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Fire Deck

Service Manual

PG

5

OF

44

M0011.09 APRIL 2019

An ongoing program of product improvement may
require us to change specifications without notice.

WOOD STONE CORPORATION

1801 W. Bakerview Rd.
Bellingham, WA 98226 USA

TOLL FREE

800.988.8103

TEL

360.650.1111

FAX

360.650.1166

E-MAIL

[email protected]

woodstone-corp.com

SERVICE INFORMATION

SERVICE DEPARTMENT AND WARRANTY INFORMATION

If you have any questions please call the Wood Stone Service Dept� at 1-800-988-8103� Normal hours are 8am–5pm� Pacific time
Monday through Friday� After hours and on weekends call and follow the instructions to leave a message on the emergency service
voice mail� A Wood Stone technician will be paged and return your call promptly�
You must contact Wood Stone before proceeding with any Warranty service� We strongly encourage you to call whenever any service
is performed� There are two reasons for this� First, though we strive to design and build equipment that is simple and easy to service,
we realize that our equipment is quite unique� We find we can often be of considerable help over the phone when a technician is
troubleshooting an oven or rotisserie� Second, we keep a record of all service that’s been performed on each individual piece of
equipment� This history can be useful for troubleshooting� Our goal is to help you service the equipment correctly and as efficiently as
possible�
Parts are available through Wood Stone� Please contact the factory for pricing� Additional Service Manuals and Installation and
Operation Manuals are also available� Installation and Operation Manuals, and additional installation information, are also available on
the Wood Stone web site at:

www.woodstone-corp.com

�

See the complete Wood Stone Limited Warranty at the end of this manual�

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Summary of Contents for FIRE DECK 6045

Page 1: ...d Gas Wood Coal Gas Combination Models FIRE DECK 6045 WS FD 6045 RFG IR W FIRE DECK 8645 WS FD 8645 RFG IR W FIRE DECK 9660 WS FD 9660 RFG IR W CL FIRE DECK 11260 WS FD 11260 RFG IR W CL FIRE DECK 9690 WS FD 9690 RFG IR W CL FIRE DECK 11290 WS FD 11290 RFG IR W CL FIRE DECK 11275 WS FD 11275 RFG IR W CL FIRE DECK 90112 WS CS 90112 RFG IR W DOC NO M0011 09 REVISED APRIL 2019 Service Manual ...

Page 2: ...ENTS TABLE OF CONTENTS Cautions Warnings 3 Overview 4 Service Information 5 Operational Overview 6 Operation Sequence W IR 7 RFG 8 RFG IR 9 Gas Oven Components 10 Controller Troubleshooting Controller 13 Radiant Burner 15 Infrared Burner Troubleshooting 20 Common Repair Procedures 22 Gas Piping Layout 26 Electrical Diagrams 28 Parts List 32 Gas Specifications FD 6045 33 FD 8645 34 FD 9660 11260 35...

Page 3: ...sult your local gas supplier for a statement outlining a procedure to be followed in the event you smell gas Post the statement in a prominent location This manual is for use only by trained qualified service personnel It is recommended that this oven be installed maintained and serviced by qualified professionals FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors or liquids in...

Page 4: ...TRODUCTION Welcome to the Wood Stone Oven Service Manual This manual covers the Fire Deck line of wood gas and coal fired ovens If the unit you are servicing does not appear in this manual please call our Service Department for assistance This manual is for use only by Trained and Qualified Service Personnel WARNING Improper installation adjustment alteration service or maintenance can result in p...

Page 5: ...ranty service We strongly encourage you to call whenever any service is performed There are two reasons for this First though we strive to design and build equipment that is simple and easy to service we realize that our equipment is quite unique We find we can often be of considerable help over the phone when a technician is troubleshooting an oven or rotisserie Second we keep a record of all ser...

Page 6: ...y a temperature control located in the oven Control Box This box is located on the front of the oven The Controller incorporates a programmable Hearth Set Point and a Hearth floor Temperature display Remember the IR Burner is not the primary heat source for the oven SOLID FUEL OPTIONS Wood W Models that are equipped with the radiant flame gas Burner RFG in the model number and include a W in the m...

Page 7: ...R OPERATION SEQUENCES W IR MODELS OVENS WITH INFRARED BURNER IR ONLY Power On Controller reads floor temperature from Thermocouple Floor temperature below Hearth Set Point Controller sends power to SV 1 Valve SV 1 powers Igniter and opens Pilot Valve Pilot does not light SV1 times out Controller will flash chec Pilot lights SV 1 senses Pilot flame Igniter off SV 1 opens Infrared Burner lights Hear...

Page 8: ...equipped with 2 Radiant Burners will have a second Valve SV 3 which will be powered at the same time as the SV 2 Valve described above The operation sequence is identical to that of SV 2 However the chec display will only come on if both Burners fail to light Pilot lights Power On SV 2 powers Igniter and opens Pilot Valve Pilot does not light SV 2 times out Touchpad style Controllers will flash ch...

Page 9: ... will power SV 1 as necessary BURNER OPERATION SEQUENCES RFG IR OVENS TOUCHPAD CONTROLLER Pilot lights Power On SV 2 Valve powers Igniter and opens Pilot Valve for radiant side Burner Pilot does not light SV 2 times out SV 2 senses Pilot flame Igniter off SV 2 opens Burner lights Dome flame indicator light comes on Radiant Burner remains on until oven is turned off Floor temperature above Hearth S...

Page 10: ...eration of the oven and will void the oven warranty High voltage connections are to be made only within the Transformer Junction Box Incoming power must be 120 VAC Do not connect to 240 VAC TRANSFORMER PLATE ASSEMBLY AFTER MAY 2015 The Transformer Plate is located beneath the oven on the back stand It consists of one of the two types of transformers within an 8x12 Junction Box It allows easy volta...

Page 11: ...vide flame sensing flame rectification for the Gas Valve It uses a tungsten Glow Coil for hot surface ignition This coil is fragile Flame rectification is achieved from the Flame Rod to ground through the Pilot Tubing The Pilot Igniter assembly wiring is connected to the Gas Valve via Molex connector On the connector the two wires closest to each other supply power to the Glow Coil THROTTLE ASSEMB...

Page 12: ...e temperature of the oven floor hearth about 1 inch beneath the hearth surface It is located slightly to the rear of the center of the oven behind the IR on an IR equipped oven It is embedded in the floor of the oven but is easily replaceable Older 9690 models only are equipped with a second calibrated Thermocouple for the overtemp module SV1 AND SV2 WIRE HARNESSES These harnesses supply the volta...

Page 13: ... supplying power to the oven on Check for loose incoming power connections at the junction box on the side of the oven Is the circuit breaker on the 24 V transformer tripped The transformer is located in the left junction box located on the Transformer Plate beneath the oven at the rear If the breaker on the transformer is tripped eliminate the short and reset the breaker In addition to a bad Gas ...

Page 14: ... 9690 RFG IR Oven All Burners go out display remains lit Hearth Temperature is above 800 F 9690 RFG IR Oven No Burners are lit Hearth Temperature is below 800 F Older 9690 models incorporate an over temperature control that shuts off power to the Gas Valves Once the oven floor temperature has dropped below 800 F it may be reset by turning the oven off and then back on If equipped the overtemp modu...

Page 15: ...gnition system The unit will attempt Pilot ignition for 90 seconds 30 seconds glow 30 seconds purge and then 30 seconds with the Glow Coil again Pilot gas will flow for the entire 90 second trial The system will then lockout and retry after 5 minutes Flame rectification is sensed through the Flame Rod on the Pilot Igniter to ground via the Pilot Tube RADIANT FLAME BURNER TROUBLESHOOTING Radiant Fl...

Page 16: ...low Coil on the Pilot Igniter Test for continuity at the Igniter MOLEX connector Between the two adjacent wires on the connector you should read about 3 5 ohms If circuit is open replace the Igniter If this is the case the Burner should be removed for cleaning and inspection See the Common Repair Procedures section of this manual If Igniter tests ok verify 24 volts going to the Gas Valve This can ...

Page 17: ...urn it off and back on again it may still be necessary to do this a few times DO NOT LEAVE THE OVEN UNATTENDED WHILE THE INLET PLUG IS REMOVED FROM THE GAS VALVE 4 Verify that the switch on the Gas Valve is in the ON position The Valve will power the Igniter even if the switch is in the OFF position 5 Check for loose wire connections at the SV 2 or SV 3 Gas Valve Verify that the MOLEX connectors f...

Page 18: ...e Rod Correct the airflow problem and make sure the Igniter gasket is in place Ideally there should be no discernible draft below the oven 6 Defective Pilot Igniter replace If the Burner is still going out replace the Gas Control Valve Burner is not lighting dome flame light is on 1 Check the outlet pressure at the Gas Valve Make sure it is adjusted as specified on the Equipment Name plate beneath...

Page 19: ...e Common Repair Procedures section of this manual Soot is forming near the Burner Note Do not run oven with Night Heat Retention doors in place 1 Some sooting is normal when the oven is cold This will burn away when the oven reaches operating temperature 2 Check for debris in the Burner remove Burner and clean See the Common Repair Procedures section If a log set is installed verify that it is pos...

Page 20: ...nd then back on to reset 1 If the Radiant Burner is running is the Controller calling for heat i e the Hearth Temperature is lower than Hearth Set Point 2 Is the switch on the Honeywell Gas Control Valve in the On position 3 Visually check for Igniter glow If the Igniter does not come on when the IR Burner is called for check that the MOLEX connectors are securely plugged into the Gas Control Valv...

Page 21: ...incoming gas pressure with the Burner running If the incoming pressure is OK but the Burner pressure is low and will not adjust as high as the pressure specified on the Equipment Name Plate OR if the Burner pressure is erratic replace the Gas Control Valve 5 If pressures are OK replace the Igniter If problem recurs replace Gas Valve Burner will not light or shuts off sometimes and the Igniter wire...

Page 22: ...rner 7 Check that Burner Jets are not blocked and that Pilot Igniter Assembly is not dirty or damaged If removing Igniter be aware of the Pilot Orifice which slips into the Igniter where the Pilot Tube is attached can fall out if you are not careful Any Burner Jets that are clogged should be removed from the Burner Manifold to prevent debris from entering the Manifold while cleaning 8 To remove th...

Page 23: ...s supply to the oven To replace the SV 1 IR Valve a 1 2 Allen wrench is necessary for removing the union from the Valve To replace an SV 2 or SV 3 Valve disconnect the Pilot tubing and wiring from the Valve Disconnect the Throttle Control Rod by removing the cotter key Valve On the FD 8645 or FD 6045 it is recommended that you first disconnect the flex piping leading to the Burner then the union l...

Page 24: ... Thermocouple slide the new unit in as far as it will go then check your reference mark Make sure the Thermocouple passes through the insulation blocks in the IR well as described in step 1 Hold the Thermocouple so that it is bottomed out in the hole before tightening the Compression fitting 8 Retighten the nut to compress the fitting on to the Thermocouple Again make certain the Thermocouple is p...

Page 25: ...rds the center of the oven On one side of the Heat Shield only use a 3 16 Allen wrench to remove the cable Position the Heat Shield so it will not fall or be damaged and proceed with Step 4 4 Continuing on the same side remove the 9 16 nut that attaches the cable to the counterweight 5 Continuing on the same side remove the four Phillips screws that hold the pulley block in place Remove the pulley...

Page 26: ...rp com woodstone corp com GAS PIPING LAYOUT Pilot Igniter Pilot Igniter Radiant Burner Assembly Pilot Tube Radiant Burner Assembly Throttle Valve Burner Jets w Flame Retention Springs Burner Jets w Flame Retention Springs 3 4 Gas Connection SV 1 Valve Control Rod SV 2 Valve SV 3 Valve Flexible Gas Pipe to Burner Infrared Burner RFG LR IR MODELS PIPING LAYOUT Note Actual layouts may vary depending ...

Page 27: ... 6045 Radiant Burner Pilot Igniter Pilot Tube and Igniter wires not shown SV 2 Gas Valve Flame Height Control throttle Valve Infrared Burner Flame Height Control Knob Flame Retention Spring Burner Jet FD 8645 9660 AND 11260 MODELS Piping will be similar to that of the FD 6045 with the exception that there can be a second Radiant Burner located on the opposite side of the oven Radiant Burners Infra...

Page 28: ...8 P TB1 2 TB1 6 TB1 4 TB1 5 TB1 R TB1 Y TB1 8 XFMR XFMR Thermo Couple TB1 P Infrared SV1 Thermo Couple Temperature Controller TB1 Control Panel Type 2 Red Yellow 2 red 5 orange P pink 8 white 4 brown 6 yellow TB4 R TB4 Y TB3 2 TB3 5 TB4 P TB4 8 TB3 4 TB3 6 green GND TB A L N G CB 4A GND XFMR 110 120 VAC 50 60Hz wired by others TB4 8 TB4 P Brown White Yellow Red FIRE DECK MODELS WITH IR BURNER ONLY...

Page 29: ... TB4 P Brown White Red Radiant SV2 White Yellow Brown Orange Brown IR w Dual RFG DATE DIAG WD079 Rev 0 3 27 2014 Bellingham WA 1 360 650 1111 www woodstone corp com TB3 2 6 4 4 5 TB4 R Y 8 8 P TB1 2 TB1 6 TB1 4 TB1 5 TB1 R TB1 Y TB1 8 XFMR XFMR Thermo Couple TB1 P Infrared SV1 Thermo Couple Temperature Controller TB1 Control Panel Type 2 Red Yellow 2 red 5 orange P pink 8 white 4 brown 6 yellow TB...

Page 30: ...Manual ELECTRICAL DIAGRAMS COAL BLOWER MOTOR Blower Motor DATE DIAG WD155 Rev 0 11 9 2015 Bellingham WA 1 360 650 1111 www woodstone corp com L N G MOTOR RUN CAPACITOR FAN SPEED CONTROL BLOWER MOTOR Green Black White Blue Black Brown Blue Green Yellow ...

Page 31: ...PG 31 OF 44 M0011 09 APRIL 2019 Fire Deck Service Manual ELECTRICAL DIAGRAMS FIRE DECK 9690 WITH DUAL RADIANT BURNERS AND IR BURNER MODELS WITH OVERTEMP DEVICE ...

Page 32: ...y 7000 0900 W IR Lexan Keypad Overlay 7000 0901 RFG Lexan Keypad Overlay 7000 0902 Temperature Probe for 6045 8645 9660 11260 7000 0727 8645 Temperature Probe for 9690 7000 0727 9690 Transformer 7000 0734 Pilot Orifice Natural Gas NG 7000 0748 NG Pilot Orifice Propane LP 7000 0748 Conversion Kit for Smart Valve to LP 7000 0747 Conversion Kit for Smart Valve to NG 7000 0747 NG Throttle Flame Height...

Page 33: ... WS FD 6045 W X NA NA Optional Decorative Flame Burner The Optional Decorative Flame Burner adds 15 000 BTU hr to total rated input DF NG 15 000 5 LP 8 HLP Call FACTORY SPECIFIED MAXIMUM HOURLY BTU INPUT RATES BURNER MANIFOLD PRESSURES This oven requires no modifications or adjustments for use at high altitudes The installation of this appliance must conform with local codes or in the absence of l...

Page 34: ... The Optional Decorative Flame Burner adds 15 000 BTU hr to total rated input DF NG 15 000 5 LP 8 HLP Call FACTORY SPECIFIED MAXIMUM HOURLY BTU INPUT RATES BURNER MANIFOLD PRESSURES This oven requires no modifications or adjustments for use at high altitudes The installation of this appliance must conform with local codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1...

Page 35: ...0 Second IR Burner Adds 75 000 BTU hr To total rated input 2nd NG 75 000 3 5 LP 9 HLP 7 This oven requires no modifications or adjustments for use at high altitudes GAS CODE LIMITATIONS The installation of this appliance must conform with local codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 or The Natural Gas Installation Code CAN CGA B149 1 as applicable SV 1 i...

Page 36: ...r RR IR CL 1 2 NG 295 000 3 5 4 6 4 6 LP 282 500 9 9 5 9 5 FD 9690 L or R IR W or FD 11290 RFG L or R IR W 1 1 W NG 220 000 3 5 4 6 LP 225 000 9 2 9 5 FD 9690 L or R IR CL or FD 11290 RFG L or R IR CL 1 1 NG 220 000 3 5 4 6 LP 225 000 9 2 9 5 FD 11275 RFG L or R IR W 1 1 W NG 187 500 3 5 4 6 LP 177 500 9 9 5 FD 11275 RFG L or R IR CL 1 1 NG 187 500 3 5 4 6 LP 177 500 9 9 5 FD 9690 IR W or FD 11290...

Page 37: ...e covered under the Warranty For ovens running on Propane LP or HLP the recommended inlet pressure to ensure optimum oven performance is 10 to 12 W C Incoming gas pressure below this range will affect oven performance the lower the pressure the greater the negative impact If the gas supply pressure is greater than 14 W C 1 2 psi an external regulator supplied by others is REQUIRED to lower the gas...

Page 38: ... different electrical requirements which will be clearly marked on the wiring diagrams and the Transformer Plate ELECTRICAL CODE LIMITATIONS Electrical grounding This appliance must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 as applicable INTERLOCKING If it is nece...

Page 39: ...e BTU hr requirements of the oven Burner gas pressures are preset at the factory The electrical connection to the oven should be made by a licensed electrician A Wood Stone representative may be available to visit the site to verify that the oven is functioning correctly and address any questions the customer may have We do understand that in some situations a customer may request a service techni...

Page 40: ...ift Pocket Covers have been installed Left side Right side Rear Done 15 Verify the customer has the Installation Operation Manual Done 16 Make sure the customer understands Make Up Air and AC vents are not directed at oven opening An accessible Gas Shut Off Valve is required on line to oven An accessible Power Disconnect or Breaker is marked for oven Controller Functions and Programming The Flame ...

Page 41: ...PG 41 OF 44 M0011 09 APRIL 2019 Blank page ...

Page 42: ...onfigurations in the event that pressed log products of any type have been burned in the equipment 9 In coal fired oven configurations in the event any type of coal other than anthracite coal fuel has been used 10 Damage resulting from the use of chemical cleaning products in the oven as well as any damage from liquids or chemicals including water being poured or sprayed into the oven If any oral ...

Page 43: ...PG 43 OF 44 M0011 09 APRIL 2019 Blank page ...

Page 44: ...Free 800 988 8103 Tel 360 650 1111 Fax 360 650 1166 www woodstone corp com WOOD STONE CORPORATION 1801 W Bakerview Rd Bellingham WA 98226 USA An ongoing program of product improvement may require us to change specifications without notice ...

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