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Whirlpool KR-28 manual

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Table of contents for the manual

  • Page 1

    JOB AID Part No. 8177893 WHIRLPOOL GAS RANGE DIRECT SP ARK IGNITION SYSTEM KR-28[...]

  • Page 2

    - ii - WHIRLPOOL CORPORA TION assumes no responsibility for any repair made on our products by anyone other than Authorized Factory Service T echnicians. Copyright 2000, Whirlpool Corporation, Benton Harbor , MI 49022 FOR W ARD This Job Aid, “Whirlpool Gas Range Direct Spark Ignition System,” (Part No. 8177893), provides the technician with inf[...]

  • Page 3

    - iii - T able of Contents SECTION 1 ................................................................................................................................ 1 THEORY OF OPERATION ........................................................................................................ 1 Introduction ..........................................[...]

  • Page 4

    - iv - IMPORT ANT SAFETY INFORMA TION Y our safety and the safety of others is very important. Important safety messages have been provided in this Job Aid. Always read and obey all safety messages. This is the safety alert symbol. This symbol alerts you to hazards that can kill or hurt you and others. All safety messages will be preceded by the sa[...]

  • Page 5

    - 1 - SECTION 1 SECTION 1 SECTION 1 SECTION 1 SECTION 1 THEOR Y OF OPERA TION The Direct Spark Ignition System contains a Gas Distribution V alve and a Direct Spark Ig- nition (DSI) Control that interfaces with the Electronic Oven Control, and spark electrodes. This provides the direct spark ignition and gas distribution for Whirlpool self-cleaning[...]

  • Page 6

    - 2 - Gas Distribution Valve The gas distribution valve can be converted to L.P . gas, when necessary . It regulates the dis- tribution of gas to the cooktop and both oven burners. The gas distribution valve is non-ser- viceable. GAS DISTRIBUTION V AL VE The gas distribution valve is made up of the following features: • Natural & L.P . gas re[...]

  • Page 7

    - 3 - When the lever is raised, the gas to the oven burners is turned on. Manual Valve Lever Down (Gas Off) Manual Valve Lever Raised (Gas On) MANUAL OVEN SHUTOFF V AL VE A manual oven shutoff valve is available on the gas distribution valve to shut off the gas to the oven burners. This valve will not af fect the operation of the cooktop burners. W[...]

  • Page 8

    - 4 - BAKE & BROIL SOLENOID- ACTIV A TED PORTS The bake and broil gas supply ports are opened and closed by electrically-operated solenoids. When voltage is received from the spark ignition control for the bake or broil function, (8-18 VDC), the solenoid for that function is activated, and the valve opens to allow gas flow to the burner . The e[...]

  • Page 9

    - 5 - b) Install the conversion cap on the gas distribution valve with the L.P . side fac- ing up (you will see L.P . stamped inside the cap, as shown). L.P. Gas The range is manufactured to use natural gas. T o convert the range to use L.P . gas, the fol- lowing steps are performed: 1. Turn off the gas and electrical supplies to the range. 2. Remo[...]

  • Page 10

    - 6 - 6. To convert the broil burner: a) Open the oven door and remove the oven racks. b) Use a 1/2" open-end wrench and turn the orifice hood down snug onto the pin (approximately 2-1/2 turns). DO NOT OVER TIGHTEN THE ORIFICE. The burner flame cannot be properly ad- justed if this conversion is not made. Broil Burner Orifice a) Use an 8 mm so[...]

  • Page 11

    - 7 - 64 3 2 1 7 9 10 10-PIN CONNECT OR GND BAKE BROIL T OP BURNERS J1 DIRECT SP ARK IGNITION CONTROL DIRECT SP ARK IGNITION CONTROL The Direct Spark Ignition (DSI) Control inter- faces with the Electronic Oven Control for the Bake, Broil, and Self-Clean functions. The DSI also interfaces with the four cooktop burner ig- nition switches, to provide[...]

  • Page 12

    - 8 - L1 N BK BK R W IGNITION SWITCH DIRECT SPARK IGNITION CONTROL 64 3 2 1 7 9 10 T OP BURNERS GND 10-PIN CONNECT OR J1 This 120 V AC is detected by the control, and generates two sparks-per-second to all of the top burners. Note that in the strip circuit be- low , 120 V AC is present at the control at all times through input pin J1-10 , and outpu[...]

  • Page 13

    - 9 - OVEN BURNER OPERA TION The spark ignition for the oven burners is started at the Electronic Oven Control (ERC). As the ERC is programmed for Bake or Broil, the appropriate relay is closed on the ERC. 120 V AC is provided from L 1 , through the ERC relay(s) to the direct spark ignition control at input pin J1-6 (Bake), or J1-7 (Broil), to the [...]

  • Page 14

    - 10 - Once the gas has ignited, the “flame safety circuit” will monitor the flame at the burner to make sure it is present. If a flame is not present at the burner: a) The control will allow the ignitor to spark for 4 seconds. b) A 40 second delay to dissipate any un- used gas inside the oven will occur . The ignition attempt will occur three [...]

  • Page 15

    - 11 - ELECTRICAL SHOCK HAZARD Disconnect power before servicing the range. Replace all panels before operating range. Failure to do so can result in death or electri- cal shock. REMOVING THE DIRECT SP ARK IGNITION CONTROL CAUTION: When you work on the gas range, be careful when handling the sheet metal parts. Sharp edges may be present, and you ca[...]

  • Page 16

    - 12 - ELECTRICAL SHOCK HAZARD Disconnect power before servicing the range. Replace all panels before operating range. Failure to do so can result in death or electri- cal shock. REMOVING THE GAS DISTRIBUTION V AL VE CAUTION: When you work on the gas range, be careful when handling the sheet metal parts. Sharp edges may be present, and you can cut [...]

  • Page 17

    - 13 - DIRECT SP ARK IGNITION CONTROL Electrical Shock Hazard Voltage is present during these tests. WARNING COMPONENT TESTING SECTION 3 SECTION 3 SECTION 3 SECTION 3 SECTION 3 TEST PROCEDURE V oltage T ests Bake Function 1. Set the voltmeter to read 120 VAC. 2. Program the range for the Bake operation. 3. If the top burners spark, proceed to step [...]

  • Page 18

    - 14 - 4 (white) 10 (black) J1 Connector Broil Function 1. Set the voltmeter to read 120 VAC. 2. Program the range for the Broil operation. 3. If the top burners spark, proceed to step 4. Touch the test leads to the J1 connector at terminals 4 (white) and 10 (black). The AC voltmeter should indicate 120 VAC. If not, check for the proper voltage at [...]

  • Page 19

    - 15 - 4 (white) 7 (blue/white) J1 Connector * When power is applied to the range, a safety delay of 40 seconds takes place before the direct spark ignition control becomes operational. The opera- tion will last for a period of 4 seconds, and the direct spark ignition will again turn off (see the “Timing Chart” for the oven burners on page 10).[...]

  • Page 20

    - 16 - 2. Turn one of the cooktop burner valves to the LITE position. 4. Touch the test leads to the J1 connector at terminals 4 (white) and 9 (red). The AC voltmeter should indicate 120 VAC. If not, check the ignition switch and the main wiring harness. 3. Touch the test leads to the J1 connector at terminals 4 (white) and 10 (black). The AC voltm[...]

  • Page 21

    - 17 - GAS DISTRIBUTION V AL VE TEST PROCEDURE Solenoid Resistance T ests 1. Disconnect power from the range. 2. Set the ohmmeter to the R x 100 scale. 3. Touch the ohmmeter terminals to termi- nals 1 and 2 (Broil). The ohmmeter should read 216 Ω ± 30. 4. Touch the ohmmeter terminals to termi- nals 3 and 2 (Bake). The ohmmeter should read 216 ?[...]

  • Page 22

    - 18 - — NOTES —[...]

  • Page 23

    - 19 - L1 BK P1-3 P1-1 P2-2 P1-2 DOOR LA TCH SW . (IF EQUIPPED) GND OVEN L T . P1-4 P1-5 DOOR LIGHT SW. OVEN CONTROL N N/C BR P2-4 P2-1 ROCKER SW. (IF EQUIPPED) P6-4 P6-3 N/O OR OR BK V V TRANSFORMER BU GY BU W R W W W W W W BK BK Y Y GY BK BK R R BU P6-1 MOT 64 3 2 1 7 9 10 OVEN TEMP SENSOR P AR T NO . 8273173 NO TE: Dr awing sho ws door latch swi[...]

  • Page 24

    - 20 - BAKE BROIL COOKT OP STRIP CIRCUITS N L1 BK BK P1-4 P1-5 O VEN TEMP SENSOR V V P2-4 R BAKE V AL VE W OR R P2-1 OVEN CONTROL (ERC) BRO IL RELA Y BAKE RELA Y J1 64 3 2 1 7 9 10 10-PIN CONNECTOR GND BAKE BROIL DIRECT SP ARK IGNITION CONTROL J1 10-PIN CONNECTOR O VEN TEMP SENSOR N L1 BROIL RELA Y OVEN CONTROL (ERC) BROIL V AL VE BU BU OR W BK BK [...]

  • Page 25

    - 21 - CLEAN BRO IL RELA Y BAKE RELA Y O VEN CONTROL N L1 P1-3 P1-1 P2-2 P1-2 LA TCH DRIVE P1-4 P1-5 DOOR SWITCH BR P2-4 P2-1 P6-4 P6-3 N/O BK V V TRANSFORMER BU GY BU W OR OR R W LA TCH RELA Y Y Y GY BROIL V AL VE BAKE V AL VE R BU DOOR LA TCH SW P6-1 MO T J1- 64 3 2 1 7 9 10 OV E N TEMP SENSOR 10-PIN CONNECT OR GND BAKE BROIL 1080 W @ 72 ˚ F DIR[...]

  • Page 26

    - 22 - — NOTES —[...]

  • Page 27

    - 23 - SECTION 5 SECTION 5 SECTION 5 SECTION 5 SECTION 5 DIAGNOSTIC FLOW CHARTS TECH TIPS COOKT OP Star t Done Does cooktop spark proper ly? Is 120 V A C present from J1-4 to J1-10? Check the high v oltage igniter wires f or continuity and proper connections from DSI control to igniters. Make sure the b ur ner caps are the correct size and are prop[...]

  • Page 28

    - 24 - BAKE Done Does the Bake cycle function properly? Does the spark continue after a flame is present? Does the Bake burner establish a flame and then turn off? Is 120 V A C present from J1-4 to J1-6? Is 120 V A C present from J1-4 to J1-7? T urn the ERC off. T est the distribution valv e for contin uity at J1-1 and J1-2, then J1-2 and J1-3. Are[...]

  • Page 29

    - 25 - BROIL Done Does the Broil cycle function properly? Does the spark continue after a flame is present? Does the Broil burner establish a flame and then turn off? Is 120 V A C present from J1-4 to J1-7? Is 120 V A C present from J1-4 to J1-6? Connect a DC voltmeter to J1-3 (+) and J1-2 ( – ). W ait 40 seconds, then start a Broil cycle. 6 seco[...]