KR-28 WHIRLPOOL GAS RANGE DIRECT SPARK IGNITION SYSTEM JOB AID Part No.
FORWARD This Job Aid, “Whirlpool Gas Range Direct Spark Ignition System,” (Part No. 8177893), provides the technician with information on the operation and service of the Direct Spark Ignition System. It is to be used as a training Job Aid and Service Manual. The Wiring Diagrams used in this Job Aid are typical and should be used for training purposes only. Always use the Wiring Diagrams supplied with the product when servicing the unit.
Table of Contents PAGE SECTION 1 ................................................................................................................................ 1 THEORY OF OPERATION ........................................................................................................ 1 Introduction ........................................................................................................................... 1 Gas Distribution Valve ...........................................................
IMPORTANT SAFETY INFORMATION Your 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 safety alert symbol and the word “WARNING.
SECTION 1 THEORY OF OPERATION INTRODUCTION The Direct Spark Ignition System contains a Gas Distribution Valve and a Direct Spark Ignition (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 gas freestanding ranges. A proper ground and the correct polarity is necessary for the DSI control to sense the pres- ence of a flame.
GAS DISTRIBUTION VALVE The gas distribution valve can be converted to L.P. gas, when necessary. It regulates the distribution of gas to the cooktop and both oven burners. The gas distribution valve is non-serviceable. The gas distribution valve is made up of the following features: • Natural & L.P. gas regulator • Manual oven shutoff valve • Bake & broil solenoids • Pressure tap - To measure gas outlet pressure Pressure Tap (1/8˝ - 27 N.P.T.) L.P.
MANUAL OVEN SHUTOFF VALVE 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 affect the operation of the cooktop burners. When the lever is down, the gas to the oven burners is turned off. When the lever is raised, the gas to the oven burners is turned on.
BAKE & BROIL SOLENOIDACTIVATED 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 electrical connections at the valve consist of three terminals, each one sized differently to prevent incorrect wiring (see below).
L.P. GAS CONVERSION The range is manufactured to use natural gas. To convert the range to use L.P. gas, the following steps are performed: 1. Turn off the gas and electrical supplies to the range. 2. Remove the storage drawer from the range. 3. Locate the gas distribution valve at the rear of the range. To convert the gas distribution valve: a) Unscrew the conversion cap from the gas distribution valve. Note the difference between the L.P. and natural gas ends of the cap. L.P. Gas 4.
5. To convert the cooktop burners: NOTE: The L.P. orifices for the cooktop burners are supplied in the literature pack inside the oven. 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 OVERTIGHTEN THE ORIFICE. The burner flame cannot be properly adjusted if this conversion is not made.
DIRECT SPARK IGNITION CONTROL The Direct Spark Ignition (DSI) Control interfaces with the Electronic Oven Control for the Bake, Broil, and Self-Clean functions. The DSI also interfaces with the four cooktop burner ignition switches, to provide ignition for the cooktop. J1 DIRECT SPARK IGNITION CONTROL 10 9 7 6 The DSI control uses a self-diagnostic test to verify that the oven ignition system is working properly. It will also continually monitor the flame presence within the oven.
ELECTRONIC SPARK IGNITION COOKTOP BURNER OPERATION The top burner spark ignition system is initiated when the burner control is turned to the LITE position. 120 VAC is supplied through the ignition switch from the L1 side of the circuit to the direct spark ignition control at input J1-9 on the control. The circuit is completed through output pin J1-4 to the neutral side of the circuit. This 120 VAC is detected by the control, and generates two sparks-per-second to all of the top burners.
OVEN BURNER OPERATION 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 VAC is provided from L1, through the ERC relay(s) to the direct spark ignition control at input pin J1-6 (Bake), or J1-7 (Broil), to the neutral side of the circuit, through output pin J1-4. This 120 VAC is used to generate two sparksper-second to both oven burners.
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 unused gas inside the oven will occur. The ignition attempt will occur three times. If the burner does not ignite after the three attempts, the system will “lockout” (see the Timing Chart below).
SECTION 2 COMPONENT ACCESS This section instructs you on how to service the direct spark ignition system components inside the Gas Range. REMOVING THE DIRECT SPARK IGNITION CONTROL WARNING 4. Disconnect the wire connectors from the direct spark ignition control. 5. 6. Remove the mounting screws. Slide the two top pins out of the bracket slots and remove the control from the bracket. ELECTRICAL SHOCK HAZARD Disconnect power before servicing the range. Replace all panels before operating range.
REMOVING THE GAS DISTRIBUTION VALVE 3. WARNING ELECTRICAL SHOCK HAZARD 4. Disconnect power before servicing the range. Replace all panels before operating range. Failure to do so can result in death or electrical shock. Remove the gas outlet lines from the gas distribution valve with a 9/16˝ open-end wrench. Remove the four mounting screws from the gas distribution valve. Gas Outlet Screws FIRE HAZARD Shut off gas supply line valve before servicing the range.
SECTION 3 COMPONENT TESTING DIRECT SPARK IGNITION CONTROL 3. WARNING Electrical Shock Hazard Voltage is present during these tests. TEST PROCEDURE Voltage Tests 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 the power supply outlet, and check the main wiring harness. 10 (black) 4 (white) Bake Function 1. Set the voltmeter to read 120 VAC. 2.
5. 6. Set the voltmeter to read between 8 and 18 volts DC. Touch the test leads to the J1 connector at terminals 1 (red) and 2 (orange). The DC voltmeter should indicate between 8 and 18 volts DC*. If not, replace the DSI control. 1 (red) Broil Function 1. Set the voltmeter to read 120 VAC. 2. Program the range for the Broil operation. J1 Connector 2 (orange) J1 Connector 3.
4. 6. Touch the test leads to the J1 connector at terminals 4 (white) and 7 (blue/white). The AC voltmeter should indicate 120 VAC. If not, check the electronic oven control for proper operation. 4 (white) Touch the test leads to the J1 connector at terminals 2 (orange) and 3 (blue). The DC voltmeter should indicate between 8 and 18 volts DC*. If not, replace the DSI control. 2 (orange) 3 (blue) 7 (blue/white) J1 Connector 5. J1 Connector * Set the voltmeter to read between 8 and 18 volts DC.
3. Cooktop Function 1. Set the voltmeter to read 120 VAC. J1 Connector 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 the power supply outlet, and check the main wiring harness. 10 (black) 4 (white) J1 Connector 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).
GAS DISTRIBUTION VALVE TEST PROCEDURE Solenoid Resistance Tests 1. 2. 3. 4. Disconnect power from the range. Set the ohmmeter to the R x 100 scale. Touch the ohmmeter terminals to terminals 1 and 2 (Broil). The ohmmeter should read 216 Ω ±30. Touch the ohmmeter terminals to terminals 3 and 2 (Bake). The ohmmeter should read 216 Ω ±30. NOTE: Always check both solenoids. If one of the solenoids is defective, neither one will operate.
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SECTION 4 WIRING DIAGRAM & STRIP CIRCUITS WIRING DIAGRAM N L1 OVEN LT. W DOOR LATCH SW. (IF EQUIPPED) ROCKER SW. (IF EQUIPPED) W W W OVEN CONTROL BK BK W BK W P6-3 P6-1 P1-2 Y P1-3 TRANSFORMER V DOOR LIGHT SW.
STRIP CIRCUITS BAKE OVEN CONTROL (ERC) L1 BK N BROIL RELAY P2-1 BAKE VALVE V P1-4 OVEN TEMP SENSOR P1-5 V P2-4 BAKE RELAY R R OR W BK J1 10 9 7 6 4 3 2 1 10-PIN CONNECTOR GND BAKE BROIL DIRECT SPARK IGNITION CONTROL BROIL BROIL VALVE L1 N OVEN CONTROL (ERC) BK P2-1 V BROIL RELAY P2-2 BU BU OR W P1-4 J1 10 9 OVEN TEMP SENSOR 7 6 4 3 2 1 10-PIN CONNECTOR P1-5 BAKE RELAY V DIRECT SPARK GND BAKE BROIL IGNITION CONTROL BK COOKTOP L1 BK IGNITION SWITCH N R BK W DI
CLEAN L1 N W OVEN CONTROL P6-3 P6-1 TRANSFORMER V P1-2 DOOR SWITCH Y GY P1-3 P1-1 P1-4 Y GY N/O BU DOOR LATCH SW LATCH DRIVE P1-5 OVEN V TEMP SENSOR LATCH RELAY 1080 W @ 72˚F BK P6-4 BR MOT W BROIL VALVE P2-2 OR BU BU P2-1 BAKE VALVE BROIL RELAY BAKE RELAY P2-4 R R J1- 10 9 7 6 4 3 2 1 10-PIN CONNECTOR DIRECT SPARK GND BAKE BROIL IGNITION CONTROL - 21 - OR
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SECTION 5 TECH TIPS DIAGNOSTIC FLOW CHARTS COOKTOP Start NOTE: The range must be plugged in for at least 40 seconds before this test can begin. Does cooktop spark properly? yes Done no Check the high voltage igniter wires for continuity and proper connections from DSI control to igniters. Make sure the burner caps are the correct size and are properly oriented. Also, if the supply voltage is less than 102 VAC, the spark might not occur. Diagnose the main wiring harness.
BAKE Done Check the polarity of the supply voltage. Even if no ground is connected, the DSI control will not be able to sense the presence of a flame at the igniter if the polarity is reversed. yes no Does the Bake cycle function properly? Replace the gas distribution valve. Does the spark continue after a flame is present? no Check the igniter for continuity. If not okay, replace the igniter. If the supply polarity is correct, check the Bake ignition wire for a loose connection.
BROIL Done yes no Does the Broil cycle function properly? Replace the gas distribution valve. Does the spark continue after a flame is present? no Check the igniter for continuity. If not okay, replace the igniter. If the supply polarity is correct, check the Broil ignition wire for a loose connection. If okay, replace the DSI control. Does the Broil burner establish a flame and then turn off? yes no yes Diagnose the main wiring harness and/or the electronic oven control (ERC).
