PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY
BEFORE SERVICING
MODEL
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 volta ge
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..)
CHAPTER 7. TROUBLESHOOTING GUIDE
CHAPTER 8. TEST PROCEDURES
CHAPTER 9. TOUCH CONTROL P ANEL ASSEMBL Y
R-209KK
CHAPTER 1. WARNING TO SERVICE PERSONNEL
CHAPTER 2. MICROWAVE MEASUREMENT PROCEDURE
CHAPTER 3. FOREWORD AND WARNING
CHAPTER 4. PRODUCT DESCRIPTION
CHAPTER 5. GENERAL INFORMATION
CHAPTER 6. OPERATION
SHARP CORPORATION
CHAPTER 10. PRECAUTIONS FOR USING LEADFREE SOLDER
CHAPTER 11. COMPONENT REPLACEMENT AND
ADJUSTMENT PROCEDURE
CHAPTER 12. CIRCUIT DIAGRAMS
Parts Guide
This document has been published to be used
for after sales service only.
The contents are subject to change without notice.
CONTENTS
PRECAUTIONS TO BE OBSERVED BEFORE AND
DURING SERVICING TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY
BEFORE SERVICING
CHAPTER 1. WARNING T O SER VICE PERSONNEL
[1] Before Servicing.........................................1-1
[2] When the testing is completed, ..................1-1
[3] After repairing.............................................1-1
PRECAUTIONS TO BE OBSERVED BEFORE AND DURING SERVICING TO AVOID
ServiceManual
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
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.
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 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.
2
i
R209KK
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.
ServiceManual
Don't Touch !
Danger High Voltage
[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 shortcircuit 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) 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.
[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.
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.
1 – 1
R209KK
R209KK
CHAPTER 2. MICROWAVE MEASUREMENT PROCEDURE
ServiceManual
[1] Requirements:
1. Microwave leakage limit (Power density limit): The power density of microwave rad iation emitted by a microwave oven should not exceed 1mW/
2
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
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
the external surface of the oven.
2
at any point 5cm or more from the external surface of the oven.
2
at any point 5cm or more from
[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°C (68°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. 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.
[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.
2
4. Measure carefully at the point of highest lea kage and make sure that the highest leakage is no greater than 4mW/cm
interlock switch and the primary interlock relay do turn the oven OFF before any door movement.
NOTE: After servicing, record data on service invoice and microwave leakage report.
, and that the secondary
2 – 1
R209KK
R209KK
CHAPTER 3. FOREWORD AND WARNING
ServiceManual
[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.
Check the interlock switches and the door seal carefully. Special attention should be given to avoid electrical shock and microwave radiation hazard.
[2] WA RNING
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 “ “ 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.
3 – 1
R209KK
CHAPTER 4. PRODUCT DESCRIPTION
ServiceManual
[1] SPECIFICATIONS
ITEMDESCRIPTION
Power Requirements
Power Consumption1170W / Approx. 10 Amperes
Power Output
Case Dimensions
Cooking Cavity Dimensions
(0.8 Cubic feet)
Control Complement
120 Volts
60 Hertz
Single phase, 3 wire grounded
800 W nominal of RF microwave energy (IEC Test procedure)
Operating frequency 2450 MHz
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. 30% of FULL Power
P-30 -------------------- approx. 40% 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
NOTE: Internal capacity is calculated by measuring
maximum width, depth and hight.
Actual capacity for holding food is less.
R209KK
POPCORN pad
SHORT CUTS pads
REHEAT pad
COOK pad
DEFROST pad
Number selection pads
TIMER / CLOCK pad
POWER LEVEL pad
START/MINUTE PLUS pad
STOP/CLEAR pad
This oven is equipped with a three prong grounding plug. It must be plugged into a w all 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:
Electrical Requirements
The electrical requirements are a 115 -120 volt 60 Hz, AC only, 15 or 20 amp. fused electrical supply. It 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 twopronged wall-receptacle is encountered, it is the personal responsibility and obligation of the customer to contact a qualified electrician and have it replaced with a properly grounded threepronged 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
Improper use of the grounding plug can re sult in a risk of electric shock.
GROUNDING PRONG FROM THIS PLUG.
[2] OVEN DIAGRAM
1. OVEN
1. Door open button
Push to open door.
2. Oven door with see-through window
3. Safety door latches
The oven will not operate unless the door is
securely closed.
4. Door hinges
5. Door seals and sealing surfaces
6. Turntable motor shaft
7. Removable turntable support
Carefully place the turntable support in the
center of the oven floor.
8. Removable turntable
Place the turntable securely on the turntable support. 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.
11.Waveguide cover: DO NOT REMOVE.
12.Auto-Touch control panel
13.Time display: 99 minutes, 99 seconds
5 – 1
2. TOUCH CONTROL PANEL
R209KK
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 – 2
R209KK
R209KK
CHAPTER 6. OPERATION
[1] DESCRIPTION OF OPERATING SEQUENCE
The following is a description of component functions during oven operation.
ServiceManual
1. OFF CONDITION
Closing the door activates 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.
through the noise filter (Figure O-1).
1) The display will show flashing "88:88".
2) To set any program or set the clock, touch the STOP/CLEAR pad.
The display will clear, and " : " will appear.
2. COOKING CONDITION
Program desired cooking time by touching the NUMBER pads. And
program the power level by touching the POWER LEVEL pad.
When the START pad is touched, the following operations occur:
1) 1.The contacts of the 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 transformer and is converted to about 3.35 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
oven lamp, turntable motor, the cooling fan 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.
a) When the door opens from the closed position, the secondary
interlock switch, door sensing switch and primary interlock relay
(RY2) open their contacts. Then the monitor switch contacts
close.
b) (2)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.
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, primary interlock relay (RY2) and secondary interlock switch,
causing the monitor fuse to blow.
3. POWER LEVEL 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 ON TIME 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 percent-
age of microwave power, because 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% powe r
level, after the first 20 minutes the power level will automatically adjust
itself to 70% power to avoid overcooking.
6 – 1
[2] OVEN SCHENATIC
1. Off Condition
SCHEMATIC
NOTE: CONDITION OF OVEN
1. DOOR CLOSED
2. CLOCK APPEARS ON DISPLAY
LN
FUSE
15A
THERMAL
CUT-OUT (OVEN)
or
TEMPERATURE
FUSE (OVEN)
NOTE: " " indicates components with potentials above 250V
N.O.
COM.
POWER
TRANSFORMER
R209KK
NOISE FILTER
120V AC
60 Hz
GRN
0.22µF / AC250V
LINE CROSS CAPACITOR
NOISE SUPPRESSION COIL
Figure O-1. Oven Schematic-Off Condition
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.
LN
FUSE
15A
CAPACITOR
LINE BYPASS
0.0033µF / AC250V
CAPACITOR
LINE BYPASS
0.0033µF / AC250V
A3
CONTROL UNIT
OLFM
OVEN
LAMP
SECONDARY
INTERLOCK
SWITCH
THERMAL
CUT-OUT (OVEN)
or
TEMPERATURE
FUSE (OVEN)
(RY-1)
TTM
TURNTABLE
MOTOR
NOTE: " " indicates components with potentials above 250V
A1
(RY-2)
B2B1
FAN
MOTOR
N.O.
PRIMARY
INTERLOCK
RELAY
DOOR
SENSING
SWITCH
COM.
MONITOR
SWITCH
POWER
TRANSFORMER
CAPACITOR
0.82µF
AC2100V
or
AC1900V
RECTIFIER
MAGNETRON
CAPACITOR
LINE BYPASS
0.0033µF / AC250V
NOISE FILTER
120V AC
60 Hz
GRN
0.22µF / AC250V
LINE CROSS CAPACITOR
NOISE SUPPRESSION COIL
CAPACITOR
LINE BYPASS
0.0033µF / AC250V
Figure O-2. Oven Schematic-Cooking Condition
TTM
(RY-1)
TURNTABLE
MOTOR
A3
CONTROL UNIT
OLFM
OVEN
LAMP
SECONDARY
INTERLOCK
SWITCH
6 – 2
A1
(RY-2)
B2B1
FAN
MOTOR
PRIMARY
INTERLOCK
RELAY
DOOR
SENSING
SWITCH
MONITOR
SWITCH
CAPACITOR
0.82µF
AC2100V
or
AC1900V
RECTIFIER
MAGNETRON
R209KK
[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
Heads
Switch Lever
Figure D-1. Door Open Mechanism.
Latch Hook
Door Sensing
Switch
Monitor Switch
Secondary
Interlock Switch
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. A cook cycle cannot 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.
2) As the door goes to a closed position, the monitor switch contacts
are first opened and then the door sensing switch and secondary
interlock switch contacts close.
3) 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 OPERA TION. (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 magnetron 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 cavity.
6. TEMPERATURE FUSE (OVEN)
The temperature fuse, 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 temperature fuse will open.
Under normal operation, the temperature fuse remains closed. However, when abnormally high temperatures are reached within the oven
cavity, 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 cutout 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 primary 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.
6 – 3
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