SHARP R209BW Service Manual

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R-209BW

SUPPLEMENTAL SERVICE MANUAL

S6013R209BPW/

MICROWAVE OVEN

EXPRESS MINUTE DEFROST

SNACKS

POPCORN BEVERAGE

COOKING

BAKED FRESH

POTATO

VEGETABLES

REHEATING

DINNER PLATE

MODEL

PLUS

In the interest of user-safety the oven should be restored to its original

ROLL, MUFFIN

condition and only parts identical to those specified should be used.

WARNING TO SERVICE PERSONNEL: Microwave ovens con-

R-209BW

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 Rectifier Assembly, High Voltage Harness etc..)

This is a supplemental Service Manual for Model R-209BW. This model is quite similar to base model R-209BK. Use this supplemental manual together with the Base Model Service Manual (Refer No. is S1803R220BPW/) 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

PRODUCT DESCRIPTION....................................................................................................................................3

TEST PROCEDURE ..............................................................................................................................................5

TOUCH CONTROL PANEL ASSEBLY .................................................................................................................7

CONTROL PANEL CIRCUIT ...............................................................................................................................10

PARTS LIST ........................................................................................................................................................11

PACKING AND ACCESSORIES .........................................................................................................................12

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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R-209BW

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.

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.

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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-209BW

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.

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R-209BW

SERVICE MANUAL

MICROWAVE OVEN

R-209BW

FOREWORD

This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service Information for the SHARP MICROWAVE OVEN, R-209BW.

The model R-209BW is quite similar to base model R-209BK (Refer No. is S1803R220BPW/). 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

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PRODUCT DESCRIPTION

SPECIFICATIONS

ITEM DESCRIPTION

Power Requirements 120 Volts

60 Hertz

Single phase, 3 wire grounded Power Consumption 1100W / Approx. 9.5 Amperes Power Output 700 W nominal of RF microwave energy (IEC Test procedure)

Operating frequency 2450 MHz Case Dimensions Width 18-1/8"

Height 11-3/8"

Depth 14-5/8" Cooking Cavity Dimensions Width 12-3/8"

(0.7 Cubic feet) Height 7-7/8"

Depth 12-5/8" 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

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

EXPRESS DEFROST pad MINUTE PLUS pad Instant Start pads Number selection pads TIMER / CLOCK pad POWER LEVEL pad START pad STOP/CLEAR pad

Oven Cavity Light Yes Safety Standard UL Listed.

FCC Authorized DHHS RUles, CFR, Title 21, Chapter 1, Subchapter J

R-209BW

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R-209BW

TOUCH CONTROL PANEL

Time display

DEF. LBS. QTY.

EXPRESS MINUTE DEFROST

POPCORN BEVERAGE

BAKED FRESH

POTATO

DINNER

PLATE

SNACKS

COOKING

VEGETABLES

REHEATING

PLUS

ROLL,

MUFFIN

CHECK

Indicator

SCHEMATIC

NOTE: CONDITION OF OVEN

1. DOOR CLOSED

2. CLOCK APPEARS ON DISPLAY

120V AC 60 Hz

GRN

C/T FUSE

CONTROL UNIT

OL FM

OVEN LAMP

SECONDARY INTERLOCK SWITCH

MAGNETRON THERMAL CUT-OUT

(RY-1)

TTM

TURNTABLE MOTOR

COM.

(RY-2)

B1 B2

FAN MOTOR

PRIMARY INTERLOCK RELAY

DOOR SENSING SWITCH

N.O.

MONITOR SWITCH

POWER TRANSFORMER

CAPACITOR

0.86µF

RECTIFIER

MAGNETRON

Figure O-1. Oven Schematic-Off Condition

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TEST PROCEDURES

R-209BW

PROCEDURE

LETTER

J 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. If the display fails to clear when the STOP/CLEAR pad is depressed, first verify the flat ribbon cable

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

is 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 6 G 5 G 4 G 3 G 2 G 1

G 7

G 8

G 9

BEVERAGE

FRESH

VEGETABLES

ROLL,

MUFFIN

6 3

TIMER

CLOCK

DINNER

PLATE

MINUTE

PLUS

EXPRESS

DEFROST

BAKED

POTATO

POWER

LEVEL

STOP

CLEAR

K RELAY 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

RELAY SYMBOL OPERATIONAL VOLTAGE CONNECTED COMPONENTS

RY1 Approx. 14.6V D.C. Oven lamp / Turntable motor / Cooling fan motor RY2 Approx. 13.0V D.C. Power transformer

G10

is good, control unit is defective.

POPCORN START

8. If any abnomal 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.

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R-209BW

TEST PROCEDURES

PROCEDURE

LETTER

11. Discharge high voltage capacitor.

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

M FOIL PATTERN ON THE PRINTED WIRING BOARD TEST

To protect the electronic circuits, this model is provided with a fine foil pattern added to the primary on the PWB, this foil pattern acts as a fuse.

1. Foil pattern check and repairs.

1) Disconnect the power supply cord and then remove outer case.

2) Open the door and block it open.

3) Discharge high voltage capacitor.

4) Follow the troubleshooting guide given below for repair.

STEPS OCCURRENCE CAUSE OR CORRECTION

1 Only pattern at "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 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

(J1)

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.

STEPS OCCURRENCE CAUSE OR CORRECTION

The rated AC voltage is not present between

1 Pin No. 3 of the 2-pin connector (A) and the Check supply voltage and oven power cord.

common terminal of the relay RY2.

2 The rated AC voltage is present at primary Low voltage transformer or secondary circuit defective.

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.

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TEST PROCEDURES

R-209BW

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.

Symbol Voltage Application

VC -5V LSI(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.

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R-209BW

DESCRIPTION OF LSI

The I/O signal of the LSI are detailed in the following table.

Pin No. Signal I/O Description

1 RESET IN Auto clear terminal.

Signal is input to reset the LSI to the initial state when power is supplied. Temporarily set to “L” level the moment power is supplied, at this time the LSI is reset. Thereafter

set at “H” level. 2 TEST IN Connected to GND. 3 VSS IN Power source voltage: -5V.

VSS voltage of power source circuit input. Connected to VC. 4 OCS3 IN Internal clock oscillation frequency setting input.

The internal clock frequency is set by inserting the resistor oscillation circuit with

respect to OCS4 terminal. 5 OCS4 OUT Internal clock oscillation frequency control output.

Output to control oscillation input of OCS3. 6 VD1 IN Power source for oscillation circuit.

7 VDD IN Power source voltage input terminal.

Connected to GND. 8 AVDD IN A/D converter power source voltage.

The power source voltage to drive the A/D converter in the LSI. Connected to GND. 9 AVREF IN A/D converter power source voltage.

The power source voltage to drive the A/D converter in the LSI. Connected to GND. 10 AVSS IN Power source voltage: -5V.

AVSS voltage of power source circuit input. Connected to VC. 11-13 P40-P42 IN Terminal to change functions 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 function. 14 P43 IN To input signal which communicates the door open/close information to LSI.

Door close “H” level signal (0V). Door open “L” level (-5V). 15 BZ OUT Signal to sound buzzer (2.0 kHz).

A: key touch sound.

B: Completion sound.

0.1 sec.

2.0 sec.

H : GND L : -5V

H : GND

L : -5V

16 R00 OUT Key strobe signal.