Whirlpool 8177893 User manual

JOB AID
Part No. 8177893
WHIRLPOOL GAS RANGE
DIRECT SPARK
IGNITION SYSTEM
KR-28

- ii -
WHIRLPOOL CORPORATION assumes no res onsibility for any re air
made on our roducts by anyone other than Authorized Factory Service
Technicians.
Copyright 2000, Whirlpool Corporation, B nton Harbor, MI 49022
FORWARD
This Job Aid, “Whirlpool Gas Rang Dir ct Spark Ignition Syst m,” (Part No. 8177893), provid s
th t chnician with information on th op ration and s rvic of th Dir ct Spark Ignition Syst m.
It is to b us d as a training Job Aid and S rvic Manual.
Th Wiring Diagrams us d in this Job Aid ar typical and should b us d for training purpos s
only. Always us th Wiring Diagrams suppli d with th product wh n s rvicing th unit.
GOALS AND OBJECTIVES
Th goal of this Job Aid is to provid d tail d information that will nabl th s rvic t chnician to
prop rly diagnos malfunctions and r pair th Dir ct Spark Ignition Syst m.
Th obj ctiv s of this Job Aid ar to:
• Und rstand and follow prop r saf ty pr cautions.
• Succ ssfully troubl shoot and diagnos malfunctions.
• Succ ssfully p rform n c ssary r pairs.
• Succ ssfully r turn th Dir ct Spark Ignition Syst m to th prop r op rational status.

- iii -
Table of Contents
SECTION 1 ................................................................................................................................ 1
THEORY OF OPERATION ........................................................................................................ 1
Introduction ........................................................................................................................... 1
Gas Distribution Valv ..........................................................................................................2
Manual Ov n Shutoff Valv .............................................................................................. 3
Bak & Broil Sol noid-Activat d Ports.............................................................................. 4
L.P. Gas Conv rsion.............................................................................................................5
Dir ct Spark Ignition Control ................................................................................................. 7
El ctronic Spark Ignition .......................................................................................................8
Cooktop Burn r Op ration ................................................................................................ 8
Ov n Burn r Op ration..................................................................................................... 9
SECTION 2 .............................................................................................................................. 11
COMPONENT ACCESS .......................................................................................................... 11
R moving Th Dir ct Spark Ignition Control ...................................................................... 11
R moving Th Gas Distribution Valv ................................................................................ 12
SECTION 3 .............................................................................................................................. 13
COMPONENT TESTING ......................................................................................................... 13
Dir ct Spark Ignition Control ............................................................................................... 13
Gas Distribution Valv ........................................................................................................ 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

- iv -
IMPORTANT SAFETY INFORMATION
Your safety and the safety of others is very im ortant.
Important saf ty m ssag s hav b n provid d in this Job Aid. Always r ad and ob y all
saf ty m ssag s.
This is th saf ty al rt symbol.
This symbol al rts you to hazards that can kill or hurt you and oth rs.
All saf ty m ssag s will b pr c d d by th saf ty al rt symbol and th word
“WARNING.”
All saf ty m ssag s will id ntify th hazard, t ll you how to r duc th chanc of injury, and t ll
you what can happ n if th instructions ar not follow d.
GENERAL INFORMATION
IMPORTANT MODEL & SERIAL
NUMBER INFORMATION
Th Dir ct Spark Ignition Syst m is us d on
Whirlpool gas rang s produc d, b ginning
January 3, 2000, S rial Cod RK02. Th Mod l
numb r of th s units will b a “-5” v rsion of
th curr nt G-lin gas rang .
Exampl : SF365PEGQ5
This Dir ct Spark Ignition Syst m will only b
availabl on s lf-cl aning gas rang s.
ELECTRICAL REQUIREMENTS
Th supply voltag is critical for prop r op ra-
tion of th Dir ct Spark Ignition (DSI) Syst m.
Th r quir m nts ar 102 to 132 VAC with th
prop r polarity and ground. If th l ctrical sup-
ply is l ss than 102 VAC, sparking will not b
r liabl . If th syst m is ov r 132 VAC, p r-
man nt damag to th DSI can occur.
NOTE TO TECHNICIAN: Im ro er olar-
ity will cause the direct s ark ignition
system to malfunction. Always check for
ro er olarity at the wall outlet before
re lacing arts.
Prop r polarity must also b suppli d. If th
supply polarity is r v rs d, th DSI control will
not b abl to d t ct th pr s nc of a flam .
R v rs polarity will not aff ct th cooktop op-
ration, but th Bak and Broil burn rs will fail
to r main lit.
A prop r ground is also r quir d. Th DSI con-
trol g n rat s a significant amount of l ctri-
cal nois . This nois is minimiz d by clamp-
ing th nois to ground. If a prop r ground is
not conn ct d, th ERC may p riodically dis-
play “PF,” which m ans that a r s t has oc-
curr d in th ERC.
GAS REQUIREMENTS
Gas supply pr ssur should b a minimum of
7˝ wat r column pr ssur for natural gas, and
11˝ wat r column pr ssur for L.P. gas. How-
v r, th gas distribution valv should main-
tain 4˝ wat r column pr ssur for natural gas,
and 10˝ wat r column pr ssur for L.P. gas.

- 1 -
SECTION 1SECTION 1
SECTION 1SECTION 1
SECTION 1
THEORY OF OPERATION
The Direct Spark Ignition System contains a
Gas Distribution Valve and a Direct Spark Ig-
nition (DSI) Control that inter aces with the
Electronic Oven Control, and spark electrodes.
This provides the direct spark ignition and gas
distribution or Whirlpool sel -cleaning gas ree-
standing ranges.
A proper ground and the correct polarity is nec-
essary or the DSI control to sense the pres-
INTRODUCTION
ence o a lame. I the polarity is reversed, or
in some cases i there is a poor ground, the
control will appear to operate normally. How-
ever, a ter an oven burner ignites, the spark
will continue to occur at the burner, and the
valve will then shut o a ter 4 seconds. This is
because the DSI control does not recognize
the presence o a lame when one is present
(see “Monitoring System,” on page 9).
Gas Valve /
Ignition S itch
Broil Burner Ignitor
Broil Burner
Gas Distribution Valve
Bake Burner
Bake Burner Ignitor
Ignitor &
Cooktop Burner
Direct Spark
Ignition Control
Gas Distribution Valve

- 2 -
Gas Distribution Valve
The gas distribution valve can be converted to
L.P. gas, when necessary. It regulates the dis-
tribution o gas to the cooktop and both oven
burners. The gas distribution valve is non-ser-
viceable.
GAS DISTRIBUTION VALVE
The gas distribution valve is made up o the
ollowing eatures:
• Natural & L.P. gas regulator
• Manual oven shuto 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

- 3 -
When the lever is raised, the gas to the oven
burners is turned on.
Manual Valve Lever
Down (Gas O )
Manual Valve Lever
Raised (Gas On)
MANUAL OVEN SHUTOFF VALVE
A manual oven shuto valve is available on
the gas distribution valve to shut o the gas to
the oven burners. This valve will not a ect the
operation o the cooktop burners. When the
lever is down, the gas to the oven burners is
turned o .

- 4 -
BAKE & BROIL SOLENOID-
ACTIVATED PORTS
The bake and broil gas supply ports are opened
and closed by electrically-operated solenoids.
When voltage is received rom the spark
ignition control or the bake or broil unction,
(8-18 VDC), the solenoid or that unction is
activated, and the valve opens to allow gas
low to the burner. The electrical connections
at the valve consist o three terminals, each
one sized di erently to prevent incorrect wir-
ing (see below).
The solenoids require special voltage/current
(8 - 18 VDC) rom the direct spark ignition con-
trol to operate properly. IMPORTANT: Do not
attempt to operate the solenoids ith any
other voltage supply.
Electrical Terminals:
Broil = 1/8˝ ide
Common = 1/4˝ ide
Bake = 3/16˝ ide
Manual Oven
Shutoff Valve
216 Ω Resistance Across
Each Solenoid Terminal
8 to 18 VDC
NOTE: Al ays check
both solenoids. If either
solenoid is defective,
neither one ill operate.

- 5 -
b)Install the conversion cap on the gas
distribution valve with the L.P. side ac-
ing up (you will see L.P. stamped inside
the cap, as shown).
L.P. Gas
The range is manu actured to use natural gas.
To convert the range to use L.P. gas, the ol-
lowing steps are per ormed:
1. Turn o the gas and electrical supplies to
the range.
2. Remove the storage drawer rom the
range.
3. Locate the gas distribution valve at the
rear o the range. To convert the gas
distribution valve:
a)Unscrew the conversion cap rom the
gas distribution valve. Note the di er-
ence between the L.P. and natural gas
ends o 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 ori ice hood down snug onto the pin
(approximately 2-1/2 turns). DO NOT
OVERTIGHTEN THE ORIFICE. The
burner lame cannot be properly ad-
justed i this conversion is not made.
Pin
Natural Gas:
Unit is manu actured
or natural gas
L.P. Gas:
Turn down 2-1/2 turns in
this direction
Ori ice Hood
Natural Gas
L.P. Gas

- 6 -
6. To convert the broil burner:
a)Open the oven door and remove the
oven racks.
b)Use a 1/2" open-end wrench and turn
the ori ice hood down snug onto the pin
(approximately 2-1/2 turns). DO NOT
OVERTIGHTEN THE ORIFICE. The
burner lame cannot be properly ad-
justed i this conversion is not made.
Broil Burner
Ori ice
a)Use an 8 mm socket and care ully re-
move the ori ice spud rom each o the
our burners.
b)Install the our L.P. gas ori ices in the
burners.
5. To convert the cooktop burners:
NOTE: The L.P. ori ices or 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 manu actured
or natural gas
L.P. Gas:
Turn down 2-1/2 turns in
this direction
Ori ice Hood

- 7 -
643217910
10-PIN CONNECTOR
GND BAKE BROIL
TOP BURNERS
J1
DIRECT SPARK
IGNITION CONTROL
DIRECT SPARK IGNITION CONTROL
The Direct Spark Ignition (DSI) Control inter-
aces with the Electronic Oven Control or the
Bake, Broil, and Sel -Clean unctions. The DSI
also inter aces with the our cooktop burner ig-
nition switches, to provide ignition or the
cooktop.
The DSI control uses a sel -diagnostic test to
veri y that the oven ignition system is working
properly. It will also continually monitor the
lame presence within the oven. The DSI con-
trol operates on 102 to 132 VAC. All input and
output testing is per ormed 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
Broil Burner Spark Output
L1
Bake Burner Spark Output
Chassis Ground
Le t Rear Spark Output
Right Rear Spark Output
Le t Front Spark Output
Right Front Spark Output
DIRECT SPARK IGNITION
ELECTRONIC CONTROL

- 8 -
L1 N
BK
BK
R
W
IGNITION
SWITCH
DIRECT SPARK
IGNITION CONTROL
643217910
TOP BURNERS GND
10-PIN CONNECTOR
J1
This 120 VAC is detected by the control, and
generates two sparks-per-second to all o the
top burners. Note that in the strip circuit be-
low, 120 VAC is present at the control at all
times through input pin J1-10, and output pin
J1-4.
120 VAC is required to:
a)Monitor the internal sel -diagnostics o
the control board.
b)Monitor the lame sa ety circuits to both
o 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
rom the L1 side o the circuit to the direct spark
ignition control at input J1-9 on the control. The
circuit is completed through output pin J1-4 to
the neutral side o the circuit.
ELECTRONIC SPARK IGNITION
Cooktop Strip Circuit

- 9 -
OVEN BURNER OPERATION
The spark ignition or the oven burners is
started at the Electronic Oven Control (ERC).
As the ERC is programmed or Bake or Broil,
the appropriate relay is closed on the ERC.
120 VAC is provided rom L1, through the ERC
relay(s) to the direct spark ignition control at
input pin J1-6 (Bake), or J1-7 (Broil), to the
neutral side o the circuit, through output pin
J1-4.
This 120 VAC is used to generate two sparks-
per-second to both oven burners. The 120 volts
AC is also stepped-down to between 8 and 18
VDC through pins J1-1 and J1-2 (Bake), and
pins J1-3 and J1-2 (Broil). This DC voltage
opens the gas distribution valve, and provides
gas to the appropriate oven burner.
Monitoring System
When power is applied to the range, a sa ety
delay o 40 seconds takes place be ore the
direct spark ignition control becomes opera-
tional. The 40 second delay allows any unused
gas inside the oven cavity to dissipate be ore
a spark is activated. When the Bake or Broil
operation is activated, the direct spark ignition
control initiates an “internal sel -test” and “ lame
sa ety check.” The lame sa ety check takes
place anytime there is a lame 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
BAKE
RELAY
J1
643217910
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
BUBU
OR W
BK
BK
P1-4
P1-5
V
V
P2-1
P2-2
643217910
GND BAKE BROIL
BAKE
RELAY
DIRECT SPARK
IGNITION CONTROL
The sel -test checks both solenoids on the gas
distribution valve to veri y that they are prop-
erly connected. I they are not, the control will
turn the oven o , or lock it out. I the test is
success ul, the control will then open the ap-
propriate valve, and initiate sparking at the
burner ignitor. Both the bake and broil ignitors
spark simultaneously. Sparking will not occur
until the gas distribution valve opens.

- 10 -
Once the gas has ignited, the “ lame sa ety
circuit” will monitor the lame at the burner to
make sure it is present. I a lame is not present
at the burner:
a) The control will allow the ignitor to spark
or 4 seconds.
b)A 40 second delay to dissipate any un-
used gas inside the oven will occur.
The ignition attempt will occur three times. I
the burner does not ignite a ter the three at-
tempts, the system will “lockout” (see the Tim-
ing Chart below).
Lockout
The control will per orm an oven system lock-
out i :
a)Any o the sel -test checks ail.
b)The oven ails to ignite a ter three igni-
tion attempts.
c) A lame is present within the oven or
more than 10 seconds a ter the gas
valve is o .
d)The lame is unexpectedly lost or any
reason a ter being established. NOTE:
I this occurs, a lockout condition will oc-
cur a ter 30 seconds with no attempt to
reignite.
During the lockout, the gas distribution valve
and ignition are turned o . 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 Technician: The cooktop spark op-
erates normally even when the oven is in the
“lockout” mode. I the oven does not appear to
work at all, veri y the operation o the cooktop
spark. I the cooktop spark is working correctly,
the DSI control is most likely okay, and the
problem is somewhere else in the range.
Timing Chart (Cooktop Burners)
Timing Chart (Oven Burners)
Timing Sequence = 4 Seconds
3 Attempts Before Lockout
Time (sec) 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
Valve open
Charge Cap
Spark
Flame Sense
Time (sec) 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
Top Spark
Valve Open

- 11 -
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.
REMOVING THE DIRECT SPARK IGNITION CONTROL
CAUTION: When you work on the gas range,
be careful when handling the sheet metal parts.
Sharp edges may be present, and you can cut
yourself if you are not careful.
WARNING
FIRE HAZARD
Shut off gas supply line valve before servic-
ing the range.
heck all gas line connections and replace
all panels before operating the range.
Failure to do so could result in explosion, 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
bracket.
4. Disconnect the wire connectors from the
direct spark ignition control.
Board Pin
In S ot
This section instructs you on how to service the direct spark ignition system components inside the
Gas Range.
COMPONENT ACCESS
SECTION 2SECTION 2
SECTION 2SECTION 2
SECTION 2
Screw (1 of 4) Top Rear Cover

- 12 -
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.
REMOVING THE GAS DISTRIBUTION VALVE
CAUTION: When you work on the gas range,
be careful when handling the sheet metal parts.
Sharp edges may be present, and you can cut
yourself if you are not careful.
WARNING
FIRE HAZARD
Shut off gas supply line valve before servic-
ing the range.
heck all gas line connections and replace
all panels before operating the range.
Failure to do so could result in explosion, 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. Remove the electrical connections. NOTE:
The terminals are different sizes to pre-
vent miswiring (see page 4).
Gas Distribution Va ve
(Back of Range)
Gas Out et
Gas Out et
Screws
Screws
Gas
Distribution
Va ve
5. Lower the gas distribution valve so that it
is free of the bake burner, and lay it down,
as shown below.

- 13 -
DIRECT SPARK IGNITION CONTROL
Electrical Shock Hazard
Voltage is present during these tests.
WARNING
COMPONENT TESTING
SECTION 3SECTION 3
SECTION 3SECTION 3
SECTION 3
TEST PROCEDURE
Volta e Tests
Bake Function
1. Set the voltmeter to read 120 VAC.
2. Program the range for the Bake operation.
3. If the top urners spark, proceed to step 4.
Touch the test leads to the J1 connector at
terminals 4 (white) and 10 ( lack). 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 ( lack)
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)
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
BAKE
RELAY
J1
643217910
10-PIN CONNECTOR
GND BAKE BROIL
DIRECT SPARK
IGNITION CONTROL
Bake Strip Circuit

- 14 -
4 (white) 10 ( lack)
J1 Connector
Broil Function
1. Set the voltmeter to read 120 VAC.
2. Program the range for the Broil operation.
3. If the top urners spark, proceed to step 4.
Touch the test leads to the J1 connector at
terminals 4 (white) and 10 ( lack). 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
* When power is applied to the range, a safety delay
of 40 seconds takes place efore the direct spark
ignition control ecomes 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 urners on page 10).
5. Set the voltmeter to read etween 8 and
18 volts DC.
6. Touch the test leads to the J1 connector at
terminals 1 (red) and 2 (orange). The DC
voltmeter should indicate etween 8 and
18 volts DC*. If not, replace the DSI con-
trol.
J1 Connector
2 (orange)1 (red)

- 15 -
4 (white) 7 ( lue/white)
J1 Connector
* When power is applied to the range, a safety delay
of 40 seconds takes place efore the direct spark
ignition control ecomes 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 urners on page 10).
4. Touch the test leads to the J1 connector at
terminals 4 (white) and 7 ( lue/white). The
AC voltmeter should indicate 120 VAC. If
not, check the electronic oven control for
proper operation.
5. Set the voltmeter to read etween 8 and
18 volts DC.
2 (orange) 3 ( lue)
J1 Connector
6. Touch the test leads to the J1 connector at
terminals 2 (orange) and 3 ( lue). The DC
voltmeter should indicate etween 8 and
18 volts DC*. If not, replace the DSI con-
trol.
J1
10-PIN CONNECTOR
OVEN
TEMP
SENSOR
N
L1
BROIL
RELAY
OVEN CONTROL (ERC)
BROIL VALVE
BUBU
OR W
BK
BK
P1-4
P1-5
V
V
P2-1
P2-2
643217910
GND BAKE BROIL
BAKE
RELAY
DIRECT SPARK
IGNITION CONTROL
Broil Strip Circuit

- 16 -
2. Turn one of the cooktop urner 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 indicate 120 VAC. If not,
check the ignition switch and the main
wiring harness.
3. Touch the test leads to the J1 connector at
terminals 4 (white) and 10 ( lack). 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 ( lack)
J1 Connector
4 (white) 9 (red)
J1 Connector
L1 N
BK
BK
R
W
IGNITION
SWITCH
643217910
TOP BURNERS GND
10-PIN CONNECTOR
J1
DIRECT SPARK
IGNITION CONTROL
Cooktop Strip Circuit