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Whirlpool 8177893, Manual

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Table of Contents

SECTION 1 ................................................................................................................................

1

THEORY OF OPERATION ........................................................................................................ 1

Introduction ........................................................................................................................... 1
Gas Distribution Valve.......................................................................................................... 2
    Manual Oven Shutoff Valve .............................................................................................. 3
    Bake & Broil Solenoid-Activated Ports .............................................................................. 4
L.P. Gas Conversion ............................................................................................................. 5
Direct Spark Ignition Control ................................................................................................. 7
Electronic Spark Ignition ....................................................................................................... 8
    Cooktop Burner Operation ................................................................................................ 8
    Oven Burner Operation ..................................................................................................... 9

SECTION 2 ..............................................................................................................................

11

COMPONENT ACCESS .......................................................................................................... 11

Removing The Direct Spark Ignition Control ...................................................................... 11
Removing The Gas Distribution Valve ................................................................................ 12

SECTION 3 ..............................................................................................................................

13

COMPONENT TESTING ......................................................................................................... 13

Direct Spark Ignition Control ............................................................................................... 13
Gas Distribution Valve........................................................................................................ 17

SECTION 4 ..............................................................................................................................

19

WIRING DIAGRAM & STRIP CIRCUITS ................................................................................. 19

Wiring Diagram ................................................................................................................... 19
Strip Circuits ....................................................................................................................... 20

SECTION 5 ..............................................................................................................................

23

TECH TIPS .............................................................................................................................. 23

Diagnostic Flow Charts ....................................................................................................... 23

PAGE

Summary of Contents for 8177893

Page 1: ...JOB AID Part No 8177893 WHIRLPOOL GAS RANGE DIRECT SPARK IGNITION SYSTEM KR 28 ...

Page 2: ...e 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 GOALS AND OBJECTIVES The goal of this Job Aid is to provide detailed information that will enable the service technician to properly diagnose malfunctions and repair the Direct Spark Ignition System The objectiv...

Page 3: ...ronic Spark Ignition 8 Cooktop Burner Operation 8 Oven Burner Operation 9 SECTION 2 11 COMPONENT ACCESS 11 Removing The Direct Spark Ignition Control 11 Removing The Gas Distribution Valve 12 SECTION 3 13 COMPONENT TESTING 13 Direct Spark Ignition Control 13 Gas Distribution Valve 17 SECTION 4 19 WIRING DIAGRAM STRIP CIRCUITS 19 Wiring Diagram 19 Strip Circuits 20 SECTION 5 23 TECH TIPS 23 Diagnos...

Page 4: ...DSI System The requirements are 102 to 132 VAC with the proper polarity and ground If the electrical sup ply is less than 102 VAC sparking will not be reliable If the system is over 132 VAC per manent damage to the DSI can occur NOTE TO TECHNICIAN Improper polar ity will cause the direct spark ignition system to malfunction Always check for proper polarity at the wall outlet before replacing parts...

Page 5: ...e DSI control to sense the pres INTRODUCTION ence of a flame If the polarity is reversed or in some cases if there is a poor ground the control will appear to operate normally How ever after an oven burner ignites the spark will continue to occur at the burner and the valve will then shut off after 4 seconds This is because the DSI control does not recognize the presence of a flame when one is pre...

Page 6: ... valve is non ser viceable GAS DISTRIBUTION VALVE 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 To Broil Burner Manual Oven Shutoff Valve Electrical Terminals L P Conversion Cap Gas Inlet 1 2 Female Threads To Cooktop To Bake Burner ...

Page 7: ...f Manual Valve Lever Raised Gas On 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 ...

Page 8: ...tions at the valve consist of three terminals each one sized differently to prevent incorrect wir ing see below The solenoids require special voltage current 8 18 VDC from the direct spark ignition con trol to operate properly IMPORTANT Do not attempt to operate the solenoids with any other voltage supply Electrical Terminals Broil 1 8 wide Common 1 4 wide Bake 3 16 wide Manual Oven Shutoff Valve ...

Page 9: ...he range To convert the gas distribution valve a Unscrew the conversion cap from the gas distribution valve Note the differ ence between the L P and natural gas ends of the cap L P GAS CONVERSION 4 To convert the bake 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 OR...

Page 10: ...de Broil Burner Orifice a Use an 8 mm socket and carefully re move the orifice spud from each of the four burners b Install the four L P gas orifices in the burners 5 To convert the cooktop burners NOTE The L P orifices for the cooktop burn ers are supplied in the literature pack inside the oven Surface Burner Orifice 8mm Socket 7 Reinstall the storage drawer and oven racks Pin Natural Gas Unit is...

Page 11: ...t to verify that the oven ignition system is working properly It will also continually monitor the flame presence within the oven The DSI con trol operates on 102 to 132 VAC All input and output testing is performed at the J1 connec tor see below J3 J4 T1 J1 T2 T3 T4 J2 J6 J5 J8 J7 1 2 3 4 6 7 9 10 J1 Bake Valve Output Bake Input Broil Valve Output Valve Common Neutral Broil Input Top Burner Input...

Page 12: ...elf diagnostics of the control board b Monitor the flame safety circuits to both of the oven burners NOTE The top burners are operator moni tored and do not require electronic monitor ing COOKTOP BURNER OPERATION The top burner spark ignition system is initi ated 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 t...

Page 13: ...to dissipate before a spark is activated When the Bake or Broil operation is activated the direct spark ignition control initiates an internal self test and flame safety check The flame safety check takes place anytime there is a flame present at ei ther oven burner Bake Operation Broil Operation N L1 BK BK P1 4 P1 5 OVEN TEMP SENSOR V V P2 4 R BAKE VALVE W OR R P2 1 OVEN CONTROL ERC BROIL RELAY B...

Page 14: ...fter being established NOTE If this occurs a lockout condition will oc cur after 30 seconds with no attempt to reignite During the lockout the gas distribution valve and ignition are turned off All lockouts can be reset by pressing the OFF Cancel keypad on the Electronic Oven Control NOTE There will be no indication on the electronic oven control display showing a lockout condition Note To Technic...

Page 15: ...ls before operating the range Failuretodosocouldresultinexplosion fire or other injury 1 Turn off the gas to the range and discon nect the power cord from the wall outlet 2 Pull the range away from the wall so you can access the back of the unit 3 Remove the top rear cover 4 screws 5 Remove the mounting screws 6 Slide the two top pins out of the bracket slots and remove the control from the bracke...

Page 16: ... operating the range Failuretodosocouldresultinexplosion fire or other injury 1 Turn off the gas to the range and discon nect the power cord from the wall outlet 2 Pull the range away from the wall so you can access the back of the unit 3 Remove the gas outlet lines from the gas distribution valve with a 9 16 open end wrench 4 Remove the four mounting screws from the gas distribution valve 6 Remov...

Page 17: ...ck 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 J1 Connector 4 white 10 black J1 Connector 4 Touch the test leads to the J1 connector at terminals 4 white and 6 red white The AC voltmeter should indicate 120 VAC If not check the electronic oven control for proper operation J1 Connector 6 red white 4 white ...

Page 18: ...ain wiring harness 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 5 Set the voltmeter to read between 8 and 18 volts DC 6 Touch the test leads ...

Page 19: ...ite and 7 blue white The AC voltmeter should indicate 120 VAC If not check the electronic oven control for proper operation 5 Set the voltmeter to read between 8 and 18 volts DC 2 orange 3 blue J1 Connector 6 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 con trol J1 10 PIN CONNECTOR OVEN T...

Page 20: ...t 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 J1 Connector Cooktop Function 1 Set the voltmeter to read 120 VAC 4 white 10 black J1 Connector 4 white 9 red J1 Connector L1 N BK BK R W IGNITION SWITCH 6 4 3 2 1 7 9 10 TOP BURNERS GND 10 PIN CONNEC...

Page 21: ...e 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 nals3and2 Bake Theohmmetershould read 216 Ω 30 NOTE Always check both solenoids If one of the solenoids is defective neither one will operate 1 2 3 ...

Page 22: ... 18 NOTES ...

Page 23: ...273173 NOTE Drawing shows door latch switch in the Cook position with oven door open oven Off and light On 1080 W 72 F 10 PIN CONNECTOR GND BAKE BROIL TOP BURNERS J1 DIRECT SPARK IGNITION CONTROL SURFACE BURNER IGNITION SWITCHES BROIL VALVE BAKE VALVE BAKE RELAY BROIL RELAY LATCH RELAY LATCH DRIVE DOOR LATCH SWITCH SEALED BURNER UNITS EQUIPPED WITH 4 IGNITORS OPEN BURNER UNITS WITH 2 IGNITORS WIRI...

Page 24: ...10 PIN CONNECTOR GND BAKE BROIL DIRECT SPARK IGNITION CONTROL J1 10 PIN CONNECTOR OVEN TEMP SENSOR N L1 BROIL RELAY OVEN CONTROL ERC BROIL VALVE BU BU OR W BK BK P1 4 P1 5 V V P2 1 P2 2 6 4 3 2 1 7 9 10 GND BAKE BROIL BAKE RELAY DIRECT SPARK IGNITION CONTROL L1 N BK BK R W IGNITION SWITCH 6 4 3 2 1 7 9 10 TOP BURNERS GND 10 PIN CONNECTOR J1 DIRECT SPARK IGNITION CONTROL ...

Page 25: ...H 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 LATCH RELAY Y Y GY BROIL VALVE BAKE VALVE R BU DOOR LATCH SW P6 1 MOT J1 6 4 3 2 1 7 9 10 OVEN TEMP SENSOR 10 PIN CONNECTOR GND BAKE BROIL 1080 W 72 F DIRECT SPARK IGNITION CONTROL ...

Page 26: ... 22 NOTES ...

Page 27: ...rner 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 120 VAC should always be present at this point Replace the DSI control With the cooktop knob in LITE is 120 VAC present from J1 4 to J1 9 Diagnose the cooktop wiring harness Check the cooktop switches for the proper function NOTE The ra...

Page 28: ...r Bake Broil exists simultaneously Measure the resistance at the distribution valve If different than measured at the DSI control diagnose the wiring harness If resistances are the same as measured at the DSI control replace the valve If the voltage is higher than 18 VDC check the main wiring harness for bad connections If okay replace the distribution valve yes no yes no no yes yes yes no yes yes...

Page 29: ...yes yes yes yes yes yes yes yes no no no no Replace the gas distribution valve Replace the DSI control Does spark occur at the Bake igniter but not the Broil Does spark occur at the igniter Check the igniter for cracks in the ceramics If cracks are found replace the igniter Diagnose the Broil igniter wiring harness If okay replace the control The igniter position is out of tolerance for the proper...

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