Wolf WKG SERIES Service Manual
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Wolf WKG SERIES Service Manual

Wolf WKG SERIES Service Manual

Wkg series full size gas convection ovens
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See also: Service Manual
WKGD2 WITH ROAST & HOLD
SHOWN
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. If you have not
attended a Wolf Range Service School for this product, you should read,
in its entirety, the repair procedure you wish to perform to determine if
you have the necessary tools, instruments and skills required to perform
the procedure. Procedures for which you do not have the necessary
tools, instruments and skills should be performed by a trained Vulcan
Service Technician.
Reproduction or other use of this Manual, without the express written
consent of Wolf Range, is prohibited.
For additional information on Wolf Range or to locate an authorized parts and service
provider in your area, visit our website at www.wolfrange.com.
WOLF RANGE
DIVISION OF ITW FOOD EQUIPMENT GROUP, LLC
SERVICE MANUAL
GAS CONVECTION OVENS
MODEL
WKG
WKGD
WKGC
WKGX
WKGDX
WKGCX
- NOTICE -
WKG SERIES
FULL SIZE
ML
126620
126621
126622
126623
126624
126625
LOUISVILLE, KY 40201-0696
F32700 (February 2006)

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  • Page 1 Reproduction or other use of this Manual, without the express written consent of Wolf Range, is prohibited. For additional information on Wolf Range or to locate an authorized parts and service provider in your area, visit our website at www.wolfrange.com.

  • Page 2: Table Of Contents

    FULL SIZE GAS CONVECTION OVENS TABLE OF CONTENTS GENERAL ................4 Introduction .
  • Page 3 CONDENSED SPARE PARTS LIST ............64 © Wolf Range 2006...

  • Page 4: General

    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 OPTIONS NORMAL MODEL...

  • Page 5: Removal And Replacement Of Parts

    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.

  • Page 6: Control Panel Components

    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.

  • Page 7: Component Panel Components

    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.

  • Page 8: Temperature Probe (Wkgd/Wkgdx)

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 7. Adjust the temperature control as outlined under TEMPERATURE PROBE SOLID STATE TEMPERATURE CONTROL (WKGD/WKGDX) CALIBRATION (WKGD/WKGDX) in SERVICE PROCEDURES AND ADJUSTMENTS. WARNING: DISCONNECT THE GAS BURNER ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / WARNING: DISCONNECT THE TAGOUT PROCEDURES.

  • Page 9: Gas Orifice

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS 4. Reverse procedure to install and check for proper 6. Reverse procedure to install the replacement operation. burner. GAS SOLENOID VALVE NOTE: Ensure that burner positioning bracket (U shaped end) is inserted into slot at the rear of the burner chamber.

  • Page 10: Ignition Control Module

    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.

  • Page 11: Blower And Motor

    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.

  • Page 12: Oven Doors And Bearings (Independent Doors)

    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.

  • Page 13: Oven Doors (Simultaneous Doors)

    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.

  • Page 14: Door Catch Ball Assembly (Independent Doors)

    FULL SIZE GAS CONVECTION OVENS - REMOVAL AND REPLACEMENT OF PARTS NOTE: The door assembly is heavy and will drop DOOR CATCH BALL ASSEMBLY down once the last screw is removed. If removing (INDEPENDENT DOORS) door assembly with-out assistance, the ignition cable, flame sense lead and gas manifold should also be removed to avoid damage to these components.

  • Page 15: Door Switch

    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 5.

  • Page 16: Mechanical Kx Thermostat (Wkg/Wkgx)

    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 3.

  • Page 17: Cooling Fan

    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 Lamp Assembly COVERS AND PANELS. NOTE: If right side panel is not accessible, this WARNING: DISCONNECT THE component can be serviced by removing the control...

  • Page 18: Service Procedures And Adjustments

    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.

  • Page 19: Mechanical Thermostat Calibration (Wkg/Wkgx)

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS NOTE: Allow the oven to cycle at least two times MECHANICAL THERMOSTAT between adjustments before performing the CALIBRATION (WKG/WKGX) calculation. If the above adjustment can not be obtained, Place a thermocouple in the geometric center of install a replacement thermostat and check the oven cavity.

  • Page 20: Temperature Probe Test (Wkgd/Wkgdx)

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS Check machine data plate for correct voltage to If correct, temperature control is oven. Refer to diagram below for proper functioning properly. terminal locations and voltages before checking If incorrect, check temperature probe as the control.

  • Page 21: Gas Pressure Adjustment

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS Reverse procedure to install. TEMP (°F) OHMS* TEMP (°F) OHMS* 90000 4077 3016 2266 1726 1332 1041 (*) Resistance in ohms ± 10% GAS PRESSURE ADJUSTMENT Remove adjustment screw cap from the gas WARNING: DISCONNECT THE valve and turn gas supply to the oven back on.

  • Page 22: Verification Of Spark At Ignitor

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS Plug the oven in and set the temperature control VERIFICATION OF SPARK AT to the maximum setting. IGNITOR Turn the power switch ON. Sparking should occur after a 4 second delay, WARNING: DISCONNECT THE for a duration of 7 seconds then repeat twice ELECTRICAL POWER TO THE...

  • Page 23: Blower Adjustment

    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. 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.

  • Page 24: Door Adjustment

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS Move the door until proper alignment is DOOR ADJUSTMENT achieved then tighten the screws on the upper door bearing hardware. WARNING: DISCONNECT THE Repeat step 3 and 4 on the opposite door, if ELECTRICAL POWER TO THE necessary.

  • Page 25: Door Chain Adjustment (Simultaneous Doors)

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS Apply lubricant at the top of the door catch assembly to lubricate the internal spring. See LUBRICATION under GENERAL. Close the doors and check them for proper Continue adjustment until proper door alignment.

  • Page 26: Computer Control (Wkgc/Wkgcx)

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS The stop cable must be positioned where it COMPUTER CONTROL moves freely and does not get pinched. (WKGC/WKGCX) Position door chain assembly to factory setting if the conditions in step 2 are not met. Operation Refer to the Owner's Manual for specific operating instructions.

  • Page 27: Computer Control Calibration (Wkgc/Wkgcx)

    FULL SIZE GAS CONVECTION OVENS - SERVICE PROCEDURES AND ADJUSTMENTS Re-assemble oven and check for proper ALTERNATING ON operation. DISPLAY MENU COMPUTER CONTROL PARAMETER DATA CALIBRATION Celsius_Fahrenheit (WKGC/WKGCX) Guard Band 4000 Temperature tcnP Compensation Place a thermocouple in the geometric center of the oven cavity.

  • Page 28: Electrical Operation

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION 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.
  • Page 29 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.

  • Page 30: Component Location

    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.
  • Page 31 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKG/WKGX - Plug, Socket and Components (Standard Controls) Page 31 of 64 F32700 (February 2006)
  • Page 32 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKGD/WKGDX - Plug, Socket and Components (Standard Controls) F32700 (February 2006) Page 32 of 64...
  • Page 33 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)
  • Page 34 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKGC/WKGCX - Plug, Socket and Components (Roast & Hold Standard) F32700 (February 2006) Page 34 of 64...

  • Page 35: Sequence Of Operation

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Power ON light (Amber) comes ON. SEQUENCE OF OPERATION Power to one side of the following WKG, WKGX With Roast & Hold Option components: Normal ROAST timer (Mechanical KX Thermostat) terminal 1, ROAST & HOLD timer terminal 1, transformer primary (T1).
  • Page 36 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION When the convection fan motor Timer Cycle (Normal Roast Cooking) reaches operating speed, the NOTE: The ROAST timer (normal cooking) operates centrifugal switch on the motor independently of the heating cycle. Additional time closes.
  • Page 37 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Roast timer (normal cooking) in the OFF Heat light (clear) comes ON. position. Power is also connected through the another set of relay R4 normally Roast and Hold timer in the OFF position. closed (N.C.) contacts to the other Oven doors Closed.
  • Page 38 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION R3 normally open (N.O.) contacts NOTE: When temperature is above open. 160°F (±12) the hold thermostat contacts are open. Ignition control module de- energized. Relay R4 is energized, R4 contacts change state and both sets of Power removed from 2 normally closed (N.C.) contacts valve (main) on the gas...

  • Page 39: Wkgd, Wkgdx With Roast & Hold Option (Solid State Temperature Control)

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION trial cycle repeats after a 15 Power switch (S1) OFF. second purge between Function switch (S3) set to Normal ROAST cycles for two additional cycle. tries before locking out. To reset after a lockout, turn Oven light switch (S2) ON/OFF (position power switch (S1) OFF then has no affect on the function of the Normal...
  • Page 40 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Motor speed relay (R1) is If a flame is not SENSED energized through hold relay after 7 seconds of sparking, (R2) normally closed contacts the NO IGNITION light (N.C.). Relay contacts (R1) comes back on, 2 valve change state and the normally...
  • Page 41 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Roast and Hold Cycle NOTE: Power is available to the oven light switch (wire #20) to turn the oven cavity lights NOTE: Refer to the Owner's Manual for a detailed ON when the light switch is turned ON; and explanation of ROAST &...
  • Page 42 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Solid state temperature control Power removed from 2 energized. If the oven valve (main) on the gas temperature is below set point, valve and gas flow to the the temperature control will burner stops.

  • Page 43: Oven Cool Cycle (Solid State Temperature Control)

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Power to one side of hold IGNITION light stays out thermostat. and burner remains lit. If a flame is not SENSED NOTE: When temperature is above 160°F (±12) the hold thermostat after 7 seconds of sparking, the NO IGNITION light contacts are open.

  • Page 44: Wkgc, Wkgcx (Roast & Hold Standard On Computer Model)

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Power Switch (S1) turned to OVEN COOL. Power (24VAC) to one side of the following components: heat NOTE: With door switch contacts OPEN (doors relay (R3) normally open (N.O.) open), the convection fan motor will still run and contacts, high limit --- connected continue to cool the oven.
  • Page 45 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Oven doors Closed. NOTE: Power is not applied to the heat relay coil (R1) Door switch contacts CLOSED. until the centrifugal switch Oven cavity temperature below 140°F. contacts on the convection Power switch (S1) turned ON. fan motor close.

  • Page 46: Oven Cool Cycle (Computer Control Model)

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Oven reaches set point temperature. At the end of the ROAST time, the electronic beeper sounds momentarily to indicate the end Computer control de-activates the 120VAC of first stage cooking (oven operates normally at output to heat relay (R1).

  • Page 47: Schematics

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION SCHEMATICS WKG, WKGX Mechanical (KX) Controls Page 47 of 64 F32700 (February 2006)

  • Page 48: Wkg, Wkgx Mechanical (Kx) Controls, Roast & Hold Option

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKG, WKGX Mechanical (KX) Controls, Roast & Hold Option F32700 (February 2006) Page 48 of 64...

  • Page 49: Wkgd, Wkgdx Solid State Temperature Control

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKGD, WKGDX Solid State Temperature Control Page 49 of 64 F32700 (February 2006)

  • Page 50: Wkgd, Wkgdx Solid State Temperature Control, Roast & Hold Option

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKGD, WKGDX Solid State Temperature Control, Roast & Hold Option F32700 (February 2006) Page 50 of 64...

  • Page 51: Wkgc, Wkgcx Computer Control (Roast & Hold Standard)

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKGC, WKGCX Computer Control (Roast & Hold Standard) Page 51 of 64 F32700 (February 2006)

  • Page 52: Wiring Diagrams

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WIRING DIAGRAMS WKG, WKGX Mechanical (KX) Controls F32700 (February 2006) Page 52 of 64...
  • Page 53 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Page 53 of 64 F32700 (February 2006)

  • Page 54: Wkg, Wkgx Mechanical (Kx) Controls, Roast & Hold Option

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKG, WKGX Mechanical (KX) Controls, Roast & Hold Option F32700 (February 2006) Page 54 of 64...
  • Page 55 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Page 55 of 64 F32700 (February 2006)

  • Page 56: Wkgd, Wkgdx Solid State Temperature Control

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKGD, WKGDX Solid State Temperature Control F32700 (February 2006) Page 56 of 64...
  • Page 57 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Page 57 of 64 F32700 (February 2006)

  • Page 58: Wkgd, Wkgdx Solid State Temperature Control, Roast & Hold Option

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKGD, WKGDX Solid State Temperature Control, Roast & Hold Option F32700 (February 2006) Page 58 of 64...
  • Page 59 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Page 59 of 64 F32700 (February 2006)

  • Page 60: Wkgc, Wkgcx Computer Control (Roast & Hold Standard)

    FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION WKGC, WKGCX Computer Control (Roast & Hold Standard) F32700 (February 2006) Page 60 of 64...
  • Page 61 FULL SIZE GAS CONVECTION OVENS - ELECTRICAL OPERATION Page 61 of 64 F32700 (February 2006)

  • Page 62: Troubleshooting

    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.

  • Page 63: Computer Control Models Only

    FULL SIZE GAS CONVECTION OVENS - TROUBLESHOOTING SYMPTOMS POSSIBLE CAUSES Normal (Roast) mode OK, no Hold mode. Roast and Hold switch (S3) malfunction. (Roast & Hold models only). R2 hold relay malfunction. Roast & Hold timer malfunction. Interconnecting wiring malfunction. Component cooling Fan does not run.

  • Page 64: Condensed Spare Parts List

    FULL SIZE GAS CONVECTION OVENS - CONDENSED SPARE PARTS LIST CODE & PROBLEM PROBABLE CAUSE SOLUTION Er06 - Zone 1 A/D underflow • Incorrect sensor type • Check the InP1 setup parameter. error Verify it matches your sensor. • Measuring temperature outside the sensor range •...

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