SHARP SERVICE MANUAL

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1 SHARP SERVICE MANUAL ELECTRIC JAR POT MODELS KP-19S KP-30S/ST KP-36S In the interests of user-safety (Required by safety regulations in some countries) the set should be restored to its original condition and onlyparts identical to those specifi ed should be used. TABLE OF CONTENTS NAME OF PARTS AND SPECIFICATIONS... CAUTIONS FOR USE... CLEANING AND CARE... WIRING DIAGRAM AND CIRCIUT DIAGRAM... COMPONENTS REPLACEMENT PROCEDURE... INSPECTION AFTER ASSEMBLING... TROUBLESHOOTING GUIDE... SERVICE PARTS LIST... Page SHARP CORPORATION

2 NAME OF PARTS Outer lid cover Inner lid packing Inner pot Inner lid Outer lid Push button for pouring water Steam outlet Upper ring Delivery base cover Handle Pour/Stop switch Body Water level indicator Swivel base Refi ll level Plug plate Bottom cover Power cord ass y BOIL indicator lamp Connector (Connected to body) WARM indicator lamp Plug SPECIFICATIONS Model Power consumption ( W ) Rated voltage ( V ) Capacity (max. water volume) ( l ) Pouring system Outside dimensions (W x D x H) (mm.) Weight (kg) KP-19S KP-30S/ST KP-36S Manual air pressure operation 201 x 247 x x 247 x x 247 x

3 CAUTIONS FOR USE 1. For power supply use the proper socket. 1.1 Do not connect too many loads to one outlet. 1.2 If any of the power supply cord, plug and connector is damaged or feel abnormally hot. Immediately call the serviceperson to repair it. Otherwise, this will cause an electric shock or fi re. 2. Do not immerse the unit in water or splash it with water. This will result in malfunctioning or electric shock. 3. Do not operate the unit without water in the pot. This will cause malfunctioning or discolouring of the inner pot. 4. Close lid firmly. Otherwise hot water outfl ow so much when tumbling. 5. Do not put milk, liquor, tea, ice cubes and etc. in the pot. This will result in malfunctioning or electric shock. 6. The power cord ass y (supplied) is only for the product. Do not use it for other apparatus or apply the other type of power cord ass y to this product. 7. When put water into the pot : 7.1 Be sure to keep the water level between the Refi ll level and Full level. 7.2 If water is put above the Full level, the hot water may be overfl ow from the spout during boiling. 7.3 Do not put water into the pot directly from the tap, because fl ooded water may intrude into the mechanism and cause an electric shock and malfunctioning. 8. Location 8.1 Do not use or place the unit on an unstable, wet fl oor or adjacent to other heat generating apparatus, as this will cause the unit to fall down, deform itself or malfunction. 8.2 Keep the pot away from child not to cause an accidental scald or injury. 9. When plugging the power cord ass y : Remove iron chip and dust from the connector plug and inner terminal. 10. When boiling and warming water : 10.1 In the beginning of operation, the unit may generate plastic smell or oily smell of the heater, but this will hardly occur as the usage lasts Sounds are emitted during the boiling and warming. But this is quite normal Keep the power cord ass y plugged during the warming, otherwise the water temperature goes down gradually Sometimes exchange the water in the pot not to degrade water quality Disinfectant contained in tap water or some water may cause a smell when it is heated Pressing the push button with undue force may cause the hot water to scatter so as to result in scald or injury If the water level in the pot go down below the Refi ll level during operation, be sure to add water. Otherwise the unit may be damaged The inner lid becomes heated during operation; use a dish cloth or the like when removing it Do not carry the pot at the condition of inclining. 3

4 11. After use 11.1 Pull out the plug from a wall outlet and detach the connector from the unit Detach the lid, and dispose hot water remained in the pot : if the hot water is left for a long time, this will cause discolouring and corrosion of the inner pot. Take care not to dispose hot water directly from the spout. Splashed hot water from the spout may course scald. 12. Water discharge amount This electrical thermo pot employs manual air-pressure system, in which the push button is pressed to inject the compressed air in the bellows into the closed vessel, so as to allow the hot water to be discharged out of the pot. Therefore, if the water temperature in the pot is high, the amount of water discharge is increased because the air pressure is increased due to air expansion and steam generated in the pot; reversely, the amount of the water discharge is decreased when the water temperature in the pot is low. CLEANING AND CARE CAUTION : DO NOT IMMERSE CORD PLUG OR BODY IN WATER OR OTHER LIQUID. BEFORE CLEANING, BE SURE TO DISCONNECT THE PLUG, POUR OUT THE REMAINED WATER AND COOL DOWN THE BODY. DO NOT USE POLISHING POWDER, HARD BRUSH, THINNER ALCOHOL OR OTHER SOLVENT : OTHERWISE THE SURFACE MAY BE DAMAGED OR DISCOLOURED. 1. Cleaning 1.1 Body and Outer lid ass y Soak a soft cloth in water, squeeze properly and wipe carefully. 1.2 Inner pot Soak a sponge with water, then rub the inside of the inner pot carefully. Rinse and drain sufficiently with water, then wipe off moisture in the inner pot. Do not splash water on parts other than the inside of inner pot. 2. Against discoloring (into milk white, black, rain bow color, etc.) It is adhesion of the impurities contained in the water. The following procedures are used to make them unnoticeable. 2.1 Fill the vessel with water mixed with 50 g Citric Acid or Lemon Juice up to the Full level and let it boil. 2.2 Keep warm for about 1 hour, then pour out the lemon water as usual. 2.3 Rinse thoroughly with water until the lemon smell is removed. However the thermal discoloring due to heating without water can not be restored. 3. When the unit is not used for long periods of time : Rinse the inner pot with water, drain off by placing the body upside down. Then wipe off moisture in the inner pot well. 4. Rusty Spots Rusty Spots result from oxidization of iron which is contained in the water. Scrub them off with a nylon cleaner or such (except Polyfl on Scrub them off with a sponge). 4

5 WIRING DIAGRAM CIRCUIT DIAGRAM 5

6 COMPONENTS REPLACEMENT PROCEDURE In disassembling or assembling the parts other than the lid assembly, the work can be done easily when the lid assembly and body assembly are left connected with each other. INNER LID PACKING REPLACEMENT The inner lid packing is non-durable parts. When it is diffi cult to pour water, please change the inner lid packing. Fig. 1 and Fig. 2 How to remove Pull the inner lid packing off from the inner lid. Fig. 1 How to attach Remove the inner lid packing as directed in the following illustration. Be sure that the inner lid packing can cover tightly into the inner lid brim. Inner lid Inner lid packing Correct Incorrect Fig. 2 6

7 DISASSEMBLE OF OUTER LID ASSEMBLY 1. Detach the lid assembly from the body. (Fig. 3) 2. Turn the lid assembly upside down and remove the screw holding the outer lid cover. 3. Detach inner lid assembly by remove 3 screws holding to outer lid cover. 4. Now inner lid assembly, ball valve, steam tube packing are free. 5. Pull steam outlet tube out of outer lid cover. 6. Detach steam cap packing-b by pull out of bellow cap-b and outer lid cover. 7. Detach the outer lid together with the outer lid cover assembly by remove the screw and unfastening the 4 claws at the outer lid. 8. Now outer lid cover are free. Note : Push button and outer lid can not disassembly. For replacement of the inner lid packing, see the instruction on INNER LID PACKING REPLACEMENT. Push button Approx. 65 Latch knob Latch spring Outer lid Removal of lid 1. Push the latch knob and open the lid at approximate Shift the lid forward and lift it up, then it can be detached. Fig. 3 Bellow cap-a Bellow cap packing-a Bellow cap spring Steam tube-b BELLOW CAP PACKING-B REPLACEMENT Outer lid cover Outer lid cover Screw Bellow cap-b Bellow cap packing-b Steam outlet tube Bellow cap-b Correct Ball valve Steam tube packing Inner lid Inner lid packing Bellow cap packing-b Screw Fig. 4 Fig. 5 7

8 REMOVE OF BOTTOM COVER 1. Upside down the unit and pry the rotating base by inserting a putty knife to remove the rotating base. 2. Remove 2 screws holding bottom cover to mounting bracket at the bottom of inner pot. 3. Disconnect 3 lead wires from plug plate ass y. 4. Detach the lamp insulator cover together with the neon lamp assembly out of of the bottom cover. 5. Push the claws and remove the plug plate. 6. Now the bottom cover is free. Temp. fuse lead wire blue Rotating base Plug plate Bottom cover Neon lamp lead wire Heater set lead wire Lamp insulator cover Bottom cover Fig. 6 Bottom cover Screw Fig. 7 REMOVE OF PLUG PLATE ASSEMBLY 1. Remove the bottom cover in accordance with REMOVE OF BOTTOM COVER. 2. Push the claws and remove the plug plate out of the bottom cover. 3. Now the plug plate ass y is free. REMOVE OF NEON LAMP ASS Y 1. Remove the bottom cover in accordance with REMOVE OF BOTTOM COVER. 2. Detach the lamp insulator cover to together with the neon lamp assembly out of the bottom cover. 3. Pull the lamp assembly out from lamp insulator cover. 4. Remove 3 lead wires to neon lamp ass y. 5. Now the neon lamp ass y is free. Lamp insulator cover Neon lamp ass y Lead wire Bottom cover 8 Fig. 8

9 REMOVE OF BODY 1. Remove the bottom cover in accordance with REMOVE OF BOTTOM COVER. 2. Remove the screw holding earth wire to body. 3. Pull out the body and delivery base cover by toward its bottom. 4. Detach the body from the delivery base cover. 5. Now body is free. REMOVE OF GLASS PIPE 1. Remove the body in accordance with REMOVE OF BODY. 2. Disconnect the connector lower from the pipe of inner pot. 3. Disconnect the glass pipe from the connect upper. 4. Remove the connector lower from the glass pipe. 5. Now the glass pipe is free. Note : Re-install glass pipe in accordance with Fig. 9. The screen must be faced to arrow mark when glass pipe is inserted to connector lower. Connector lower Glass pipe Insert by approx. 10 mm. Glass pipe Screen Screen Connector lower Connector upper Fig. 9 REMOVE OF TEMPERATURE FUSE ASS Y 1. Remove the body in accordance with REMOVE OF BODY. 2. Disconnect 3 lead wire of temp. fuse ass y. 3. Disconnect the 2 terminal of thermostat. 4. Now temp. fuse ass y is free. Temp. fuse lead wire yellow Temp. fuse ass y Thermostat Terminal Thermostat lead wire blue Fig. 10 9

10 REMOVE OF THERMOSTAT 1. Remove the body in accordance with REMOVE OF BODY. 2. Disconnect 2 terminals from the thermostat. 3. Remove 2 screws holding the thermostat. 4. Now the thermostat is free. Inner pot Screw Thermostat Fig. 11 REMOVE OF HEATER SET ASS Y 1. Remove the body in accordance with REMOVE OF BODY. 2. Remove the nut at terminal ass y to release lead wire from the heater set ass y. 3. Detach the mounting bracket by remove 2 screws holding the mounting bracket. 4. Disconnect the connector lower from the pipe of inner pot. 5. Unfasten 2 screws at heater set ass y and then pull heater set ass y out from inner pot. 6. Now heater set ass y is free. Inner pot Heater set ass y Approx. 7-8 mm. Heater holder-a Screw Fig. 12 REMOVE OF UPPER RING ASSEMBLY AND HANDLE 1. Detach the lid ass y and remove the body in accordance with REMOVE OF BODY. 2. Remove the thermostat, mounting bracket and heater set assembly in accordance with REMOVE OF THERMOSTAT and REMOVE OF HEATER SET ASS Y. 3. Remove the glass pipe in accordance with REMOVE OF GLASS PIPE and remove the ball holder ass y. 4. Remove the upper ring assembly by pulling it downwards. 5. Remove the handle. Note 1 : When setting the handle, position it correctly. If reversely set, the handle will come off while using. Note 2 : For alignment of the inner pot and upper ring, have the corner of hitch part of the upper ring engaged with welded mark of the inner pot. Welded mark of the upper ring Upper ring Upper ring Handle Fig. 13 Fig. 14 Ball holder ass y 10

11 INSPECTION AFTER ASSEMBLING On completion of assembling, the following should be inspected. 1. Verification of operations 1.1 Is there any part left uninstalled (magnet plate, in particular)? 1.2 Is there any wrong wiring? 1.3 Is the body engaged securely with the upper ring and bottom cover? 1.4 Are screws tightened fi rmly? 2. Measurement of insulation resistance 2.1 Measure the insulation resistance by a 500V d.c. insulation resistance meter and be sure that resistance in at least 1 MΩ. (Check it before and just after the performance test.) 2.2 Be sure that the unit can stand against a 1000V a.c. high voltage for one minute. (Check it just after the performance test.) 3. Boiling and warming capacity 3.1 Fill the pot full of water (up to the full-water level) and boil it. Be sure that hot water temperature is more than 90 o C. 3.2 After boiling, the WARM lamp should light up instead of the BOIL lamp. 3.3 Approximate one hour after boiling, be sure that the hot water temperature still stays at 80 o C or more. 4. Water discharge capacity After checking the boiling-warming capacity, keep the hot water quantity at its discharge level and make sure that the hot water is discharged by 150 ml in average when the push button is pressed. (Water discharge in average = Total water discharge ) Number times of pressing the button If the hot water quantity is insuffi cient, recheck that the bellow packing-b, inner lid packing, etc. Due to the troubleshooting guide. 11

12 TROUBLESHOOTING GUIDE Problem Check point Possible cause Correction action No power is supplied. Plug of Power cord Not inserted into outlet. Insert it into outlet. ( BOIL indicator lamp dose ass y. not light up.) Connector of Power cord Disconnected from inlet Connect with inlet. ass y. terminal. Power cord ass y. Disconnection. Replace. Temperature fuse. Blown out Replace and explain (by repeated heating without the users not to heat water). the pot without water. Blown out Replace. (by deformation of heater). Indication lamp Disconnection. Replace. assembly. Internal wiring. Erroneous wiring. Correct wiring. Terminal screw. Loosened or missing. Retighten. (Inlet terminal) Thermostat. Poor operation Replace. (no conduction). BOIL indicator lamp lights up Heater set assembly. Disconnection. Replace. but water is not heated. Boiling continues. Thermostat. Poor operation. Replace. Internal wiring. Erroneous wiring. Correct wiring. Outer lid ass y. Not secured on the body. Secured on the body. Water temperature is kept Heater set assembly. Disconnection in heating Replace. low. circuit. Internal wiring. Erroneous wiring. Correct wiring. Thermostat. Poor operation. Replace. Hot water is not or hardly Water temperature. Water is tepid or cold. Explain users that pouring poured from spout. amount is very small for tepid or cold water. Push button. Pushing with undue force. Instruct the users to push with a proper force. Pushing the outer edge of Instruct the users to push the button. at the center of the button. Inner lid. No inner lid. Attach inner lid. Poor installation of inner lid. Set correctly. Defective packing. Loosened inner lid packing. Defective inner lid packing. Replace. Secure correctly. Replace. Incorrect attachment of inner lid Set correctly. packing. Bellows assembly. Air leak from the bellows. Replace. Dislocation of bellows cap Set correctly. packing-b 12

13 Problem Check point Possible cause Correction action During boiling, steam escapes Steam route. Steam pipe dislocated. Set correctly. from around the push button Steam tube packing. Deteriorated perforated. Replace. or dew collects inside the Bellow cap packing-b. outer lid. Hot water leaks. Using place. Use at an inclined place. Instruct the users to use the pot on a level place. Water level. Water is fi lled more than full Instruct the users not to feed water level. water more than full water level. Inner pot. Perforated. Replace. Upper and lower Defective rubber joints. Replace. connectors. Disconnected joints. Set correctly. Inner pot packing. Deteriorated. Replace. Steam discharge route. Stuffed with foreign matters. Remove foreign matters. Stained inner pot. Inner pot. Spot stain. Caused by adhesion of iron content in water. Explain the users that such adhesion does not affect the corrosion resistance of stainless steel. Discolouring. Caused by water quality and this has no effect on the corrosion resistance of stainless steel. 13

14 SERVICE PARTS LIST KP-19S REF. NO PARTS CODE (FEC) PRINTING & PACKAGING MATERIAL DESCRIPTION Q TY PRICE 1-1 3C6092 * INSTRUCTION BOOK D6021 SET PACKING CASE D6051 CARTON BOX C6041 BOTTOM PAD C606B UPPER PAD-B C606F UPPER PAD-F 1 MECHANICAL PARTS 2-1 3C102SET OUTER LID SET {KP-19S..FG, PL} 1 3C102MNSET OUTER LID SET {KP-19S..SK} C118 PUSH BUTTON {KP-19S..FG, PL} 1 3C118MN PUSH BUTTON {KP-19S..SK} C121 LATCH KNOB {KP-19S..FG, PL} 1 3C121MN LATCH KNOB {KP-19S..SK} C119 LATCH SPRING C102 OUTER LID {KP-19S..FG, PL} 1 3C102MN OUTER LID {KP-19S..SK} C1071 ASY BELLOW AS Y {SERVICE SET} X316 STEAM TUBE-B C108B BELLOW CAP PACKING-B X617 STEAM OUTLET TUBE C619 STEAM TUBE PACKING X509 INNER LID PACKING C607 INNER LID D205ASY INNER POT AS Y C123 INNER POT PACKING C2155 MOUNTING BRACKET C218ASY TERMINAL AS Y C206 UPPER RING {KP-19S..FG, PL} 1 3C206MN UPPER RING {KP-19S..SK} C223 UPPER RING COVER {KP-19S..FG, PL} 1 3C223MN UPPER RING COVER {KP-19S..SK} C203 HANDLE {KP-19S..FG, PL} 1 3C203MN HANDLE {KP-19S..SK} C300 DELIVERY PIPE C312 DELIVERY BASE COVER {KP-19S..FG, PL} 1 3C312MN DELIVERY BASE COVER {KP-19S..SK} 1 14

15 REF. NO PARTS CODE (FEC) MECHANICAL PARTS DESCRIPTION Q TY PRICE C216ASY BALL HOLDER AS Y C124 CONNECTOR UPPER D213 GLASS PIPE C4061 CONNECTOR LOWER D1201FGASY ** BODY AS Y {FG} 1 3D1201PLASY ** BODY AS Y {PL} 1 3D1201SKASY ** BODY AS Y {SK} D402ASY BOTTOM COVER AS Y {KP-19S..FG, PL} 1 3D402JASY BOTTOM COVER AS Y {KP-19S..SK} C307 LAMP INSULATOR COVER C415 ROTATING BASE {KP-19S..FG, PL} 1 3C415J ROTATING BASE {KP-19S..SK} C4104ASY PLUG PLATE AS Y 1 ELECTRIC PARTS 3-1 3C4123ASY POWER CORD AS Y C2933SET TEMPERATURE FUSE SET D2313SET HEATER SET {SERVICE SET} B2121 THERMOSTAT 91 o C C4931ASY NEON LAMP AS Y 1 15

16 SERVICE PARTS LIST KP-30S / 30ST REF. NO PARTS CODE (FEC) PRINTING & PACKAGING MATERIAL DESCRIPTION Q TY PRICE 1-1 3C6092 * INSTRUCTION BOOK C6021 SET PACKING CASE {KP-30S} 1 3C6021T SET PACKING CASE {KP-30ST} C6051 CARTON BOX {KP-30S} 1 3C6051T CARTON BOX {KP-30ST} C6041 BOTTOM PAD C606B UPPER PAD-B C606F UPPER PAD-F 1 MECHANICAL PARTS 2-1 3C102SET OUTER LID SET {KP-30S / 30ST..FG, PL} 1 3C102MNSET OUTER LID SET {KP-30S..SK, WL} C118 PUSH BUTTON {KP-30S / 30ST..FG, PL} 1 3C118MN PUSH BUTTON {KP-30S..SK, WL} C121 LATCH KNOB {KP-30S / 30ST..FG, PL} 1 3C121MN LATCH KNOB {KP-30S..SK, WL} C119 LATCH SPRING C102 OUTER LID {KP-30S / 30ST..FG, PL} 1 3C102MN OUTER LID {KP-30S..SK, WL} C1071 ASY BELLOW AS Y {SERVICE SET} X316 STEAM TUBE-B C108B BELLOW CAP PACKING-B X617 STEAM OUTLET TUBE C619 STEAM TUBE PACKING X509 INNER LID PACKING C607 INNER LID C122ASY INNER POT AS Y {KP-30S} 1 3C122TASY INNER POT COATING AS Y {KP-30ST} C123 INNER POT PACKING C2155 MOUNTING BRACKET C218ASY TERMINAL AS Y C206 UPPER RING {KP-30S / 30ST..FG, PL} 1 3C206MN UPPER RING {KP-30S..SK, WL} C223 UPPER RING COVER {KP-30S / 30ST..FG, PL} 1 3C223MN UPPER RING COVER {KP-30S..SK, WL} C203 HANDLE {KP-30S / 30ST..FG, PL} 1 3C203MN HANDLE {KP-30S..SK, WL} 1 16

17 REF. NO PARTS CODE (FEC) MECHANICAL PARTS DESCRIPTION Q TY PRICE C300 DELIVERY PIPE C312 DELIVERY BASE COVER {KP-30S / 30ST..FG, PL} 1 3C312MN DELIVERY BASE COVER {KP-30S..SK, WL} C216ASY BALL HOLDER AS Y C124 CONNECTOR UPPER C125 GLASS PIPE C4061 CONNECTOR LOWER C2101FGASY ** BODY AS Y {KP-30S..FG} 1 3C2101PLASY ** BODY AS Y {KP-30S..PL} 1 3C2101SKASY ** BODY AS Y {KP-30S..SK} 1 3C2101WLASY ** BODY AS Y {KP-30S..WL} 1 3C2102FGASY ** BODY AS Y {KP-30ST..FG} 1 3C2102PLASY ** BODY AS Y {KP-30ST..PL} C402ASY BOTTOM COVER AS Y {KP-30S..FG, PL} 1 3C402JASY BOTTOM COVER AS Y {KP-30S..SK, WL} 1 3C402TASY BOTTOM COVER AS Y {KP-30ST..FG, PL} C307 LAMP INSULATOR COVER C415 ROTATING BASE {KP-30S / 30ST..FG, PL} 1 3C415J ROTATING BASE {KP-30S..SK, WL} C4104ASY PLUG PLATE AS Y 1 ELECTRIC PARTS 3-1 3C4123ASY POWER CORD AS Y C2933SET TEMPERATURE FUSE SET C2095SET HEATER SET {SERVICE SET} B2121 THERMOSTAT 91 o C C4931ASY NEON LAMP AS Y 1 17

18 SERVICE PARTS LIST KP-36S / 36ST REF. NO PARTS CODE (FEC) PRINTING & PACKAGING MATERIAL DESCRIPTION Q TY PRICE 1-1 3C6092 * INSTRUCTION BOOK E6021 SET PACKING CASE E6043 CARTON BOX C6041 BOTTOM PAD C606B UPPER PAD-B C606F UPPER PAD-F 1 MECHANICAL PARTS 2-1 3C102SET OUTER LID SET C118 PUSH BUTTON C121 LATCH KNOB C119 LATCH SPRING C102 OUTER LID C1071 ASY BELLOW AS Y {SERVICE SET} X316 STEAM TUBE-B C108B BELLOW CAP PACKING-B X617 STEAM OUTLET TUBE C619 STEAM TUBE PACKING X509 INNER LID PACKING C607 INNER LID E205ASY INNER POT AS Y C123 INNER POT PACKING C2155 MOUNTING BRACKET C218ASY TERMINAL AS Y C206 UPPER RING C223 UPPER RING COVER C203 HANDLE C300 DELIVERY PIPE C312 DELIVERY BASE COVER C216ASY BALL HOLDER AS Y C124 CONNECTOR UPPER E209 GLASS PIPE C4061 CONNECTOR LOWER E5071PLASY ** BODY AS Y {KP-36S.. PL} E402ASY BOTTOM COVER AS Y C307 LAMP INSULATOR COVER C415 ROTATING BASE C4104ASY PLUG PLATE AS Y 1 18

19 REF. NO PARTS CODE (FEC) ELECTRIC PARTS DESCRIPTION Q TY PRICE 3-1 3C4123ASY POWER CORD AS Y C2933SET TEMPERATURE FUSE SET C2095SET HEATER SET {SERVICE SET} B2121 THERMOSTAT 91 o C C4931ASY NEON LAMP AS Y 1 19

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USER MANUAL Model DWP-55/DWP-66

USER MANUAL Model DWP-55/DWP-66 ELECTRIC THERMO POT BY D A E W O O E L E C T R O N I C S S AL E S & SERVICES ( M ) S DN BH D CONTENTS TITLES PAGE NO General Safety Precautions 1 Parts Introduction 3 Technical