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.
9
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,
R-204CW
possibly fatal, electrical shock. (High Voltage Capacitor, High
Voltage Power Transformer, Magnetron, High Voltage Rectifier
Assembly, High Voltage Harness etc..)
This is a supplemental Service Manual for Model R-204CW. This model is quite similar to base
model R-203CW. Use this supplemental manual together with the Base Model Service Manual
(Refer No. is S2902R203CPW/) for complete operation, service information, 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
FOREWORD AND WARNING...............................................................................................................................2
TEST PROCEDURE ..............................................................................................................................................3
TOUCH CONTROL PANEL ASSEBLY .................................................................................................................5
CPU UNIT CIRCUIT ..............................................................................................................................................6
PARTS LIST ..........................................................................................................................................................7
PACKING AND ACCESSORIES ...........................................................................................................................8
SHARP CORPORATION
This document has been published to be used for after
sales service only.
The contents are subject to change without notice.
Page 2
R-204CW
PRECAUTIONS TO BE OBSER VED BEFORE AND
DURING SER VICING TO A VOID POSSIBLE
EXPOSURE TO EXCESSIVE MICROW A VE
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 release 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 The Food and Drug Administration's
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/cm2. The owner of the unit should be instructed not to use the unit
until the oven has been brought into compliance.
Page 3
W ARNING TO SER VICE PERSONNEL
Microwave ovens contain circuitry capable of producing very high voltage and current, contact with
following parts
fatal, electrical shock.
(Example)
High Voltage Capacitor, High Voltage Power Trans-
former, Magnetron, High Voltage Rectifier Assembly, High Voltage Harness etc..
Read the Service Manual carefully and follow all
instructions.
may result in a severe, possibly
R-204CW
Don't Touch !
Danger High Voltage
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 highvoltage capacitor (that is the connecting lead of the highvoltage 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 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. 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 reexamine 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 a microwave leakage test should be carried out.
1
Page 4
R-204CW
SERVICE MANUAL
MICROWAVE OVEN
R-204CW
FOREWORD
This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service
Information for the SHARP MICROWAVE OVEN, R-204CW.
The model R-204CW is quite similar to base model R-203CW (Refer No. is S2902R203CPW/).
It is recommended that service personnel carefully study the entire text of this manual and the base model's 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 no 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 “*” 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 “∆” on parts list may cause undue microwave exposure, by themselves, or when they are
damaged, loosened or removed.
SHARP ELECTRONICS CORPORATION
SHARP PLAZA, MAHWAH,
NEW JERSEY 07430-2135
2
Page 5
TEST PROCEDURES
R-204CW
PROCEDURE
LETTER
JKEY 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. If the display fails to clear when the STOP/CLEAR pad is depressed, first verify the flat ribbon cable is
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.
COMPONENT TEST
making good contact, verify that the door sensing switch (stop switch) operates properly; that is the
contacts are closed when the door is closed and open when the door is open. If the door sensing
switch (stop switch) is good, disconnect the flat ribbon cable that connects the key unit to the control
unit and make sure the door sensing switch is closed (either close the door or short the door sensing
switch connecter). Use the Key unit matrix indicated on the control panel schematic and place a
jumper wire between the pins that correspond to the STOP/CLEAR pad making momentary contact. If
the control unit responds by clearing with a beep the key unit is faulty and must be replaced. If the
control unit does not respond, it is faulty and must be replaced. If a specific pad does not respond, the
above method may be used (after clearing the control unit) to determine if the control unit or key pad is
at fault.
G 6G 5G 4G 3G 2G 1
KRELAY TEST
1. Disconnect the power supply cord and then remove outer case.
2. Open the door and blocked 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, re-connect the power supply cord.
7. Remove the outer case and check voltage between Pin No. 3 of the 2 pin connector (A) and the common
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 operated by 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 ........ Check diode which is connected to the relay coil. If diode is good, control
RY1Approx. 14.6V D.C.Oven lamp / Turntable motor / Cooling fan motor
RY2Approx. 13.0V D.C.Power transformer
8. If any abnormal condition is detected, replace the control unit.
9. Disconnect the power supply cord and then remove outer case.
10. Open the door and block it open.
11. Discharge high voltage capacitor.
3
Page 6
R-204CW
TEST PROCEDURES
PROCEDURE
LETTER
12. Reconnect all leads removed from components during testing.
13. Re-install the outer case (cabinet).
14. Reconnect the power supply cord after the outer case is installed.
15. Run the oven and check all functions.
MFOIL PATTERN ON THE PRINTED WIRING BOARD TEST
To protect the electronic circuits, this model is provided with a fine foil pattern added to the primary on the
PWB, this foil pattern acts as a fuse.
1. Foil pattern check and repairs.
1) Disconnect the power supply cord and then remove outer case.
2) Open the door and block it open.
3) Discharge high voltage capacitor.
4) Follow the troubleshooting guide given below for repair.
STEPSOCCURRENCECAUSE OR CORRECTION
1Only pattern at "a" is broken.*Insert jumper wire J1 and solder.
2Pattern 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 transformer with a tester for the presence of layer short-circuit (check the
primary coil resistance which is approximately 563Ω ± 10%). If any abnormal
condition is detected, replace the control
unit.
COMPONENT TEST
RY1
c
(J1)
a
b
d
1
P
RY2
6) Reconnect all leads removed from components during testing.
7) Re-install the outer case (cabinet).
8) Reconnect the power supply cord after the outer case is installed.
9) Run the oven and check all function.
2. Follow the troubleshooting guide given below, if indicator does not light up after above check and
repairs are finished.
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, re-connect the power supply cord.
7) Follow the troubleshooting guide given below for repair.
STEPSOCCURRENCECAUSE OR CORRECTION
The rated AC voltage is not present between
1Pin No. 3 of the 2-pin connector (A) and theCheck supply voltage and oven power cord.
common terminal of the relay RY2.
The rated AC voltage is present at primaryLow voltage transformer or secondary circuit defective.
2
side of low voltage transformer.Check and replace control unit.
8) Disconnect the power supply cord and then remove outer case.
9) Open the door and block it open.
4
Page 7
TEST PROCEDURES
R-204CW
PROCEDURE
LETTER
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.
TOUCH CONTROL PANEL ASSEMBLY
OUTLINE OF TOUCH CONTROL PANEL
The touch control section consists of the following units as
shown in the touch control panel circuit.
(1) Key Unit
(2) Control Unit
COMPONENT TEST
3) Power Source Circuit
This circuit generates voltage necessary in the control
unit from the AC line voltage. In addition, the synchronizing
signal is available in order to compose a basic standard
time in the clock circuit.
The principal functions of these units and their related
signals are explained below.
Key Unit
The key unit is composed of a matrix, signals generated in
the LSI are sent to the key unit through R00, R01, R02, R03,
R20 and R21.
When a key pad is touched, a signal is completed through
the key unit and passed back to the LSI through R23, K00,
K01 and K02 to perform the function that was requested.
Control Unit
Control unit consists of LSI, ACL circuit, indicator circuit,
power source circuit, relay circuit, buzzer circuit and synchronizing signal circuit.
1) ACL
This circuit generates a signal which resets the LSI to the
initial state when power is supplied.
2) Indicator Circuit
This circuit consists of 4-digits, 12-segments and 3common electrodes using a Liquid Crystal Display.
SymbolVoltageApplication
VC-5VLSI(IC1)
4) Relay 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 compose a basic standard time in the clock
circuit. It accompanies a very small error because it
works on commercial frequency.
7) 2nd. Interlock Relay Control Switch (Door Sensing
Switch)
A switch to “tell” the LSI if the door is open or closed.
5
Page 8
R-204CW
1
A
LIQUID CRYSTAL DISPLAY
B
C
CPU UNIT
D
2
ON DEF. LBS QTY. CHECK
GND
C 3
C 2
C 1
S 1
S 2
S 3
S 4
S 5
S 6
S 7
S 8
S 9
S10
S11
S12
1k
R5
C4
/25v
0.01µ
C5 0.1µ/25v
Q1
2SA1037AK
C6
0.1µ/25v
HZ4C3
ZD1
C3 0.01µ/25v
R6 15k
4554
VC
SEG13
SEG14
SEG15
SEG16
SEG17
SEG18
SEG19
VC1
VC2
VC3
44
SEG12
1
RESET
R10 15k
SEG11
TEST
SEG10
VSS
C11 0.01µ/25v
3
SEG9
SEG8
SEG7
VD1
OCS3
OCS4
R50 20kF
SEG6
SEG5
SEG4
SEG3
IC1
VDD
AVSS
AVDD
AVREF
C7
0.1µ
/25v
(J15) 4.7k
(J11) 4.7k(J10) 10k
(J14)
SEG2
SEG1
SEG0
COM3
P40
P41
P42
(J13) 4.7k
(J12)
R20 15k
COM2
P43
45
15k
R62
Stop
START
Clear
Level
COMPU
DEFROST
PLATE
DINNER
2
6
G 6G 5G 4G 3G 2G 1
BEVERAGE
G 7
C60 330p/50v
C61 330p/50v
Power
BAKED
POTATO
4
1
5
0
3
Timer
Clock
FRESH
ROLL,
MUFFIN
VEGETABLES
G 9
G 8
15k
R63
15k
R64
15k
30
COM1
COM0
K03
K02
K01
K00
P23
P22
P21
P20
R03
R02
R01
R00
B Z
1529
14
R65
15k
R66
15k
R67
C62 330p/50v
C63 330p/50v
R75 100k
R76 100k
R77 100k
R78 100k
R70 15k
R71 15k
R72 15k
Minute Plus
POPCORN
7
8
9
KEY UNIT
G10
R73 15k
6
A
B
C
D
C40 0.01µ/25v
C20
0.1µ
/25v
/25v
0.1µ
C10
Q10 DTA143EKA
E
GND
C8 47µ/16v
–
+
R4
910 1/2w
C1 0.1µ/50v
VR
POWER UNIT
C2 470µ/25v
–
F
D1-D4
11ES1
D3
D1
+
D4
D2
3.3k 1/4w
R30
PKM22EPT
SP1
Q30 DTA143EKA
Q20
DTA143EKA
Q21
DTD143ES
D20
C21 10µ/35v
–
+
Q22
DTA143ES
D21
R40 4.7k
D22
R41 15k
D40
: IF NOT SPECIFIED, 1/10W ± 5%
NOTE : IF NOT SPECIFIED, 1SS270A
E
Figure S-3. CPU Unit Circuit
F
G
T1
d
RY1
RY2
G
(J1)
VRS1 10G471K
c
ab
FAN MOTOR
NO
MICRO
COM
AC(H)
B 2
GND
B 1
DOOR
SENSING
45
H
6
A 3
A 1
H
OVEN LAMP
TURNTABLE
AC(N)
AC120V
60Hz
1
2
3
MOTOR
6
Page 9
PARTS LIST
Note: The parts marked “∆” may cause undue microwave exposure.
The parts marked “*” are used in voltage more than 250V.
REF. NO.PART NO.DESCRIPTIONQ'TYCODE
ELECTRIC PARTS
1- 1QSW-MA131WRE0Secondary interlock switch & door sensing switch 2AG
1- 2FFS-BA020WRK0
1- 3FACCDA079WRE0Power supply cord 1AF
1- 4QSOCLA021WRE0Oven lamp socket 1AH
1- 5FH-DZA081WRK0High voltage rectifier 1AQ
*
1- 6RC-QZA228WRE0High voltage capacitor 1AT
*
1- 6RC-QZA201WRE0High voltage capacitor (Interchangeable) 1AW
*
1- 7RMOTEA355WRE0Fan motor 1AU
1- 7RMOTEA338WRE0Fan motor (Interchangeable)1AV
1- 8RV-MZA226WRE0Magnetron1BE
∆
*
1- 8RV-MZA282WRE0Magnetron (Interchangeable)1BP
∆
*
1- 9RLMPTA030WRE0Oven lamp 1AF
1-10RMOTDA211WRE0Turntable motor 1AS
1-10RMOTDA186WRE0Turntable motor (Interchangeable) 1AW
1-11RTHM-A078WRE0Thermal cut-out 125˚C 1AK
1-12RTRN-A561WRE0Power transformer 1BM
*
2- 1GCABUA696WRP0Outer case cabinet 1AF
2- 2GDAI-A304WRW0Bottom plate 1AF
2- 3GLEGPA074WRE0Foot 2AC
3- 1DPWBFB973WRU0Control unit1BA
3- 2FPNLCB426WRK0Control panel frame with key unit and LCD1BE
3- 2-1FUNTKA928WRE0Key unit1AY
3- 2-2RLCDSA045DRE0Liquid crystal display1AM
3- 3QCNC-A012WRE0Rubber connector1AF
3- 4XEPSD30P08XS0Screw; Control unit mtg.3AA
To have your order filled promptly and correctly, please furnish the following information.
1. MODEL NUMBER2. REF. NO.3. PART NO.4. DESCRIPTION
Order Parts from the authorized SHARP parts Distributor for your area.
Defective parts requiring return should be returned as indicated in the Service Policy.
PACKING AND ACCESSORIES
DOOR PROTECTION SHEET
SPADPA580WRE0
6-3 INSTRUCTION BOOK
6-2 TURNTABLE TRAY
MICROWAVE OVEN
6-1 TURNRABLE SUPPORT
INTO THE
OVEN CAVITY
TOP PAD ASSEMBLY
FPADBA387WRK0
POLYETHYLENG BAG
SSAKHA014WRE0
BOTTOM PAD ASSEMBLY
FPADBA388WRK0
TRAY PAD ASSY
(CPADBA244WRK0)
Not replaceable items.
8
PACKING CASE
SPAKCD416WREZ
Page 11
R-204CW
1
OVEN AND CABINET PARTS
A
1-4
B
C
4-3
4-2
4-17
4-14
2
1-2
1-9
7-8
6-9
4-14
7-9
3
45
6
7-11
7-10
2-1
7-11
A
7-10
B
7-1
1-8
7-9
C
6-7
6-10
7-12
4-5
6-10
1-3
D
4-6
7-5
7-5
D
4-7
7-5
4-11
A
6-11
A
1-7
7-1
1-6
4-9
7-8
E
F
G
E
6-2
7-3
4-16
1-11
7-7
7-6
4-4
1-5
1-10
1-12
4-10
4-1
1-1
1-2
1-1
4-8
7-2
F
6-1
7-1
4-15
G
2-2
7-4
2-3
4-13
7-8
H
7-8
2-3
7-4
H
4-12
7-8
1
2
3
45
6
9
Page 12
R-204CW
1
A
Before attaching Control unit to
Control panel, foil side of Control
2
3
45
6
A
unit must be cleaned by ethylalcohol.
B
3-2
3-2-2
3-1
3-3
CONTROL PANEL PARTS
3-4
DOOR PARTS
B
5-6
5-8
6-8
C
D
3-2-1
5-2
5-1
5-7
C
D
5-8
5-3
E
E
5-4
F
5-5
F
MISCELLANEOUS
G
6-4
Actual wire harness may be different than illustration.
No part of this publication may be reproduced, stored in retrieval systems, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher.
10
2000SHARP CORP. (5S2.530E) Printed in U.S.A
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