KitchenAid Waffle Iron KPWB100 User Manual

®
PRO LINEWAFFLE BAKER  
SERVICE MANUAL  
Table of Contents .........................................................................2  
Model: KPWB100  
8204590  
 
IMPORTANT SAFEGUARDS  
IMPORTANT SERVICE WORKPLACE SAFETY  
RECOMMENDATIONS  
Ensure the KitchenAid service technician is aware of the  
operating safeguards recommended to the customer:  
WARNING  
1. Read the Pro Line™ Series Waffle Baker Instructions and  
Recipes booklet.  
2. Do not touch hot surfaces. Use handles or knobs.  
3. To protect against electrical shock, do not immerse cord,  
plugs, or waffle baker in water or other liquids.  
4. Close supervision is necessary when any appliance is used  
by or near children.  
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.  
5. Unplug waffle baker from outlet when not in use and before  
cleaning. Allow it to cool before putting on or taking off  
parts.  
6. Do not operate any appliance with a damaged cord or plug,  
or after the appliance malfunctions or has been damaged in  
any manner.  
This Waffle Baker Service Manual is written for the professional  
service technician who has familiarity with KitchenAid®  
Pro Line™ Appliances.  
7. The use of accessory attachments not recommended by  
KitchenAid may cause fire, shock or injuries. There are no  
accessories for the waffle baker.  
The purpose of this service manual is to familiarize the  
professional house wares technician with the techniques  
required to repair the KPWB100 KitchenAid Pro Line Waffle  
Baker.  
8. Do not use the waffle baker outdoors.  
9. Do not let cord hang over edge of table or counter, or touch  
hot surfaces.  
10. Do not place on or near a hot gas or electric burner, or in a  
heated oven.  
The following safety guidelines should be adhered to when  
servicing the waffle baker:  
11. When finished baking waffles, press the On/Off Button to  
turn the waffle baker off, then remove plug from outlet.  
Ensure the workplace is dry and sanitary at all times.  
12. Do not use appliance for other than intended use.  
Ensure that your hands are clean at all times during the  
13. This product is UL Listed for household and commercial  
use.  
service procedure.  
Ensure the workplace has properly polarized AC outlets that  
adhere to all local electrical codes applicable at the time of  
repair.  
14. This product is cUL Listed for household use only in  
Canada.  
Conduct all disassembly and assembly procedures with the  
waffle baker switched off and disconnected from the AC  
supply or mains.  
TOOL RECOMMENDATIONS  
Do not immerse the waffle baker in water. Do not use abrasive  
The following tools are necessary to service the KitchenAid  
Pro Line Waffle Baker:  
cleansers or scouring pads to clean it.  
In a well-lit area, visually inspect the waffle baker for  
cleanliness before starting work. Open the baker lids and  
wipe the waffle plates clean with paper towels or a damp  
cloth.  
Phillips Screwdriver Set  
Straight Screwdriver  
Needle Nose Pliers  
Super Glue or Soldering Iron  
Hot Glue and Gun  
Tape  
Wipe the exterior of the waffle baker with a warm, sudsy  
cloth; then wipe the exterior of the baker clean with a damp  
cloth and dry with a soft cloth.  
Inspect the power cord before testing the waffle baker’s  
operation.  
The following equipment will greatly assist you:  
Power Phillips Screwdriver  
Thermometer  
Do not run the waffle baker if the power cord is damaged.  
Replace with a new cord assembly.  
Do not leave the waffle baker unattended while operating  
during testing.  
3
 
PERFORMANCE  
Electrical Requirements  
You can observe the performance of a waffle baker by  
establishing benchmarks on the performance seen on prior  
waffle bakers. Here is a list of performance parameters to  
observe.  
WARNING  
EXAMPLE: Bake time: 3 minutes 30 seconds (3:30)  
Bake temperature: 350º F  
Time to Bake Two Waffles – Measure the time needed to bake  
two waffles (one cup batter each) on the two waffle plates.  
Longer baking times will produce darker, crispier waffles.  
For your first waffles, a good starting time is 3 minutes, 30  
seconds. The baking time can be set in 15-second increments  
from a minimum of 2 minutes, 30 seconds to maximum of 5  
minutes, 30 seconds.  
Electrical Shock Hazard  
Plug into a grounded 3 prong outlet.  
Do not remove ground prong.  
Do not use an adapter.  
Waffle Plate Temperature – Pre-heat waffle baker, then  
Do not use an extension cord.  
measure the temperature on each waffle plate.  
Failure to follow these instructions can result in death,  
fire, or electrical shock.  
Service Procedures  
This waffle maker is designed for use with 120 V, 60 Hz only. It  
has a 3-prong grounded plug. To reduce the risk of electrical  
shock, this plug will fit in an outlet only one way. If the plug does  
not fit in the outlet, contact a qualified electrician. Do not modify  
the plug in any way.  
WARNING  
A short power-supply cord is provided to reduce the risk  
resulting from becoming entangled in or tripping over a longer  
cord. Do not use an extension cord. If the power supply cord is  
too short, have a qualified electrician or service technician install  
an outlet near the appliance.  
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.  
Service Preparation  
WARNING  
Perform all service on the Pro Line™ Waffle Baker with the unit  
disconnected from the AC mains.  
CLAMSHELL BAKING UNIT REPLACEMENT  
The clamshell unit is not replaceable – we do not replace top or  
bottom lids, waffle plates or heating elements.  
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.  
TIMER ADJUSTMENT KNOB REPLACEMENT  
The timer adjustment knob sets the baking time in 15-second  
increments from 2 minutes and 30 seconds (2:30) to 5 minutes  
and 30 seconds (5:30). Turn knob clockwise to increase baking  
time; turn counter-clockwise to decrease baking time.  
Cushion the service area to keep from scratching the waffle  
baker or damaging the controls and display surfaces. A clean  
folded towel will usually work well for this purpose.  
1. Unplug the waffle baker.  
2. Place the waffle baker upside down on a cushioned surface.  
TESTING THE WAFFLE BAKER  
3. Remove four (4) recessed Phillips screws from feet and two  
(2) recessed Phillips screws from base cover.  
In some situations you will have to test the performance of the  
waffle baker to identify and diagnose the problem.  
4. Remove one Phillips screw from the ferrite bead fastener.  
Then remove the 5-pin connector from the power PCB. This  
will allow for easy access to the control PCB.  
5. LIft off base.  
4
 
6. Using thumbs, push down on control PCB board (located in  
cradle arm) until clamps release. (See Figure 1).  
Component Access  
WARNING  
Electrical Shock Hazard  
Disconnect power before servicing.  
Figure 1  
Replace all parts and panels before operating.  
Failure to do so can result in death or electrical shock.  
7. Reach inside the waffle baker cradle and squeeze the timer  
adjustment knob’s three slips and pull out knob from bezel.  
8. Push timer adjustment knob through bezel hole until it locks  
into place. Be sure the timer adjustment knob location is  
rotated correctly with the control board. If the alignment is  
not correct the Max and Min time will be incorrect.  
Access the waffle baker’s power supply cord, power supply PCB  
board, control PCB board and button covers from the bottom of  
the unit.  
1. Unplug the waffle baker.  
2. Place the waffle baker upside down on a cushioned surface.  
DIAL THERMOSTAT REPLACEMENT  
3. Remove four (4) recessed Phillips screws from feet and two  
(2) recessed Phillips screws from base cover.  
A properly working dial thermometer will indicate:  
Cool Temperature – ambient temperature  
Preheat Temperature – ambient temperature to 350º F  
Ready – 350º F  
4. Lift off base.  
POWER CORD REPLACEMENT  
If the dial thermometer is warped or the needle does not move  
to indicate waffle plate temperature changes, replace the dial  
thermometer.  
Do not run the waffle baker if the power cord is damaged.  
Replace with a new cord assembly immediately.  
1. Unplug the waffle baker.  
1. Unplug the waffle baker.  
2. Remove base, see Component Access.  
3. Remove two (2) Phillips screws from power cord wire clamp.  
2. Remove black screw  
cover located left of the  
unit’s top hinge. (See Figure 2)  
4. Remove the power cord ground wire terminal (green) and the  
MOV board ground wire terminal from the ground lug.  
5. Remove two (2) power cord MOV blue-capped AC leads [one  
(1) black and one (1) white] from printed circuit board (PCB)  
located on base. (See Figure 4)  
Figure 2  
3. Remove two (2) Phillips screws and lift metal cover.  
4. Replace the dial thermometer and reassemble. (See Figure 3)  
Figure 4  
Figure 3  
6. Remove MOV power board and cord assembly.  
7. Hot glue new MOV board to base. Reassemble leads. Be  
sure that the green lead terminals are connected securely to  
ground lug. Be sure AC leads are connected securely to PCB.  
The black lead goes to the ACL terminal and the white lead  
goes to the ACN terminal.  
RUBBER FEET REPLACEMENT  
Check the four (4) rubber feet on the bottom of the waffle baker  
when servicing.  
1. Remove the screw from each foot.  
2. Remove each rubber foot and replace.  
5
 
11. Insert button shaft through bezel hole. Be sure spring is  
between button top and outer bezel. (See Figure 6)  
POWER SUPPLY PCB REPLACEMENT  
The power supply printed circuit board (PCB) provides DC voltage  
to power the control PCB located in the cradle arm and AC  
voltage to the heating elements in the waffle plates. (See Figure 5)  
Figure 6  
12. Slide button cover over shaft. Add a  
small drop of super glue or solder into  
the cover hole. (See Figure 7)  
Figure 5  
1. Unplug the waffle baker.  
2. Remove base; see Component Access.  
3. Remove six (6) blue-capped black and white AC leads from  
the power supply PCB located in the base.  
4. Remove white, 5-pin connector from the PCB.  
5. Remove four (4) Phillips screws from PCB; remove board  
from base.  
Figure 7  
6. Reassemble with new board. Be sure six (6) blue-capped  
leads and white 5-pin connector are connected securely in  
their proper positions. Replace base cover.  
13. Be sure the timer start and timer reset button covers align  
with contact points on control board.  
14. Be sure the LED lens and digital display line up with holes in  
bezel.  
CONTROL PCB BOARD REPLACEMENT  
15. Using thumbs, press control PCB board until it clamps  
securely into cradle.  
The control board regulates the light, timer and power on/off  
button. It is located in the cradle.  
16. Reassemble the ferrite bead fastener with one Phillips screw.  
Be sure 5-pin connector is securely connected to power  
supply PCB. Reassemble base to cradle.  
1. Unplug the waffle baker.  
2. Remove the base; see Component Access.  
3. Remove one Phillips screw from the ferrite bead fastener.  
Then remove the white, 5-pin connector from the power  
PCB. This will allow for easy access to the control PCB.  
Button Replacement  
4. Remove the timer adjustment knob; see Timer Adjustment  
Knob Replacement instructions.  
There are three (3) push buttons on the control bezel: power  
on/off, timer start and timer reset:  
5. Remove the start and reset buttons; see Button Replacement  
instructions.  
1. Unplug the waffle baker.  
2. Remove the base; see Component Access.  
3. Remove one screw from the ferrite bead fastener.  
6. Remove the control PCB from the cradle. Remove (4) four  
Phillips screws from the control PCB plastic cover.  
2. Using thumbs, push down on control PCB board (located in  
cradle arm) until clamps release.(See Figure 1)  
7. Remove three (3) white pin connectors from bottom of  
control board; two (2), 2-pin connectors and one (1), 5-pin  
connector.  
3. Place tape over button front. This will help prevent losing the  
button’s small spring.  
8. Replace the old control PCB with the new control PCB. Be  
sure three white (3) pin connectors are connected securely  
to board; two (2), 2-pin connectors and one (1), 5-pin  
connector.  
4. Reach inside the waffle baker cradle and grasp the button  
cover sleeve with needle nose pliers. Pull straight back to  
release the sleeve.  
9. Reassemble with new control PCB board to the plastic cover  
with 4 Phillips screws. Slide control board into cradle.  
5. Remove tape and pull out button cover and shaft from bezel,  
being careful not to lose small spring.  
10. Reassemble the timer adjustment knob; see Timer  
Adjustment Knob Replacement instructions.  
6. Insert new button shaft through bezel hole. Be sure spring is  
between button top and outer bezel. (See Figure 6)  
7. Slide button cover over shaft. Add a small drop of super glue  
or solder into the cover hole. (See Figure 7)  
8. Be sure button cover lines up with contact point on control  
PCB board.  
9. Using thumbs, press control PCB board until it clamps  
securely into cradle. Reassemble.  
10. Check each button and the timer adjustment knob to make  
sure each works properly.  
6
 
Problem Guide  
PROBLEM: Waffle baker emits smoke and odor the first time it is used.  
CAUSE: Normal result of manufacturing process. The smoke is harmless and will dissipate.  
SOLUTION: Discard first waffles made on each side of clamshell unit.  
PROBLEM: Excessive steam or condensation on and/or around the base of the unit.  
CAUSE: Steam is a natural byproduct of baking waffles. Different recipes create different amounts of steam while baking.  
Occasionally the steam will condense and form puddles.  
SOLUTION: Steam cannot be eliminated.  
PROBLEM: Sticky or gummy waffle plates.  
CAUSE: The waffle baker plates have a non-stick surface. Coating the plates with oil or cooking spray will eventually cause the  
plates to become gummy.  
SOLUTION: Do not coat or spray the plates with oil. To clean, be sure the waffle baker is switched off, unplugged and cool. Wipe  
the waffle plates with a clean, damp cloth or paper towels. Suggest that the owner use a little more butter/oil in the recipe to prevent  
sticking.  
PROBLEM: Waffles are thin or uneven, with gaps and spaces.  
CAUSE: Uneven coating of waffle plates with batter.  
SOLUTION: Always rotate the baking unit after filling the waffle plate with batter. This coats the upper and lower plates with batter  
and ensures the finest consistency.  
PROBLEM: Clamshell unit tilts or will not stay horizontal.  
CAUSE: Overspray or worn paint on the axle’s mating surface. Wires may be bunched in cradle base.  
SOLUTION: Check for overspray paint and remove excess. If there is no overspray or worn paint surfaces, open base and gently  
jiggle or reposition wires in cradle arm so they set evenly.  
PROBLEM: Uneven heat; waffles are too light or too dark.  
CAUSE: There are many factors that affect waffle baking including improper baking time setting, recipe ingredients, batter  
temperature and ambient humidity. Mechanically, the cause may be pinched or worn out wires, a defective or worn out thermistor or  
defective or worn out heating element. If waffles are heating or burning on one side, there is 75% probability that the thermistor is  
defective or worn out.  
SOLUTION: First, adjust baking time. If too light, increase the baking time; if too dark, decrease baking time. If the problem persists:  
The wires, thermistor and heating elements in the clamshell unit cannot be repaired or replaced. Replace unit according to warranty.  
PROBLEM: Waffle baker will not turn on, display remains dark, will not heat.  
CAUSE: The waffle baker uses 1400 watts total with all three heating elements (one in each lid and one in the center) when in use.  
This wattage level may cause the circuit breaker to trip if other appliances are drawing power from the same circuit (not just the same  
outlet).  
SOLUTION: Be sure that the waffle baker is plugged into a 3-prong grounded outlet.  
Unplug and re-plug back into a live, separate outlet. You cannot have any other appliance drawing from the same circuit. Another  
appliance may draw enough power to shut off the waffle baker but not trip the circuit breaker.  
If the baking unit display remains unlit, check the fuse or circuit breaker that the unit is connected to and make sure the circuit is  
closed.  
Check power PCB board located inside base for damage. Replace damaged power PCB board.  
If the unit still does not turn on, check the power on/off button on the control cradle for damage. Look inside cradle to be sure the  
button cover lines up with contact on control board. Replace damaged button. If button is not damaged, replace control PCB board.  
If waffle baker still will not turn on, replace the unit according to warranty.  
PROBLEM: Resets or turns off frequently.  
CAUSE: Faulty or damaged control PCB board.  
SOLUTION: Replace control PCB board.  
PROBLEM: No audible preheat tone or countdown tone.  
CAUSE: Defective or damaged control PCB board.  
SOLUTION: If lights work, but tone does not sound, replace control PCB board located in cradle. If lights and tone do not work,  
replace power PCB board in base.  
PROBLEM: Timer does not count down.  
CAUSE: Defective or damaged control PCB board.  
SOLUTION: Replace control PCB board located in cradle.  
PROBLEM: Ready light does not turn on.  
CAUSE: Defective or damaged LED lens or power PCB board.  
SOLUTION: If waffle plates still heat, replace control PCB board. If there is no heat or lights, replace power PCB board.  
7
 
PROBLEM: Ready light does not stop flashing.  
CAUSE: Damaged or defective control PCB board or thermistor.  
SOLUTION: Check control PCB board located in cradle for damage. If the control board is not damaged, then it is the thermistor.  
The thermistor cannot be repaired or replaced. Replace unit according to warranty.  
PROBLEM: Thermometer warps or needle does not indicate preheat, ready or cool.  
CAUSE: Thermometer casing leaks and condensation gets inside.  
SOLUTION: Replace thermometer.  
PROBLEM: LCD timer fades.  
CAUSE: Wears out over time.  
SOLUTION: Replace control PCB board.  
PROBLEM: Rotating handle turns white.  
CAUSE: Handle rubbing on the base each time it rotates. The handle material is Phenolic and discoloration occurs naturally over  
time.  
SOLUTION: Rub a little vegetable or mineral oil with a paper towel on the discolored area. The normal color will return.  
PROBLEM: One or more of the four black clips on the back of the waffle baker break.  
CAUSE: Defective material or user damage.  
SOLUTION: The black clip that holds the stainless steel cover in place may be replaced. The clips that hold the clamshell together  
are not replaceable.  
PROBLEM: Owner upset about formaldehyde used in insulation.  
CAUSE: Formaldehyde is used in the manufacturing of the insulation in the clamshell unit lids so that the lids will not become  
excessively hot even after extended use. Proposition 65 in California requires that KitchenAid® put a warning on the waffle baker for  
this reason. In testing, no amounts of formaldehyde release were found.  
SOLUTION: Let owner know that there is no risk associated with using the unit. If they are not convinced, instruct owner to return  
the waffle baker to the place where it was purchased for a full refund.  
8
 
Control Panel Parts  
For Models: KPWB100  
Illus. Part  
No.  
No. DESCRIPTION  
1
Literature Parts  
8204569 Guide, Use & Care  
8204590 Repair Parts List  
8204592 Wiring Diagram  
8211486 Button, Start  
8211487 Button, Power  
8211489 Lens, LED  
8211485 Knob  
2
3
4
5
6
8211488 Bezel  
7
8211490 Screw  
8
8211491 MCU PCB Assembly  
8211513 Bracket, Knob  
8211508 Cover, Button  
8211492 Nameplate  
8211493 Holder, PCB  
8211514 Spring  
9
10  
11  
12  
13  
FOR ORDERING INFORMATION REFER TO PARTS PRICE LIST  
9
 
Cradle Parts  
For Models: KPWB100  
Illus. Part  
No.  
No. DESCRIPTION  
1
2
8211498 Clamp  
Cap  
8211497 Pearl Metallic  
8212149 Nickel Pearl  
8211499 Holder, Axle  
Base  
3
4
8211496 Pearl Metallic  
8212148 Nickel Pearl  
8211494 Bracket  
8211495 Screw  
5
6
7
8211500 Power Supply  
8211505 Cover, Bottom  
8211503 Clamp, Cord  
8211501 Feet  
8
9
10  
11  
12  
13  
8211502 Screw  
8211504 Cover, Spring  
8212256 Cord, Power  
(Incl. MOV Board)  
FOR ORDERING INFORMATION REFER TO PARTS PRICE LIST  
10  
 
Notes  
11  
 
FOR THE WAY IT’S MADE.™  
BIEN PENSÉ. BIEN FABRIQUÉ.™  
® Registered trademark/Marque déposée/Marca registrada KitchenAid, U.S.A.  
Trademark/Marque de commerce/Marca de comercio KitchenAid, U.S.A.  
KitchenAid Canada licensee in Canada/Emploi sous licence par KitchenAid Canada au Canada.  
© 2008. All rights reserved. Tous droits reserves. Todos los derecchos reservados.  
Specifications subject to change without notice. / Les specifications sont sujettes à changement  
sans préavis. / Especificaciones sujetas a cambio sin previo aviso.  
8204590  
02-2008  
Printed in U.S.A.  
 

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