Whirlpool KR-28 User Manual
KR-28
WHIRLPOOL GAS RANGE
DIRECT SPARK
IGNITION SYSTEM
JOB AID
Part No. 8177893
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 provide detailed information that will enable the service technician to
properly diagnose malfunctions and repair the Direct Spark Ignition System.
The objectives of this Job Aid are to:
• Understand and follow proper safety precautions.
• Successfully troubleshoot and diagnose malfunctions.
• Successfully perform necessary repairs.
• Successfully return the Direct Spark Ignition System to the proper operational status.
WHIRLPOOL CORPORATION assumes no responsibility for any repair
made on our products by anyone other than Authorized Factory Service
Technicians.
Copyright 2000, Whirlpool Corporation, Benton Harbor, MI 49022
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Table of Contents
PAGE
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
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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 what can happen if the instructions are not followed.
GENERAL INFORMATION
IMPORTANT MODEL & SERIAL
NUMBER INFORMATION
The Direct Spark Ignition System is used on
Whirlpool gas ranges produced, beginning
January 3, 2000, Serial Code RK02. The Model
number of these units will be a “-5” version of
the current G-line gas range.
Example: SF365PEGQ5
This Direct Spark Ignition System will only be
available on self-cleaning gas ranges.
ELECTRICAL REQUIREMENTS
The supply voltage is critical for proper operation of the Direct Spark Ignition (DSI) System.
The requirements are 102 to 132 VAC with the
proper polarity and ground. If the electrical supply is less than 102 VAC, sparking will not be
reliable. If the system is over 132 VAC, permanent damage to the DSI can occur.
Proper polarity must also be supplied. If the
supply polarity is reversed, the DSI control will
not be able to detect the presence of a flame.
Reverse polarity will not affect the cooktop operation, but the Bake and Broil burners will fail
to remain lit.
A proper ground is also required. The DSI control generates a significant amount of electrical noise. This noise is minimized by clamping the noise to ground. If a proper ground is
not connected, the ERC may periodically display “PF,” which means that a reset has occurred in the ERC.
GAS REQUIREMENTS
Gas supply pressure should be a minimum of
7˝ water column pressure for natural gas, and
11˝ water column pressure for L.P. gas. However, the gas distribution valve should maintain 4˝ water column pressure for natural gas,
and 10˝ water column pressure for L.P. gas.
NOTE TO TECHNICIAN: Improper polarity will cause the direct spark ignition
system to malfunction. Always check for
proper polarity at the wall outlet before
replacing parts.
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SECTION 1SECTION 1
SECTION 1
SECTION 1SECTION 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-
Direct Spark
Ignition Control
Gas Valve /
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. However, 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 present
(see “Monitoring System,” on page 9).
Gas Distribution Valve
Ignitor &
Cooktop Burner
Ignition Switch
Broil Burner Ignitor
Broil Burner
Gas Distribution Valve
Bake Burner Ignitor
Bake Burner
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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.
Pressure Tap
(1/8˝ - 27 N.P.T.)
L.P. Conversion Cap
Gas Inlet (1/2˝
Female Threads)
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
Electrical
Terminals
To Bake Burner
To Broil Burner
Gas Distribution Valve
Manual Oven
Shutoff Valve
To Cooktop
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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.
Manual Valve Lever
Raised (Gas On)
Manual Valve Lever
Down (Gas Off)
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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
Electrical Terminals:
Broil = 1/8˝ wide
Common = 1/4˝ wide
Bake = 3/16˝ wide
flow to the burner. The electrical connections
at the valve consist of three terminals, each
one sized differently to prevent incorrect wiring (see below).
The solenoids require special voltage/current
(8 - 18 VDC) from the direct spark ignition control to operate properly. IMPORTANT: Do not
attempt to operate the solenoids with any
other voltage supply.
Manual Oven
Shutoff Valve
216 Ω Resistance Across
Each Solenoid Terminal
8 to 18 VDC
NOTE: Always check
both solenoids. If either
solenoid is defective,
neither one will operate.
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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
Natural Gas
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 ORIFICE. The
burner flame cannot be properly adjusted if this conversion is not made.
Pin
Orifice Hood
Natural Gas:
Unit is manufactured
for natural gas
L.P. Gas:
Turn down 2-1/2 turns in
this direction
b)Install the conversion cap on the gas
distribution valve with the L.P. side facing up (you will see L.P. stamped inside
the cap, as shown).
L.P. Gas
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