Sharp R-204EWA Service Manual Download Page 33

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R-204EWA

HOW TO ORDER REPLACEMENT PARTS

To have your order filled promptly and correctly, please furnish the following information.

1. MODEL NUMBER 2. REF. NO. 3. PART NO. 4. DESCRIPTION

Order Parts from the authorized SHARP parts Distributor for your area.
Defective parts requiring return should be returned as indicated in the Service Policy.

REF. NO.

PART NO.

DESCRIPTION

Q'TY

CODE

6- 5

FW-VZB831WREZ

Main wire harness

6- 6

QW-QZA242WRZZ

High voltage wire B

6- 7

TCAUAA265WRRZ

DHHS caution label

6- 8

TCAUAA257WRRZ

Monitor caution

6- 9

TCAUAA266WRRZ

Earth caution

6-10

TCAUAA156WRR0

User caution label

SCREWS AND WASHERS

7- 1

XHPSD40P08K00

Screw : 4mm x 8mm

7- 2

LX-EZA042WRE0

Special screw

7- 3

LX-WZA028WRE0

Special washer

7- 4

XHTSD40P12RV0

Screw : 4mm x 12mm

7- 5

XHTSD40P08RV0

Screw : 4mm x 8mm

7- 6

XHPSD30P06000

Screw : 3mm x 6mm

7- 7

LX-CZ0052WRE0

Special screw

7- 8

XOTSD40P12000

Screw : 4mm x 12mm

7- 9

XOTSE40P08000

Screw : 4mm x 8mm

7-10

LX-CZA070WRE0

Special screw

7-11

XHPSD40P08000

Screw : 4mm x 8mm

7-12

XOTSD40P08000

Screw : 4mm x 8mm

6-2 TURNTABLE TRAY

6-3 OPERATION MANUAL

6-1

TURNRABLE SUPPORT

INTO THE
OVEN CAVITY

Not replaceable items.

TRAY PAD ASSY

(CPADBA244WRK0)

PACKING CASE

MICROWAVE OVEN

TOP PAD ASSEMBLY

FPADBA387WRK0

POLYETHYLENG BAG

SSAKHA070WREZ

DOOR PROTECTION SHEET

SPADPA580WRE0

FPAK-A404WRKZ

BOTTOM PAD ASSEMBLY

FPADBA388WRK0

PACKING AND ACCESSORIES

Summary of Contents for R-204EWA

Page 1: ...D 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 SPECIFICATIONS 4 GENERAL INFORMATION 4 OPERATION 6 TROUBLESHOOTING GUIDE 9 TEST PROCEDURE 10 TOUCH CONTROL PANEL 18 COMPONENT REPLACEMENT AND ADJUSTMENT PROCEDURE 22 PICTORI...

Page 2: ...n 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 Microw...

Page 3: ...tor 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 t...

Page 4: ...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 ...

Page 5: ...maged 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 DANGER Certaininitialpartsareintentionallynotgroundedandpresent a risk of electrical shock only during servicing Service personnel Do not contact the following parts while the appliance is energized HighVoltageCapacitor Pow...

Page 6: ... 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...

Page 7: ...table where it can be pulled on by children or tripped over accidentally OVEN DIAGRAM 1 Oven door with see through window 2 Safety door latches 3 Door hinges 4 Door seals and sealing surfaces 5 Turntable motor shaft 6 Removable turntable support 7 Removable turntable 8 Ventilation openings Rear 9 Oven lamp 10 Wave guide cover 11 Door open handle 12 Control panel 13 Power supply cord CAUTION DO NOT...

Page 8: ... 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 Themonitorswitchiselectricallymonitoringtheoperation of the secondary interlock switch and primary interlock relay RY2 andismechanicallyassociatedwiththedoor so that it will function in the following sequence 1 When the door...

Page 9: ...SFORMER 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 POWER TRANSFORMER RECTIFIER CAPACITOR 0 86µF C T FUSE 120V AC 60 Hz OVEN LAMP TURN TABLE MOTOR FAN MOTOR MONITOR SWITCH SECOND...

Page 10: ...OND ARY INTERLOCK SWITCH AND MONITOR SWITCH FOR PROPER OPERATION RE FER TO CHAPTER TEST PROCEDURE NOTE C T FUSE AND MONITOR SWITCH ARE REPLACED AS AN ASSEMBLY 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 COOLING FAN MOTOR The cooling fan motor drives a...

Page 11: ... assembly IMPORTANT Whenever troubleshooting is performed with the power supply cord disconnected It may in some cases be necessary to connect the power supply cord 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 t...

Page 12: ...er cord is plugged into wall receptacle Any letters or indicators do not ap pear in display when power cord is first plugged into wall outlet Display does not operate properly when STOP CLEAR key is touched Buzzer should sound and time of day should appear in display C T fuse blows when the door is opened Fan motor does not operate All other electric components function Oven lamp does not light at...

Page 13: ...rming a water temperature rise test This test shouldonlybeusedifabovetestsdonotindicateafaultymagnetronandthereisnodefectinthefollowing componentsorwiring siliconrectifier highvoltagecapacitorandpowertransformer Thistestwillrequire a 16 ounce 453cc measuring cup and an accurate mercury thermometer or thermocouple type temperature tester For accurate results the following procedure must be followed...

Page 14: ...ing fan air guide 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 CAUTION IFTHETHERMALCUT OUTINDICATESANOPENCIRCUITATROOMTEMPERATURE REPLACE THERMAL CUT OUT C HIGH VOLTAGE RECTIFIER TEST 1 Disconnect the power supply cord and then remove outer c...

Page 15: ...7 Reconnect the power supply cord after the outer case is installed 8 Run the oven and check all functions PRIMARY INTERLOCK SYSTEM TEST DOOR SENSING SWITCH 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 Isolatetheswitchandconnecttheohmmetertothecommon COM andnormallyopen NO terminal of the switch The meter shoul...

Page 16: ...RCUIT AT ROOM TEMPERATURE REPLACE THE C T FUSE 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 The touch control panel consists of circuits including semiconductors such as LSI ICs etc Therefore unlike conventional microwave ovens proper mainten...

Page 17: ...ents during testing 5 Re install the outer case cabinet 6 Reconnect the power supply cord after the outer case is installed 7 Run the oven and check all functions TEST PROCEDURES PROCEDURE LETTER COMPONENT TEST 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 S...

Page 18: ...ndicate 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 COM...

Page 19: ...oes 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 po...

Page 20: ...en 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 t...

Page 21: ...e 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 t...

Page 22: ...G1 OUT Terminal not used 34 SEG2 OUT Magnetron high voltage circuit driving signal To turn on and off the cook relay RY2 The signalsholds L levelduringmicrowavecook ing and H level while not cooking In other cooking modes variable cooking the signal turns to H level and L level in repetition according to the power level 35 SEG3 OUT Terminal not used 36 SEG4 OUT Oven lamp fan motor and turntable mo...

Page 23: ...lf is so short that the two can t be separated For those models check and repair all the controls sensor relatedonesincluded ofthetouchcontrolpanel while keeping it connected to the oven B On some models the power supply cord between the touch control panel and the oven proper is so long enough that they may be separated from each other For thosemodels therefore itispossibletocheckandrepair the co...

Page 24: ...d High voltage rectifier assembly 2 Hot parts Oven lamp Magnetron High voltage transformer WARNING FOR WIRING 1 Disconnect the power supply cord 2 Visuallycheckthedoorandcavityfaceplatefordamage dents cracks signs of arcing etc Carry out any remedial work that is necessary before operating the oven Do not operate the oven if any of the following conditions exist 1 Door does not close firmly 2 Door...

Page 25: ...VOLTAGE RECTIFIER ASSEM BLY HIGH VOLTAGE COMPONENTS REMOVAL HIGH VOLTAGE CAPACITOR AND HIGH VOLTAGE RECTIFIER ASSEMBLY POWER TRANSFORMER REMOVAL 1 Disconnect the power supply cord and remove outer case 2 Open the oven door and block it open 3 Discharge high voltage capacitor 4 Disconnect the wire leads main wire harness and H V wire from power transformer 5 Disconnect the lead from magnetron filam...

Page 26: ...Remove the any sharp edges on the turntable motor cover and the bottom plate with the cutting pliers 2 Re install the O ring 3 Apply the grease Shinetsu silicone grease G 420 of Sinetsu Chemical Co Ltd or Toray Silicone grease SH 14 of Toray Silicone Co Ltd to the O ring and the base of the turntable motor shaft as shown in Figure C 4 4 Re install the turntable motor with the O ring and washer to ...

Page 27: ...the oven cavity rear cabinet 10 Re install the chassis support to the oven cavity front plate with the one 1 screw 11 Install the filament lead and the H V wire into the hole of the fan duct 12 Re install the wire leads to the oven lamp to the hole of the fan duct 13 Connect the wire leads to the fan motor referring to the pictorial diagram Side View Rear View 1 Disconnect the power supply cord an...

Page 28: ...ould be less than 0 5mm 2 The contacts of door sensing switch and secondary interlock switch open within 1 6mm gap between right side of cavity face plate and door when door is open 3 The monitor switch contacts close when the door is opened 4 Re install outer case and check for microwave leakage around the door with an approved microwave survey meter Refer to Microwave Measurement Procedure Figur...

Page 29: ...ve survey meter should be used to assure compliance with proper microwave 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 Deviation of door alignment from horizontal line of cavity face plate is to be less than 1 0mm 3 Door is positioned with...

Page 30: ...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 Blue Mark NOTE Hot RED wire must be connected to the terminal with blue mark on the oven light socket WHT GRN GRY ORG ORG WHT ORG MA...

Page 31: ...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 ...

Page 32: ...04WRW0 Bottom plate 1 AF 2 3 GLEGPA074WRE0 Foot 2 AC CONTROL PANEL PARTS 3 1 DPWBFC195WRUZ Control unit 1 BL 3 2 FPNLCB569WRKZ Control panel frame with key unit and LCD 1 BC 3 2 1 FUNTKB065WREZ Key unit 1 AZ 3 2 2 RLCDSA089DRZZ Liquid crystal display 1 AM 3 3 QCNC A013WRZZ Rubber connector 1 AE 3 4 XEPSD30P08XS0 Screw 3mm x 8mm 3 AA OVEN PARTS 4 1 PHOK A105WRF0 Latch hook 1 AL 4 2 LANGQA530WRWZ Li...

Page 33: ...AF SCREWS AND WASHERS 7 1 XHPSD40P08K00 Screw 4mm x 8mm 2 AA 7 2 LX EZA042WRE0 Special screw 2 AB 7 3 LX WZA028WRE0 Special washer 1 AB 7 4 XHTSD40P12RV0 Screw 4mm x 12mm 1 AA 7 5 XHTSD40P08RV0 Screw 4mm x 8mm 5 AA 7 6 XHPSD30P06000 Screw 3mm x 6mm 1 AA 7 7 LX CZ0052WRE0 Special screw 2 AA 7 8 XOTSD40P12000 Screw 4mm x 12mm 12 AA 7 9 XOTSE40P08000 Screw 4mm x 8mm 4 AA 7 10 LX CZA070WRE0 Special sc...

Page 34: ...TS 7 8 2 1 7 8 7 10 7 10 7 9 7 5 7 5 A 4 6 4 4 4 9 7 1 7 8 7 7 4 10 7 1 1 4 7 8 7 8 7 8 4 1 2 2 2 3 7 8 7 8 7 8 4 13 2 3 7 2 4 16 7 3 1 10 1 11 7 5 7 4 1 3 1 7 7 6 1 1 1 1 1 2 1 6 4 3 1 5 7 9 7 11 1 8 6 9 6 8 1 2 7 8 4 3 4 14 4 7 4 11 6 2 6 1 4 15 4 8 6 7 4 5 4 12 4 17 A 7 12 1 9 4 2 4 14 ...

Page 35: ...6 6 5 5 5 2 5 4 5 8 5 8 5 6 5 7 5 1 Actual wire harness may be different than illustration 3 2 6 10 3 2 2 3 2 1 3 3 3 1 3 4 6 4 Befor attaching Control unit to Control panel foil side of Control unit must be cleaned by ethyl alcohol CONTROL PANEL PARTS DOOR PARTS MISCELLANEOUS ...

Page 36: ...1 BY SHARP CORPORATION ALL RIGHTS RESERVED No part of this publication may be reproduced stored in retrieval systems or transmitted in any form or by any means electronic mechanical pho tocopying recording or otherwise without prior written permission of the publisher ...

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