Sharp R-209EK User manual

15
R-209EK
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
MICROWAVE MEASUREMENT PROCEDURE ...................................................................................................2
FOREWORD AND WARNING...............................................................................................................................3
PRODUCT DESCRIPTION....................................................................................................................................4
TEST PROCEDURE..............................................................................................................................................6
PICTORIAL DIAGRAM ..........................................................................................................................................7
CONTROL PANEL CIRCUIT .................................................................................................................................8
PARTS LIST ..........................................................................................................................................................9
PACKING AND ACCESSORIES .........................................................................................................................13
S4111R209EPK/
MICROWAVE OVEN
MODEL R-209EK
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-209EK. This model is quite similar to base
model R-220EW. Use this supplemental manual together with the Base Model Service Manual
(Refer No. is S0101R220EPW/) for complete operation, service information, etc..
EXPRESS
DEFROSTPOPCORNMINUTE
PLUS
Power
Level
Stop
Clear
Timer
Clock
START
BAKED
POTATOESFRESH
VEGETABLES
FROZEN
ENTREESDINNER
PLATE
BEVERAGEROLLS
MUFFINS
TOADJUSTQUANTITYTOUCHSAMEPADAGAIN
DEF.LBS.QTY.
CHECK
ON

16
R-209EK
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.
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.

1
R-209EK
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. 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
secondsaftertheovenhasbeenswitchedoff.Waitfor60
secondsandthenshort-circuittheconnectionofthehigh-
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
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 cordafterthe outercaseis
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 cordafterthe outercaseis
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 minutes haselapsed (timerat zero)
carefully check that the water is now hot. If the water
remainscoldcarryoutBeforeServicing procedureandre-
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-209EK
MICROWAVE MEASUREMENT PROCEDURE
A. Requirements:
1) Microwave leakage limit (Power density limit): The power density of microwave radiation emitted by a microwave oven
shouldnotexceed1mW/cm2atanypoint5cmormorefromtheexternalsurfaceoftheoven,measuredpriortoacquisition
bya purchaser,and thereafter (throughthe usefullife ofthe oven),5 mW/cm2atany point5cm or morefrom the external
surface of the oven.
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/cm2at any point 5cm or more from the external surface of the oven.
B. 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±15 ml (9.8 oz) of tap water initially at 20±5˚C (68˚F) in the center of the oven cavity.
Thewater containershall bealow formof 600ml (20oz)beaker withan insidediameterof approx.8.5 cm(3-1/2in.) 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.
C. Leakage test:
Closed-door leakage test (microwave measurement)
1) Grasptheprobeofthesurveyinstrumentandholditperpendicularto the gap between thedoorandthebodyoftheoven.
2) Movethe probe slowly,not fasterthan 1in./sec. (2.5cm/sec.) alongthe gap,watching forthe maximumindication onthe
meter.
3) Checkforleakageatthedoorscreen,sheetmetalseamsandotheraccessiblepositionswherethecontinuityofthemetal
has been breached (eg., around the switches, indicator, and vents).
Whiletestingforleakagearoundthedoorpullthedoor away from the frontoftheovenasfarasis permitted by the closed
latch assembly.
4) Measure carefully at the point of highest leakage and make sure that the highest leakage is no greater than 4mW/cm2.
NOTE: After servicing, record data on service invoice and microwave leakage report.

3
R-209EK
SHARP ELECTRONICS CORPORATION
SHARP PLAZA, MAHWAH,
NEW JERSEY 07430-2135
SERVICE MANUAL
MICROWAVE OVEN
R-209EK
FOREWORD
This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service
Information for the SHARP MICROWAVE OVEN, R-209EK.
The model R-209EK is quite similar to base model R-220EW (Refer No. is S0101R220EPW/).
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.
Alltheparts marked “∆” on partslistmaycauseunduemicrowaveexposure,bythemselves,orwhentheyaredamaged,
loosened or removed.

4
R-209EK
ITEM DESCRIPTION
Power Requirements 120 Volts
60 Hertz
Single phase, 3 wire grounded
Power Consumption 1200W / Approx. 10.2 Amperes
Power Output 800 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"
(0.8 Cubic feet) Height 8-3/8"
Depth 13"
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
POPCORN pad, MINUTE PLUS pad
REHEAT CENTER pad, Instant Start pads
EXPRESS DEFROST pad
Number selection pads, CLOCK pad
KITCHEN TIMER pad, POWER LEVEL pad
STOP/CLEAR pad, START pad
Oven Cavity Light Yes
Safety Standard UL Listed.
FCC Authorized
DHHS RUles, CFR, Title 21, Chapter 1, Subchapter J
PRODUCT DESCRIPTION
SPECIFICATIONS

5
R-209EK
TOUCH CONTROL PANEL
NOTE:
The directed features 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.
EXPRESS
DEFROST POPCORN MINUTE PLUS
Power
Level
Stop
Clear
Timer
Clock
START
BAKED
POTATOES FRESH VEGETABLES
FROZEN
ENTREES DINNER PLATE
BEVERAGE ROLLS
MUFFINS
TO ADJUST QUANTITY TOUCH SAME PAD AGAIN
See note
See note
Figure O-1. Oven Schematic-Off Condition
SCHEMATIC
NOTE: CONDITION OF OVEN
1. DOOR CLOSED
2. CLOCK APPEARS ON DISPLAY NOTE: " " indicates components with potential above 250V.
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

6
R-209EK
TEST PROCEDURES (CONT'D)
COMPONENT TEST
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
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
connector). 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.
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.
LEXPRESS DEFROST TEST
(1) Place one cup of water in the center of the turntable tray in the oven cavity.
(2) Close the door, touch the " EXPRESS DEFROST " pad once for 0.5lbs in weight.
(3) The oven is in Express Defrost cooking condition.
(4) The oven will operate as follows.
MENU 1ST STAGE 2ND STAGE 3RD STAGE 4TH STAGE
EXPRESS DEFROST LEVEL TIME LEVEL TIME LEVEL TIME LEVEL TIME
0.5lb 70% 57sec. 0% 57sec. 50% 32sec. 30% 45sec.
(5) If improper operation is indicated, the control unit is probably defective and should be checked.
1
2
345
6
7
89
0
POPCORN START
Power
Level
Timer
Clock
MINUTE
PLUS
FRESH
VEGETABLES
EXPRESS
DEFROST
ROLLS
MUFFINS
DINNER
PLATE
BAKED
POTATOES
BEVERAGE
FROZEN
ENTREES
G 6 G 5 G 4 G 3 G 2 G 1
G 7
G 8
G 9
G10
Stop
Clear

7
R-209EK
6
45
123
6
45
123
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
WHT
RED
WHT
WHT
HIGH VOLTAGE COMPONENTS
MAGNETRON
HIGH VOLTAGE CAPACITOR
H.V. RECTIFIER
MONITOR SWITCH
TURNTABLE MOTOR
FAN MOTOR
OVEN LAMP
GRY
SECONDARY INTERLOCK SWITCH
COM
COM
ORG
GRY
RED
GRY
N.C.
N.O.
N.O.
COM
GRY
GRN GRN
GRY
RED
WHT
C/T FUSE
To chassis support
POWER SUPPLY CORD 120V 60Hz
GRD
HN
NOTE: The grounding conductor of the power supply cord has been grounded by power supply cord fixing screw. The screw must always be kept tight.
NOTE: The neutral (WHT) wire must be connected to the terminal with "N" mark on the power supply cord.
RED
WHT
DOOR SENSING SWITCH
GRY
RED
POWER TRANSFORMER
HIGH VOLTAGE WIRE B
BLK
WHT
GRN
GRY
ORG
ORG
WHT
ORG
MAGNETRON THERMAL CUT-OUT
BLK
ORG
RED
ORG
WHT
CN-A
2
ORG
1 3
CN-B
2 1
GRN
GRY
ORG
CONTROL UNIT
SP1
RY1
CN-B
2
1
CN-A
31
RY2
Figure S-1. Pictorial Diagram

8
R-209EK
6
45
123
6
45
123
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
Figure S-2. Control Panel Circuit
+
–
+
–
+
–
A 3 A 1
NO
COM
G10
G 9 G 8 G 7
G 6 G 5 G 4 G 3 G 2 G 1
B 2
B 1
AC(N) T1
POWER UNIT
ab
d
c
RY1
D1 D2
D3
R4 910 1/2w
VR
R41 15k
NOTE : IF NOT SPECIFIED, 1SS270A
: IF NOT SPECIFIED, 1/10W ±5%
R70 15k R71 15k R72 15k R73 15k
R40 4.7k
R78 220k
R77 220k
R76 220k
R67
15k
R66
15k
R65
15k
R64
15k
R63
15k
R62
15k
R75 220k
C63 330p/50v
C62 330p/50v
C61 330p/50v
C60 330p/50v
D22 D40
Q10 DTA143EKA
Q30 DTA143EKA
Q20 DTA143EKA
Q22 DTA143ES
Q21 DTD143ES
Q1 2SA1037AK
D1-D4 11ES1
1 2 3 4 5 6 7
IC1 IXA078DR
D4
VRS1 10G471K
C2 470µ/25v
R30
3.3k 1/4w
C1 0.1µ/50v
C10
0.1µ
/25v
C20 0.1µ /25v
C8 47µ/16v
C21 10µ/35v
R10 15k
R50 20kF
R20 15k
R6 15k
R5
1k
HZ4C3
ZD1
C3 0.01µ/25v
C40 0.01µ/25v
C5 0.1µ/25v
C6 0.1µ/25v
C7 0.1µ /25v
C4
S12
SEG19
VC3
B Z
R00
R01
R02
R03
P20
P21
P22
P23
K00
K01
K02
K03
COM0
COM1
VC2
VC1
SEG18
SEG17
SEG16
SEG15
SEG14
SEG13
S11
S10
S 9
S 8
S 7
S 6
S 5
S 4
S 3
S 2
S 1
C 1
C 2
C 3
0.01µ
/25v
C11 0.01µ/25v
SP1
PKM22EPT
D20
(J1)
D21
RY2
AC120V 60Hz
OVEN LAMP TURNTABLE MOTOR FAN MOTOR
DOOR SENSING SWITCH
MICRO
AC(H)
GND
(J15) 4.7k (J11) 10k
(J12) 20k (J13) 4.7k
15 29
30 44
4554
1 14
(J14)
RESET SEG12
SEG11 SEG10
SEG9 SEG8 SEG7 SEG6 SEG5 SEG4 SEG3 SEG2 SEG1 SEG0
COM3 COM2
TEST
VSS
OCS3 OCS4
VD1
VDD
AVDD
AVREF
AVSS
P40 P41 P42 P43
FRESH
VEGETABLES
Power
Level
Stop
Clear
ROLLS
MUFFINS
DINNER
PLATE MINUTE
PLUS
BAKED
POTATOES
START
EXPRESS
DEFROST
POPCORN
BEVERAGE
6 3 9
2 5 0 8
4 1 7
CPU UNIT
ON DEF. LBS QTY. CHECK
LIQUID CRYSTAL DISPLAY
KEY UNIT
VC
GND
GND
Timer
Clock
FROZEN
ENTREES
(J10) 7.5k