KAC-49 TECHNICAL EDUCATION FLUSH-MOUNT GAS COOKTOP MODELS: KFGS306VSS, KFGU706VSS, KFGS366VSS, KFGU766VSS JOB AID 4317428
FORWARD This KitchenAid Job Aid “Flush-Mount Gas Cooktop” (Part No. 4317428), provides the In-Home Service Professional with information on the installation, operation, and service of the Flush-Mount Gas Cooktop. For specific information on the model being serviced, refer to the “Use and Care Guide,” or “Wiring Diagram” provided with the cooktop. The Wiring Diagram used in this Job Aid is typical and should be used for training purposes only.
TABLE OF CONTENTS Page GENERAL ............................................................................................................................... 1-1 Cooktop Safety................................................................................................................... 1-1 Model & Serial Number Designations................................................................................. 1-2 Model & Serial Number Label And Tech Sheet Locations.........................................
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GENERAL COOKTOP SAFETY Your safety and the safety of others are very important. We have provided many important safety messages in this manual and on the appliance. Always read and obey all safety messages. This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and either the word “DANGER” or “WARNING.
KITCHENAID MODEL & SERIAL NUMBER DESIGNATIONS MODEL NUMBER MODEL NUMBER K FG PRODUCT GROUP K = KITCHENAID PRODUCT IDENTIFICATION EC = ELECTRIC COOKTOP GC = GAS COOKTOP IC = ELECTRIC INDUCTION COOKTOP FG = FLUSH GAS COOKTOP ED = ELECTRIC DOWNDRAFT COOKTOP ID = ELECTRIC INDUCTION DOWNDRAFT COOKTOP GL = GAS LP COOKTOP MERCHANDISING SCHEME K = STANDARD KITCHENAID S = SUPERBA U = ULTIMA MATERIAL / STYLE / WIDTH 1ST POSITION 2ND POSITION 0 = TEMPERED GLASS 0 = 30" WIDE 1 = STAINLESS STEEL 5 = 15" WIDE 4 = C
MODEL & SERIAL NUMBER LABEL AND TECH SHEET LOCATIONS The Model/Serial Number label and Tech Sheet locations are shown below.
SPECIFICATIONS Model Number Canadian Model Number Colors Installs Over Undercounter Oven Agency Ratings Electric Supply Power Cable Location Total Connected Load COOKTOP Surface Clear Coat BURNERS Electronic Ignition with Electronic Re-ignition L.P. Convertible (No Additional Kit Needed) Number of Burners & Burner BTU (Nat./L.P..
CONTROLS Location Removable Dials/Knobs Lock Out Hot Indicator Light Control Graphics DIMENSIONS - IN.
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INSTALLATION INFORMATION INSTALLATION REQUIREMENTS TOOLS AND PARTS Gather the required tools and parts before starting installation. Read and follow the instructions provided with any tools listed here.
Installation Clearances • Provide cutout in right rear corner of cutout enclosure as shown to provide clearance for gas inlet, power supply cord, and to allow the rating label to be visible. IMPORTANT: To avoid damage, check with your builder or cabinet supplier to make sure that the materials used will not discolor, delaminate or sustain other damage. Product Dimensions A B C J D K E G F A B M L H N I C A. 30 �⁄�� " (76.7 cm) on 30" (76.2 cm) models, 36 �⁄� " (92.0 cm) on 36" (91.
NOTES: After making the countertop cutout, some installations may require notching down the base cabinet side walls to clear the cooktop base. To avoid this modification, use a base cabinet with sidewalls wider than the cutout. If cabinet has a drawer, a 4" (10.2 cm) depth clearance from the countertop to the top of the drawer (or other obstruction) in base cabinet is required. The drawer depth may need to be shortened to avoid interfering with the regulator.
Gas Supply Line • Provide a gas supply line of 3/4" (1.9 cm) rigid pipe to the cooktop location. A smaller size pipe on longer runs may result in insufficient gas supply. Pipe-joint compounds that resist the action of LP gas must be used. Do not use TEFLON®† tape. With LP gas, piping or tubing size should be 1/2" minimum. Usually, LP gas suppliers determine the size and materials used in the system. Flexible metal appliance connector: • If local codes permit, use a 1/2" or 3/4" I.D.
INSTALLATION REQUIREMENTS INSTALL COOKTOP 2. The clamping brackets can be installed before or after the cooktop is placed into the cutout. Complete the following steps for the option you choose. Installing Brackets Before Placing Cooktop in Cutout 1. Using 2 or more people, place the cooktop upside down on a covered surface. 2. Remove the attachment screws for the selected bracket locations from the bottom of the cooktop base. 3.
NOTE: Make sure that the front edge of the cooktop is parallel to the front edge of the countertop. If repositioning is needed, lift entire cooktop up from cutout to avoid scratching the countertop. 8. Loosen the screws and rotate the brackets so that they are perpendicular to the edge of the cooktop base and extend beyond its edge. Securely tighten screws. Installing Brackets After Placing Cooktop in Cutout 1. Using 2 or more people, place cooktop right side up into the cutout.
Complete Connection 1. Open the manual shutoff valve in the gas supply line. The valve is open when the handle is parallel to the gas pipe. Use only pipe-joint compound made for use with Natural and LP gas. Do not use TEFLON® tape. You will need to determine the fittings required depending on your installation. A Typical flexible connection 1. Apply pipe-joint compound made for use with LP gas to the smaller thread ends of the flexible connector adapters (see G in following illustration). 2.
COMPLETE INSTALLATION WARNING Electronic Ignition System Initial lighting and gas flame adjustments Surface burners use electronic igniters in place of standing pilots. When the cooktop control knob is pushed in and turned to the “LITE” position, the system creates a spark to light the burner. This sparking continues, as long as the control knob is pushed in and turned to “LITE.” Check Operation of Surface Burners 1. Push in and turn the surface burners control knobs to the “LITE” position.
Turn adjustment screw “C” to the right to reduce flame height, turn adjustment screw to the left to increase flame height. Adjust Flame Height The surface burner “low” flame should be a steady blue flame approximately 1/4" (0.64 cm) high. A B A C B A. Low flame B. High flame A. �⁄�� " (#0 [2.0 mm]) flat blade screwdriver (screwdriver shaft must be a minimum of 1 �⁄� " (28.0 mm) long) B. Control knob stem opening C.
2. 3. 4. Remove the control knob. Remove the black rubber grommet. Using needle-nose pliers, remove the gray shield inside the burner valve opening. A Med B 12. Replace the control knob. 13. Test the flame by turning the control from LO to HI, checking the flame at each setting. If you need Assistance or Service: Please reference the “Assistance or Service” section of the Use and Care Guide or contact the dealer from whom you purchased your cooktop. C A. Control knob B. Black rubber grommet C.
LP GAS AND HIGH ALTITUDE CONVERSION INSTRUCTIONS TOOLS AND PARTS WARNING Gather the required tools and parts necessary for correct LP gas conversion. Tools needed • Flat-blade screwdriver • T20 TORX®† screwdriver • 3/32"(#0[2mm]) flat blade screwdriver (screwdriver shaft must be a minimum of 1 1/8" [28.
To Convert Gas Pressure Regulator B A C Explosion Hazard Use a new CSA International approved gas supply line. Install a shut-off valve. Securely tighten all gas connections. If connected to LP, have a qualified person make sure gas pressure does not exceed 14˝ (36 cm) water column. Examples of a qualified person include: licensed heating personnel, authorized gas company personnel, and authorized service personnel. Failure to do so can result in death, explosion, or fire. D A. Access cap B.
Style 2: The cap does not have a slot and requires a wrench to be removed. Remove the access cap by using a wrench, turning the access cap counterclockwise. Remove spring retainer from the cap by pushing against the flat side of the spring retainer. Look at the spring retainer to locate the “NAT” or “LP” position. Turn over the spring retainer so the “LP” is showing on the bottom. Snap the spring retainer back into the cap. Reinstall the cap onto the regulator.
High Altitude Conversions 6. IMPORTANT: You must convert LP gas with LP gas high altitude or Natural gas with Natural gas high altitude. If you need to convert LP gas to Natural gas high altitude or Natural gas to LP gas high altitude you must convert the pressure regulator, for this you must follow steps 1, 2, and 3 of the respective conversion that you need. LP Gas Orifice Spud Chart for High Altitude Conversion Burner Rating Stamp (A) Remove all burner caps and burner bases.
On all models, remove the metal cooktop and the sheet of insulation from the cooktop base. A B C D A E B A. Orifice B. Venturi C. Second Groove (16.0 mm LP gas setting) D. First groove (12.0 mm natural gas setting) E. Venturi screw C • Use 15.0 mm wrench to loosen the nut securing the tube to the orifice pack. Remove the tube from the orifice pack. A. Metal cooktop B. Sheet of insulation C. Cooktop base A 9. To Convert Right or Left Burners: • Insert 7.
IMPORTANT: The igniter electrode is ceramic and could break during conversion. Be sure that the electrode comes through the hole in the burner head smoothly while tightening screws. A The gas pressure regulator has 2 settings which are stamped on either side of the cap. Turn the cap and reinstall into regulator with the stamp “NAT” visible from the outside of the regulator. B NAT C A. Burner cap B. Electrode C. Burner base 16. Open shutoff valve in the gas supply line.
Use the following charts to match the correct gas orifice spud with the burner location and model being converted. Natural Gas Orifice Spud Chart for High Altitude Conversion Burner Rating Natural Gas Orifice Spud Chart Burner Rating Stamp (A) Size Stamp (A) Size 6,000 BTU 105 1.05 mm 7,000 BTU 118 1.18 mm 9,100 BTU 128 1.28 mm 6,000 BTU 110 1.10 mm 10,000 BTU 142 1.42 mm 7,000 BTU 118 1.18 mm 12,000 BTU 148 1.48 mm 9,100 BTU 134 1.34 mm 10,000 BTU 142 1.
6. Using a T20 TORX® screwdriver, remove the orifice holder screws (C). C A A B C D C B A. Igniter electrode B. Orifice spud C. Orifice holder screws D. Orifice holder 7. On KFGU models only, lift the front part of the cooktop and unhook the wire harness to detach it from the glass control panel of the metal cooktop. On all models, remove the metal cooktop and the sheet of insulation from the cooktop base. 8. To Convert Right or Left Burners: • Insert 7.
LO M HI LITE A The cooktop burners use electronic igniters in place of standing pilots. When the cooktop control knob is pushed, the system creates a spark to light the burner. This sparking continues until the control knob is turned to the desired setting. To Check Operation of the Cooktop Burners: 1. Push in and turn knobs to the LITE position. The cooktop burner flame should light within 4 seconds.
Flame Height Adjustment Each burner flame has been factory set to the lowest position available to provide reliable and constant reignition of the burner; however, each burner can be adjusted. To Adjust: The flame can be adjusted using the adjustment screws underneath the control knob. 5. 6. For Natural gas conversion: Tighten screw “C” to reduce flame height. Loosen screw to increase flame height. See “Complete Burner Adjustment” section. Replace the control knob.
5. For LP gas conversion: Completely tighten screw “A” to set the minimum flame height. For Natural gas conversion: Tighten screw “A” to reduce flame height. Loosen screw to increase flame height. See “Complete Burner Adjustment” section. Complete Burner Adjustment 1. Check burner flame(s) for proper size and shape. The cooktop “low” burner flame should be a steady blue flame approximately 1/4" (0.64 cm) high. A A B B A. Inner crown adjustment screw B. Outer crown adjustment screw A. Low flame B.
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PRODUCT OPERATION Control Panel (Glass) A B C A. Left rear burner control knob B. Surface burner locator C. Left front burner control knob D E F D. Hot surface indicator E. Center burner control knob F. Control lock keypad and indicator light Cooktop F H G G. Right front burner control knob H. Right rear burner control knob G E D H C I B A J K A. 12,000 Btu/h burner on 36" (91.4 cm) models 9,100 Btu/h burner on 30" (76.2 cm) models B. Surface burner cap C. Left surface burner grate D.
Tones To Light: Tones are audible signals, indicating the following: One Long Beep • Activation/deactivation of the Cooktop Lock function Three Short Beeps • Invalid operation - attempting to lock or unlock cooktop with 1 or more burners are on. 1. Push in and turn knob counterclockwise to LITE. All surface burners will click. Only the burner with the control knob turned to Lite will produce a flame. 2. Turn knob to anywhere between HI and LO. Use the following chart as a guide when setting heat levels.
COMPONENT ACCESS This section instructs you on how to service each component inside the KitchenAid Flush-Mount Gas Cooktop. The components and their locations are shown below.
REMOVING THE COOKTOP WARNING Spreader Cap Cap Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. Spreader Bezel NOTE: The electronic control is part of the cooktop and cannot be serviced separately. 1. Turn manual gas line shutoff valve to the closed position. 2. Unplug cooktop or disconnect power. 3. Remove the burner grates from the cooktop. 4. Pull the knobs off the gas valves. 5.
8. Lift the front of the cooktop just high enough to access the electronic control connector, and pull the wire connector off the connector pins. (KFGU models only) 8. Lift the cooktop off the burner box and remove it. Lift Cooktop Connector 9. Lift the cooktop off the burner box and remove it.
REMOVING THE SPARK SWITCHES, AND THE STANDARD OR CROWN BURNER GAS VALVES b) Pull the spark switches off each of the standard gas valves. Pull the switches straight out from the valves to unclip and remove them. WARNING Standard Burner Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. P O ull ut Spark Switch 1. 2. Unplug cooktop or disconnect power.
d) Remove the screw from the gas manifold clamp and remove the gas valve. d) Unlatch and disconnect the main wire connector from the spark switches and remove the switches. Spark Switch Connector 4. To remove a standard gas valve: a) Remove the spark switch from the valve you are accessing (see step 3). b) Remove the six screws from the front burner box access panel and remove the panel.
5. To remove the Crown burner gas valve: a) Remove the spark switch from the Crown burner gas valve (see step 3c). b) Remove the six screws from the front burner box access panel and remove the panel. f) Remove the screw from the gas manifold clamp and remove the Crown burner gas valve. Access Panel & 6 Screws c) Disconnect the two wire connectors from the from the switch terminals on the Crown burner gas valve. d) Push the locking tab and lift the switch off the Crown burner gas valve holder pins.
REMOVING THE POWER SUPPLY TRANSFORMER AND THE SPARK MODULE WARNING 5-Wire Connector 2-Wire Connector Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. 2. Power Supply Transformer 4. Unplug cooktop or disconnect power. Remove the cooktop (see page 4-2 for the procedure). To remove the spark module: a) Remove the two screws from the shield and remove the shield.
REMOVING THE GAS SHUTOFF VALVE WARNING 5. Remove the burner assembly then 4 screws securing manifold pipe. Manifold Pipe Screws Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. 2. Unplug cooktop or disconnect power. Remove the cooktop (see page 4-2 for the procedure). Gas Shutoff Valve Gas Shutoff Valve 3. 4.
REMOVING A SPARK IGNITOR FROM STANDARD OR CROWN BURNER b) Remove igniter retainer clip from standard burner. WARNING Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Igniter Igniter Retainer Clip Failure to do so can result in death or electrical shock. 1. 2. Unplug cooktop or disconnect power. Remove the cooktop (see page 4-2 for the procedure). Igniter Retainer Clip Crown Burner 3. c) Remove igniter from standard burner.
4. To remove spark igniter from crown burner. a) Disconnect spark ignitor wire from spark module. Spark Module d) Lift crown burner up and rotate to expose two screws on back of mounting plate. e) Remove two screws from back of mounting plate attached to crown burner and remove mounting plate. Igniter Wires b) Disconnect two gas fittings from crown burner. Mounting Screws Crown Burner f) Remove c-clip from crown burner igniter to release igniter from crown burner.
REMOVING STANDARD OR CROWN BURNER WARNING Hold Down Clamp Screw Mounting Screws Ground Screw Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. 2. Mounting Screws Unplug cooktop or disconnect power. Remove the cooktop (see page 4-2 for the procedure). c) Remove 4 mounting screws located on outside of burner box holding burner supports to burner box.
g) Disconnect gas line fitting from standard burner. h) Remove igniter from standard burner (see removing a spark igniter from standard or crown burner 4-9). i) Turn burner assembly upside down on protected surface. j) Remove 2 screws from bottom of standard burner attaching it to burner support. Mounting Screws Mounting Screws f) Lift burner assembly out of burner box. Gas Line Fitting Burner Assembly Mounting Screws 4. 4-12 To remove crown burner from cooktop.
REMOVING THE POWER SUPPLY CORD 3. WARNING 4. 5. Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. 2. Remove the screw from the power supply cord ground wire. Press the locking tab on the power supply cord connector and disconnect it from the main connector. Remove the strain relief from the power supply cord and pull the cord out of the burner box mounting hole.
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COMPONENT TESTING Before testing any of the components, perform the following checks: • The most common cause for control failure is corrosion on connectors. Therefore, disconnecting and reconnecting wires will be necessary throughout test procedures. • All tests/checks should be made with a VOM or DVM having a sensitivity of 20,000 ohms-per-volt DC, or greater.
WARNING Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. CROWN BURNER SWITCH POWER SUPPLY TRANSFORMER Switch (N.O.) Primary Connector Refer to page 4-3 for the procedure for accessing the Crown burner switch. 1. Unplug cooktop or disconnect power. 2. Disconnect the wire connectors from the switch terminals. 3. Set the Crown burner to the OFF position. 4. Set the ohmmeter to R x 1. 5.
DIAGNOSTICS & TROUBLESHOOTING WARNING Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. DIAGNOSTICS IMPORTANT Electrostatic Discharge (ESD) Sensitive Electronics ESD problems are present everywhere. ESD may damage or weaken the electronic control assembly. The new control assembly may appear to work well after repair is finished, but failure may occur at a later date due to ESD stress.
TROUBLESHOOTING P R OB LEM P OS S I B LE CAUS E ACTI ON No spark when any control is turned. 1. No power to unit. 1. Check power is on. 2. Control connection not correctly plugged in 2. Check connector for contamination or loose connections. 3. Transformer not properly working. 3. Check transformer coil resistances according to transformer table, page 6-3. 4. Bad ground connection. 4. Check all ground connections for continuity. 5. Burners not properly grounded. 5. Check ground continuity. 6.
TRANSFORMER TABLE R ES IS TANCE TES T TYP UNITS CONDITIONS Rp Primary Coil Resistance 60 ± 6 Ω 22 °C Rs 1-2 Secondary Coil Resistance 4.7 ± 0.5 Ω 22 °C Rs 2-3 Secondary Coil Resistance 4.7 ± 0.5 Ω 22 °C Rs 4-5 Secondary Coil Resistance 306 ± 30 Ω 22 °C ELECTRODE ASSEMBLY FOR CENTER BURNER ELECTRODE GAP FOR CENTER BURNER 6.31 CAP +0.70 -1.20 mm (0.248" +0.028 -0.047 ) OUTER SPREADER SEE DETAIL B BEAUTY RING DETAIL B CROSS RING 1.70 INNER CROWN SUPPORT +0.028 -0.
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WIRING DIAGRAM & STRIP CIRCUIT CONTROL POWER INDICATOR CENTER POWER ON INDICATOR SEE OPERATION DIAGRAM 1 & 2 HOT SURFACE 15°±10° CONTROL LOCK HOLD FOR 5 SEC 0° 0° 230° 165°±10° SWITCH ELECTRIC CONTACTS CLOSED OPERATION DIAGRAM 1 230° SWITCH ELECTRIC CONTACTS CLOSED OPERATION DIAGRAM 2 ELECTRONIC CONTROL STRIP CIRCUIT P2-10 W BK SOLENOID VALVE P2-9 BK NEUTRAL LINE P2-8 GR HOT SURFACE INDICATOR SWITCH PN 8286917 SEE OPERATION DIAGRAM 2 P2-7 W P2-6 GY W W P2-5 BR RF BURNER SWITCH P2-4
7-2 JI CONTR OL LOCK HOLD FOR 5 S EC P4-4 P4-6 P4-7 P4-8 V R GR OR P4-5 GY P4-3 W ELECTRODES OUTPUT HOT S UR FACE W P2-1 P2-2 OR Y GY ELECTRODE POWER CONTROL CONNECTION COMMUNICATION S WITCH HAR NES S PN 8286687 LF BUR NER S WITCH LR BUR NER S WITCH CENTER BUR NER S WITCH R R BUR NER S WITCH BU P2-4 P2-3 R F BUR NER S WITCH BR P2-5 W HOT S UR FACE INDICATOR S WITCH PN 8287058 W W BK BK P4-2 P4-1 W P2-7 GY GR P2-8 S OLENOID VALVE NOR MALLY CLOS ED PN 9758382 P2-6 BK
PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION SOURCES IN THE UNITED STATES: FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL: FOR WHIRLPOOL PRODUCTS: 1-800-253-1301 FOR KITCHENAID PRODUCTS: 1-800-422-1230 FOR ROPER PRODUCTS: 1-800-447-6737 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER’S HOME CALL: THE TECHNICAL ASSISTANCE LINE: 1-800-832-7174 HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED IN-HOME SERVICE PROFESSIONAL FOR LITERATURE ORDERS: PHONE: 1-800-851-4605 FOR TECHNICAL INFORM
