Sharp R-209BW User manual

R-209BW
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
S6013R209BPW/
MICROWAVEOVEN
MODEL R-209BW
Intheinterestofuser-safetytheovenshouldberestoredtoitsoriginal
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
VoltagePowerTransformer,Magnetron,HighVoltageRectifier
Assembly, High Voltage Harness etc..)
SHARP CORPORATION This document has been published to be used for after
sales service only.
The contents are subject to change without notice.
SUPPLEMENTAL SERVICE MANUAL
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..
DEFROST
EXPRESS MINUTE
PLUS
SNACKS
COOKING
REHEATING
POPCORN BEVERAGE
BAKED FRESH
POTATO
VEGETABLES
DINNER
PLATE ROLL,
MUFFIN

R-209BW
PRECAUTIONS TO BE OBSERVED BEFOREAND
DURING SERVICING TOAVOID 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.
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.
ServicepersonnelshouldinformSHARPELECTRONICSCORPORATIONofanycertifiedunitfound
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.

1
R-209BW
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)
HighVoltageCapacitor,HighVoltagePowerTrans-
former,Magnetron,HighVoltageRectifierAssem-
bly, High Voltage Harness etc..
Read the Service Manual carefully and follow all
instructions.
Before Servicing
1. Disconnectthe powersupply cord ,and thenremove
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
secondsaftertheovenhasbeenswitchedoff.Waitfor60
secondsandthenshort-circuittheconnectionofthehigh-
voltagecapacitor (thatisthe connectingleadofthehigh-
voltage rectifier) against the chassis with the use of an
insulated screwdriver.
Whenever troubleshooting is performed the power supply
mustbedisconnected.Itmay,insomecases,benecessary
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. Reconnectthe powersupply cordafter theoutercase 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. Reconnectthe powersupply cordafter theoutercase 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 thetwo minuteshas elapsed(timer atzero)
carefully check that the water is now hot. If the water
remainscoldcarryoutBeforeServicingprocedureandre-
examine the connections to the component being tested.
When all service work is completed and the oven is fully
assembled,themicrowavepoweroutputshouldbechecked
and a microwave leakage test should be carried out.
Don't Touch !
Danger High Voltage

2
R-209BW
SHARP ELECTRONICS CORPORATION
SHARP PLAZA, MAHWAH,
NEW JERSEY 07430-2135
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
Certaininitialpartsareintentionallynotgroundedandpresentariskofelectricalshockonlyduringservicing.
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
R-209BW
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
PRODUCT DESCRIPTION
SPECIFICATIONS

4
R-209BW
TOUCH CONTROL PANEL
DEF. LBS. QTY. CHECK ON
Time display
Indicator
DEFROST
EXPRESS MINUTE
PLUS
SNACKS
COOKING
REHEATING
POPCORN BEVERAGE
BAKED FRESH
POTATO
VEGETABLES
DINNER
PLATE ROLL, MUFFIN
POWER
TRANSFORMER
RECTIFIER MAGNETRON
CAPACITOR
0.86µF
C/T FUSE
120V AC
60 Hz
OVEN
LAMP TURN-
TABLE
MOTOR FAN
MOTOR
MONITOR
SWITCH
SECONDARY
INTERLOCK
SWITCH
TTM
OL FM
GRN
A3
COM.
N.O.
DOOR
SENSING
SWITCH
B1 B2
(RY-1) (RY-2)
CONTROL UNIT
PRIMARY
INTERLOCK
RELAY
MAGNETRON
THERMAL CUT-OUT
A1
SCHEMATIC
NOTE: CONDITION OF OVEN
1. DOOR CLOSED
2. CLOCK APPEARS ON DISPLAY
Figure O-1. Oven Schematic-Off Condition

5
R-209BW
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
ismakinggoodcontact,verifythatthedoorsensingswitch(stopswitch)operatesproperly;thatisthe
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
unitand makesurethedoorsensing switchisclosed (eitherclosethedooror shortthedoor sensing
switch connecter). Use the Key unit matrix indicated on the control panel schematic and place a
jumperwirebetweenthepinsthatcorrespondtotheSTOP/CLEAR padmakingmomentarycontact.
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.
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.
TEST PROCEDURES
PROCEDURE
LETTER COMPONENT 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. Ensurethattheseleadsremainisolatedfromothercomponentsandovenchassisbyusinginsulation
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 unit is defective.
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
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.
KRELAY TEST
1
2
345
6
7
89
0
POWER
LEVEL
DINNER
PLATE
MINUTE
PLUS
BAKED
POTATO
EXPRESS
DEFROST
POPCORN START
BEVERAGE
FRESH
VEGETABLES
ROLL,
MUFFIN TIMER
CLOCK
G 6 G 5 G 4 G 3 G 2 G 1
G 7
G 8
G 9
G10
STOP
CLEAR

6
R-209BW
TEST PROCEDURES
PROCEDURE
LETTER COMPONENT 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.
Checkforburneddamageandexaminethe
transformerwithatesterforthepresenceof
layer short-circuit (check the primary coil
resistance which is approximately 563Ω±
10%).Ifanyabnormalconditionisdetected,
replace the control unit.
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.
M FOIL PATTERN ON THE PRINTED WIRING BOARD TEST
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
1
P
RY1 a
b
cd
RY2
(J1)

7
R-209BW
TEST PROCEDURES
PROCEDURE
LETTER COMPONENT TEST
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.
The touch control section consists of the following units as
shown in the touch control panel circuit.
(1) Key Unit
(2) Control Unit
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
theLSIaresenttothekeyunitthroughR00,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 syn-
chronizing signal circuit.
1) ACL
ThiscircuitgeneratesasignalwhichresetstheLSItothe
initial state when power is supplied.
2) Indicator Circuit
This circuit consists of 4-digits, 12-segments and 3-
common electrodes using a Liquid Crystal Display.
TOUCH CONTROL PANEL ASSEMBLY
OUTLINE OF TOUCH CONTROL PANEL
3) Power Source Circuit
This circuit generates voltage necessary in the control
unitfromtheAClinevoltage.Inaddition,thesynchronizing
signal is available in order to compose a basic standard
time in the clock circuit.
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
audiblesounds(keytouchsoundandcompletionsound).
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.

8
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.
16 R00 OUT Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P23, K00, K01 and K02
terminal while one of G6 line keys on key matrix is touched.
17 R01 OUT Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P23, K00, K01 and K02
terminal while one of G5 line keys on key matrix is touched.
18 R02 OUT Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P23, K00, K01 and K02
terminal while one of G4 line keys on key matrix is touched.
19 R03 OUT Key strobe signal.
SigMnalappliedtotouch-keysection.ApulsesignalisinputtoP23,K00,K01andK02
terminal while one of G3 line keys on key matrix is touched.
20 P20 OUT Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P23, K00, K01 and K02
terminal while one of G2 line keys on key matrix is touched.
21 P21 OUT Key strobe signal.
Signal applied to touch-key section. A pulse signal is input to P23, K00, K01 and K02
terminal while one of G1 line keys on key matrix is touched.
22 P22 OUT Terminal not used.
A
B
0.1 sec.
2.0 sec.
H : GND
L : -5V
H : GND
L : -5V