU DEFROST key is a special function key to
    defrost meats and poultry faster and better. COMPU DE-
    FROST automatically defrosts roast beef, etc.. Touch the
    COMPU COOK pad and number pad to select menu and
    enter the food weight  by touching the number pads. When
    the START pad is touched, the oven will cook according to
    the special cooking sequence. 
    						
    							8
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    2. HORIZONTAL VENTING
    The air handing is the same as VERTICAL VENTING
    except that the final air discharge is directed horizontally
    out from the top rear of the oven into the customers vent
    system.
    _: AIR FLOW
    3. RE-CIRCULATION (INSIDE VENTING)
    The air handing is the same as VERTICAL VENTING
    except that the final air discharge is directed horizontally
    through  the upper front of the oven into the kitchen. IN
    this case, the accessory charcoal filter RK-230 must be
    provided to filter the air before it leaves the oven.
    _: AIR FLOW
    VENTILATION METHODS HOT AIR EXHAUST
    1. VERTICAL VENTING
    For this venting method, hot air rising from the
    conventional range below is drawn in by the hood fan
    motor through the grease filters at the right and left sides
    of the base cover, up through the right and left sides of
    the oven cavity, then discharged vertically at rear center
    top of the oven, into the customers vent system.
    _: AIR FLOW
    GREASE 
    FILTER
    
     HOOD FAN MOTORTO DUCT
    TO DUCT
    HOOD 
    INTAKE 
    DUCT 
    HOOD 
    INTAKE 
    DUCT  HOOD FAN MOTOR
    GREASE 
    FILTER
    
    TO DUCT
    HOOD 
    INTAKE 
    DUCT  HOOD EXHAUST 
    LOUVER
    HOOD FAN MOTORCHARCOAL 
    FILTER 
    						
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