SERVICE MANUAL WKG SERIES FULL SIZE GAS CONVECTION OVENS MODEL WKG WKGD WKGC WKGX WKGDX WKGCX ML 126620 126621 126622 126623 126624 126625 WKGD2 WITH ROAST & HOLD SHOWN - NOTICE This Manual is prepared for the use of trained Wolf Range Service Technicians and should not be used by those not properly qualified. If you have attended a Wolf Range Service School for this product, you may be qualified to perform all the procedures described in this manual. This manual is not intended to be all encompassing.
FULL SIZE GAS CONVECTION OVENS TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FULL SIZE GAS CONVECTION OVENS Computer Control (WKGC/WKGCX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Computer Control Calibration (WKGC/WKGCX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ELECTRICAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Component Function . . . . . . . . . . . . .
FULL SIZE GAS CONVECTION OVEN - GENERAL GENERAL INTRODUCTION Procedures in this manual will apply to all models unless specified. Pictures and illustrations can be of any model unless the picture or illustration needs to be model specific. Models FEATURES MODEL WKG CAVITY TEMPERATURE DEPTH CONTROL 26.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS COVERS AND PANELS WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. Top Front Cover 1. The top front cover is secured with four (4) screws, two on each side of cover. Remove these screws then remove the cover from the oven. NOTE: If the oven has a mechanical (KX type) thermostat, it must be removed from the control panel first, before removing the control panel.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS CONTROL PANEL COMPONENTS Removable Components Procedure WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. Remove the control panel as outlined under COVERS AND PANELS. 2. Remove the component being replaced. 3. Reverse the procedure to install the replacement component, then check oven for proper operation.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS COMPONENT PANEL COMPONENTS Removable Components Procedure WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. Remove the right side panel as outlined under COVERS AND PANELS. NOTE: If right side panel is not accessible, this component can be serviced by removing the control panel as outlined under COVERS AND PANELS. 2. Disconnect the wire leads to the component being replaced. 3.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 7. Adjust the temperature control as outlined under SOLID STATE TEMPERATURE CONTROL CALIBRATION (WKGD/WKGDX) in SERVICE PROCEDURES AND ADJUSTMENTS. TEMPERATURE PROBE (WKGD/WKGDX) WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. GAS BURNER WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 4. Reverse procedure to install and check for proper operation. 6. Reverse procedure to install the replacement burner. GAS SOLENOID VALVE NOTE: Ensure that burner positioning bracket (U shaped end) is inserted into slot at the rear of the burner chamber. 7. Check for proper operation. WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 4. Loosen the bolts securing the valve and bracket assembly then remove the screws securing the valve to the bracket. 3. Disconnect the lead wires and igniter cable from the ignition module board. 5. Reverse the procedure to install the replacement gas valve. NOTE: Clean the pipe threads and apply pipe joint compound to threads. Any pipe joint compound used, must be resistant to the action of propane gases. 6.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 3. Reverse the procedure to install the assembly and check for proper operation. NOTE: Check to ensure the spark gap distance is approximately 1/8". If the gap appears to be excessive or poor sparking is occurring then adjust. 3. Remove screws securing baffle panel and remove the panel. BLOWER AND MOTOR WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS NOTE: Check data plate on motor for wiring schematic. The motor must rotate clockwise when viewed from the shaft end. 6. Remove the nuts that secure the motor mounting plate to the rear wall. 7. Place a piece of cardboard on the bottom of the oven cavity to protect its surface from any damage during motor assembly removal. 13. Slide blower onto motor shaft until hub is flush with end of shaft then tighten set screws. 14.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 2. Remove the door switch lever. 8. Reverse procedure to install door assembly and check for proper adjustment as outlined under DOOR ADJUSTMENT and DOOR SWITCH ADJUSTMENT in SERVICE PROCEDURES AND ADJUSTMENTS. OVEN DOORS (SIMULTANEOUS DOORS) Assembly Removal 3. Remove the lower door seal strip to expose the mounting screws of the door assembly. WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS NOTE: The door assembly is heavy and will drop down once the last screw is removed. If removing door assembly with-out assistance, the ignition cable, flame sense lead and gas manifold should also be removed to avoid damage to these components. DOOR CATCH BALL ASSEMBLY (INDEPENDENT DOORS) WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 5.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 2. Independent doors: A. Remove the door handle then remove the outer door panel. B. Lift out the inner door panel and window assembly. NOTE: Left door only - remove door seal from the inside edge of the door. 3. Simultaneous doors: 5. Reverse procedure to install the replacement window. DOOR SWITCH A. If replacing window on the left door, remove the handle from the front of the door then remove door seal from the inside edge of the door.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS MECHANICAL KX THERMOSTAT (WKG/WKGX) WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. Remove the racks and right rack support. 2. Remove the thermostat knob and mounting screws from the control panel and then remove the control panel. 3. Remove the probe guard from the oven cavity wall. 3.
FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS COOLING FAN WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. Remove the right side panel as outlined under COVERS AND PANELS. Lamp Assembly WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. NOTE: If right side panel is not accessible, this component can be serviced by removing the control panel as outlined under COVERS AND PANELS. 2.
FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES AND ADJUSTMENTS WARNING: CERTAIN PROCEDURES IN THIS SECTION REQUIRE ELECTRICAL TEST OR MEASUREMENTS WHILE POWER IS APPLIED TO THE MACHINE. EXERCISE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASILY ACCESSIBLE, DISCONNECT POWER AND FOLLOW LOCKOUT/TAGOUT PROCEDURES, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST. SOLID STATE TEMPERATURE CONTROL CALIBRATION (WKGD/WKGDX) 1.
FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS MECHANICAL THERMOSTAT CALIBRATION (WKG/WKGX) NOTE: Allow the oven to cycle at least two times between adjustments before performing the calculation. 1. Place a thermocouple in the geometric center of the oven cavity. 9. 2. Set the ON-OFF-OVEN COOL switch to ON. 3. Set the thermostat dial to 350°F. 4. Allow the oven temperature to stabilize (normally 3 cycles). 5.
FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS 4. 5. Check machine data plate for correct voltage to oven. Refer to diagram below for proper terminal locations and voltages before checking the control. Use the correct terminals for the corresponding voltage. A. If correct, temperature control is functioning properly. B. If incorrect, check temperature probe as outlined under TEMPERATURE PROBE TEST (WKGD/WKGDX). Turn the ON-OFF-OVEN COOL switch to ON.
FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS 5. Reverse procedure to install. TEMP (°F) OHMS* TEMP (°F) OHMS* 77 90000 360 822 240 4077 380 656 260 3016 400 529 280 2266 425 424 300 1726 450 334 320 1332 475 266 340 1041 (*) Resistance in ohms ± 10% GAS PRESSURE ADJUSTMENT WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS VERIFICATION OF SPARK AT IGNITOR WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 4. Plug the oven in and set the temperature control to the maximum setting. 5. Turn the power switch ON. 6. Sparking should occur after a 4 second delay, for a duration of 7 seconds then repeat twice after a 15 second purge time. Arching from the ignition cable to the oven frame should be observed.
FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS BLOWER ADJUSTMENT WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. WARNING: SHUT OFF THE GAS BEFORE SERVICING THE UNIT. 1. Remove the blower motor and mounting assembly by following steps 1 through 8 as outlined under BLOWER AND MOTOR in REMOVAL AND REPLACEMENT OF PARTS. 2. Loosen the motor mounting bolts. 3.
FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS DOOR ADJUSTMENT WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. 4. Move the door until proper alignment is achieved then tighten the screws on the upper door bearing hardware. 5. Repeat step 3 and 4 on the opposite door, if necessary.
FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS 4. Apply lubricant at the top of the door catch assembly to lubricate the internal spring. See LUBRICATION under GENERAL. 5. Close the doors and check them for proper alignment. A. 6. 2) Doors should be centered and parallel at the top and bottom in the oven cavity opening as outlined under DOOR ADJUSTMENT. Open right side door and view the left side catch ball and door strike position.
FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS F. 3. The stop cable must be positioned where it moves freely and does not get pinched. Position door chain assembly to factory setting if the conditions in step 2 are not met. COMPUTER CONTROL (WKGC/WKGCX) Operation Refer to the Owner's Manual for specific operating instructions. Setup Mode NOTE: Use the setup mode to verify that the control is configured to the factory settings which result in the proper operation of the oven.
FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS MENU 5. ALTERNATING ON DISPLAY PARAMETER DATA C_F F gb 4000 Temperature Compensation tcnP OFF Input Type 1 InP1 J Range Low 1 rL1 75 Range High 1 rH1 500 Hysteresis HYS1 3 Calibration Offset CAL1 0 Celsius_Fahrenheit Guard Band Exit Setup Mode and return to Operation Mode. set point temperature is displayed or if call for heat, dashes (----) displayed. Re-assemble oven and check for proper operation.
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION 7. 2) If the thermocouple reading is lower than set point temperature, press the up arrow key and enter a positive offset value that is equal to the number of degrees below the 5°F tolerance. 3) Exit the setup mode. Allow the oven to cycle at least two times between adjustments. A. If the temperature variance still differs more than 5°F from the set point, verify the correct calibration offset value was entered and retained. 1) B.
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Blower Motor . . . . . . . . . . . . . . . . . Operates the oven cavity blower (convection fan). Also, an internal centrifugal switch on the motor is utilized to allow the connection of power to the heat relay (R3) when the motor is at operating speed. Motor Speed Relay (R1) . . . . . . . . . Supplies power to the blower motor through (R1) relay contacts. Available on models with Roast & Hold option only. Hold Relay (R2) . . . . . . . . . . . . . . . .
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Temperature Probe . . . . . . . . . . . . Senses the oven temperature for the solid state temperature control or the computer control. On WKGD/WKGDX models, converts the temperature into a resistance valve which is monitored by the temperature control board. The probe is an RTD (resistance temperature detector) of the Thermistor type. As temperature increases the resistance value decreases. On WKGC/WKGCX models, the probe is a J type thermocouple.
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FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKG, WKGX/WKGD, WKGDX - Plug, Socket and Components (Roast & Hold Option) Page 33 of 64 F32700 (February 2006)
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FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION SEQUENCE OF OPERATION WKG, WKGX With Roast & Hold Option (Mechanical KX Thermostat) Schematic diagram 10832 will be used to explain the electrical sequence of operation for both the Normal ROAST cycle (normal cooking) and the ROAST & HOLD cycle. Normal Roast Cycle 1. Conditions. A. Oven connected to correct voltage. 1) L1 (HOT) to power switch (S1).
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION b. When the convection fan motor reaches operating speed, the centrifugal switch on the motor closes. The heat relay (R3) is then energized, R3 relay contacts normally open (N.O.) close and the heating circuit is powered. Timer Cycle (Normal Roast Cooking) 1. With the power switch turned ON, power is supplied to timer. a) Ignition control module is energized. 2. Set ROAST timer to desired time (normal cooking).
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION J. Roast timer (normal cooking) in the OFF position. K. Roast and Hold timer in the OFF position. L. Oven doors Closed. Power is also connected through the another set of relay R4 normally closed (N.C.) contacts to the other side of motor speed relay (R1). 1) a. M. 2. a. 3) Door switch contacts CLOSED. Oven cavity temperature below 140°F. Set controlling thermostat to desired ROAST then Hold temperature (Roast & Hold cooking). 3.
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION 1) R3 normally open (N.O.) contacts open. a. NOTE: When temperature is above 160°F (±12) the hold thermostat contacts are open. Ignition control module deenergized. a) 3) nd Power removed from 2 valve (main) on the gas valve and gas flow to the burner stops. NOTE: This is considered first stage cooking in the ROAST AND HOLD cycle. 5.
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION 5. trial cycle repeats after a 15 second purge between cycles for two additional tries before locking out. To reset after a lockout, turn power switch (S1) OFF then ON. E. Power switch (S1) OFF. F. Function switch (S3) set to Normal ROAST cycle. G. Oven light switch (S2) ON/OFF (position has no affect on the function of the Normal ROAST cycle). Oven reaches the fixed HOLD temperature and the hold thermostat opens. H.
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION a. a) Power is connected through the function switch (S3) contacts and convection fan motor is energized (fan speed hi). b) When the convection fan motor reaches operating speed, the centrifugal switch (N.O.) on the motor closes. c) 3) If a flame is not SENSED after 7 seconds of sparking, the NO IGNITION light comes back on, 2nd valve (main) on the gas valve is de-energized and gas flow to the burner stops.
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Roast and Hold Cycle NOTE: Refer to the Owner's Manual for a detailed explanation of ROAST & HOLD cooking. 1. Conditions. A. Oven connected to correct voltage. 1) L1 (HOT) to power switch (S1).
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION a. Solid state temperature control energized. If the oven temperature is below set point, the temperature control will energize its internal relay. The normally open (N.O.) contacts close and apply power to the following components: a) Heat light (clear) comes ON. b) Power is connected through the centrifugal switch contacts on the convection fan motor, heat relay (R3) is energized, (R3) contacts (N.O.) close and the heating circuit is powered.
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION a. IGNITION light stays out and burner remains lit. Power to one side of hold thermostat. If a flame is not SENSED after 7 seconds of sparking, the NO IGNITION light comes back on, 2nd valve (main) on the gas valve is de-energized and gas flow to the burner stops. Ignition trial cycle repeats after a 15 second purge between cycles for two additional tries before locking out. To reset after a lockout, turn power switch (S1) OFF then ON.
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION 2. a. Power Switch (S1) turned to OVEN COOL. NOTE: With door switch contacts OPEN (doors open), the convection fan motor will still run and continue to cool the oven. However, power would be removed from the following components: Power ON light (goes out), Normal ROAST timer, ROAST & HOLD timer, transformer T1 (de-energized) and to the component cooling fan. A. Motor speed (Hi/Low) relay (R1) is energized and contacts change state. a.
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION I. 2. Oven doors Closed. 1) Door switch contacts CLOSED. J. Oven cavity temperature below 140°F. Power switch (S1) turned ON. A. Power (120VAC) to computer control pin 3 (C3-3). B. C. D. E. NOTE: Power at pin 3 is not transferred to other components until computer control is energized and operating conditions are met. Power is available to the oven light switch (S2).
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION 3. Oven reaches set point temperature. A. At the end of the ROAST time, the electronic beeper sounds momentarily to indicate the end of first stage cooking (oven operates normally at the temperature and time selected until time expires). 4. The display flashes HOLD as the oven enters HOLD mode. This is also considered second stage cooking (oven heating stops but product continues to cook on residual heat).
FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION SCHEMATICS WKG, WKGX Mechanical (KX) Controls Page 47 of 64 F32700 (February 2006)
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FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKGD, WKGDX Solid State Temperature Control Page 49 of 64 F32700 (February 2006)
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FULL SIZE GAS CONVECTION OVENS - TROUBLESHOOTING TROUBLESHOOTING WARNING: CERTAIN PROCEDURES IN THIS SECTION REQUIRE ELECTRICAL TEST OR MEASUREMENTS WHILE POWER IS APPLIED TO THE MACHINE. EXERCISE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASILY ACCESSIBLE, DISCONNECT POWER AND FOLLOW LOCKOUT/TAGOUT PROCEDURES, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST. ALL MODELS SYMPTOMS POSSIBLE CAUSES Blower motor doesn’t run with 1S in OVEN COOL position. 1. 2. 3. 4. 5. Line voltage.
FULL SIZE GAS CONVECTION OVENS - TROUBLESHOOTING SYMPTOMS POSSIBLE CAUSES Normal (Roast) mode OK, no Hold mode. (Roast & Hold models only). 1. 2. 3. 4. Roast and Hold switch (S3) malfunction. R2 hold relay malfunction. Roast & Hold timer malfunction. Interconnecting wiring malfunction. Component cooling Fan does not run. 1. 2. Motor inoperable. Interconnecting wiring malfunction. Uneven Cooking. 1. 2. 3. Convection Fan motor speed/direction. Poor combustion. A. Gas pressure incorrect. B.
FULL SIZE GAS CONVECTION OVENS - CONDENSED SPARE PARTS LIST CODE & PROBLEM PROBABLE CAUSE SOLUTION Er06 - Zone 1 A/D underflow error • Incorrect sensor type • Measuring temperature outside the sensor range • Check the InP1 setup parameter. Verify it matches your sensor. • Check sensor and connections for a reversed or open sensor. If the condition causing the error is resolved, the error will clear. Er07 - Zone 1 A/D overflow error Open sensor • Check the InP1 setup parameter.