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Wolf WKGX 126623 manual

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  • Page 1

    WOLF RANGE DIVISION OF ITW FOOD EQUIPMENT GROUP, LLC LOUISVILLE, KY 40201-0696 F32700 (February 2006) WKGD2 WITH ROAST & HOLD SHOWN SERVICE MANUAL WKG SERIES FULL SIZE GAS CONVECTION OVENS MODEL ML WKG 126620 WKGD 126621 WKGC 126622 WKGX 126623 WKGDX 126624 WKGCX 126625 For additional information on Wolf Range or to locate an authorized parts a[...]

  • Page 2

    FULL SIZE GAS CONVECTION OVENS F32700 (February 2006) Page 2 of 64 TABLE OF CONTENTS G E N E R A L ................................................................................ 4 Introduction ............................................................................ 4 I n s t a l l a t i o n ....................................................[...]

  • Page 3

    FULL SIZE GAS CONVECTION OVENS F32700 (February 2006) Page 3 of 64 C o m p u t e r C o n t r o l ( W K G C / W K G C X ) ....................................................... 2 6 C o m p u t e r C o n t r o l C a l i b r a t i o n ( W K G C / W K G C X ) .............................................. 2 7 E L E C T R I C A L O P E R A T I O N ....[...]

  • Page 4

    FULL SIZE GAS CONVECTION OVEN - GENERAL F32700 (February 2006) Page 4 of 64 GENERAL INTRODUCTION Procedures in this manual will apply to all models unless specified. Pictures and illustrations can be of any model unless the picture or illustration needs to be model specific. Models MODEL FEATURES OPTIONS CAVITY DEPTH TEMPERATURE CONTROL DOORS (50/5[...]

  • Page 5

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 5 of 64 REMOVAL AND REPLACEMENT OF PARTS COVERS AND PANELS WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. Top Front Cover 1. The top front cover is secured with four (4) screws, two on each side of cover. Re[...]

  • Page 6

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 6 of 64 CONTROL PANEL COMPONENTS Removable Components Procedure WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. Remove the control panel as outlined under COVERS AND PANELS. 2. Remove the component being r[...]

  • Page 7

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 7 of 64 COMPONENT PANEL COMPONENTS Removable Components Procedure WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. Remove the right side panel as outlined under COVERS AND PANELS. NOTE: If right side panel [...]

  • Page 8

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 8 of 64 TEMPERATURE PROBE (WKGD/WKGDX) WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. Remove the right side panel as outlined under COVERS AND PANELS. NOTE: If right side panel is not accessible, this com[...]

  • Page 9

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 9 of 64 6. Reverse procedure to install the replacement burner. NOTE: Ensure that burner positioning bracket (U shaped end) is inserted into slot at the rear of the burner chamber. 7. Check for proper operation. GAS ORIFICE WARNING: DISCONNECT THE ELECTRIC[...]

  • Page 10

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 10 of 64 4. Loosen the bolts securing the valve and bracket assembly then remove the screws securing the valve to the bracket. 5. Reverse the procedure to install the replacement gas valve. NOTE: Clean the pipe threads and apply pipe joint compound to thre[...]

  • Page 11

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 11 of 64 3. Reverse the procedure to install the assembly and check for proper operation. NOTE: Check to ensure the spark gap distance is approximately 1/8". If the gap appears to be excessive or poor sparking is occurring then adjust. BLOWER AND MOTO[...]

  • Page 12

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 12 of 64 6. Remove the nuts that secure the motor mounting plate to the rear wall. 7. Place a piece of cardboard on the bottom of the oven cavity to protect its surface from any damage during motor assembly removal. 8. Pull the motor assembly into the oven[...]

  • Page 13

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 13 of 64 2. Remove the door switch lever. 3. Remove the lower door seal strip to expose the mounting screws of the door assembly. 4. Remove the two (2) lower sill bolts by the lower door shaft and the four (4) counter-sunk screws from the lower sill. NOTE:[...]

  • Page 14

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 14 of 64 NOTE: The door assembly is heavy and will drop down once the last screw is removed. If removing door assembly with-out assistance, the ignition cable, flame sense lead and gas manifold should also be removed to avoid damage to these components. 5.[...]

  • Page 15

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 15 of 64 2. Independent doors: A. Remove the door handle then remove the outer door panel. B. Lift out the inner door panel and window assembly. NOTE: Left door only - remove door seal from the inside edge of the door. 3. Simultaneous doors: A. If replacin[...]

  • Page 16

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 16 of 64 MECHANICAL KX THERMOSTAT (WKG/WKGX) WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. Remove the racks and right rack support. 2. Remove the thermostat knob and mounting screws from the control pane[...]

  • Page 17

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS F32700 (February 2006) Page 17 of 64 Lamp Assembly WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. Remove the lens and bulb. 2. Remove the springs from the retaining tabs (2 places) on the socket. 3. Depress the retaining tabs and pu[...]

  • Page 18

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS F32700 (February 2006) Page 18 of 64 SERVICE PROCEDURES AND ADJUSTMENTS WARNING: CERTAIN PROCEDURES IN THIS SECTION RE QUIRE ELECTRICAL TEST OR MEASUREMENTS WHILE POWER IS APPLIED TO THE MACHINE. EXERCI SE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASILY ACCESSIBLE, DISC[...]

  • Page 19

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS F32700 (February 2006) Page 19 of 64 MECHANICAL THERMOSTAT CALIBRATION (WKG/WKGX) 1. Place a thermocouple in the geometric center of the oven cavity. 2. Set the ON-OFF-OVEN COOL switch to ON. 3. Set the thermostat dial to 350°F. 4. Allow the oven temperature to stabilize (normally[...]

  • Page 20

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS F32700 (February 2006) Page 20 of 64 4. Check machine data plate for correct voltage to oven. Refer to diagram below for proper terminal locations and voltages before checking the control. Use the correct terminals for the corresponding voltage. 5. Turn the ON-OFF-OVEN COOL switch [...]

  • Page 21

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS F32700 (February 2006) Page 21 of 64 5. Reverse procedure to install. TEMP (°F) OHMS* TEMP (°F) OHMS* 77 90000 360 822 240 4077 380 656 260 3016 400 529 280 2266 425 424 300 1726 450 334 320 1332 475 266 340 1041 (*) Resistance in ohms ± 10% GAS PRESSURE ADJUSTMENT WARNING: DISC[...]

  • Page 22

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS F32700 (February 2006) Page 22 of 64 VERIFICATION OF SPARK AT IGNITOR WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. WARNING: SHUT OFF THE GAS BEFORE SERVICING THE UNIT. 1. Remove the bottom front cover as outlined under COVERS AND P[...]

  • Page 23

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS F32700 (February 2006) Page 23 of 64 BLOWER ADJUSTMENT WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. WARNING: SHUT OFF THE GAS BEFORE SERVICING THE UNIT. 1. Remove the blower motor and mounting assembly by following steps 1 through [...]

  • Page 24

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS F32700 (February 2006) Page 24 of 64 DOOR ADJUSTMENT WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. Check the doors to make sure they have an equal gap between them and that the vertical edge of the door is parallel to the vertica[...]

  • Page 25

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS F32700 (February 2006) Page 25 of 64 4. Apply lubricant at the top of the door catch assembly to lubricate the internal spring. See LUBRICATION under GENERAL. 5. Close the doors and check them for proper alignment. A. Doors should be centered and parallel at the top and bottom in t[...]

  • Page 26

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS F32700 (February 2006) Page 26 of 64 F. The stop cable must be positioned where it moves freely and does not get pinched. 3. Position door chain assembly to factory setting if the conditions in step 2 are not met. 4. If right door does not lead the left door in closing: A. Loosen l[...]

  • Page 27

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS F32700 (February 2006) Page 27 of 64 MENU ALTERNATING ON DISPLAY PARAMETER DATA Celsius_Fahrenheit C_F F Guard Band gb 4000 Temperature Compensation tcnP OFF Input Type 1 InP1 J Range Low 1 rL1 75 Range High 1 rH1 500 Hysteresis HYS1 3 Calibration Offset CAL1 0 Exit Setup Mode and [...]

  • Page 28

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 28 of 64 2) If the thermocouple reading is lower than set point temperature, press the up arrow key and enter a positive offset value that is equal to the number of degrees below the 5°F tolerance. 3) Exit the setup mode. 7. Allow the oven to cycle at least two times[...]

  • Page 29

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 29 of 64 B l o w e r M o t o r ................. Operates the oven cavity blower (convection fan). Also, an internal centrifugal switch on the motor is utilized to allow the connection of power to the heat relay (R3) when the motor is at operating speed. M o t o r S p[...]

  • Page 30

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 30 of 64 T e m p e r a t u r e P r o b e ............ Senses the oven temperature for the solid state temperature control or the computer control. On WKGD/WKGDX models, converts the temperature into a resistance valve which is monitored by the temperature control boar[...]

  • Page 31

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 31 of 64 WKG/WKGX - Plug, Socket and Components (Standard Controls)[...]

  • Page 32

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 32 of 64 WKGD/WKGDX - Plug, Socket and Components (Standard Controls)[...]

  • Page 33

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 33 of 64 WKG, WKGX/WKGD, WKGDX - Plug, Socket and Components (Roast & Hold Option)[...]

  • Page 34

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 34 of 64 WKGC/WKGCX - Plug, Socket and Components (Roast & Hold Standard)[...]

  • Page 35

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 35 of 64 SEQUENCE OF OPERATION WKG, WKGX With Roast & Hold Option (Mechanical KX Thermostat) Schematic diagram 10832 will be used to explain the electrical sequence of operation for both the Normal ROAST cycle (normal cooking) and the ROAST & HOLD cycle. Norma[...]

  • Page 36

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 36 of 64 b. When the convection fan motor reaches operating speed, the centrifugal switch on the motor closes. The heat relay (R3) is then energized, R3 relay contacts normally open (N.O.) close and the heating circuit is powered. a) Ignition control module is energiz[...]

  • Page 37

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 37 of 64 J. Roast timer (normal cooking) in the OFF position. K. Roast and Hold timer in the OFF position. L. Oven doors Closed. 1) Door switch contacts CLOSED. M. Oven cavity temperature below 140°F. 2. Set controlling thermostat to desired ROAST then Hold temperatu[...]

  • Page 38

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 38 of 64 1) R3 normally open (N.O.) contacts open. a. Ignition control module de- energized. a) Power removed from 2 nd valve (main) on the gas valve and gas flow to the burner stops. NOTE: This is considered first stage cooking in the ROAST AND HOLD cycle. 5. The ove[...]

  • Page 39

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 39 of 64 trial cycle repeats after a 15 second purge between cycles for two additional tries before locking out. To reset after a lockout, turn power switch (S1) OFF then ON. 5. Oven reaches the fixed HOLD temperature and the hold thermostat opens. A. Heat light goes [...]

  • Page 40

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 40 of 64 a. Motor speed relay (R1) is energized through hold relay (R2) normally closed contacts (N.C.). Relay contacts (R1) change state and the normally open (N.O.) set of contacts close. a) Power is connected through the function switch (S3) contacts and convection[...]

  • Page 41

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 41 of 64 Roast and Hold Cycle NOTE: Refer to the Owner's Manual for a detailed explanation of ROAST & HOLD cooking. 1. Conditions. A. Oven connected to correct voltage. 1) L1 (HOT) to power switch (S1). 2) L2 (NEUTRAL or SECOND LINE) to one side of the follow[...]

  • Page 42

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 42 of 64 a. Solid state temperature control energized. If the oven temperature is below set point, the temperature control will energize its internal relay. The normally open (N.O.) contacts close and apply power to the following components: a) Heat light (clear) come[...]

  • Page 43

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 43 of 64 a. Power to one side of hold thermostat. NOTE: When temperature is above 160°F (±12) the hold thermostat contacts are open. 3) Motor speed relay (R1) de-energized, (R1) contacts change state and the normally open (N.O.) contacts OPEN. a. Convection fan moto[...]

  • Page 44

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 44 of 64 2. Power Switch (S1) turned to OVEN COOL. NOTE: With door switch contacts OPEN (doors open), the convection fan motor will still run and continue to cool the oven. However, power would be removed from the following components: Power ON light (goes out), Norma[...]

  • Page 45

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 45 of 64 I. Oven doors Closed. 1) Door switch contacts CLOSED. J. Oven cavity temperature below 140°F. 2. Power switch (S1) turned ON. A. Power (120VAC) to computer control pin 3 (C3-3). NOTE: Power at pin 3 is not transferred to other components until computer contr[...]

  • Page 46

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 46 of 64 3. Oven reaches set point temperature. A. Computer control de-activates the 120VAC output to heat relay (R1). 1) Heat relay (R1) de-energized and the normally open (N.O.) contacts OPEN. a. Power removed from ignition control module. a) The 2 nd valve (main) o[...]

  • Page 47

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 47 of 64 SCHEMATICS WKG, WKGX Mechanical (KX) Controls[...]

  • Page 48

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 48 of 64 WKG, WKGX Mechanical (KX) Controls, Roast & Hold Option[...]

  • Page 49

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 49 of 64 WKGD, WKGDX Solid State Temperature Control[...]

  • Page 50

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 50 of 64 WKGD, WKGDX Solid State Temperature Control, Roast & Hold Option[...]

  • Page 51

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 51 of 64 WKGC, WKGCX Computer Control (Roast & Hold Standard)[...]

  • Page 52

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 52 of 64 WIRING DIAGRAMS WKG, WKGX Mechanical (KX) Controls[...]

  • Page 53

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 53 of 64[...]

  • Page 54

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 54 of 64 WKG, WKGX Mechanical (KX) Controls, Roast & Hold Option[...]

  • Page 55

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 55 of 64[...]

  • Page 56

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 56 of 64 WKGD, WKGDX Solid State Temperature Control[...]

  • Page 57

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 57 of 64[...]

  • Page 58

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 58 of 64 WKGD, WKGDX Solid State Temperature Control, Roast & Hold Option[...]

  • Page 59

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 59 of 64[...]

  • Page 60

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 60 of 64 WKGC, WKGCX Computer Control (Roast & Hold Standard)[...]

  • Page 61

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION F32700 (February 2006) Page 61 of 64[...]

  • Page 62

    FULL SIZE GAS CONVECTION OVENS - TROUBLESHOOTING F32700 (February 2006) Page 62 of 64 TROUBLESHOOTING WARNING: CERTAIN PROCEDURES IN THIS SECTION RE QUIRE ELECTRICAL TEST OR MEASUREMENTS WHILE POWER IS APPLIED TO THE MACHINE. EXERCI SE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASILY ACCESSIBLE, DISCONNECT POWER AND FOLLOW LOCKOUT/TAGOUT[...]

  • Page 63

    FULL SIZE GAS CONVECTION OVENS - TROUBLESHOOTING F32700 (February 2006) Page 63 of 64 SYMPTOMS POSSIBLE CAUSES Normal (Roast) mode OK, no Hold mode. (Roast & Hold models only). 1. Roast and Hold switch (S3) malfunction. 2. R2 hold relay malfunction. 3. Roast & Hold timer malfunction. 4. Interconnecting wiring malfunction. Component cooling [...]

  • Page 64

    FULL SIZE GAS CONVECTION OVENS - CONDENSED SPARE PARTS LIST CODE & PROBLEM PROBABLE CAUSE SOLUTION F32700 (February 2006) Printed in U.S.A. Er06 - Zone 1 A/D underflow error • Incorrect sensor type • Measuring temperature outside the sensor range • Check the InP1 setup parameter. Verify it matches your sensor. • Check sensor and connect[...]