Sharp R-630DKA User manual

15
R-630DKA
R-630DSA
R-630DWA
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
Voltage Power Transformer, Magnetron, High Voltage Recti-
fier Assembly, High Voltage Harness etc..)
S7118R630DPWA
R-630DKA
R-630DSA
R-630DWA
MICROWAVE OVEN
MODELS
SERVICE MANUAL
SHARP CORPORATION This document has been published to be used for after
sales service only.
The contents are subject to change without notice.
Breakfast
Bar
SensorCooking
MorefromyourMicrowave
Vegetables
Popcorn
Linchon
theRun
Super
DefrostCompu
Defrost
OneDish
Dinners
Beverage
center
Frozen
Foods
Main
EntreesKitchen
Timer/Clock
Sensor
Reheat
Baked
PotatoesCustom
HelpPower
Level
STOP
ClearSTART
Touchon
Minute
PLus
12345
67890
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
OVEN SCHEMATIC...............................................................................................................................................5
TEST PROCEDURE..............................................................................................................................................5
COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE..................................................................6
PICTORIAL DIAGRAM ..........................................................................................................................................8
PARTS LIST ..........................................................................................................................................................9
PACKING AND ACCESSORIES .........................................................................................................................11
ThisisasupplementalServiceManualforModelsR-630DKA,R-630DSAandR-630DWA.These
modelsarequitesimilartobasemodelsR-630DK,R-630DSandR-630DW.Usethissupplemen-
tal manual together with the Base Model Service Manual (Refer No. is S7017R630DPW/) for
complete operation, service information, etc..

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R-630DKA
R-630DSA
R-630DWA
PRECAUTIONSTOBEOBSERVEDBEFOREAND
DURING SERVICING TO AVOID POSSIBLE EX-
POSURETOEXCESSIVEMICROWAVEENERGY
(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
microwavesource,andmakerepairsasnecessary:(1)interlockoperation,(2)properdoorclosing,(3)
sealand sealing surfaces(arcing,wear, and otherdamage),(4) damage toorloosening of hingesand
latches, (5) evidence of dropping or abuse.
(c) Beforeturning onmicrowave power forany servicetestor inspectionwithin the microwavegenerating
compartments,checkthemagnetron,waveguideortransmissionline,andcavityforproperalignment,
integrity, and connections.
(d) Any defective or misadjusted components in the interlock, monitor, door seal, and microwave
generationandtransmissionsystemsshallberepaired,replaced,oradjustedbyproceduresdescribed
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 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-630DKA
R-630DSA
R-630DWA
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-
voltagecapacitor(that istheconnectingleadof thehigh-
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 powersupplycord aftertheouter caseis
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 powersupplycord aftertheouter caseis
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 minuteshaselapsed (timerat zero)
carefully check that the water is now hot. If the water
remainscold,carryoutBeforeServicingprocedureandre-
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

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R-630DSA
R-630DWA
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
byapurchaser,and thereafter (throughthe usefullifeoftheoven),5 mW/cm2atany point 5cmor morefromtheexternal
surface of the oven.
2) Safety interlock switches: Primary interlock relay and door sensing switch shall prevent microwave radiation emission
inexcessoftherequirementasabovementioned,secondaryinterlockswitchshallpreventmicrowaveradiationemission
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.
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.
Theplacing ofthisstandard loadin the ovenis importantnotonly toprotectthe oven,but also toinsure that anyleakage
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) Grasptheprobeofthesurveyinstrumentandholditperpendiculartothegapbetweenthedoorandthebodyoftheoven.
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) Checkforleakageatthedoorscreen,sheetmetalseamsandotheraccessiblepositionswherethecontinuityofthemetal
has been breached (eg., around the switches, indicator, and vents).
Whiletestingforleakagearoundthedoorpullthedoorawayfromthefrontoftheovenasfarasispermittedbytheclosed
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-630DKA
R-630DSA
R-630DWA
SHARP ELECTRONICS CORPORATION
SHARP PLAZA, MAHWAH,
NEW JERSEY 07430-2135
SERVICE MANUAL
MICROWAVE OVEN
R-630DKA/ R-630DSA/ R-630DWA
FOREWORD
This Manual has been prepared to provide Sharp Electronics Corp. Service Personnel with Operation and Service
Information for the SHARP MICROWAVE OVEN, R-630DKA, R-630DSA, R-630DWA.
The models R-630DKA, R-630DSA, R-630DWA are quite similar to base models R-630DK, R-630DS and R-630DW
(Refer No. is S7017R630DPW/).
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.

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R-630DKA
R-630DSA
R-630DWA
ITEM DESCRIPTION
Power Requirements 120 Volts / 14 Amperes
60 Hertz
Single phase, 3 wire grounded
Power Output 1100 watts (IEC TEST PROCEDURE)
Operating frequency of 2450MHz
Case Dimensions Width 19-1/2"
Height 14"
Depth 20-5/8"
Cooking Cavity Dimensions Width 17-3/4"
Height 8-1/4"
1.4 Cubic Feet Depth 17"
Control Complement Touch Control System
Clock ( 1:00 - 12:59 )
Timer (0 - 99 min. 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
Breakfast Bar pad, Lunch on the Run pad, One Dish Dinners pad
Super Defrost pad, Compu Defrost pad, Beverage Center pad
Sensor Cooking pads, Custom Help pad, Kitchen Timer/Clock pad
Number selection pads, Power Level pad, Minute Plus pad
STOP/Clear pad, START/Touch On pad
Oven Cavity Light Yes
Safety Standard UL Listed FCC Authorized
DHHS Rules, CFR, Title 21, Chapter 1, Subchapter J
SPECIFICATION

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R-630DKA
R-630DSA
R-630DWA
Figure O-1. Oven Schematic-Off Condition
SCHEMATIC
NOTE: CONDITION OF OVEN
1. DOOR CLOSED
2. CLOCK APPEARS ON DISPLAY
120V AC
60 Hz
OVEN
LAMP
TURN-
TABLE
MOTOR FAN
MOTOR
POWER
TRANSFORMER
MONITOR
SWITCH
RECTIFIER MAGNETRON
SECONDARY
INTERLOCK
SWITCH
TTM
OL FM
MONITOR
FUSE 20A
A1
A2
N.O.
COM.COM.
N.O.
DOOR
SENSING
SWITCH
(RY-1) (RY-2)
CONTROL UNIT
PRIMARY
INTERLOCK
RELAY
THERMAL
CUT-OUT (OVEN) THERMAL
CUT-OUT (MG.)
GRN
F3
F1 F2
AH SENSOR
B2 B1
CAPACITOR 0.94µF AC 2200V
BPOWER TRANSFORMER TEST
TEST PROCEDURES
PROCEDURE
LETTER COMPONENT TEST
1. Disconnect the power supply cord, and then remove outer case.
2. Open the door and block it open.
3. Discharge the high voltage capacitor.
4. Disconnect the primary input terminals and measure the resistance of the transformer with an
ohmmeter. Check for continuity of the coils with an ohmmeter. On the R x 1 scale, the resistance of
the primary coil should be less than 1 ohm and the resistance of the high voltage coil should be
approximately 77 ohms; the resistance of the filament coil should be less than 1 ohm.
5. Reconnect all leads removed from components during testing.
6. Reinstall the outer case (cabinet).
7. Reconnect the power supply cord after the outer case is installed.
8. Run the oven and check all functions.
(HIGHVOLTAGESAREPRESENTATTHE HIGH VOLTAGE TERMINAL,SO DONOT ATTEMPT TO
MEASURE THE FILAMENT AND HIGH VOLTAGE.)

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R-630DKA
R-630DSA
R-630DWA
3. Door is positioned with its face pressed toward cavity
face plate.
4. Check for microwave leakage around door with an
approvedmicrowavesurveymeter. (RefertoMicrowave
Measurement Procedure.)
Note: The door on a microwave oven is designed to act as
an electronic seal preventing the leakage of
microwaveenergyfromovencavityduringcookcycle.
This function does not require that door be air-tight,
moisture(condensation)-tightorlight-tight.Therefore,
occasional appearance of moisture, light or sensing
ofgentlewarmair movement aroundovendoorisnot
abnormalanddonotofthemselvesindicatealeakage
of microwave energy from oven cavity.
Figure C-7. Door Replacement
Figure C-8. Routing of 12-pin wire harness
SEALER FILM
Installation
1. Put the adhesive tape on the backing film of the sealer
film as shown in Fig. C-9.
2. Tear the backing film by pulling the adhesive tape.
3. Put the pasted side of the sealer film on the door panel.
Figure C-9. Sealer film
REMOVAL
1. Disconnect the power supply cord and then remove the
outer case.
2. Open the door slightly.
3. Todischargehighvoltagecapacitor,waitfor 60seconds.
4. Disconnect the 12-pin wire harness from the power unit
on the base plate.
5. Insert a putty knife (thickness of about 0.5mm) into the
gap between the choke cover and door frame as shown
in Figure C-6 to free engaging parts.
6. Pry the choke cover by inserting a putty knife as shown
Figure C-6.
7. Release choke cover from door panel.
8. Now choke cover is free.
NOTE: Whencarryingout anyrepairtothe door, donot
bend or warp the slit choke (tabs on the door
panelassembly)to prevent microwaveleakage.
Figure C-6. Door Disassembly
9. Release two (2) pins of door panel from two (2) holes of
upper and lower oven hinges by lifting up.
10.With pulling out the 12-pin wire harness from the hole of
the oven cavity front plate and the front leg, remove the
door from the oven cavity.
11.Now, the door is free from the oven cavity.
REINSTALLATION
1. Insertthe12-pinwireharnesstotheholesofthefrontleg
and the oven cavity front plate.
2. Catchtwo(2) pinsofdoorpanelon two(2)holeof upper
and lower oven hinges.
3. Re-install choke cover to door panel by pushing.
4. Connectthe12-pinwireharnesstothepowerunitonthe
base plate.
5. Now the door is installed.
Note: After any service to the door;
(A) Makesurethatdoorsensingswitchandsecondary
interlock switch are operating properly. (Refer to
chapter “Test Procedures”.).
(B) An approved microwave survey meter should be
usedto assure compliance with propermicrowave
radiation emission limitation standards.
After any service, make sure of the following :
1. Door latch heads smoothly catch latch hook through
latch holes and that latch head goes through center of
latch hole.
2. Deviationofdooralignmentfromhorizontallineofcavity
face plate is to be less than 1.0mm.
DOOR REPLACEMENT
Putty knife
Door frame
Choke cover
COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE
Upper oven hinge
Upper
oven
hinge
Slit choke of
door panel
Lower oven
hinge
Lower
oven
hinge
Choke cover
Pin
Pin
Tab
Hole
Door Screen
Hole
Front leg
Oven cavity front plate
12-pin wire harness
12-pin wire
harness
Power unit
Base plate
Door
Front leg
Sealer film Backing film
Adhesive tape

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R-630DKA
R-630DSA
R-630DWA
DOOR PANEL
1. Disconnect the power supply cord.
2. Remove the door from the oven. Refer to "DOOR
REPLACEMENT".
3. To discharge the high voltage capacitor, wait for 60
seconds.
4. The choke cover should have been removed.
5. Remove the five (5) screws holding the door panel to
the door frame.
6. Remove the two (2) screws holding the handle mounting
angle to the door panel.
7. Now, door panel is free.
HANDLE
8. Remove the two (2) screws holding the handle mounting
angle to the handle through the door frame.
9. Now, the handle is free.
LATCH HEAD AND LATCH SPRING
8. Slide the latch head and remove it from the door frame
with releasing the latch spring from the door frame and
the latch head.
9. Now, the latch head and the latch spring are free.
CPU UNIT
8. Remove the two (2) screws holding the PWB cover to
the door frame.
9. Releasingthe two(2)tabs, removethePWB coverfrom
the door frame.
10.Disconnect the 12-pin wire harness from the CPU unit.
11.DisconnecttheribboncableofthekeyunitfromtheCPU
unit.
12.Removethetwo(2)screwsholdingtheLCDholdertothe
door frame.
13.Remove the LCD holder from the door frame. Release
the four (4) tabs.
14.Release the LCD of the CPU unit from the LCD holder.
15.Remove the two (2) screws holding the CPU unit to the
LCD holder.
16.RemovetheCPUunitfromtheLCDholder.Releasethe
four (4) tabs.
17.Now the CPU unit is free.
DOOR FRAME ASSEMBLY
18.Remove the handle from the door frame assembly.
Refer to the chapter of HANDLE.
19.Now, the door frame assembly is free.
NOTE: For 12-pin wire harness
1.WhenthePWBcoverisreinstalled,routethe12-pin
wire harness under the hole of the PWB cover.
2.Beforethedoorpanelisreinstalledtothedoorframe
assembly,makesurethatthe12-pinwireharnessis
Figure C-10. Routing of 12-pin wire harness
NOTE: For key unit
1. Beforeattachinganewkeyunit,wipeoff remaining
adhesive on the door frame surfaces completely
with a soft cloth soaked in alcohol.
2. When attaching the key unit to the door frame,
adjusttheupperedgeandleftedgeofthekeyunit
to the correct position of door frame.
3. Stick the key unit firmly to the door frame by
rubbing with a soft cloth so not to scratch.
NOTE: For CPU unit
Handle the CPU unit carefully so that the ribbon
cable does not come off. Because the ribbon cable
is glued onto the LCD and the printed wiring board
only by heated paste.
Figure C-11. CPU unit
INDIVIDUAL DOOR PARTS REMOVAL
Printed wiring board
of CPU unit
Liquid Crystal
Display (LCD)
Ribbon cable
PWB Cover Tabs
Tab
Tab
12-pin wire harness
Hole on door frame
Hole on
door frame
Hole of
PWB cover
Hole on door frame
held by the four (4) tabs and the three (3) holes on
the door frame as shown in Figure C-10.

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R-630DKA
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R-630DWA
6
45
123
6
45
123
A
B
C
D
E
F
G
H
A
B
C
D
E
F
G
H
Figure S-1. Pictorial Diagram
HIGH VOLTAGE CAPACITOR
HIGH VOLTAGE WIRE B
H.V. RECTIFIER
POWER SUPPLY CORD 120V 60Hz
HIGH VOLTAGE COMPONENTS
OVEN LAMP
MAGNETRON
COM.
MONITOR SWITCH
COM.
N.O.
N.C.
DOOR SENSING SWITCH
SECONDARY INTERLOCK SWITCH
TURNTABLE MOTOR
POWER TRANSFORMER
COM.
NO
NOTE: The neutral (WHT) wire must be connected to the neutral (WHT) wire of the power supply cord.
GRY
RED
RED
WHT
YLW
WHT
BLK
GRY
GRN
WHT
GRY
BLKBLK
WHT
BLK BLK
GRY
WHT
YLW
BLK
BLK
THERMAL CUT-OUT (MG)
FAN MOTOR
THERMAL CUT-OUT (OVEN)
MONITOR FUSE
& HOLDER
BLK
BLK
WHT
2 1
WHT WHT
WHT
WHT
GRY
CN-A
CN-A
CN-B
HN
NOTE: The grounding conductor of the power supply cord has been grounded by power supply cord fixing screw. The screw must allways be kept tight.
WHT
BLK
WHT
BLK 2
1
GRN
GRY
2 3 1
CN-B
BRN RED
ORG
YLW
GRN
BLU
PPL
GRY
WHT
BLK
PNK
GRN
BLU/
2 1 4 3 6 5 8 9
10 11 12
7
CN-C
BRN
RED
ORG
YLW
GRN
BLU
PPL
GRY
WHT
BLK
PNK
BLU/
GRN
2 1
4
3 6 5 8 9
10 11 12
7
CN-C
BLK
RED RED RED
YLW YLW
RED
RY2
RY1
PRIMARY INTERLOCK RELAY
CN-G CN-C
1
1
1
2
12
12
CPU UNIT
(on the door)
POWER UNIT
1
2
CN-F
1 3
CN-C
1
12
BLK AH SENSOR RED
WHT
1 2 3
CN-F