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ADJUSTMENT AND REPAIR PROCEDURES TO MINIMIZE CARBON MONOXIDE (CO)

LEVELS IN GAS OVENS

INTRODUCTION and on the surface above it. The baffle also reduces the amount of air going to the bake burner, so that the com- The maximum carbon monoxide (CO) levels allowed bustion process tends to increase the level of carbon in gas ovens are as follows: dioxide (CO2). This increase typically results in higher amounts of air-free carbon monoxide, and is the reason Non-self-cleaning ovens = 200 PPM, stabilized for the higher allowable level of CO for self-cleaning after 5-minutes of operation. ovens.

Self-cleaning ovens = 300 PPM, stabilized af- The standard location used for measuring the maximum ter 5-minutes of operation. allowable CO levels is at the oven’s exhaust vent, rather than from inside the room. This is because of the dif- The reason for the differences in the maximum allow- ferences in room sizes, the airtightness of the living area, able CO levels is due to the differences in construction and the number of air exchanges. The readings are also between the non-self-cleaning (see Figure 1), and the intended to minimize the amount of time that the tech- self-cleaning ovens (see Figure 2). Self-cleaning ovens nician will have to spend at the location, and still be have an additional baffle that is located below the bake able to determine the acceptability of the oven’s com- burner. This baffle is included to help vent hot air from bustion process. inside the oven during the self-clean cycle, and reduce the temperature buildup from inside the storage drawer,

OVEN BOTTOM OVEN BOTTOM

UPPER HEAT SHIELD HEAT BAFFLE

FIGURE 1 UPPER HEAT SHIELD Non-Self-Cleaning Oven FIGURE 2 Page 1 Self-Cleaning Oven

SURFACE BURNERS Air Shutter Adjustment

Most concerns about the maximum allowable CO lev- If the cooktop flame is not properly set, perform the els have been with the oven, and not with the surface following steps, and adjust the air shutter: burners. Taking field CO measurements on surface burn- 1. Locate the air shutter for the burner (see Figure 4). ers that relate directly to the AGA (American Gas As- 2. Loosen the air shutter locking screw and turn the sociation) requirements and methods, (i.e. chrome- plated “pots” and a hood to place over the collective shutter over the orifice hood in either direction un- burners), is currently impractical. Surface cooktop burn- til the proper flame appears. ers and all standing pilots should, however, be checked 3. Retighten the air shutter locking screw. by the technician before making any CO measurements. NOTE: To replace a burner or an orifice hood, see “Re- Procedures for making these checks, and any adjust- placing A Cooktop Burner & Orifice Hood” on page 3. ments, are described in the following sections. These are typical procedures, and some may not apply to your BURNER particular oven. PILOT Check each cooktop burner for the proper flame. Typi- cally, the flame should be 5/8″ long with an inner cone that is bluish-green in color, and a dark-blue mantle (see Figure 3). There should be no yellow tips, blowing, or lifting of the flame.

5/8″

VENTURI ORIFICE HOOD AIR SHUTTER COOKTOP BURNER FIGURE 4 FIGURE 3 The Burner Air Shutter Cooktop Burner Flame

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Low-Flame Adjustment Replacing A Cooktop Burner & Orifice Hood Some burners have a low flame (simmer) adjustment that is located inside the gas valve stem. If the low set- A burner venturi or orifice can become damaged, ting is unsteady, or goes out, use the following proce- (plugged or deformed), and cause improper combus- dure to adjust it. tion, or proper adjustment of the burner flame. As a result, carbon monoxide levels may substantially in- 1. Turn the burner knob to the “low” setting. crease. If this occurs, replace the burner or orifice.

2. Remove the knob from the burner valve shaft. To replace a venturi or an orifice hood, (see Figure 6), use the following procedure: 3. Use a small-bladed screwdriver, and insert it into the opening of the burner valve (see Figure 5). 1. Remove any mounting screws holding the burner to the cooktop. 4. Turn the burner valve adjustment screw until there is a steady blue flame. 2. Lift the burner from the cooktop and slide the end of the venturi off the orifice hood. 5. Replace the knob. 3. Use a 1/2″ socket, remove the defective orifice hood 6. Turn the burner knob to its “hi” setting and check from the front panel, and replace it with a new ori- for the proper flame. If the proper flame is not fice hood. present, adjust the air shutter, using the procedure outlined in the “Air Shutter Adjustment” section, 4. Slide the end of the venturi over the orifice hood or replace the burner. and secure the burner to the cooktop.

ADJUSTMENT 5. If necessary, adjust the air shutter for the proper SCREW INSIDE pilot flame (see “Standing Pilot (Cooktop),” page BURNER VALVE 4). STEM

BURNER PILOT

FIGURE 5 Burner Flame Adjustment

VENTURI ORIFICE HOOD AIR SHUTTER

FIGURE 6 Burner & Orifice Hood Replacement

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STANDING PILOT (COOKTOP ) COOKTOP GAS VALVE KNOB Flame Adjustment Check each standing pilot for the proper flame. Typi- PILOT cally, the flame should be 1/4″ to 3/8″ long. The inner cone should be bluish-green in color, with a dark-blue BURNER BURNER mantle (see Figure 7). There should be no yellow tips, blowing, or lifting of the flame. FIGURE 8A Lighting The Pilot MANTLE

INNER CONE

FIGURE 7 ADJUSTMENT The Standing Pilot Flame SCREW PILOT GAS The adjustment control for a cooktop burner pilot flame LINE is located on the manifold pipe. To light and adjust the standing pilot ranges, perform the following steps. FIGURE 8B Pilot Adjustment 1. Make sure that the cooktop gas valve control knobs are turned off (see Figure 8A).

2. Raise the cooktop.

3. Place a lighted match near the opening of the pilot between the two burners, and the pilot should light (see Figure 8A).

4. Adjust the pilot adjustment screw (see Figure 8B) so that the flame is between 1/4″ to 3/8″ high and centered in the hole in the pilot housing.

5. Lower the cooktop.

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GUIDELINES FOR MEASURING CARBON MONOXIDE (CO)

TEST EQUIPMENT 2. In the home:

When making CO measurements, use a meter* that has a) Read and record the room CO level. the following features: Record whether any gas appliances were op- a) Portable and battery-operated. erating, either during this initial measuring b) Zeroing control. time, or just prior to it. c) Digital display. d) Minimum tolerance of ± 10 PPM +5%. Note whether any of the occupants smoke, and e) Pump that can obtain air samples. if so, how often. f) 40-second minimum response time. b) Turn down the furnace or air conditioner. * Recommended: Bacharach Monoxor II or Kane-May KM SGA 90 Series c) Turn off any gas cooking products. SETUP PROCEDURE d) Turn the gas water heater to the “pilot” setting. 1. Set the test meter: e) Cease all tobacco smoking. a) The operating temperature of meter should be from 23˚F to 104˚F. f) If possible, evacuate the air in the room.

b) Turn the meter on and allow it to warm up for g) Read and record the room level once again. approximately 1-minute. 3. Inspect all of the appliances: c) If necessary, zero the meter. NOTE: When you zero the meter, you have to a) Check the operation of any standing pilots on be outside the house. Also, keep the meter away the appliances and adjust them, if necessary (see from operating vehicles, and there should be page 4). NO smoking. b) Verify whether the appliance was either in use when the CO alarm sounded, or whether it had been in use just prior to the alarm sounding.

Record the time lapse from the end of the product’s use to when the alarm sounded.

Identify the modes of operation that were in use, and use the appropriate test procedure on the following page to test the operation.

4. Fill out the “Whirlpool Repair Services Carbon Monoxide Investigation Form.” A sample of this form is shown on pages 9 and 10.

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BAKE OPERATION TEST 3. When the time has elapsed: a) Place the probe tip of the meter inside the oven’s 1. Set the temperature to 500˚F and start the bake op- vent. eration (this temperature will prevent the oven b) Allow the reading to stabilize. burner from cycling on and off during testing). Al- c) Record the reading. low the oven to operate for 5-minutes. 4. Remove the probe tip from the vent, and: 2. When the time has elapsed: a) Allow the reading to stabilize at room level. a) Place the probe tip of the meter inside the oven’s b) Record the reading. vent. b) Allow the reading to stabilize. If the CO readings are higher than the levels established c) Record the reading. by the manufacturer, refer to “Corrective Action” on the next page. 3. Remove the probe tip from the vent, and: a) Allow the reading to stabilize at room level. SELF-CLEAN OPERATION TEST b) Record the reading. 1. Start the self-clean operation and allow the oven to If the CO readings are higher than the levels established cycle for 1-hour. by the manufacturer, refer to “Corrective Action” on the next page. 2. When the time has elapsed: a) Place the probe tip of the meter inside the oven’s BROILER OPERATION TEST vent. b) Allow the self-clean operation to cycle two or 1. If the bake operation was previously used, open the three additional times. oven door, and allow the oven to cool for a mini- c) Record the reading. mum of 10-minutes. 3. Remove the probe tip from the vent, and: 2. Set the temperature to 500˚F and start the broil op- a) Allow the reading to stabilize at room level. eration (this temperature will prevent the oven b) Record the reading. burner from cycling on and off during testing). Al- low the oven to operate for 5-minutes. If the CO readings are higher than the levels established by the manufacturer, refer to “Corrective Action” on the next page.

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CORRECTIVE ACTION

PROBLEM SOLUTION

Incoming air is blocked. Remove the source of the blockage (i.e. shag carpet- The vent (flue) is plugged. ing is covering the bottom vent intake openings). The air shutter is set incorrectly. Remove the source of the blockage.

Adjust the air shutter to obtain the proper flame set- ting (see page 2 ).

The burner orifice venturi is misaligned (see page 3). Adjust the venturi.

The oven is dirty (grease and other food products are Clean the oven. burning). Use a manometer and check the gas line pressure. The gas line pressure is incorrect (too high or too low). Verify the gas regulator operation at the proper pres- sure setting.

NOTE: The following two corrective actions may require the removal of the burner.

The wrong burner orifice is being used. Adjust or install the correct orifice (see page 3).

The burner orifice is burred causing the incoming gas Replace the orifice (see page 3). to scatter in the venturi.

NOTE: The following two corrective actions may require the removal of the oven bottom and the flame spreader.

The burner flame is restricted (misaligned ignitor, Realign/replace the ignitor or the flame spreader. warped flame spreader, blocked ports, etc.).

The burner ports are blocked. Clean the ports or replace the burner.

NOTES: 1. After you perform a corrective action, repeat the CO measurement to make sure that the problem was corrected. 2. If the corrective action does not fix the CO level problem, the product should be traded out.

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WHIRLPOOL REPAIR SERVICES CARBON MONOXIDE INVESTIGATION FORM

SECTION 1 — INFORMATION

Customer Name Date Time Address Service Order No. City State Zip Code Technician Name Phone ( )

SECTION 2 — TEST EQUIPMENT

Brand: Type: Model No.: Serial No.: Warmup Time: Battery Test: OK (Minutes) Calibrate: Y N Outdoor Temperature: ˚F

Page 9 SECTION 3 — CUSTOMER INTERVIEW Reason For Call:

Was Gas Company Called?: Y N Respond? Y N If Yes – Report No.

Date: Time: Utility Name:

Their Recommendations:

SECTION 4 — SITE SURVEY/CO DETECTORS Ambient Indoor CO Level: (PPM) Indoor Temperature ˚F

DETECTOR(S): BRAND LOCATION OPERATIONAL DETECTOR SENSOR COMMENT NUMBER 1. 2. 3.

(over)

SECTION 5 — POTENTIAL CO SOURCES

SOURCE LOCATION BRAND FUEL CONDITION OPERATION FLUE CO (PPM) Cooktop Range, Gas N Oven, Gas Dryer, Clothes

How many fans are installed? Location(s) Attached Garage? Y N If yes, are the vehicles ever started for warmup purposes? Y Additional Comments:

Page 10 SECTION 6 — EXTENDED MONITORING

Datalogger Brand: Start Time: Model No: Stop Time: TWA: Peak: Start Date: Stop Date:

SECTION 7 — CONCLUSIONS

SECTION 8 — ACTION TAKEN

TEST PROCEDURES FOR MEASURING CARBON MONOXIDE (CO) LEVELS IN GAS OVENS

SETUP PROCEDURE BAKE OPERATION TEST

1. Set the test meter: 1. Set the temperature to 500˚F and start the bake operation (this temperature will prevent the oven burner from cycling on and off a) The operating temperature of meter should be from 23˚F to during testing). Allow the oven to operate for 5-minutes. 104˚F. 2. When the time has elapsed: b) Turn the meter on and allow it to warm up for approximately 1- a) Place the probe tip of the meter inside the oven’s vent. minute. b) Allow the reading to stabilize. c) Record the reading. c) If necessary, zero the meter. NOTE: When you zero the meter, you have to be outside the 3. Remove the probe tip from the vent, and: house. Also, keep the meter away from operating vehicles, and a) Allow the reading to stabilize at room level. there should be NO smoking. b) Record the reading.

2. In the home: If the CO readings are higher than the levels established by the manufacturer, refer to “Corrective Action” on the other side of the a) Read and record the room CO level. sheet. Record whether any gas appliances were operating, either during this initial measuring time, or just prior to it. BROILER OPERATION TEST

Note whether any of the occupants smoke, and if so, how 1. If the bake operation was previously used, open the oven door, and often. allow the oven to cool for a minimum of 10-minutes.

b) Turn down the furnace or air conditioner. 2. Set the temperature to 500˚F and start the broil operation (this c) Turn off any gas cooking products. temperature will prevent the oven burner from cycling on and off d) Turn the gas water heater to the “pilot” setting. during testing). Allow the oven to operate for 5-minutes. e) Cease all tobacco smoking. f) If possible, evacuate the air in the room. 3. When the time has elapsed: g) Read and record the room level once again. a) Place the probe tip of the meter inside the oven’s vent. b) Allow the reading to stabilize. 3. Inspect all of the appliances: c) Record the reading. a) Check the operation of any standing pilots on the appliances and adjust them, if necessary. 4. Remove the probe tip from the vent, and: b) Verify whether the appliance was either in use when the CO a) Allow the reading to stabilize at room level. alarm sounded, or whether it had been in use just prior to the b) Record the reading. alarm sounding. Record the time lapse from the end of the product’s use to If the CO readings are higher than the levels established by the when the alarm sounded. manufacturer, refer to “Corrective Action” on the other side of the Identify the modes of operation that were in use, and use the sheet. appropriate test procedure to test the operation. SELF-CLEAN OPERATION TEST 4. Fill out the “Whirlpool Repair Services Carbon Monoxide Investigation Form.” 1. Start the self-clean operation and allow the oven to cycle for 1- hour.

2. When the time has elapsed: a) Place the probe tip of the meter inside the oven’s vent. b) Allow the self-clean operation to cycle two or three additional times. c) Record the reading.

3. Remove the probe tip from the vent, and: a) Allow the reading to stabilize at room level. b) Record the reading.

If the CO readings are higher than the levels established by the manufacturer, refer to “Corrective Action” on the other side of the sheet.

CORRECTIVE ACTION

PROBLEM SOLUTION

Incoming air is blocked. Remove the source of the blockage (i.e. shag carpeting is The vent (flue) is plugged. covering the bottom vent intake openings).

Remove the source of the blockage.

The air shutter is set incorrectly. Adjust the air shutter to obtain the proper flame setting. The burner orifice venturi is misaligned. Adjust the venturi.

The oven is dirty (grease and other food products are burning). Clean the oven. The gas line pressure is incorrect (too high or too low). Use a manometer and check the gas line pressure. Verify the gas regulator operation at the proper pressure setting.

NOTE: The following two corrective actions may require the removal of the burner.

The wrong burner orifice is being used. Adjust or install the correct orifice.

The burner orifice is burred causing the incoming gas to scatter Replace the orifice. in the venturi.

NOTE: The following two corrective actions may require the removal of the oven bottom and the flame spreader.

The burner flame is restricted (misaligned ignitor, warped Realign/replace the ignitor or the flame spreader. flame spreader, blocked ports, etc.). Clean the ports or replace the burner.

The burner ports are blocked.

NOTES: 1. After you perform a corrective action, repeat the CO measurement to make sure that the problem was corrected. 2. If the corrective action does not fix the CO level problem, the product should be traded out.