Intellifire Plus troubleshooting guide - A
Contents
1. Warning DO NOT CONNECT 120V AC TO CONTROL MODULE Intelile 8 27 2009 Hearth amp Home Technologies Page8 System Basics IntelliFire Plus Troubleshooting IPI Gas Valve w Stepper Motor 3 Manifold Pressure 2 Inlet Pressure E i L 7 n que TT E ae ae AUS a e rel Stepper motor 1 Pilot regulator is stamped as Nat ee AA p wi iaer en or LP designating the factory set XY A disassembled ting If converted the main burner N regulator has fuel type stamped along the side indicating the con version The orange wire from the ipi ignition module is connected to the pilot regulator Optimum appliance performance requires proper input pressures 2 Test the inlet pressure at this tap Gas line sizing requirements will be determined in ANSI 223 1 National Fuel Gas Code in the USA and CAWN 3 Test the manifold pressure at this CGA B149 in Canada tap P Pressure requirements are 4 The stepper motor is not a replace able as a separate part only available Natural Gas assembled to the main burner regulator It s function is to modulate the flame There is no reliable field voltage test for the stepper motor Valve will function without functioning stepper motor but WARNING Risk of Fire or Explosion High pressure flame will not modulate Note An will damage valve Low pressure may cause explosion audible noise will be heard when the stepper motor is mod2. REMOTE Allows wireless controls amp optional wired wall switch to operate Must be in the ON or MOTE setting for unit fo operate Isolate remote A TT from system when trot bleshooting Switch toj ON to test operation J 4 STATUS INDICATOR LED FLAME HI LO SWITCH NG LP SETTING RC300 OR WIRED WALL SWITCH ONLY intelle 8 27 2009 Hearth amp Home Technologies Page31 System Checklist IntelliFire Plus Troubleshooting Electrical System continued b Optional Wired Wall Switch Overrides remote Must be in OFF position for remote to work Wireless con trols in use selector switch in the REMOTE position and c Proper Gap between pilot hood and igniter 3 System Ground The black wire grouped with the or ange and green wire is the ground wire Make sure it tightly secured to metal chassis of fireplace intelifFire 8 27 2009 Hearth amp Home Technologies Page32 System Checklist IntelliFire Plus Troubleshooting Electrical System continued 4 Voltage a 120 VAC to and from Junction Box Switch from OFF to ON If diagnostic light blinks green 3 times there is power to the Insert red probe inside cord Touch black probe to outside of power supply Testing 6 Volts DC With transformer plugged into junction box pull from transformer transformer power supply cord from module Should read between 110 a
3. amp installation manual pb Pilot Pilot Marked on orifice REC Air shutter setting Refer to conversion matrix fo 5 Control Module Gas Type Turn clockwise 3 4 turn to set to LP SELECTOR AN J Turn counter clockwise 3 4 turn to set to NG im x y LP 7 r Y pg Direction of switch slot in p NG setting SZ aS Ji RYS A siot is not colored on module ATUS INDICATOR LED i NG LP SETTIN LL SWITCH ONLY Direction of switch slot in O LP setting NW siot is not colored on module Switch intelifFire 8 27 2009 Hearth amp Home Technologies Page36 Pris f 7 Peter a M 1 Manifold M oe We he i x J kil 2 4 s 7 JES 7 4 Inlet Min NG 5 in w c 7 Manifold NG 3 5 in w c Inlet Min LP 11 in w c i 0 ia Manifold LP 10 in w c Captive slotted screws will not come of towers ALWAYS tighten after testing to prevent gas leaks at towers 3 3 Orifice Size Size D System Checklist IntelliFire Plus Troubleshooting Gas System continued eve a Ohms Valve Ohms Test Disconnect wires from valve One probe on B noid Pilot solenoid body of valve amp one mag ae chaud read betwee probe on pilot OR burner snou i ead betwee 37 to 47 wire solenoid connection b Proper regulator de rueseR PAROS GASKET ge SN Stepper motor VO AN regulator assembly K A should never be g disassembled lu W Page37 intelle 8 27 2009 Hearth amp Home Technologies
4. is noise from the module ignition coil which creates voltage for pilot igniter intelifFire 8 27 2009 Hearth amp Home Technologies Page18 Problem Scenarios 2 continued IntelliFire Plus Troubleshooting Problem The module makes noise but no spark 1 Loose or improper wiring 2 Pilot assembly is not grounded Intellifire Plus IPI Ignition System Wiring AUX300 MODULE RC300 4 5V DC AA X 3 AUX AUX eS CONTROL MODULE JU y TO JUNCTION n l i AUX200 MODULE rh Aux Modules sup Wire Harness ir A plied with wireless to Modul Hall controls RC100 RC200 et A Right OPTIONAL WALL CONTROLS i Red Zz Black Brown BATTERY PACK Orange 6V DC AA X 4 Black Green PILOT THERMOSTAT WIRE ASSEMBLY WALL SWITCHWIRE Before replacing a part al ways check the continuity of the wires supplying the voltage etc Grounded to metal on fireplace smaller valve connector i grouped with the or Larger valye connector to main regulator ange and green wire FRE is the ground wire i Make sure it tightly ss n secured to metal chassis of fireplace D oe Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system intellfFie 8 27 2009 Hearth amp Home Technologies Pagel9 Problem Scenarios 2 continued IntelliFire Plus Troubleshooting Proble
5. C100 control RC100 Wall mounted control w cover plate riisi AC 100 RC200 Control docking station and AUX200 module to control fan kit RC300 Control docking station and AUX300 module to control fan kit and 2 auxiliary func tions RC200 Control amp AUX200 Control AUX200 Replacement EDEN AUX300 2166 335 AUX200 Powers and controls voltage for AUX300 Powers and controls volt variable fan speeds age for variable fan speeds high medium low AUX1 and on amp off AUX2 ir a RCS00 4 57 OC RC200 12V DC p E NAAA X 3 Ra A23 X 1 SP TE ES ro JUNCTION BOX 120VAC TO JUNCTION BOX 120VAC PACK TO OPTIONAL AA 4 COMPONENTS intelifFire 8 27 2009 Hearth amp Home Technologies Pagel1 System Checklist IntelliFire Plus Troubleshooting Diagnose Root Cause Going into a service call with a conclusion prior to checking the complete system can lead to replacing unnecessary parts multiple service calls and wasted time and money for you the customer and HHT When servicing any HHT product the complete sys tem needs to be checked to diagnose the cause Using the checklist to document the diagnos tic information will e Instills consumer confidence e Consistent service performance e Provides unit history for future service calls e Improves communication when seeking technical assistance Areas to be checked e Visual Inspection for proper installation and condition of ins
6. IntelliFire HEARTH amp HOME technologies Troubleshooting Guide IntelliFire Plus Ignition System For authorized gas technicians use only intelifFire 8 27 2009 Hearth amp Home Technologies Pagel IntelliFire Plus Troubleshooting Guide Table of Contents INTTOCGUCTION 0 cececcececceccccecceceaveceuecseaecuecesaecrsaeeneerentenentens 3 Tools and Instruments 5 System Basics 6 Problem Scenario 1 13 Problem Pilot wont light no noise and no spark Problem Scenario 2 inner 18 Problem The module makes noise but no spark Problem SC NARIOS a a 21 Problem Pilot sparks but pilot will not light Problem Scenario 4 24 Problem Pilot lights but continues to spark and main burner will not ignite Problem Scenario 5 27 Problem Pilot lights stops sparking and pilot remains lit Burner will not light Diagnostic Codes 29 System Checklist cccceccccscceseeeseeeeseeseeeeeeeeeeeseeeeeeaneetaeeens 30 Frequently Asked Questions later edition 38 Intellfre 3 27 2009 Hearth amp Home Technologies Page2 _ Pirs Introduction IntelliFire Plus Troubleshooting Use of this Guide This troubleshooting guide provides an overview of the IntelliFire Plus system reviews problem scenarios provides a system s checklist and frequently asked questions The purpose of this guides is to provide a tool To educate To aid in proper diagno
7. e makes sparking noise but no spark The problem may be Notice Go to page 29 to familiarize yourself with e Disconnect power to the system prior to disconnecting any compo nents by switching the ON OFF Loose or improper wiring REMOTE module switch to the system is not grounded OFF position Igniter wire is loose or disconnected Improper gap between igniter and pilot hood Itis not recommended to operate the ignition control module with disconnected wire connections A short could cause permanent dam age module diagnostic codes ede D TE e Introducing the pilot sensor rod with How to reset a false flame such as from a flame from stick will cause the module to go Lockout Mode into lock out mode This is due to a safety feature SELECTOR SWITCH Turn only during unit conversion d DO NOT USE FORCE WHEN TURNING Using a plastic screwdriver is recommended For example To change from Pga N NG to LP setting you would turn LP f P NG switch clockwise 3 4 turn to set ATUS INDICATOR LED A 2 to LP F i NG LP SETTING X P RUBBER ALL SWITCH ONLY As soon as you feel resistance GASKET stepper motor regulator assembly should never be Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system IntellifFire Plus IPI ignition module emits beeps during operation The noise referred to in this section
8. e module 1 Verify proper inlet pressure to the gas line 2 Verify that pilot leads are correctly termi nated to the control module Pilot sparks and may ignite for up to 1 Inadequate gas supply land that no shorted wires ex 60 secs but main will not open If 2 False flame detected ist 4 condition occurs for gt 60 sec mod 3 Short in sense lead Verify that the pilot sense rod ule flashes error code shuts down 4 Sense and or igniter igniter rod and hood are Flash pilot and goes into lockout mode lead disconnected clean After error code displays module will go into lockout odule Must watch light during service to view error code Intellfre 3 27 2009 Hearth amp Home Technologies Page29 _ Pie System Checklist IntelliFire Plus Troubleshooting Visual Inspection Area System Proper Readings Reference Info ltems to be checked ri Visual Inspection Refer to appropriate installation and operation manual for all areas 1 Proper Installation Condition a Vent System Does the installation meet venting requirements for rise to run ratio vent cap type vent cap location venting size b Gas Supply Components Gas line sizing and components must meet ANSI 2223 1 and local codes requirements Supply pipe must be 2 minimum Note all appliances supplied inline with fireplace Locate all shut off valves What position are they in c Proper Clearances Does the installati
9. e module to go into lock out mode This is due to a safety feature SELECTOR SWITCH ATUS INDICATOR LED i NG LP SETTING ALL SWITCH ONLY Turn only during unit conversion DO NOT USE FORCE WHEN TURNING Using a plastic screwdriver is recommended For example To change from NG to LP setting you would turn LP NG switch Beie SH turn to set As soon as you feel resistance Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system intelifFire 8 27 2009 Hearth amp Home Technologies Page21 Problem Scenarios 3 continued IntelliFire Plus Troubleshooting Problem Pilot sparks but pilot will not light 1 Gas supply Open Open Closed Ensure all valves in the gas supply line are open AND purged of air Gas OFF Manifold Inlet Min NG 5 inw c Manifold NG 3 5 in w c Inlet Min LP 11 in w c Manifold LP 10 in w c Inlet Max NG 10 in w c Inlet Max LP 13 in w c roe 4 Captive slotted screws will not come of towers ALWAYS tighten after testing to prevent gas leaks at towers Check gas supply to pilot assembly ae 4 Spider Nests Construction Debris Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system Intelile 8 27 2009 Hearth amp Home Technologies Page22 Problem Scenarios 3 continued IntelliFire Plus Troubleshootin
10. enoid Voltage to Main Valve Solenoid test during lighting sequence Volts DC 1 6 V to open valve 3 V to keep valve open Black probe to body of valve Red probe to green wire connected to valve pull wire slightly away from connector to touch connector Valve Ohms Test Disconnect wires from valve One probe on body of valve amp one probe on pilot OR burner 27 to 47 wire solenoid connection Burner solenoid should read betwee 5 Pilot solenoid should read between Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system InteliiFire 8 27 2009 Hearth amp Home Technologies Page28 Diagnostic Codes IntelliFire Plus Troubleshooting Diagnostic Codes are listed below and should be used as a additional tool to help di agnose failure modes Use the troubleshooting guide to check all possible failures be fore changing any component parts CODE RESPONSE ERROR CAUSE ERROR RESOLUTION 1 Fuel type selector in 1 Verify that the selector incorrect position 2 stops at the correct position Module flashes error code and goes Fuel type selector switch when rotated gently with a into lockout mode damaged precision screwdriver Insufficient voltage from Clear Lock Out and attempt Module flashes error code and goes ignition coil to pilot flame ignition If condition persists into lockout mode igniter replac
11. g Problem Pilot sparks but pilot will not light 2 Faulty module voltage to valve 3 Faulty valve pilot solenoid Voltage to Pilot Solenoid test during lighting sequence Volts DC 1 2 V to open valve 3 V to keep valve open Black probe to body of valve Red probe to orange wire connected to Valve pull wire slightly away from connector to touch connector Valve Ohms Test Disconnect wires from valve One probe on body of valve amp one probe on pilot OR burner 27 to 47 wire solenoid connection Burner solenoid should read betwee 5 Pilot solenoid should read between Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system InteliiFire 8 27 2009 Hearth amp Home Technologies Page23 Problem Scenarios 4 IntelliFire Plus Troubleshooting Problem Pilot lights but continues to spark and main burner will not ignite The problem may be 1 Gas Supply 2 Sensor rod shorted or disconnected 3 Poor flame rectification or contaminated sen sor 4 Faulty valve Go to page 29 to familiarize yourself with module diagnostic codes Turn switch to How to reset OFF from Lockout Mode J Wait 5 seconds Turn to ON Stepper motor regulator assembly Y should never be 4 disassembled SCREWS WIRELEAD W Notice Disconnect power to the system prior t
12. ilot flame engulfs the sensor rod it conducts electrical current from the sen sor through the flame to ground in one direction which acts as a switch to the control module at this connection Gas flows to the main burner 4 8 seconds after continuity happens via flame rectification 3 Sends commands from the wireless controls to the AUX200 300 modules controlling fan kits AUX200 amp 300 and 2 additional auxiliary functions AUX300 4 Fuel setting is factory set but must be adjusted if fireplace is converted Switch does not regulate gas pressure to valve but it does allow for appropriate variability settings for flame modulation Take care when adjusting this switch Use of a plastic screwdriver is recom mended 5 Learn Button is used to program up to 3 wireless controls to fireplace Instructions pro vided in controls instructions 6 Diagnostic light assists with troubleshooting Error code chart provided later in this guide 7 ON OFF REMOTE Switch Ignition Control Connections and Functions 8 Manual HI LOW flame switch is operable with RC100 use only with ON OFF REMOTE switch in RE MOTE setting Modulates 2 flame settings 9 Power from battery pack wall switch connection and connection to valve pilot and burner regulators 10 Flame Modulation stepper mo tor connection Li ecco Liu 11 Power supply connection to 6 R HE Lo o KO Volt DC adapter plugged into the g 16 i 5 F 4 junction box
13. le end wrenches 8 and 10 e 1 4 5 16 nut driver 77 e Straight screwdrivers including small 1 8 blade for pressure check and stubby Straight e Phillips screwdrivers 1 and 2 and stubby Phillips e Plastic straight screwdriver Rhino style e Electrical pliers e Needle nose pliers e Flashlight e Numbered drill index e 1 20 tamper resistant Torx bit HHT part 810 225 e Soft bristle toothbrush e Soft 1 paint brush e Electric drill 1 4 3 8 Required Testing Equipment e Multi meter must measure millivolts e Manometer e Leak detection fluid e 2to 4 12 14 jumper wires e flame stick lighter wand Miscellaneous e Smoke Match e Drop Cloth Tarp e Glass cleaner towels e Vacuum e Personal Protection Equipment ALL TOOLS AND TEST EQUIPMENT SHOULD BE PROPERLY STORED AND MAINTAINED IntellfFre 8 27 2009 Hearth amp Home Technologies Page5 Pius System Basics IntelliFire Plus Troubleshooting The IntelliFire Plus IPI intermittent pilot ignition Ignition System and Wireless Con trols is a total control system from the components under the fireplace to the re mote control in your hand HHT Hearthville offers Sales and Product Knowledge Training modules as companions to this troubleshooting guide Taking Hearthville modules is recommended Ignition Control Components Ignition Control Box includes receiver for wireless remotes 6 DC Volt Transformer Wiring Harness IPI Va
14. lve with Stepper Motor IPI pilot assembly Battery Backup Wireless Controls e RC100 RC200 amp RC300 wireless controls w batteries e Wall Mounted Docking Station RC200 amp RC300 e Auxiliary modules RC200 amp RC300 Intellifire Plus IPI Ignition System Wiring RC300 4 5V DC AA X 3 FAN AUX AUX2 TT TO JUNCTION BOX 110V AUX200 MODULE iaaa j m FR Aux Modules sup 1 lied with wireless Wire Harness P Fe LJ CONTROL MODULE M controls RC100 RC200 ents ck OPTIONAL WALL CONTROLS Left to Right Red Black Brown Orange Black Green BATTERY PACK 6V DC AA X 4 Before replacing a part al ways check the continuity of the wires supplying the voltage etc This guide assumes the wireless controls and battery backup components have been elimi nated from the system for purposes of troubleshooting the ignition system intelifFire 8 27 2009 Hearth amp Home Technologies Page6 System Basics Wireless Controls TO JUNCTION BOM 1200 Ge DC _ SUPPLY SWITCH ONE ON OFF REMOTE switch on module must be in REMOTE position for wireless con trols to operate the remote and optional wired wall switch The wireless control and receiver housed in the control module communicate to and from each component via radio frequency They must remain within 30 feet of each other For the RC300 when in thermostat mode transmission of information happe
15. m The module makes noise but no spark 6 Igniter is disconnected loose or shorted to fireplace 7 Improper gap between igniter and pilot hood If igniter is shorted it will at tempted to light for 60 sec onds before module times out Diagnostic code is 3 red flashes disconnected before going to Sensor lead is It will flash green 3 times and go into lockout Voltage shorted to ground may cause damage to mod ule resulting in damaged module Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system IntellfFre 8 27 2009 Hearth amp Home Technologies Page20 Plus Problem Scenarios 3 Problem Pilot sparks but pilot will not light The problem may be 1 Gas supply 2 Faulty module voltage to valve 3 Faulty valve Go to page 29 to familiarize yourself with module diagnostic codes How to reset from Lockout Mode Stepper motor regulator assembly Y should never be 4 disassembled SCREWS WIRE LEAD IntelliFire Plus Troubleshooting Notice Disconnect power to the system prior to disconnecting any compo nents by switching the ON OFF REMOTE module switch to the OFF position It is not recommended to operate the ignition control module with disconnected wire connections A short could cause permanent dam age Introducing the pilot sensor rod with a false flame such as from a flame stick will cause th
16. mber which is dedicated to trade channel partners Please do not give these numbers to homeowners builders etc Be prepared to provide the following information e Fireplace model and serial number e Previous service history if with previous HHT reference number if any e Detailed problem description Technical Service will assign a reference number to troubleshooting calls when infor mation is provided To ensure a more timely repair and processing of claims involving multiple service calls HHT expects a dealer to contact Technical Service after 2 failed attempts to repair a product A completed checklist may be requested to assist with diagnosis 07722709 01 37 PH CUT Via VSI FAX Page I of I 3544696 Claim System HEARTH SHO ME Acknowledgement vy HHT Cust Number Reference Number 1369359 S et e gt n FHH RICHMOND VA D En 90E 2227 DABNEY RD Technician Curt Marx RICHMOND VA 23230 Claim Status Open US Approval Status Approved Recording the reference number improves com munication between dealer and HHT This number is also used when and if a warranty claim is filed for the service call Intelifmire 3 27 2009 Hearth amp Home Technologies Page4 Plo Tools and Instruments IntelliFire Plus Troubleshooting You will need the following tools and equipment to execute troubleshooting outlined in this guide Required Tools e Open end wrenchs 3 8 7 16 9 16 e Adjustab
17. n to set to LP LP N NG Turn counter clockwise 3 4 AN ae yp turn to set to NG SELECTOR SWITCH Direction of switch slot in NG setting siot is not colored on module ATUS INDICATOR LED i NG LP SETTIN O ALL SWITCH ONLY Direction of switch slot in LP setting siot is not colored on module Wireless con trols in use selector switch in the REMOTE position If the NG LP selector switch is not turned com pletely to NG or LP set ting the fireplace will not ignite and will go into lockout mode If the selector switch spins freely and does not engage into NG or LP position the switch is damaged and the mod ule go into lockout mod ule Damaged switch requires module replace ment Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system intellfFre 8 27 2009 Hearth amp Home Technologies Pagel6 Problem Scenarios 1 continued IntelliFire Plus Troubleshooting Problem Pilot wont light no noise and no spark 8 Faulty Module Insufficient voltage Diagnostic code from ignition coil to is 2 red flashes pilot flame igniter before going to lockout mode with red green Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system intelifFire 8 27 2009 Hearth amp Home Technologies Pagel7 Problem Scenarios 2 IntelliFire Plus Troubleshooting Problem The modul
18. nd 120 volts ac Testing 120 VAC to and from junction box intelle 8 27 2009 Hearth amp Home Technologies Page33 System Checklist IntelliFire Plus Troubleshooting Electrical System continued c To valve pilot solenoid Voltage to Pilot Solenoid test during lighting sequence Volts DC 1 2 V to open valve 3 V to keep valve open Black probe to body of valve Red probe to orange wire connected to valve pull wire slightly away from connector to touch connector d To valve burner solenoid Voltage to Main Valve Solenoid test during lighting sequence Volts DC 1 6 V to open valve 3 V to keep valve open Black probe to body of valve Red probe to green wire connected to valve pull wire slightly away from connector to touch connector iIntellfFie 8 27 2009 Hearth amp Home Technologies Page34 System Checklist IntelliFire Plus Troubleshooting Electrical System continued 5 Continuity a Wiring Harness Example of how to test continuity Meter set to ohms setting IntellfFie 8 27 2009 Hearth amp Home Technologies Page35 System Checklist IntelliFire Plus Troubleshooting Gas System Area System Proper Readings Reference Info ltems to be checked Gas Supply Refer to appropriate installation and operation manual for all areas 1 Inlet Pressure 2 Manifold Pressure a Refer to conversion matrix or service parts list in owner
19. ns every 60 seconds For optimum operation you may need to try different locations for the wireless control If a wired wall switch is installed and in the ON position it will override the commands of the wireless controls Must be OFF to use remote From the wireless control commands data signals are transmitted to the AUX200 amp 300 modules Voltage is sent to igniter stepper motor pilot regulator and main burner regulator Intelile 8 27 2009 BATTERY PACH TO OPTIONAL Gi DE LE COMPONENTS TONE MROWNREU OPTIONAL CDIMOFF Hearth amp Home Technologies IntelliFire Plus Troubleshooting RC900 54 DC ASAK H Eliminate wireless controls from the system when troubleshooting system wa AUX200 amp 300 module controls the EAN and incorporates timer and rheostat functionality opi _ AUX300 module also controls 2 auxiliary functions AUX1 offers high med low settings p AUX2 offers ON OFF control Page7 System Basics IntelliFire Plus Troubleshooting IPI Ignition Control Module see labeled diagram below w remote receiver 1 Igniter sparks when commanded via wall switch wireless control or control module switch to turn on main burner Voltage through the wire to igniter on pilot assembly creates spark to ignite gas released to pilot assembly 2 Sensor rod acknowledges pilot flame is present before releasing gas to the main burner for ignition When a p
20. o disconnecting any compo nents by switching the ON OFF REMOTE module switch to the OFF position It is not recommended to operate the ignition control module with disconnected wire connections A short could cause permanent dam age Introducing the pilot sensor rod with a false flame such as from a flame stick will cause the module to go into lock out mode This is due to a safety feature SELECTOR SWITCH ATUS INDICATOR LED 1 NG LP SETTING ALL SWITCH ONLY Turn only during unit conversion DO NOT USE FORCE WHEN TURNING Using a plastic screwdriver is recommended For example To change from NG to LP setting you would turn LP A NG switch clockwise 3 4 turn to set to LP AS As soon as you feel resistance Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system intellffi e 8 27 2009 Hearth amp Home Technologies Page24 Problem Scenarios 4 continued IntelliFire Plus Troubleshooting Problem Pilot lights but continues to spark and main burner will not ignite 1 Gas supply 2 Sensor rod shorted or disconnected Inlet Min NG 5 in w c Inlet Min LP 11 in w c Manifold NG 3 5 in w c Manifold LP 10 in w c Inlet Max NG 10 in w c Inlet Max LP 13 in w c Captive slotted screws will not come of towers ALWAYS tighten after testing to prevent gas leaks at towers Diagnos
21. on maintain proper clearances to walls amp ceiling combustible mantels amp surrounds household goods and furniture e Glass Assembly IS the glass clean free of soot properly retained with all appropriate fasteners gasket pliable and free of damage Are the logs f Logs appropriately placed free of soot J Firebox h Wiring Ignition Components Do the wiring connections and or components show signs of heat damage loose or damaged wiring connections Burner Is the burner set up with properly placed embers free of corrosion properly seated to the burner orifice aligned with pilot igniter over burner ports Intelifmire 3 27 2009 Hearth amp Home Technologies Page30 Plow System Checklist IntelliFire Plus Troubleshooting Electrical System Electrical System Refer to appropriate installation and operation manual for all areas 1 Proper Wiring Intellifire Plus IPI Ignition System Wiring m i AUX300 MODULE RC300 4 5V DC AA X 3 AUX AUK FLAME bat IGNITER TT TO JUNCTION BOX 110V Aux Modules sup plied with wireless Wire Harness controls to Module Left to Right Red Black Brown an BATTERY PACK Orange Aa 6V DC AA X 4 Black 3 Green ORANG GREEN RED paon THERMOSTAT WIRE ASSEMBLY WALL SWITCH WIRE a Control Module ON OFF OFF Module is dead REMOTE Setting ON Used during set up or testing
22. power to the former module Pulling and re connecting the power supply cord from transformer does not serve as the same test as turning switch from OFF to ON If this is no power from junction box trace electri cal supply to junction box including proper wiring at junction box Should read between 110 and 120 volts ac Testing 120 VAC to and from junction box Insert red probe inside cord Touch black probe to outside of power supply i aa a Testing 6 Volts DC With transformer plugged into junction box pull from transformer transformer power supply cord from module Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system intellfFie 8 27 2009 Hearth amp Home Technologies Pagel5 Problem Scenarios 1 continued Problem Pilot wont light no noise and no spark 6 Wired wall switch not wired properly IntelliFire Plus Troubleshooting 7 LP NG switch on module damaged or not fully engaged into LP or NG setting The wiring to the wall switch may not be correct if fireplace does not turn on when the switch on the module is in the REMOTE position AND the optional wired wall switch is in the ON po sition Red and Brown wire con nect to wall switch Diagram to the right re views proper switch opera tion when wired wall switch and wireless controls are both installed Turn clockwise 3 4 tur
23. sis for accurate parts replacement To reduce multiple service calls To gather necessary information to assist with proper diagnosis of problems Qualified Service Technicians Only This troubleshooting guide is for use by qualified service technicians only It is de signed to help qualified service technicians troubleshoot gas fireplace with IntelliFire Plus ignition systems Warning Do not attempt to service appliances which you are not qualified to service Service attempted by unqualified persons could result in risk of bodily injury and prop erty damage Obligation of Service Professionals Service technicians must be attentive to appropriate codes understand and follow manufacturer s installation instructions and use the proper parts and materials when servicing and installing gas appliances One of the most important tools you bring to a service call is the installation manual Communicating with the Owner Ask the owner a few simple questions prior to service Has What are the symptoms When does the problem occur How long has the appliance been installed Model Number Serial Number Operating Gas LP or NG i ntellffre 8 27 2009 Hearth amp Home Technologies Page3 Pius Introduction IntelliFire Plus Troubleshooting Technical Assistance Distributors amp Dealers Heat amp Glo 877 228 5012 Heatilator 8 7 7 7 943 2848 Quadrafire 866 804 7 783 For technical assistance call the appropriate branded nu
24. switch on module damaged or not fully engaged into LP or NG setting Faulty module oot N ad H t t Turn switch to ow to rese OFF from Lockout Mode Wait 5 seconds Turn to ON Notice Disconnect power to the system prior to disconnecting any compo nents by switching the ON OFF REMOTE module switch to the OFF position It is not recommended to operate the ignition control module with disconnected wire connections A short could cause permanent dam age Introducing the pilot sensor rod with a false flame such as from a flame stick will cause the module to go into lock out mode This is due to a safety feature stepper motor regulator assembly should never be Turn only during unit conversion DO NOT USE FORCE WHEN TURNING Using a plastic screwdriver is recommended For example To change from SELECTOR T I H ese e r E 7E on NG to LP setting you would turn LP N P 1 NG switch clockwise 3 4 turn to set ATUS INDICATOR LED KL P to LP l NG LP SETTING amp bi ALL SWITCH ONLY As soon as you feel resistance Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system intelifFire 8 27 2009 Hearth amp Home Technologies Pagel3 Problem Scenarios 1 continued IntelliFire Plus Troubleshooting Problem Pilot wont light no noise and no spark 1 Loose or improper wiring S
25. tallation e Electrical e Gas Supply Area System Proper Readings Reference Info ltems to be checked y Visual Inspection Refer to appropriate installation and operation manual for all areas 1 Proper Installation Condition a Vent System Does the installation meet venting requirements for rise to run ratio vent cap type vent cap location venting size b Gas Supply Components Gas line sizing and components must meet ANSI Z223 1 and local codes requirements Supply pipe must be 72 minimum Note all appliances supplied inline with firep Complete system checklist is provided at the back of the guide Sections of the system checklist are Locate all shut off valves What position ari duplicated and used with specific problem scenar OS l i HHT Technical Service may request a complete i checklist for units in the field that have not been repaired after 2 or more service calls Intelifmire 3 27 2009 Hearth amp Home Technologies Pagel2 Plow Problem Scenarios 1 IntelliFire Plus Troubleshooting Problem Pilot wont light no noise and no spark Go to page 29 to familiarize yourself with module diagnostic codes The problem may be 1 Control Module selector switch NOT set properly Loose or improper wiring System not grounded No power from junction box No power to junction box No power from 6Volt DC transformer Wired wall switch not wired properly LP NG
26. tic code is 3 red flashes disconnected before going to lockout mode with red green flash Sensor lead Is Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system intellfFre 8 27 2009 Hearth amp Home Technologies Page25 Problem Scenarios 4 continued IntelliFire Plus Troubleshooting Problem Pilot lights but continues to spark and main burner will not ignite 3 Poor flame rectification or contaminated sensor 4 Faulty Valve Burner Solenoid 3 lf contaminated sensor wire prevents continuity the system will time out after 60 seconds and go into lockout mode Visible carbon will be on sensor rod and will need to be cleaned with emery cloth Example of how to test continuity Meter set to ohms setting Disconnect wires from valve One probe on body of valve amp one probe on pilot OR burner wire solenoid connection Burner solenoid should read betwee 5 Pilot solenoid should read between 37 to 47 Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system InteliiFire 8 27 2009 Hearth amp Home Technologies Page26 Problem Scenarios 5 IntelliFire Plus Troubleshooting Problem Pilot lights stops sparking and pilot remains lit Burner will not light The problem may be 1 Faulty module 2 Faulty valve Go to page 29 to familiarize yourself with module diagnos
27. tic codes H t t gt Turn switch to ow to rese OFF from Lockout Mode Wait 5 seconds Turn to ON Stepper motor regulator assembly Y should never be 4 disassembled SCREWS WIRE LEAO W Po 4 Notice Disconnect power to the system prior to disconnecting any compo nents by switching the ON OFF REMOTE module switch to the OFF position It is not recommended to operate the ignition control module with disconnected wire connections A short could cause permanent dam age Introducing the pilot sensor rod with a false flame such as from a flame stick will cause the module to go into lock out mode This is due to a safety feature SELECTOR SWITCH Turn only during unit conversion DO NOT USE FORCE WHEN TURNING Using a plastic screwdriver is recommended For example To change from NG to LP setting you would turn LP A NG switch clockwise 3 4 turn to set ATUS INDICATOR LED N J to LP l NG LP SETTING XQ ts fi ALL SWITCH ONLY As soon as you feel resistance Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system intellffi e 8 27 2009 Hearth amp Home Technologies Page27 Problem Scenarios 5 continued IntelliFire Plus Troubleshooting Problem Pilot lights stops sparking and pilot remains lit Burner will not light 1 Faulty module burner solenoid 2 Faulty valve burner sol
28. ulating flame dur ing flame adjustment in thermostat mode and when flame is turned off Install regulator upstream of valve if line pressure Is greater than 1 2 psig Verify inlet pressures Verity minimum pressures when other household gas appliances are operating 5 Main burner regulator is changed when unit is converted and comes with Important gas supply information provided in stepper motor installed The green wire HHT gas fireplace Owner s Manual Installa from the ipi ignition module is connected tion and Operation to the main burner regulator InteliiFire 8 27 2009 Hearth amp Home Technologies Page9 System Part Numbers IPI valve NG 2166 302 LP 2166 303 Pilot Assembly NG 2166 370 LP 2166 371 Sold complete Battery Backup with 1 amp fuse 2166 323 Grounded bo roetal on fireplace Smaller valve connecter to pilot regulator Larger valve commector to mim regulator 5 IntelliFire Plus Troubleshooting stepper motor regulator assembly LPK DXV 50 NGK DXV 50 Control Module 2166 307 Transformer 2166 305 IntelliFire Plus Wiring Harness Battery Backup Optional Wall Switch Valve Part 2166 304 Black Sleeve Refer to current service parts list for most accurate information InteliiFire 8 27 2009 Hearth amp Home Technologies Pagel0 System Part Numbers IntelliFire Plus Troubleshooting Main Components of Wireless Controls R
29. ystem not grounded 2 Control Module selector switch NOT set properly Must be in the ON or RE MOTE setting for unit to operate Isolate remote from system when trou bleshooting Switch to ON to test operation STATUS INDICATOR LED FLAME HI LO SWITCH NG LP SETTING IntelliFire Plus IPI Ignition System Wiring RC300 4 5V DC AA X 3 AUX AUX2 Jt y CONTROL MODULE NE BOX 110V ss AUX200 MODULE nes 4 CE FLAME Aux Modules sup irs Kam Es MODULATION plied with wireless cel RC100 RC200 one ANA m OPTIONAL WALL CONTROLS E m Red k Black Brown Orange Black Green ORANGE PILOT BATTERY PACK 6V DC AA X 4 2 ra e i THERMOSTAT WIRE ASSEMBLY WALL SWITCH WIRE fl Before replacing a part al ways check the continuity B of the wires supplying the voltage etc GROUND Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system intellfFre 8 27 2009 Hearth amp Home Technologies Pagel4 Problem Scenarios 1 continued IntelliFire Plus Troubleshooting Problem Pilot wont light no noise and no spark 3 No power from junction box 4 No power to junction box 5 No power from 6Volt DC transformer Switch from OFF to ON If the module does not If diagnostic flash trace power supply to ae Et junction box from junction there is box and from 6 Volt trans
Download Pdf Manuals
Related Search