Benutzeranleitung / Produktwartung 4322452 des Produzenten Whirlpool
Zur Seite of 88
GAS RANGES 4322452.
ii Copyright 1998 Whirlpool Corporation, Benton Harbor, MI WHIRLPOOL CORPORA TION assumes no responsibility for any repair made on our products by anyone other than qualified TECH-CARE ® Service T echnicians.
iii T able Of Contents Fundamental Properties Of Gas ............................................................................................ 1-1 Measuring Heat Energy ...............................................................................
iv Page Natural And L.P. Gas Conversion .......................................................................................... 5-1 General ............................................................................................................
v INTRODUCTION This program is designed to teach the servicer basic skills in handling common service procedures for gas ranges. This program does not cover the diagnosis and repair of all range problems and components, (oven liner , wiring harness, etc.
vi — NOTES —.
Page 1-1 FUNDAMENT AL PROPERTIES OF GAS MEASURING HEA T ENERGY When burning a gas fuel, heat energy is produced. This heat energy is usually expressed in British Thermal Units, or B.T.U.’s. One B.T.U. is equal to the amount of heat needed to raise one pound of water one degree Fahrenheit (see Figure 1-1).
Page 1-2 FUEL TYPES Gas Fuels are categorized as follows: #1 = Natural Gas #2 = Mixed Gas #3 = Manufactured Gas #4 = Liquefied Petroleum Gas #1 — NATURAL GAS Natural Gas is found underground. It is referred to as “ wet gas, ” because it contains heavy hydrocarbons, such as propane and butane.
Page 1-3 Categor y 1 – Natural Gas – Contains Methane & Ethane . Sour Natural Gas Contains Hydrogen Sulfide Which Corrodes Copper & Brass . It Has A Heat V alv e Of 900 to 1200 B .T .U . P er-Cubic-F oot. Specific Gra vity Is 0.65 T o 0.70.
Page 1-4 CHARACTERISTICS OF GAS FUELS Each of the four types of gas has a specific boiling point (see Figure 1-2). The boiling point is referred to as the temperature where gas turns from a liquid to a gas at atmospheric pressure.
Page 1-5 DISTRIBUTION OF NA TURAL GAS Utility companies send natural gas through underground pipes, called “ mains. ” The gas in these mains is pressurized at between 25 and 60 pounds-per-square-inch (psi). Branches carry the pressurized gas to the various buildings, and are connected to gas meters.
Page 1-6 DISTRIBUTION OF L.P . GAS For Liquid Propane (L.P.) gas, appliances generally operate on gas pressure rated at between 10 and 12 inches water column pressure. Each appliance usually has its own pressure regulator to more accurately meet the designed requirements (see Figure 1-8).
Page 2-1 PRESSURE REGULA T ORS FUNCTIONS A Gas Pressure Regulator is a mechanical device that performs the following two functions: • Reduces higher incoming gas pressure to a desired lower outgoing gas pressure. • Maintains a steady, even flow of gas as it leaves the regulator.
Page 2-2 REGULA T OR OPERA TION The pressure of the gas coming into the pressure regulator pushes against a spring-loaded diaphragm, forcing it upward.
Page 2-3 The amount of spring tension applied to the diaphragm determines the output pressure of the regulator (see Figure 2-5). Figure 2-5 Cap (L.P. Position) Tension Spring Diaphragm Gas Outlet To C.
Page 2-4 REGULA TOR DIAGNOSTICS Common causes for regulator failure are: A. Ruptured diaphragm. B. Broken or worn valve. C. Debris accumulating around the valve seat. D. Restricted (plugged) vent. E. Internal corrosion due to water in the L.P. gas system.
Page 2-5 MEASURING GAS PRESSURE Gas pressure is measured in Inches of Water Column Pressure (WCP) . It takes 28 " WCP to equal one pound per-square-inch (PSI). In most locations, natural gas pressure entering the home is regulated to 7 inches water column.
Page 2-6 4 4 3 3 2 2 1 0 Hose Ne w W ater Le v els T otal Change In W ater Column = 4.00 IN. W .C . 2.00 IN. 2.00 IN. Incoming Gas Flow 1 8. Observe the movement of the water in the manometer. The gas pressure is read by adding the water movement in both legs of the tube, as shown in Figure 2-10.
Page 3-1 THE COOKT OP BURNER SYSTEM GAS DISTRIBUTION After gas passes through the gas pressure regulator, it enters the gas manifold for distribution to the cooktop burners, or the oven safety valve. The components that provide the safe distribution and operation of the cooktop burner system (see Figure 3-1) will be discussed in this section.
Page 3-2 GAS V AL VE A typical Whirlpool gas valve and its component breakdown is shown in Figure 3-2. The gas valves are used to control the gas flow to the top burners. The gas valves are usually mounted to the top of the manifold pipe with a screw and rubber washer.
Page 3-3 GAS V AL VE ORIFICES An orifice is an opening used to control the direction and amount of gas that is discharged to a burner. Orifices are available in different sizes and shapes and can be removed and replaced without replacing the valve. PLUG-TYPE ORIFICES The cooktop burner orifice uses a plug-type orifice, as shown in Figure 3-5.
Page 3-4 L.P . AND NA TURAL GAS ORIFICES The actual size and configuration of each orifice depends on several factors. The most important factor, however, is the type of gas that will be used by the gas range system. The two most frequently used types are: liquefied petroleum (L.
Page 3-5 When L.P. gas is used, the cap is tightened down 2-1/2 turns so that it rests against the L.P. insert, closing off the spacing between the two (see Figure 3-8). The amount of gas leaving the orifice is now controlled by the size of the L.P. insert.
Page 3-6 GAS V AL VE ORIFICE DIAGNOSTICS A gas valve orifice is often a source for gas range problems. Some of the problems that arise with an orifice are as follows: 1. The orifice may become clogged from dirt, or slag in the gas lines. The result will be an over- restricted gas flow, causing the mixture to become too “ lean ” .
Page 3-7 PERFORMANCE CHECK 1. Remove the gas valves. 2. Remove the orifices..
Page 3-8 BURNER OPERA TION To understand how a burner operates, it is important to understand the following terms (see Figure 3-9): Gas: The fuel used by the burner, either natural or L.P. Primary Air: The air mixed with the gas in order to make the gas combustible.
Page 3-9 = Gas = Air V enturi (Constricting Area) Adjustment Screw Adjustable Air Shutter Expanding Area Primar y Air Gas Inlet Mix ed Air & Gas Outlet Figure 3-12 The Cooktop Burner Assembly controls the combustion of gas and directs its flame (see Figure 3-11).
Page 3-10 BURNER HEAD When gas leaves the orifice, it passes through the venturi, and is forced into the burner head. As the gas passes between the orifice and the burner head, primary air is mixed with the gas to form a combustible mixture. The burner head disperses the gas/air mixture for ignition.
Page 3-11 Outer Envelope Inner Cone Pushes Through Outer Cone Outer Cone Flame Lifts Off Burner Figure 3-15 The outer cone surrounds the inner cone. The outer cone is the hottest part of the flame. Secondary air is drawn into the flame at this point and accelerates combustion.
Page 3-12 The inner-cone combustion process will occur in increased levels, and will release more of the harmful by-products, CO and Aldehydes. The level of secondary air will no longer be enough to convert these chemicals into the safe by-products CO 2 and H 2 O, and there will be higher levels of dangerous chemicals released into the room.
Page 3-13 Flame Quenching Flame quenching occurs when the flame is cooled before complete combustion occurs. Placing an object, such as an oven flame spreader into the flame, will cool or quench the flame, resulting in incomplete combustion.
Page 3-14 Figure 3-20 In the case of an over-fueled burner, the excessive length of the flames can result in the quenching at the oven flame spreader or top burner grate even though the flame spreader and grate may be at the proper distance. Check for this before adjusting the burners.
Page 3-15 IMPROPER FLAME DIAGNOSTICS For any of the improper flames discussed, refer to the following chart for the appropriate corrective actions. In most of the malfunctions described thus far, the burner flames will change character- istics when a problem develops.
Page 3-16 Burner Climber Port CLEANING THE BURNERS The most common burner maIfunction is clogging due to excess dirt and debris, which can enter the burner through the burner ports. This excess dirt can block one or several of the ports so that the burner will have trouble lighting, or will not light at all.
Page 3-17 1/4 " Flame Brack et Pilot Flame Size Figure 3-23 ST ANDING PILOT IGNITION SYSTEM OPERA TION The ignition system provides heat, which is the third element necessary for combustion. Whirlpool ranges use two different processes to provide this element.
Page 3-18 When the gas control valve is turned on, gas flows to the burner head, and out the ports. There are ports at both the top and side of the burner head, as shown in Figure 3-25. The side ports direct gas to a flash tube , where it is drawn through the tube to the pilot flame, where it is ignited inside the tube.
Page 3-19 ADJUSTING THE PILOT FLAME HEIGHT A pilot that frequently blows out may be set too high, or too low. To adjust the pilot flame to the correct height, perform the following steps: 1.
Page 3-20 CLEANING THE PILOT The small opening of a pilot can easily become clogged with dust, grease, or food, preventing proper gas flow. A pilot that will not light, or will not stay lit, may simply need to be cleaned.
Page 3-21 ELECTRONIC IGNITION SYSTEM OPERA TION The Electronic Ignition System performs the same function as the standing pilot ignition system. However, instead of using a standing pilot flame to ignite the main burners, a spark from a surface burner ignitor is used.
Page 3-22 IGNITOR SPARK MODULE TO IGNITOR SWITCHES TO SURFACE BURNER IGNITOR Figure 3-30 Figure 3-31 Ground Strap (Brac ket) Metal Rod Electrode Wire Ceramic Insulated Body The Ignitor Spark Module is a solid-state device that is used to provide high voltage for the top burner ignitors (see Figure 3-30).
Page 3-23 CONVENTIONAL BURNER When a main burner control knob q is turned to the “ lite ” position, the gas valve r opens, and gas flows through the pressure regulator s into the manifold t through the open valve.
Page 3-24 PRESSURE REGULATOR GAS INLET IGNITOR SPARK MODULE AIR SHUTTER GAS VALVE IGNITOR SWITCH VENTURI BURNER CONTROL KNOB GAS MANIFOLD SPARK IGNITOR BURNER CAP TO SPARK IGNITOR SPARK BURNER BURNER .
Page 3-25 ELECTRONIC IGNITION DIAGNOSTICS Problems with electronic ignition systems usually occur in one of two ways: the electrode will not spark, or the sparking will not stop. If the ignitors are in series, and one is not sparking, none will spark.
Page 3-26 PERFORMANCE CHECK 1. Remove the burners. 2. Remove the ignition system (ignitor spark module, ignitor switches, and surface burner ignitors).
Page 4-1 THE OVEN BURNER SYSTEM ST ANDING PILOT IGNITION OFF N A T L P Ov en Ther mostat Ov en Bur ner Main Gas Line Pilot Gas Line Sensing Bulb & Capillar y T ube Pilot Assembly Saf ety V alv e P.
Page 4-2 The Thermostat is a hydraulic valve that has two separate gas lines and a sensing bulb (see Figure 4-2 ). The pilot gas line maintains a pilot flame in the oven, and the main gas line provides gas to the oven safety valve.
Page 4-3 The interaction between the thermostat and the safety valve is very important and critical to the operation of the oven. The thermostat provides two separate functions each time it is turned on, but first, we need to know what the thermostat does when it is in the “OFF” position.
Page 4-4 As this is taking place, the thermostat also opens the main gas line, and provides gas to the safety valve (see Figure 4-6). As soon as the safety valve is hydraulically opened by the signal from the sensing bulb, gas is released from the safety valve to the oven burner, and ignited by the heater pilot flame.
Page 4-5 OFF N A T L P OFF N A T L P Ov en Ther mostat Main Gas Line Pilot Gas Line Natural Gas Setting Adjustment Screw Gas “ OFF ” Setting L.P . Gas Setting NOTE: The thermostat used in the Standing Pilot range needs to be converted if L.P. gas is being used.
Page 4-6 GLO-BAR IGNITION The Glo-Bar Ignition System (see Figure 4-10) is a 120-volt electrical system that consists of three important components. The three components, a thermostat that is controlled by the customer, an ignitor and a safety valve, both located inside the oven, create a very efficient system that is safe and dependable.
Page 4-7 BROIL 200 250 300 350 400 450 500 550 OFF BROIL 200 250 300 350 400 450 500 550 OFF 1. Oven Off Switch Open 2. Oven On 3. Oven T emp Reached Pressure Expands Sensor Actuator & Pushes Agai.
Page 4-8 The Oven Ignitor is made of a silicon-carbide material (see Figure 4-13). Ov en Glo-Bar Ignitor Figure 4-13 When voltage is applied to the ignitor, it heats up to 2000 ˚ F. As its temperature increases, its resistance decreases, allowing 2.5 to 3.
Page 4-9 Gas Outlet (T o Oven Burner) No Current Flow - V alv e Is Closed Gas Inlet (F rom Regulator) 120 V olt Supply T er minal Saf ety V alv e Bimetal & Heater Coil Figure 4-16 Gas is available at the safety valve at all times, but can be shut off by a manual shutoff valve on the regulator (see Figure 4-17).
Page 4-10 Throughout the cooking cycle, the oven will continue to “ heat up ” and “ cool down ” to maintain the selected temperature (see Figure 4-19). This operation is controlled by the thermostat ’ s sensing bulb. Safety V alve Opens & Gas Flows T o Ov en Burner Saf ety V alv e N L1 3.
Page 4-11 Safety V alve Closed No Gas Flow T o Ov en Burner Saf ety V alv e N L1 Low Amperage T o Ov en Burner Ov en Glo-Bar Ignitor 200˚ Heat F rom Oven Thermostat Switch Contacts Open Oven Is Cooli.
Page 4-12 Oven Control P anel (Thermostat) Bake Burner Wires T o Broil Rela y Wires T o Bake Rela y Broil Burner Main Gas Inlet Broil Gas Line Glo-Bar Ignitors Dual Saf ety V alve Pressure Regulator 1.
Page 4-13 Figure 4-23 Figure 4-24 Dual Saf ety V alv e Main Gas Inlet Broil Bimetal T er minals Bake Bimetal T er minals Bake Burner Gas Outlet Broil Bur ner Gas Outlet The electrical circuit is initiated by relays on the electronic control board.
Page 4-14 The electronic board is constructed with individual relays to operate the Bake, Broil, and Self Clean functions independently of each other. The Microcomputer board electrical diagrams (see Figure 4-26) show how opening and closing the relays operate the various customer-selected cycles.
Page 4-15 By the construction of the relays, both the Bake Function (see Figure 4-27), and the Broil function (see Figure 4-28), can not operate at the same time. The normally-closed position of the opposite relay is needed to complete the circuit. N L1 W W BU N.
Page 4-16 F-CODE GUIDELINES F0 = If the most recent F-code is recalled via user input, F0 indicates no failure has occurred. F1 = Electronics Subsystem Failure. Replace electronic control board. E0 = EEPROM communication error. E1 = EEPROM checksum error.
Page 4-17 PERFORMANCE CHECK 1. Remove the oven ’ s operating system (burners, safety valves, and ignitors)..
Page 4-18 THE SELF-CLEAN OVEN DOOR LOCKING SYSTEM At any time a range is in a self-clean operation, it needs to provide a safe environment for the customer.
Page 4-19 Figure 4-30 When the solenoid plunger extends, two things happen (see Figure 4-30). As the latch solenoid locks the door, it also activates the two door latch switches.
Page 4-20 Figure 4-31 L1 N BK W OVEN CONTROL LATCH SOLENOID RELAY LATCH SOLENOID P4 P1-3 P1-5 BU GY Y Y W W W BK R DOOR LATCH SWITCH DOOR LATCH SWITCH DOOR LIGHT SW. OVEN LIGHT MANUAL OVEN LIGHT SWITCH N.O. N.O. P1-1 1 SEC PULSE When the oven temperature reaches 600 ˚ , the oven door cannot be opened until the oven cools down to below 550 ˚ .
Page 5-1 NA TURAL AND L.P . GAS CONVERSION GENERAL Ranges must be adjusted when going from one type of fuel to another due to the characteristics of the gases. This means that, for efficient combustion, air must be mixed with the gas. The amount of air to be mixed with the amount of gas is called the air-to-gas ratio .
Page 5-2 Natural L.P. Spring Retainer Cap Gasket Gas Intlet Spring Figure 5-1A Spring Gas Outlet Figure 5-1B Gas Intlet Gas Outlet L.P. Natural Cap CONVERTING A PRESSURE REGULA T OR By varying the tension of the regulator spring, the gas outlet pressure can be controlled for natural and L.
Page 5-3 CONVERTING AN OVEN THERMOST A T If the range is equipped with a standing pilot in the oven, an adjustment for the pilot must be made. The gas for the oven’s standing pilot is supplied by the oven thermostat. Thermostats used on standing pilot ranges have a screw to adjust for natural or L.
Page 5-4 Bake Burner Air Shutter BURNER FLAME ADJUSTMENT After converting the range to L.P. gas operation, it may be necessary to adjust each burner flame (cooktop and oven burners). A proper cooktop burner flame should be approximately 5/8 " high and have a well-defined blue flame.
Page 5-5 PERFORMANCE CHECK 1. Convert the pressure regulator, cooktop and oven burners, for use with L.P. gas..
Page 5-6 — NOTES —.
Page 6-1 TESTING THE COMPONENTS W ARNING LABELS This manual is intended for factory-service technicians only. We recommend that customers DO NOT service their own units, because of the complexity and risk of high-voltage electrical shock. The following information should be read carefully.
Page 6-2 GENERAL INFORMA TION 1. When diagnosing a problem, always begin by checking the range for the proper line voltage, open fuses, and defective components. 2. New ranges that have been in operation for only a short time should be checked for loose connections or incorrect wiring.
Page 6-3 Steady State Current = 3.0 Amps @ 115 ± 1 VAC @ 75˚F ± 10˚ Ambient. Cold Resistance = 500 Ω TO 1100 Ω @ 75˚F ± 10˚ Ambient. Maximum Operating Temperature Not To Exceed 2650˚F @ 115 ± 1 VAC @ 75˚F ± 10˚ Ambient.
Page 6-4 OFF LITE Control OFF Switch Open OFF LITE Control Set T o Lite Switch Closed 5. Turn the control knob to the LITE position, and the meter should indicate continuity .
Page 6-5 TESTING AN OVEN LIGHT SWITCH The oven light switch can be a rocker-type, (see Figure 6-4A), or a pushbutton-type (see Figure 6-4B) switch. The rocker switch is manually operated, and the pushbutton switch is operated by the oven door. The pushbutton switch may have more that two terminals, depending on the model.
Page 6-6 TESTING AN OVEN TEMPERA TURE SENSOR Some oven controls use an oven temperature sensor (see Figure 6-5) to operate the bake, broil, and self-clean functions. The oven temperature sensor is a “ Resistance Temperature Detector (RTD) ” and is composed of a stainless steel tube with a thin film of platinum on the end.
Page 6-7 To test the solenoid windings, perform the following steps: 1. Turn off the gas and electrical power to the range. 2. Set the ohmmeter to the R x 1 position. 3. Remove the wire from either solenoid terminal (see Figure 6-7). 4. Touch the ohmmeter leads to the terminals of the solenoid.
Page 6-8 SWITCH COM NO TERMINALS Figure 6-8 To test the switch(es) : 1. Turn off the gas and electrical power to the range. 2. Disconnect the wires from the switch terminals. 3. Set the ohmmeter to the R x 1 position. 4. Connect one of the ohmmeter leads to the common (COM) terminal.
Page 6-9 TESTING A GAS SAFETY V AL VE Some gas ranges use an electrically-controlled gas safety valve to control the flow of gas to the oven burner. The electric safety valve controls the gas flow by means of a bimetal-controlled diaphragm. Self-clean models have a single inlet, dual outlet, bimetal-operated safety valve.
Page 6-10 TESTING THE GAS CONTROL V AL VES The top burner gas valves control the gas flow to the top burners. The valve is a barrel and core, grease sealed, locking type valve (see Figure 6-12). Before the stem can be turned, it must be pushed in to unlock the valve.
Page 6-11 TESTING THE GAS PRESSURE REGULA TOR The pressure regulator is a mechanical device that reduces the higher incoming gas pressure to a lower outgoing pressure, and maintains a steady, even flow of gas. The pressure regulator has one outlet that is connected directly to the gas safety valve.
Page 6-12 PROBLEM POSSIBLE CAUSE SOLUTION Gas odor. Gas odor with all pilots lit or with electronic ignition. Surface burner does not light. Surface burner pilot does not stay lit. Surface burner flame low or uneven. Surface burner flame too high, noisy, or blowing.
Page 6-13 Oven burner does not light. Oven burner pilot does not stay lit. Oven does not hold set tempera- ture so that oven bakes unevenly. Self-cleaning oven does not clean. Pilot light set too low. Pilot opening blocked. Check door and oven gasket.
Page 6-14 SCHEMA TIC DIAGRAMS Standard Range L1 N BK BK V V RR W W W BK Y Y BK OVEN TEMP SENSOR SURFACE BURNER IGNITOR SWITCHES IGNITOR MODULE DOOR SW.
Page 6-15 L1 N BK BK V V W W W BU BU RR BR BU GY Y Y W W W W W BK BK BK BK OVEN TEMP SENSOR OVEN CONTROL TRANSFORMER P5 P1-1 P1-5 P1-3 P4 P1-6 P1-7 P3-1 P2-1 P3-4 P3-2 P2-4 P2-2 LATCH SOLENOID RELAY BROIL RELAY BAKE RELAY LATCH SOLENOID DOOR LATCH SW.
Page 6-16 L1 N W BK BK R W VV OVEN CONTROL OVEN CONTROL TRANSFORMER SENSOR BAKE RELAY BAKE VALVE BAKE IGNITOR BROIL RELAY P3-4 P3-1 P1-6 P1-7 P5 P2-1 P2-4 BAKE STRIP CIRCUITS BROIL L1 N W BK BK BU W V.
Page 6-17 L1 N W BK BK BU BR BU GY GY Y W W VV OVEN CONTROL OVEN CONTROL TRANSFORMER SENSOR BAKE RELAY BAKE VALVE BAKE IGNITOR BROIL RELAY LATCH RELAY* P3-4 P4 P3-1 P1-6 (N.
Page 6-18 — NOTES —.
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