Sharp R-209KK Service Manual
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Sharp R-209KK Service Manual

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PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE EXPO-
SURE TO EXCESSIVE MICROWAVE ENERGY
BEFORE SERVICING
CHAPTER 1. WARNING TO SERVICE PERSONNEL
CHAPTER 2. MICROWAVE MEASUREMENT PRO-
CEDURE
CHAPTER 3. FOREWORD AND WARNING
CHAPTER 4. PRODUCT DESCRIPTION
CHAPTER 5. GENERAL INFORMATION
CHAPTER 6. OPERATION
SHARP CORPORATION
SERVICE MANUAL
MICROWAVE OVEN
MODEL
In the interest of user-safety the oven should be restored to
its original condition and only parts identical to those speci-
fied 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
CHAPTER 7. TROUBLESHOOTING GUIDE
CHAPTER 8. TEST PROCEDURES
CHAPTER 9. TOUCH CONTROL PANEL ASSEMBLY
CHAPTER 10. PRECAUTIONS FOR USING LEAD-
FREE SOLDER
CHAPTER 11. COMPONENT REPLACEMENT AND
ADJUSTMENT PROCEDURE
CHAPTER 12. CIRCUIT DIAGRAMS
Parts Guide
No. S2503R209KPK/
R-209KK
This document has been published to be used
for after sales service only.
The contents are subject to change without notice.
R209KK

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  • Page 1 R209KK SERVICE MANUAL No. S2503R209KPK/ MICROWAVE OVEN R-209KK MODEL In the interest of user-safety the oven should be restored to its original condition and only parts identical to those speci- fied should be used. WARNING TO SERVICE PERSONNEL: Microwave ovens...

  • Page 2: Table Of Contents

    CONTENTS PRECAUTIONS TO BE OBSERVED BEFORE AND [11] Procedure I : NOISE FILTER TEST... 8-4 DURING SERVICING TO AVOID POSSIBLE EXPO- [12] Procedure J : TOUCH CONTROL PANEL SURE TO EXCESSIVE MICROWAVE ENERGY ASSEMBLY TEST........8-4 [13] Procedure K : KEY UNIT TEST ....

  • Page 3: Precautions To Be Observed Before And During Servicing To Avoid Possible Expo

    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.

  • Page 4: When The Testing Is Completed

    R209KK Service Manual R209KK   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.

  • Page 5: Chapter 2. Microwave Measurement Pro- Cedure Requirements

    R209KK Service Manual R209KK   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/ 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.

  • Page 6: Chapter 3. Foreword And Warning Foreword

    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-209KK. 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.

  • Page 7: Chapter 4. Product Description

    R209KK Service Manual R209KK   CHAPTER 4. PRODUCT DESCRIPTION [1] SPECIFICATIONS ITEM DESCRIPTION 120 Volts Power Requirements 60 Hertz Single phase, 3 wire grounded Power Consumption 1170W / Approx. 10 Amperes 800 W nominal of RF microwave energy (IEC Test procedure) Power Output Operating frequency 2450 MHz Width 18-1/8"...

  • Page 8: Chapter 5. General Information Grounding Instructions

    R209KK Service Manual R209KK   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.
  • Page 9 R209KK 2. TOUCH CONTROL PANEL NOTE: Some one-touch cooking features such as "MINUTE PLUS" are disabled after three minutes when the oven is not in use. These features are automatically enabled when the door is opened and closed or the STOP/ CLEAR pad is pressed. 5 –...

  • Page 10: Chapter 6. Operation Description Of Operating Se- Quence

    R209KK Service Manual R209KK   CHAPTER 6. OPERATION [1] DESCRIPTION OF OPERATING SEQUENCE The following is a description of component functions during oven operation. 1. OFF CONDITION 3. POWER LEVEL COOKING Closing the door activates door sensing switch and secondary inter- When Variable Cooking Power is programmed, the 120 volts A.C.

  • Page 11: Oven Schenatic

    R209KK [2] OVEN SCHENATIC 1. Off Condition SCHEMATIC NOTE: CONDITION OF OVEN 1. DOOR CLOSED 2. CLOCK APPEARS ON DISPLAY THERMAL CUT-OUT (OVEN) NOTE: " " indicates components with potentials above 250V TEMPERATURE FUSE (OVEN) FUSE N.O. POWER TRANSFORMER COM. (RY-2) (RY-1) PRIMARY...

  • Page 12: Description And Function Of Components

    R209KK [3] DESCRIPTION AND FUNCTION OF COMPONENTS 1. DOOR OPEN MECHANISM 4. TURNTABLE MOTOR The door is opened by pushing the open button on the control panel, The turntable motor rotates the turntable located on the bottom of the refer to the Figure D-1. oven cavity, so that the food on the turntable is cooked evenly.

  • Page 13: Chapter 7. Troubleshooting Guide

    R209KK Service Manual R209KK   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 require that a specific test be performed.

  • Page 14: Chapter 8. Test Procedures Procedure A : Magnetron Assembly Test

    R209KK Service Manual R209KK   CHAPTER 8. TEST PROCEDURES [1] Procedure A : MAGNETRON 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.

  • Page 15: Procedure D : High Voltage Capacitor Test

    R209KK 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. 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.

  • Page 16: Procedure F : Primary Interlock System Test

    R209KK 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. [8] Procedure F : PRIMARY INTERLOCK SYSTEM TEST 1.

  • Page 17: Procedure I : Noise Filter Test

    R209KK 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 switch according to the "TEST PROCEDURE" for those switches before replacing the blown monitor fuse. CAUTION: BEFORE REPLACING A BLOWN MONITOR FUSE, TEST THE PRIMARY INTERLOCK RELAY, SECONDARY INTERLOCK SWITCH, DOOR SENSING SWITCH AND MONITOR SWITCH FOR PROPER OPERATION.

  • Page 18: Procedure K : Key Unit Test

    R209KK 2) Open the door and block it open. 3) Discharge high voltage capacitor. 4) Replace the key unit. 5) Reconnect all leads removed from components during testing. 6) Re-install the outer case (cabinet). 7) Reconnect the power supply cord after the outer case is installed. 8) Run the oven and check all functions.

  • Page 19: Procedure L : Relay Test

    R209KK [14] Procedure L : RELAY 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 leads to the primary of the power transformer. 5.
  • Page 20 R209KK 5) Make a visual inspection of the varistor. Check for burned damage and examine the transformer with a tester for the presence of layer short-circuit (check the primary coil resistance which is approximately 915Ω±10%). If any abnormal condition is detected, replace the control unit.

  • Page 21: Chapter 9. Touch Control Panel Assem

    R209KK Service Manual R209KK   CHAPTER 9. TOUCH CONTROL PANEL ASSEMBLY [1] OUTLINE OF TOUCH CONTROL PANEL This circuit consists of 4-digits, 12-segments and 3-common elec- trodes using a Liquid Crystal Display. The touch control section consists of the following units as shown in 3) Power Source Circuit the touch control panel circuit.
  • Page 22 R209KK Pin No. Signal Description COM2 OUT Common data signal. Connected to LCD signal COM2. COM3 OUT Terminal not used. 26-37 SEG0-SEG11 OUT Segment data signal. Connected to LCD.The relation between signals are as follows: LSI signal (Pin No.) LCD (segment) LSI signal (Pin No.) LCD (segment) SEG 0 (26) ----------------- SEG 1...

  • Page 23: Servicing For Touch Control Panel

    R209KK Pin No. Signal Description Terminal not used. Terminal not used. BZO90 Signal to sound buzzer (2.0 kHz). A: key touch sound. B: Completion sound. 0.1 sec. H : GND L : -5V 2.0 sec. H : GND L : -5V Terminal not used.

  • Page 24: Chapter 10. Precautions For Using Lead- Free Solder

    R209KK Service Manual R209KK   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.

  • Page 25: Chapter 11. Component Replacement And

    1. Door does not close firmly. 4. If the outer case (cabinet) is not fitted. WARNING FOR WIRING To prevent an electric shock, take the following precau- 3) Sharp edge: tions. Bottom plate, Oven cavity, Waveguide flange and 1. Before wiring, other metallic plate.

  • Page 26: Outer Case Removal

    R209KK [2] OUTER CASE REMOVAL To remove the outer case, procedure as follows. 1. Disconnect the power supply cord. 2. Open the oven door and block it open. 3. Remove the two (2) screws from the lower portion of the rear cab- inet using a T20H Torx type or GTXH20-100 screw driver.

  • Page 27: Positive Lock Connector (No-Case Type) Removal

    R209KK [6] POSITIVE LOCK CONNECTOR (NO-CASE TYPE) REMOVAL Terminal 1. Disconnect the power supply cord, and remove outer case. Positive lock¨ 2. Open the door and block it open. connector 3. Discharge high voltage capacitor. Push 4. Push the lever of positive lock connector. Lever 5.

  • Page 28: Power Supply Cord Replacement

    5. Re-install the turntable motor cover to the bottom plate with one (1) 4. Where the corners have been snipped off bend corner areas flat. screw. No sharp edges must be evident after removal of the turntable motor cover. TTM packing 5.

  • Page 29: Door Sensing Switch/Secondary Interlock Switch And Monitor Switch Removal

    R209KK 8. Remove the fan blade assembly from the shaft of the fan motor by 3. Apply the screw lock tight into the hole (for shaft) of the fan blade. pulling and rotating the fan blade with your hand. 4. Install the fan blade to the shaft of fan motor by pushing the fan 9.

  • Page 30: Door Replacement

    R209KK 2. After adjustment, check the following. 1. In and out play of door remains less than 0.5mm when in the latched position. First check upper position of latch hook, pushing and pulling upper portion of door toward the oven face. Then check Latch Hook Door lower portion of the latch hook, pushing and pulling lower portion of...
  • Page 31 R209KK 4. SEALER FILM 1. Put the adhesive tape on the backing film of the sealer film as shown in Fig. C-8 2. Tear the backing film by pulling the adhesive tape. Upper Oven Upper Hinge Oven Hinge 3. Put the pasted side of the sealer film on the door panel Sealer film Backing film Adhesive tape...

  • Page 32: Chapter 12. Circuit Diagrams

    R209KK Service Manual R209KK   CHAPTER 12. CIRCUIT DIAGRAMS [1] Pictorial Diagram (Figure S-1) R Y 1 (RED) WHT RED Figure S-1. Pictorial Diagram 12 – 1...

  • Page 33: Control Panel Circuit (Figure S-2)

    R209KK [2] Control Panel Circuit (Figure S-2) Figure S-2. Control Panel Circuit 12 – 2...

  • Page 34: Printed Wiring Board (Figure S-3)

    R209KK [3] Printed Wiring Board (Figure S-3) Figure S-3. Printed Wiring Board 12 – 3...
  • Page 35 R209KK PARTS LIST MICROWAVE OVEN HOW TO ORDER REPLACEMENT PARTS To have your order filled promptly and correctly, please R-209KK MODEL furnish the following information. 1. MODEL NUMBER 2. REF. NO. 3. PART NO. 4. DESCRIPTION Parts marked "*" may cause undue microwave exposure.
  • Page 36 R209KK [1] OVEN PARTS 1-10 4-11 1-12 4-14 4-12 4-10 4-13 1-11...
  • Page 37 R209KK PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK [1] OVEN PARTS ELECTRIC PARTS QSW-MA085WRE0 Secondary interlock switch/ Door sensing switch QSW-MA137WRE0 Secondary interlock switch/ Door sensing switch (Interchangeable) QSW-MA147WRE0 Secondary interlock switch/ Door sensing switch (Interchangeable) FFS-BA026WRKZ Monitor fuse (15A) and monitor switch assembly (SwitchAM51620C53Y1) FACCDA107WREZ Power supply cord FACCDA108WREZ...
  • Page 38 R209KK [2] DOOR AND CONTROL PANEL PARTS 3-1-2 3-1-1...
  • Page 39 R209KK PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK [2] DOOR AND CONTROL PANEL PARTS CONTROL PANEL PARTS FPNLCB856WRKZ Control panel frame with key unit 3-1-1 PSHEPB107WREZ Graphic sheet 3-1-2 QSW-KA053DRZZ Membrane switch JBTN-B309WRFZ Open button MSPRCA050WRE0 Open button spring DPWBFC479WRUZ Control unit QCNC-A014WRZZ...
  • Page 40 1-4-13 PCUSGA662WRP0 1-4-12 PCUSUA501WRP0 1-4-11 PCUSUA633WREZ 2-3-8 PDUC-A908WRWZ 1-4-4 PDUC-A909WRPZ 1-4-9 COPYRIGHT © 2005 BY SHARP CORPORATION PHOK-A144WRFZ 1-4-1 PPACGA176WREZ 1-4-10 PSHEPA782WREZ 2-5-6 ALL RIGHTS RESERVED. PSHEPB107WREZ 2-3-1-1 [ Q ] No part of this publication may be reproduced, stor-...

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