Intellifire Plus troubleshooting guide intl Nov 2011.pub
Contents
1. 33 51 53 50 39 057 42 057 55 42 057 55 30 49 Orifice Metric mm 2 18 P32 1 18 2 49 1 450 LZ 2 87 1 70 1 51 1 78 2 53 1 45 2 39 1 45 1 325 pie 1 45 1 325 3 26 1 85 1 55 7 hole 2 33 Hearth amp Home Technologies Shutter Setting 9 5mm 11 mm 12 5 mm 11 mm Full Open Full Open 12 5 Full Open Full Open 11 mm 13 mm 11 mm Full Open 11 mm Full Open 13 mm Full open 9 5mm Full Open Page29 Unit Orifice and Shutter Setting Reference UNIT Max Heat MJ h Orifice DMS Orifice Metric mm Shutter Setting 550TRSI AUF Using 28 40 2 49 Full Open DVP HE KIT 550TRSILP AUF 26 057 1 45 Full Open Using DVP HE KIT Supreme N 130AU 31 36 2 37 Supreme P 130AU 31 52 1 61 Cosmo N I30AU 26 42 2 37 5mm Cosmo P I30AU 24 54 1 40 XLR PLUS N AU Media XLR PLUS PB AU Media Propane XLR PLUS PB AU Media Butane XLR PLUS N AU LOGS XLR PLUS PB AU LOGS Propane XLR PLUS PB AU LOGS Butane B Technical Service Contacts and Information Website www heatnglo com or fireplaces com Toll free number Technical Service Email How to access most recent revision manuals E fome me m om H OC EE Tig as perire LA HEATS GLO FELEL ETAST niukin m inna 1h Lhe HEATS GLO as z ee ee ee Selection the amw of the International Manuals drop down menu 4 Sel2. Frequently Asked Questions scccccccsscccccssccccsssccccccssssssccccssssseoo 20 IPFI Plus Noteworthy se ccrscesesaccacceususiessccuseesssecsssasaccnvenassesensateusavesuesuseaseviese 27 28 Unit Orifice and Shutter ReferenCe scscseseceseceseococscocccocosecosoccseseseses 29 30 Technical service Contact information esesesesesescocoeococccoccccsocoseseseseo 31 inteligcire J Halverson 12 1 2011 Hearth amp Home Technologies Page2 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 diagnosis 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
3. Hearth amp Home Technologies Pagel 1 System Checklist IntelliFire Plus Troubleshooting Troubleshooting Checklist 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 and the customer When servicing any Heat amp Glo product the root cause of the problem should be identified This will lead to confidence and ease of diagnosing problems in future service calls Using the troubleshooting checklist to assist in your service call This will e Enhance consumer confidence e Provide consistent service performance e Provides unit history for future service calls e Improves communication when seeking technical assistance Checklist e Gas Supply Gas shutoff is in ON position Assure proper gas sizing of line How many appliance are operating on line Meets standards of AS5601 plumbing code Standard Inlet and Outlet Gas Pressures T Inlet Gas Pressure 1 13 3 40 kPa 2 75 3 40 kPa Outlet Manifold Gas Pressure 80 95 kPa 2 36 2 61 kPa e Visual Inspection for proper installation and condition of installation e Does the vent configuration comply with approved venting diagrams for the unit Proper vent cap and clearances Proper rise to run ratio of venting All flue components connected and secured e Electrical supply and components Proper position of On off switches Isolation swi
4. Blower assembly kit low profile Supreme I30 Cosmo I30 Soho GFK210 240V DC power voltage regulator 2166 369 DC power voltage regulator Inserts 2 prong flat spade 2166 305 Junction power box 2078 027 Junction power cord 2222 374 Jumper wire for Heat Zone connect to Aux box 2166 191 Intellfire J Halverson 12 1 2011 Hearth amp Home Technologies Page10 System Part Numbers RC100 control IntelliSwitch RC100 freatilator RC300AU Remote Control IntelliFire Plus Troubleshooting Main Components of Wireless Controls RC100 Wireless wall mounted control On off capability only RC300AU Handheld remote control with wall mount holder Thermostat timer Aux 1 Aux 2 and blower control See instructions on RC300AU and RC100 for programming and function control AUX300CE ATTON 2166 340 The Aux300CE is not needed for remote control operation but it is needed for blower connection and con trol of the blower through the module The remote interfaces with the gray module which controls functions on the Aux300CE s G40 NOLLIN ak f BOLT INSSY J0 Note Pictured is the junction power cord If you have an existing 2078 027 junction box and are experiencing electrical connection issues with the socket of the junction box please contact your dealer for a replacement junction power cord intelifcire J Halverson 12 1 2011
5. damaged or loose A damaged insulator will cause a short which is sometimes intermittent D If A thru C do not apply replace the control module If replacing the control module resolves the failure send the failed module with notes on the failure to your local distributor intellfcire J Halverson 12 1 2011 Hearth amp Home Technologies Page23 Diagnostic Codes IntelliFire Plus Troubleshooting Diagnostic Codes are listed below and should be used as a additional tool to help diagnose failure modes Use the troubleshooting guide to check all possible failures before changing any component parts CODE RESPONSE ERROR CAUSE ERROR RESOLUTION Fuel type selector in incorrect position 1 Verify that the selector Module flashes error code and goes stops at the correct position into lockout mode when rotated gently with a i precision screwdriver 2 Fuel type selector switch damaged Insufficient voltage from Clear Lock Out and attempt ignition coil to pilot flame ignition If condition persists igniter replace module Module flashes error code and goes into lockout mode 1 Verify proper inlet pressure to the gas line Pilot sparks and may ignite for upto 1 Inadequate gas supply 60 secs but main will not open If 2 False flame detected condition occurs for gt 60 sec mod 3 Short in sense lead ule flashes error code shuts down 4 Sense and or igniter pilot and goes into lockout mode lead disconnected 2 Verif
6. ignition until 60 sec An example of a data log a n 6e oR 8 The 8K 1 module requirement for rectification ranges from 0 11 to 0 14 WA The 6K green IPI module requires 0 44 0 55 uA Once this requirement is met for a sufficient time the pilot should stop sparking and the module should send DC voltage to the green wire to energize the main valve A typical current vs time plot would look like the following graph Pilot Rectification vs Time Sense Current uA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 T Pilot Ignition sec Intellffire J Halverson 12 1 2011 Hearth amp Home Technologies Page22 Troubleshooting Pilot Rectification Issues 1 If the pilot sense current does not achieve a stable average 0 11 to 0 14 UWA during the initial 30 sec of the pilot being ignited then the current flow at the pilot may be impaired A Clean the pilot sense rod ground rod and or hood to ensure any contamination or oxidation is minimized This should increase the rate of current flow increase and help it attain a higher value In controlled laboratory tests cleaning the initial oxidative layer that forms on the pilot will restore long term pilot function B Verify that gas inlet pressure is within rating plate specifications This must be verified while the pilot and main burner are operating and preferable when other gas appliances on the same gas inlet are operating C The pilot may be altered or da
7. to shut off the fireplace because it has reached the thermostat set point the fireplace will shut the unit off and go in to lock out mode This is rare but to avoid assure remote is out of thermo stat mode before turning fireplace on with wall switch Disconnect wall switch wires and turn on unit with the sliding switch on top of the module If unit lights with module then verify wall switch connections IntelliFire Plus Troubleshooting CONTROL MODULE 2166 340 Wireless con trols in use selector switch in the REMOTE position and Turn clockwise 3 4 turn to set TY fa to LP O LP NG Turn counter clockwise 3 4 Lp turn to set to NG 7 LO TAO AO SELECTOR i i Direction of switch slot in NG setting siot is not colored on module ATUS INDICATOR LED i NG LP SETTIN ALL SWITCH ONLY Direction of switch slot in LP setting siot is not colored on module If the NG LP selector switch is not turned completely to NG or LP setting 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 module go into lockout mod ule Damaged switch requires module replacement selector switch must turn all the way until it stops Do not turn too far as It will break the switch Troubleshooting assumes the wireless controls amp battery bac
8. 4 yyy yy fe J Ka ifs A f A B af r i r 4 E 7 r l f i HEATEGGLO Troubleshooting Guide Australian NZ Edition IntelliFire Plus Ignition System For Authorized Gas Technicians and Service Personnel Only inteligcire J Halverson 12 1 2011 Hearth amp Home Technologies Pagel Table of Contents MTGE OOUCH OM 4 caren ceasiessan tan E EE 3 4 Toob ANG Sr ONS ee E A E 5 System DISC Serrar na E E EE E ES 6 12 Problem Scenario GH Uescessececsvaccsceeiacnes shesandseeeseeseaeneseaeenasecsents 13 17 Problem Pilot wont light no noise and no spark Problem Scenario Fi cg etcdcsaecesgucesndosessscwesesesstousrveneeunewonesssonens 18 Problem The module makes noise but no spark Problem Scenario FH 51000 ees sees ctunsscesontoosssesesssccasceveseoinsaeeavousas 19 Problem Pilot sparks but pilot will not light Problem SCCM AIO Has cnescscecuscsrcececgceenneraresesausesscasersesmocuecsssacs 20 Problem Pilot lights but continues to spark and main burner will not ignite PFODICHI SCONATIO 13 oeenn r N EEE E EN ENEE EOE 20 Problem Pilot lights stops sparking and pilot remains lit Burner will not light Measuring Pilot Rectification Curent ssseccccccsscccccccccssecccccccsceccccceso 21 22 Troubleshooting Pilot Rectification ISSUeS ecossssssecccccssssscoccccssssecee 23 Diorio ne COUES sorrerara EEEE E EAEE EE 24 SVEM NCCKINSE pu cencccas ences seseeesussuee ses casestescesatencacswese EERE 25
9. E sole noid Pull back wire shield of green wire and connect red meter probe to green lead of valve Connect black meter probe to valve body as shown Turn system on to start lighting sequence There should be 1 2 volts to 3 volts running through orange lead from module If there is appropriate voltage to green solenoid of valve then the valve is bad or the wir ing harness is compromised Replace wiring harness and then module Voltage to Main Valve Solenoid The voltage reading will start at 1 6 volts for the first couple seconds and then drops voltage down to low setting As long as start volt age is at least 1 6 volts and it BS halaan maintains 3 volts to keep wire connected to the valve open then the Ive pull wi a ee tows main valve solenoid is good connector to touch connector Volts DC 1 6 V to open valve 3 V to keep valve open Black probe to body of valve intellfcire J Halverson 12 1 2011 Hearth amp Home Technologies Pagel9 Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system Problem Scenarios 3 continued 4 and 5 IntelliFire Plus Troubleshooting Problem Pilot lights but continues to spark and main burner will not ignite Reference prior troubleshooting steps 7 Continuity or earth ground issue 9 Gas Supply 2 Loose or improper wiring Faulty Valve NOTE Revision A module is more
10. MAINTAINED Hearth amp Home Technologies Page5 System Basics IntelliFire Plus Troubleshooting The IntelliFire Plus IPI intermittent pilot ignition Ignition System and Wireless Con trols is a total control system comprised of components under the fireplace to the remote control in your hand HHT Hearthville offers Sales and Product Knowledge Training modules as companions to this troubleshooting guide Taking Hearthville modules is recommended Information is also readily available at heatnglo com Ignition Control Components Ignition Control Box 8k1 CE 240V to 6 DC Volt DC regulator power adapter Wiring Harness IPI Valve with Stepper Motor or Single rate fixed with XLR IPI pilot assembly Battery Backup C battery unit specific Auxiliary component box Aux300CE Wireless Controls e RC300 AU wireless controls w batteries and docking wall mount e RC100 wireless wall switch Not recommended for units with fan This guide assumes the wireless controls and battery backup components have been elimi nated from the system for purposes of troubleshooting the ignition system inteligcire J Halverson 12 1 2011 Hearth amp Home Technologies Page6 System Basics Eliminate wireless controls from the sys tem when troubleshooting system Refer ence individual unit manuals for wiring for detailed electrical schematics fr OC GUFPLY peasan k he ORANGE IHLA HAR IPI Wiring Diagram RC300AU
11. ON OFF REMOTE switch on module must be in REMOTE position for wireless con trols to enable use of the remote and op tional 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 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 User can still operate auxiliary functions Heat Zone intelifcire J Halverson 12 1 2011 IntelliFire Plus Troubleshooting Iiri PaF TO JUST Bog ADAE wa i i o C FTOR OHNE a ae WaLL aTe TH GRED SELECTOR SWITCH P STATUS INDICATOR LED FLAME HI LO SWITCH NG LP SETTING 2Ux300CE module controls the FAN and incorporates timer and rheostat functionality AUX300CE module also controls 2 auxiliary functions AUX1 offers high med low settings AUX2 offers ON OFF control Hearth amp Home Technologies 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 rel
12. an be made Once a remote has been pro grammed there is no longer flame adjustment at module Even if module selector switch is moved back to ON position the only way gain manual functional control of the flame adjust is to clear the memory A module can be de programmed by pressing the learn button of module and intentionally not depress ing a button on the remote receiver within the learn time If a remote does not pair with a module it is necessary to repeat this step and clear the module memory and attempt to pair again 5 second child lock on remote The power button must be depressed for 5 seconds toe enable the remote This is a requirement of the testing and agency approval for multi functional controls After you turn the fireplace off the stepper motor will default back to the high flame position then once the fireplace is turned back on it will light on high but after the 10 second delay it will resume the flame height position it was set to when turned off Basically always lights on high but will remember where you left it set to and will return to that setting Aux 1 or 2 functions can be run at any time with or without fire on and there is no delay There are 3 settings for Aux 1 and On off control for Aux 2 The system will also remember what setting these were set to and will resume that setting when turned on each time Heat zone can be connected to either The blower speed can be set at any time after turning firep
13. 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 P N or B inteligcire J Halverson 12 1 2011 Hearth amp Home Technologies Page3 Introduction IntelliFire Plus Troubleshooting Technical Assistance Distributors amp Dealers Be prepared to provide the following information when contacting Hearth and Home Technologies 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 Claim System HEARTH SHO ME Acknowledgement egies HHT Cust Number FHH RICHMOND VA 2227 DABNEY RD RICHMOND VA 23230 US Reference Number 136933593 gt OS Q0 Technician Curt Marx Claim St
14. atus Open 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 inteligcire J Halverson 12 1 2011 Hearth amp Home Technologies Page4 Tools and Instruments IntelliFire Plus Troubleshooting You will need the following tools and equipment to execute troubleshooting outlined in this guide Required Tools Open end wrenchs 3 8 7 16 9 16 Adjustable end wrenches 8 and 10 1 4 5 16 nut driver Straight screwdrivers including small 1 8 blade for pressure check and stubby Straight Phillips screwdrivers 1 and 2 and stubby Phillips Plastic straight screwdriver Rhino style Electrical pliers Needle nose pliers Flashlight Numbered drill index T 20 tamper resistant Torx bit HHT part 810 225 soft bristle toothbrush Soft 1 paint brush Electric drill 1 4 3 8 Fine Steel Wool Pilot Cleaning Digital Volt Meter intelifcire J Halverson 12 1 2011 Required Testing Equipment e Multi meter must measure millivolts e Manometer e Leak detection fluid e 2 to 4 300 mm 350 mm jumper wires e flame stick lighter wand Miscellaneous Smoke Match e Drop Cloth Tarp e Glass cleaner towels e Vacuum e Personal Protection Equipment Gas leak detector ALL TOOLS AND TEST EQUIPMENT SHOULD BE PROPERLY STORED AND
15. easing gas to the main burner for ignition When a pilot 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 AUX modules controlling fan kits AUX module and 2 additional auxiliary functions 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 We recommend using a small straight ce ramic anti static screwdriver which is supplied by electrical supply companies 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 Power from battery pack wall switch connection and connection to valve pilot and burner requlators 9 Flame Modulation stepper motor connection 10 Power supply connection 6 volt regulated DC from power regulator Plugged in to junction box 11 Rectification When the pilot flame bridges the sensor rod a
16. ect the desired manual to start download Intellfire J Halverson 12 1 2011 Hearth amp Home Technologies Page31
17. hares ground with valve Note If the module cycles through the lighting cycle without igniting the appliance it could be a symptom of too large of an igniter gap If there is no pilot light after 60 seconds or igniter is shorted and attempts to light for 60 seconds then the module will go in to lock out It will flash green 3 times and go into lockout Voltage shorted to ground may cause damage to 9 Additional Verify gas flow to valve and air bled out of line Also assure proper appliance gas line sizing Pressure loss occurs when too many appliances are on one gas line gas line undersized or distance from meter to appliance is excessive If there is a sputtering sound and intermittent pilot lighting the gas line may be undersized or there is air in the gas line Again the module will lock out after 60 seconds of no lighting Reset module Verify that there is a gas regulator installed before the valve for any gas supply that exceeds 3 4 kPa open At pressures above this the valve will start to pulsate Proper inlet and manifold gas pressures are in each gas appliance manual Reference Australian Plumbers Code AS5601 for additional codes and regulations The valve is non adjustable and is Closed Ensure a pe in the preset at the factory The following are the standard inlet as Su Ine are open Se RIT i oe TE and outlet pressures for the variable valve oo J s O o OS Verify that the appliance ga
18. here an NG and LP switch on the module This allows a software alignment for control to the valve for the different fuel Why do you need to disconnect power to system prior to disconnecting any components If the stepper motor has a disruption of power it will be stuck in the last position prior to lose of power Properly disconnecting power will set a sequence to the stepper motor to start on high once powered again Why is it not possible to field test the stepper motor There a2 reasons The pin connectors from the wiring harness to the module are very small and difficult to connect to multi meter test probes Complicated voltage sequence Why does the unit make an unusual clicking noise when changing flame setting A This is an audible response that the valve is changing flame height There are 6 flame height settings and it is not always easy to distinguish the change in height Q Why is there a fuse in the battery backup A To meet CE and AGA requirements there must be a fail safe for surge or interrupt Q Are the Intellifire and Intellifire Plus components interchangeable A No intellfcire J Halverson 12 1 2011 Hearth amp Home Technologies Page26 IPI Plus Noteworthy IntelliFire Plus Troubleshooting System will always light on high flame when turned on Wall switch will always override remote Wall switch needs to be off for remote operation There is a 10 second delay before any flame adjustment c
19. in 10 meters of module for proper reception and transmission Transmission is via radio frequency Remote program is set as a randomizing function of remote range of available radio frequencies Module must be in remote setting for wall switch or remote to operate A static charge across the LP NG fuel selector switch in rare instances may cause harm to module Use a non conductive or plastic screw driver when interfacing with module selector switch For the RC300 AU when in thermostat mode transmission of information happens every 60 seconds For optimum operation you may need to try different locations for the wireless control The RC100 uses CR2032 Batteries intellfcire J Halverson 12 1 2011 Hearth amp Home Technologies Page28 Unit Orifice and Shutter Setting Reference UNIT 350TRSI AUF 350TRSILP AUF 350TRSILP AUF Butane SSOTRSI AUF 550TRSILP AUF 550TRSILP AUF Butane 6TRSI AUD 6TRSILP AUD 6TRSILP AUD Butane SOHO N AUB VRT N xx AUB VRT P xx AUB XLR N AU XLR PB AU XLR PB AU Butane XLR N AU Logs XLR P AU Logs XLR PB AU Logs Butane ST HVBI AUB ST HVBILP AUB GRL 850 AU GRL 850LP AU Max Heat MJ h 21 19 8 17 2 WN OO DO NO ON W ON U N 29 5 iN Nw N ON WN WN NWN NO ON WN WN K AK ENN NI N gt S A D N aJ N Intellfire J Halverson 12 1 2011 Orifice DMS 44 55 56 40 057 55
20. iter Verify system voltages from module before replacing module Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system intellfcire J Halverson 12 1 2011 Hearth amp Home Technologies Pagel6 Check voltage from module to valve PILOT solenoid Pull back wire shield of orange wire and connect red meter probe to orange lead of valve Connect black meter probe to valve body as shown Turn system on to start lighting sequence There should be 1 2 volts to 3 volts running through orange lead from module If there is not then the module is bad or the wiring harness is compromised Replace wiring harness and then module 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 lf the pilot lights but the burner will not check voltage from module to MAIN VALVE sole noid Pull back wire shield of green wire and connect red meter probe to green lead of valve Connect black meter probe to valve body as shown Turn system on to start lighting sequence There should be 1 2 volts to 3 volts running through orange lead from module lf there is not then the module is bad or the wiring harness is compromised Replace wir ing harness and then module Voltage to Main Valve S
21. kup have been eliminated from the system intelifcire J Halverson 12 1 2011 Hearth amp Home Technologies Pagel5 Problem Scenarios 1 continued IntelliFire Plus Troubleshooting Problem Pilot wont light no noise and no spark 7 Continuity issue Spark gap or object interference Check to assure pilot spark lead and sensor rod are intact Verify that neither the sensor or igniter rod are contacting the pilot hood assembly Assure that ceramic insulator of sensor rod is not cracked or bro ken Make sure that there is no media or excess carbon build up on sen sor lead This can cause a false sense situation and put the mod ule in to lock out Remove any debris or objects that are in con Test for Continuity tact with the sensor or spark leads of the system as shown Make con nections as shown and set meter for Ohms setting If there is BAD read ing check wiring of system If all wiring is intact replace pilot as sembly and retest for continuity Example of how to test continuity Meter set to ohms setting Q Spark Gap between hood and igniter should be 115 or 2 92 mm 015 or 38 mm Faulty Module 2 red flashes does not designate the mod i l i hat there is insuffi TE Diagnostic code ule as bad it states t at there is insuffi from ignition coil to is 2 red flashes cient voltage from the ignition coil to picinamegniter before going to pilot flame ign
22. lace on However there is a built in delay of 7 minutes from start up until it comes on and also a 12 minute delay in which the blower will run after the fireplace is turned off These settings were implemented to replicate the blower temp sensor disc that used to command the blower on and off according to firebox temperature There is a lock out mode If pilot fails to light after a 60 second attempt the module will go in to a lock out mode and will require a manual reset No functions will work while in a lock out mode The light on the module will signify the lock out status It will be flashing 2 flashes one red and then one green The module can be reset by sliding the switch on the top of module to the off position and then back to remote or by turning your appliance isolation switch off and then back on Leave off for a short time The on position on top of the module will run the system if no remote or wall switch is installed By slid ing the switch to on the pilot and then the burner will light A flame adjustment can also be made from the module using the high low sliding switch However if a remote has already been programmed in to the system this flame high low switch becomes disabled If a remote has not been programmed in the switch will change the flame height setting only from max height to min low but after the 10 second de lay The stepper motor will still function on battery back up and full f
23. lame adjustment can be made from the remote or using the high low sliding switch on module There will still be a 10 second delay before any flame height adjustments can be made Aux 1 an Aux 2 will not function in battery backup mode Blower will not function on battery back up mode It is safe to leave batteries in the battery holder even when operating on normal current from junction box the batteries will not be drained nor will the system attempt to charge them However batteries will loose power when exposed to an area of high temperature for extended periods of time and battery life will shorten intellfcire J Halverson 12 1 2011 Hearth amp Home Technologies Page27 If a wall switch has been installed it will override the remote You will want to leave the wall switch in the off position if remote operation is desired There is a safe auto shut down built in to the control module for the instance where there has been 9 hours of uninterrupted continuous operation of the appliance This is not a function of the remote If us ing the wall switch or the remote in the full time on mode unit will only run for 9 hours continuously verify the remote control thermostat function and possible bypass The remote and thermostat mode will still operate in battery back up mode No accessory functions will operate off the battery back up Transmission of information occurs every 60 seconds in thermostat mode Remote must be with
24. maged Check to make sure the igniter electrode is not bent D Verify that the sense rod is not bent up or back out of the flame E Check for a normal and stable flame at the pilot burner to ensure that the flame is pro jecting from the hood to the sense rod consistently The pilot flame should ignite and extinguish within 1 second of full fuel delivery If it ignite sor extinguishes slowly the gas valve may be defective If the flame is weak despite adequate gas inlet pressure there may be contamination in the orifi ce a damaged hood malfunctioning valve etc F If A thru E do not apply replace the pilot assembly If replacing the pilot resolves the fail ure send the failed module with notes on the failure to your distributor 2 If the pilot sense current exceeds 0 14 uA during the initial 30 seconds of the pilot being ignited then the current flow at the pilot may be impaired A Check for a shorted or damaged sense lead both inside and outside the firebox This would include melted insulation on the sense lead within the firebox and also any pinched or damaged wire elsewhere B Verify that the ceramic insulator hood or sense rod is not contaminated with soot This will cause a short in the sense circuit resulting in the same failure symptoms as a bad pilot If soot is contaminating the pilot an abnormal condition may exist warranting review of the entire installation C Verify that ceramic insulator is not cracked
25. meter lead to the black earth lead on control module Resistance should be almost zero or provide an audible beep PLOT Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system Intellfire J Halverson 12 1 2011 Hearth amp Home Technologies Page13 Problem Scenarios 1 continued IntelliFire Plus Troubleshooting Problem Pilot wont light no noise and no spark No power to junction box or from junction box OZ ear spe e tn poles lf there is no power from junction box trace electrical supply to junction box including proper wiring at junction box ig WIRES MUST REMAIN CONNECTED S n 1 Assure power cord is attached within B the junction box 2 Verify black leads are connected These are unused in new IPI plus sys tem G 3 Check voltage by connecting voltage tester to Brown hot and Blue hot Reading should be 220 240V BROWN GREEN ED YELLOW BROWN BLUE f oo GREEN YELLOW maa 4 No power from 6 volt DC transformer Check to assure 6 Volt adapter is secure in junction box Switch from OFF to ON If the module does not flash trace If diagnostic i i i z ight blinks power supply to junction box from junc green 3 times tion box and from 6 Volt transformer there is ower to the f oita Pulling and re connecting the power supply cord from transformer does not serve as the same test as
26. nd ground a signal is generated at the module that enables the valve to turn the main burner solenoid on WARNING DO NOT CONNECT 240 V AC LINE VOLTAGE TO CONTROL MODULE Intell Fire J Halverson 12 1 2011 Hearth amp Home Technologies Pages System Basics IntelliFire Plus Troubleshooting IPI Gas Valve w Stepper Motor 3 Manifold Pressure Tap 2 Inlet Pressure Tap 1 Pilot Regulator Pils EN b E ce TE g S T E eae rae tea LS Stepper motor 1 Pilot regulator is stamped as Nat screws regulator assembly or LP designating the factory set Zs guild never be disassembled ting If converted the main burner a regulator has fuel type stamped along the side indicating the con version The orange wire from the ignition module is connected to the pilot regulator Important gas supply information provided in HHT gas fireplace Owner s Manual Installation and 2 Test the inlet pressure at this tap Operation A Test the manifold pressure at this DANGER A gas supply regulator must be installed 4 The stepper motor is not a replace in line with the gas supply to the valve if able as a separate part only available assembled to the main burner regulator Its function is to modulate the flame pressure supply line is above 3 4 kPa If not the diaphragm in the valve will start to pulsate and damage valve Note An audible noise will be heard when the steppe
27. ntinuity issue Spark gap or object interference cause the module to go into lock out mode gaged into LP or NG setting This is due to a safety feature built in to the module 8 Faulty module Control Module selector switch NOT set properly The module must be in the ON or REMOTE setting for unit to operate Isolate remote from system when trouble shooting Switch module to ON or REMOTE to test operation of unit SELECTOR SWITCH R on ieor oh versed 2s oF a B oor p D STATUS INDICATOR LED FLAME HI LO SWITCH NG LP SETTING 2 Loose or improper wiring System not grounded Verify all wire connections Grounded to metal on fireplace Smaller valve connector to pilot regulator Larger valve connector to main regulator The black wire grouped with the or ange and green wire is the ground wire Make sure it tightly _ secured to metal ll chassis of fireplace Verify that the ground wire igniter wire and sensor wire are all in tact and have continuity A pinch or splice in the wires can cause a short to the ipiwiring Diagram Rc300AU system or a break in continuity and Use a DVM digital volt meter to test for system ground earth connection cause the module to go immediately Set meter to resistance ohms or audible diode test Connect red lead to the pilot assembly in to lock out mode orange lead and the black
28. olenoid test during lighting sequence E S a Volts DC 1 6 V to open valve 3 V to keep valve open Black probe to body of valve Red probe to green e wire connected to valve pull wire slightly away from connector to touch connector Make sure orange and green female terminals do not have the protective rubber sleeve pulled away This could potentially short the leads to the valve which is grounded Intellfire J Halverson 12 1 2011 Hearth amp Home Technologies Pagel7 Problem Scenarios 2 IntelliFire Plus Troubleshooting Problem The module makes sparking noise but Notice no spark kk Disconnect power to the system prior to disconnecting any components by switching the ON OFF REMOTE module switch to Reference prior troubleshooting steps the OFF position N It is not recommended to operate the igni Loose or Improper WIFING Check that igniter IS tion control module with disconnected wire not disconnected loose or shorted to fireplace AAO O E cipal ead can cause a short and permanent con 7 trol module damage Continuity or earth issue Spark gap There ee a T ntroducing the pilot sensor rod with a false should be about a 2 92 mm 1 18 pore flame such as from a flame stick will from Ign iter to cause the module to go into lock out mode pi lot hood V erify l oe oo to a safety feature built in to the sensor lead wire _ Igniter Check that pilot s
29. propriately placed free of soot g Firebox ooo h Wiring Ignition Components i Burner Do the wiring connections and or components show signs of heat damage loose or damaged wiring connections 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 Make as many pertinent notes to the installation as possible This will aid significantly in trouble shooting and diagnosing any future instances Intellfire J Halverson 12 1 2011 Hearth amp Home Technologies Page25 Frequently Asked Questions IntelliFire Plus Troubleshooting Ignition Control Module with control receiver Q A gt 2O FO gt O Q What is the high to low turndown for the Intellifire Plus system The modules have the capability of regulating the gas pressure to the main burner with the manual High Low switch This allows the flame variability without the use of a wireless control 2166 340 has a 30 turndown lf the fireplace is on and being operated via a wireless control power is lost and there are batteries in the battery backup carriage do need to switch the ON OFF REMOTE switch on the control mod ule to ON As long as the batteries in the carriage have voltage the fireplace will seamlessly revert to the power from the batteries to power the operation Fresh batteries will keep fireplace running up to 72 hours Why is t
30. r motor is modu Normal operating pressures lating flame during flame adjustment in Inlet 1 13 kPa for natural gas thermostat mode and when flame is 2 75 kPa for propane butane gas turned off Manifold 8 kPa for natural gas 5 Main burner regulator is changed 2 4 kPa for propane butane gas when unit is converted and comes with stepper motor installed The green wire from the ignition module is connected to the main burner regulator inteligcire J Halverson 12 1 2011 Hearth amp Home Technologies Page9 System Part Numbers IntelliFire Plus Troubleshooting Part Name Part Number IPI Plus Valves Variable N 30 2166 302 Variable P 30 2166 303 Fixed NG XLR only 2166 308 B amp P Fixed XLR only 2166 309 Valve Regulator Assembly Variable N NGK DXV 50 Variable P LPK DXV 50 Fixed N XLR only NGK DXF NP Fixed P XLR only LPK DXF NP Pilot Assembly Natural 2198 014 Propane Butane 2198 015 Natural XLR only 2090 012 Propane Butane XLR only 2090 013 IPI Plus Controls Components Remote Control Australia No standby pilot REM300 HNG AU Power cord replacement for 2078 027 Junction box 2099 161 Fuse Harness Cosmo and Supreme Units for Fan 2166 341 Aux300CE auxiliary box 2166 340 Control Module Gray 2166 306 Jumper wire GFK 240V fan to Aux300CE 2166 375 Battery Backup C batteries 4067 223 Wiring Harness 2166 304 Blower assembly kit 350 550 6000 ST Vrtkl XLR GFK 240V
31. s shut off valve and any other appliance shut off valves are on Intellfire J Halverson 12 1 2011 Hearth amp Home Technologies Pagel8 Plus Troubleshooting assumes the wireless controls amp battery backup have been eliminated from Problem Scenarios 3 IntelliFire Plus Troubleshooting Problem Pilot sparks but pilot will not light Reference prior troubleshooting steps 9 Gas supply Faulty module Faulty valve Check voltage from module to valve PILOT solenoid Pull back wire shield of orange wire and connect red meter probe to orange lead of valve Connect black meter probe to valve body as shown Turn system on to start lighting sequence There should be 1 2 volts to 3 volts running through orange lead from module If there is appropriate voltage to orange solenoid of valve then the valve is bad or the wiring harness is compromised Replace Voltage to Pilot Solenoid The voltage reading will start at 1 2 volts for the first couple seconds and then drops voltage down to low setting As long as start volt Volts DC 1 2 V to open valve 3 V to keep valve open Black probe to body of valve age is at least 1 2 volts and it maintains 3 volts to keep Red probe to orange the valve open then the wire connected to A valve pull wire pilot solenoid is good slightly away from connector to touch connector If the pilot lights but the burner will not check voltage from module to MAIN VALV
32. susceptible to pilot rectification issues Please notify dealer of revision module that you have Problem Pilot lights stops sparking and pilot remains lit Burner will not light Reference prior troubleshooting steps Faulty Module Faulty Valve 2 Loose or improper wiring Specifically the green wire Note It is possible that the green wire is shorted to valve ground intellfcire J Halverson 12 1 2011 Hearth amp Home Technologies Page20 Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system Measuring Pilot Rectification Current Notes It is possible to determine if the system is meeting the rectification threshold that is generated by the pilot assembly If the rectification threshold there a number of possible reasons Please follow the steps to determine if there is a rectification issue You will need a Multimeter that is capable of measuring uA DC with a resolution of 0 01 WA All de sign and validation work at HHT is performed with the Fluke 189 multimeter or equivalent A Fluke 189 multimeter is highly recommended A low grade multimeter will not work to test flame sense due to the level of sensitivity of measurement The rectification or sense current occurs as direct DC current Some 8K 1 control modules will not accept a multimeter in series with the flame sense circuit Turning the unit to ON mode with the meter in series will cause the 8K 1 to detec
33. t an unsafe condition and go into lockout mode Following this procedure will prevent this occurrence Procedure 1 Disconnect the green wire from the valve This will cause the system to operating the pilot inde pendent of the main burner The is important to fully evaluate the pilot rectification 2 Disconnect white pilot sense lead from the control module Connect the wire terminal to the black negative lead on the multimeter 3 Prepare the red positive lead of the multimeter so it can be quickly connected to the male sense terminal on the control module An alligator clip is required for this connection 4 Turn unit ON preferably with the selector switch on the module for optimal control 5 Immediately connect the red positive lead from the multimeter to the sense spade terminal on the control module intellifire J Halverson 12 1 2011 Hearth amp Home Technologies Page21 6 Immediately turn the multimeter ON and to uA DC When using a Fluke 189 immediately press the MIN MAX button three times so the meter will display the rolling average sense cur rent Monitoring the average value will help cancel out the variation in the actual sense cur rent flow The average value is similar to what the control module software recognizes HOLD MNMAX RELA Hz ms RANGE 0 a mv de d V Record the uA average value vs time For pA Average example record the value at 10 sec in tervals from immediate pilot
34. tch installed and ON Remote control batteries are good Power to junction box and valve firebox control module connected to earth ground Power to Ignition module Module switch is in the Remote position No wires are compromised and all connections secure and made Wire harness from module to valve Wire harness from Aux to module Pilot wires to proper module terminals and S Green and orange leads from module harness to valve Ground wire secure e Documentation Serial number Problem and resolution and how determined Parts kept for return to dealer with paper work intelifcire J Halverson 12 1 2011 Hearth amp Home Technologies Page12 IntelliFire Plus Troubleshooting Problem Pilot wont light no noise and no spark Notice Disconnect power to the system prior to disconnecting any components by switch Possible reasons ing the ON OFF REMOTE module switch 1 Control Module selector switch NOT set properly to the OFF position 2 Loose or improper wiring System not grounded EEA E EAE E 3 No power to or from junction box tion control module with disconnected wire 4 No power from 6Volt DC transformer connections A disconnection of the igni f i tion lead can cause a short and permanent 5 Wired wall switch not wired properly control module damage 6 LP NG switch on module damaged or not fully en Introducing the pilot sensor rod with a false flame such as from a flame stick will Co
35. turning switch from OFF to ON Insert red probe inside cord j BY DG SUPPLY Touch black penesutaron probe to outside n of power supply ci T E f f _ if Testing 6 Volts DC With transformer plugged into junction box pull from transformer transformer power supply cord from module The DC regulator converts 220 240 volts AC to 6 volts DC Check to assure that your electrical meter is set to measure DC If you get a minimum of 6 volts DC from adapter the adapter is good Troubleshooting assumes the wireless controls amp battery backup have been eliminated from the system Intellffiro J Halverson 12 1 2011 Hearth amp Home Technologies Pagel4 Problem Scenarios 1 continued Problem Pilot wont light no noise and no spark 5 Wired wall switch not wired properly 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 position Red and Brown wire connect to wall switch Diagram to the right reviews proper switch opera tion when wired wall switch and wireless controls are both installed NOTICE In the instance where the fireplace is off because it has been set with the RC300 to operate in thermostat mode and the fireplace is turned on with the wall switch the fireplace will turn on How ever when the remote attempts to signal a com mand
36. y that pilot leads are correctly terminated to the control module and that no shorted wires exist 3 Verify that the pilot sense rod igniter rod and hood are clean After error code displays module will go into lockout odule Must watch light during service to view error code Error Code is not constant It must be caught immediately or dupli cated by testing the appliance and watching the module for the in stant error code intellfcire J Halverson 12 1 2011 Hearth amp Home Technologies Page24 System Checklist Visual Inspection IntelliFire Plus Troubleshooting Proper Readings Reference Info ltems to be checked a k d Visual Inspe 1 Proper Installation Condition a Vent System b Gas Supply Components c Proper Clearances e Glass Assembly Does the installation meet venting requirements for rise to run ratio vent cap type vent cap location venting size Gas line sizing and components must meet ANSI Z223 1 and local codes requirements Supply pipe must be 12 minimum Note all appliances supplied inline with fireplace Locate all shut off valves What position are they in Does the installation maintain proper clearances to walls amp ceiling combustible mantels amp surrounds household goods and furniture Is the glass clean free of soot properly retained with all appropriate fasteners gasket pliable and free of damage Are the logs ap
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