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KR-28
WHIRLPOOL GAS RANGE
DIRECT SPARK
IGNITION SYSTEM
JOB AID
Part No. 8177893
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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. GOALS AND OBJECTIVES The goal of this Job Aid is to provid
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Table of Contents PAGE SECTION 1 ................................................................................................................................ 1 THEORY OF OPERATION ........................................................................................................ 1 Introduction ........................................................................................................................... 1 Gas Distribution Valve................................................
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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.” All safety messages will identify the hazard, tell you how to reduce the chance of injury, and tell you wh
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SECTION 1 SECTION 1 SECTION 1 SECTION 1 SECTION 1 THEORY OF OPERATION INTRODUCTION ence of a flame. If the polarity is reversed, or The Direct Spark Ignition System contains a in some cases if there is a poor ground, the Gas Distribution Valve and a Direct Spark Ig- control will appear to operate normally. How- nition (DSI) Control that interfaces with the ever, after an oven burner ignites, the spark Electronic Oven Control, and spark electrodes. will continue to occur at the burner, and the Th
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GAS DISTRIBUTION VALVE The gas distribution valve can be converted to The gas distribution valve is made up of the L.P. gas, when necessary. It regulates the dis- following features: tribution of gas to the cooktop and both oven • Natural & L.P. gas regulator burners. The gas distribution valve is non-ser- • Manual oven shutoff valve viceable. • Bake & broil solenoids • Pressure tap - To measure gas outlet pressure Pressure Tap (1/8˝ - 27 N.P.T.) L.P. Conversion Cap Gas Inlet (1/2˝ Female Thread
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When the lever is raised, the gas to the oven MANUAL OVEN SHUTOFF VALVE burners is turned on. 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. Manual Valve Lever Raised (Gas On) Manual Valve Lever Down (Gas Off) - 3 -
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flow to the burner. The electrical connections BAKE & BROIL SOLENOID- at the valve consist of three terminals, each ACTIVATED PORTS one sized differently to prevent incorrect wir- The bake and broil gas supply ports are opened ing (see below). and closed by electrically-operated solenoids. The solenoids require special voltage/current When voltage is received from the spark (8 - 18 VDC) from the direct spark ignition con- ignition control for the bake or broil function, trol to operate properly.
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L.P. GAS CONVERSION The range is manufactured to use natural gas. 4. To convert the bake burner: To convert the range to use L.P. gas, the fol- a)Open the oven door and remove the lowing steps are performed: oven racks. 1. Turn off the gas and electrical supplies to b)Use a 1/2" open-end wrench and turn the range. the orifice hood down snug onto the pin 2. Remove the storage drawer from the (approximately 2-1/2 turns). DO NOT range. OVERTIGHTEN THE ORIFICE. The burner flame cannot be properly ad
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5. To convert the cooktop burners: 6. To convert the broil burner: NOTE: The L.P. orifices for the cooktop burn- a)Open the oven door and remove the ers are supplied in the literature pack inside oven racks. the oven. 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 ad- justed if this conversion is not made. a)Use an 8 mm socket and carefully re- Broil Burner move the ori
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DIRECT SPARK IGNITION CONTROL The Direct Spark Ignition (DSI) Control inter- The DSI control uses a self-diagnostic test to faces with the Electronic Oven Control for the verify that the oven ignition system is working Bake, Broil, and Self-Clean functions. The DSI properly. It will also continually monitor the also interfaces with the four cooktop burner ig- flame presence within the oven. The DSI con- nition switches, to provide ignition for the trol operates on 102 to 132 VAC. All input and
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ELECTRONIC SPARK IGNITION This 120 VAC is detected by the control, and COOKTOP BURNER OPERATION generates two sparks-per-second to all of the The top burner spark ignition system is initi- top burners. Note that in the strip circuit be- ated when the burner control is turned to the low, 120 VAC is present at the control at all LITE position. times through input pin J1-10, and output pin 120 VAC is supplied through the ignition switch J1-4. from the L1 side of the circuit to the direct spark 120
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This 120 VAC is used to generate two sparks- OVEN BURNER OPERATION per-second to both oven burners. The 120 volts The spark ignition for the oven burners is AC is also stepped-down to between 8 and 18 started at the Electronic Oven Control (ERC). VDC through pins J1-1 and J1-2 (Bake), and As the ERC is programmed for Bake or Broil, pins J1-3 and J1-2 (Broil). This DC voltage the appropriate relay is closed on the ERC. opens the gas distribution valve, and provides 120 VAC is provided from L1, th
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Once the gas has ignited, the “flame safety c) A flame is present within the oven for circuit” will monitor the flame at the burner to more than 10 seconds after the gas make sure it is present. If a flame is not present valve is off. at the burner: d)The flame is unexpectedly lost for any reason after being established. NOTE: a)The control will allow the ignitor to spark If this occurs, a lockout condition will oc- for 4 seconds. cur after 30 seconds with no attempt to b)A 40 second delay to di
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SECTION 2 SECTION 2 SECTION 2 SECTION 2 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 4. Disconnect the wire connectors from the direct spark ignition control. WARNING 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. FIRE HAZARD Shut off gas
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REMOVING THE GAS DISTRIBUTION VALVE 3. Remove the gas outlet lines from the gas distribution valve with a 9/16˝ open-end WARNING wrench. ELECTRICAL SHOCK HAZARD 4. Remove the four mounting screws from the gas distribution valve. Disconnect power before servicing the range. Gas Outlet Replace all panels before operating range. Screws Failure to do so can result in death or electri- cal shock. FIRE HAZARD Shut off gas supply line valve before servic- ing the range. Gas Check all gas line connectio
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SECTION 3 SECTION 3 SECTION 3 SECTION 3 SECTION 3 COMPONENT TESTING DIRECT SPARK IGNITION CONTROL 3. If the top burners spark, proceed to step 4. Touch the test leads to the J1 connector at WARNING terminals 4 (white) and 10 (black). The AC voltmeter should indicate 120 VAC. If not, Electrical Shock Hazard check for the proper voltage at the power Voltage is present during these tests. supply outlet, and check the main wiring harness. TEST PROCEDURE 10 (black) 4 (white) Voltage Tests Bake Functi
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5. Set the voltmeter to read between 8 and Broil Function 18 volts DC. 1. Set the voltmeter to read 120 VAC. 6. Touch the test leads to the J1 connector at 2. Program the range for the Broil operation. terminals 1 (red) and 2 (orange). The DC J1 Connector voltmeter should indicate between 8 and 18 volts DC*. If not, replace the DSI con- trol. 1 (red) 2 (orange) J1 Connector 3. If the top burners spark, proceed to step 4. Touch the test leads to the J1 connector at terminals 4 (white) and 10 (bla
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4. Touch the test leads to the J1 connector at 6. Touch the test leads to the J1 connector at terminals 4 (white) and 7 (blue/white). The terminals 2 (orange) and 3 (blue). The DC AC voltmeter should indicate 120 VAC. If voltmeter should indicate between 8 and not, check the electronic oven control for 18 volts DC*. If not, replace the DSI con- proper operation. trol. 2 (orange) 3 (blue) 4 (white) 7 (blue/white) J1 Connector J1 Connector * When power is applied to the range, a safety delay 5. Se
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Cooktop Function 3. Touch the test leads to the J1 connector at terminals 4 (white) and 10 (black). The AC 1. Set the voltmeter to read 120 VAC. voltmeter should indicate 120 VAC. If not, J1 Connector 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). The AC voltmeter should indica
