Troubleshooting Guide - A
Contents
1. ine HEARTH amp HOME Troubleshooting Guide For Authorized Gas Technicians Use Only Table of Contents Introduction Tools and Instruments Component Parts Basics Problem The ignitor makes Noise but No Spark Problem Pilot won t Light No Noise or Spark Problem Pilot Lights but Continues to Spark Problem Pilot sparks but Pilot wil not light Problem Pilot lights stops sparking rectification has occurred and remains lit but burner will not turn on Problem Burner Lights but Burner will Cycle Off and On FAQ Wall Switch Installation FAQ Cabin Kit and Cold Climate Features FAQ Ground Strap FAQ Gas Fuel Conversions Inlet and Manifold Pressure Specifications Conversion Components Basic IPI Wiring Diagram Wiring With CABIN KIT Wiring with power exhaust B Vent Not For PVK 80 IPI Wiring with PVK 80 10 12 13 18 16 17 19 21 23 24 25 Intelig Introduction The Intellifre system Intermittent Pilot Ignition is an electronic system which uses an electrode to ignite the pilot gas In turn the pilot flame lights the main burner gas The term intermittent is used because the pilot burner flame is only present when the main bumer is operating If Cabin Kit Kit is installed the pilot can remain with out the burner When the main burner is off the pilot is also off The Intellfire system ensures the2. Pilot lights and stops sparking and pilot remains lit but burner will not turn on Continued Solution 4 Conduct the following test to verify if the problem is the Module or Valve Valve solenoid Multimeter To measure voltages turn multimeter to place the red lead from the multimeter on the solenoid spade terminal you are checking and touch the black lead to ground valve body See Figure 1 Importantly a Zero volts readings does not automatically indicate a bad module there may be too little resistance in the valve solenoid Check Green wire disconnected from the valve the voltage output of a module should be between 2 and 3 Volts See Ohms Readings below AC Voltage Readings When using the AC adapter transformer with the On Off switch On the orange wire that runs from the module to the pilot solenoid on the gas valve uses 0 98 volts to open the pilot solenoid pilot is stil sparking Upon proof of pilot flame rectification on the sensor probe on the pilot assembly pilot is and is not sparking the orange wire voltage will drop to 0 46 volts and the green wire from the module to the regulator solenoid is a minimum of 1 09 volts during main burner operation DC Voltage Readings Batteries Actual voltages will vary depending upon battery voltage When using DC battery pack with the On Off switch the orange wire from the module to the pilot solenoid on the gas valve Uses 1 05 volts to
3. Cabin Kit The Cabin Kit cannot be used in conjunction with the WSK MLT The WSK MLT has some of the shared features of the Cabin Kit The Cabin Kit consists of a cold climate control switch and an automatic relay The Cabin Kit is also an available option for non power draft assisted Intellifire IPI units The Geld Climate feature enables tne pilot to remain even when the main burner is Off In colder climates the pilot light may lessen cold surface transfer through the glass when the fireplace is not in use It may also reduce the amount of condensation that may appear on the glass and may help the main burner of the fireplace light more easily on those extra cold Minnesota type winter mornings As we all know one of the best features of the Intellifire system is the standard battery backup which enables homeowner to use their fireplace in the event of a power outage with one catch the batteries are to be installed only when a power outage occurs This is due to the fact that when both the AC transformer and the DC battery backup are used in conjunction with each other the Intellifire system will always use the DC voltage from the batteries first before the AC voltage from the transformer Thus the batteries will drain even with 120 Volts AC available CABIN KIT eliminates the need to worry about installing batteries during a power outage It fas a relay wil automatically sense a power outage no 120 no A
4. Drop cloth tarp Glass cleaneritowels Vacuum Grate from wood burning fireplace to set hot logs on ALL TOOLS AND TEST EQUIPMENT SHOULD BE PROPERLY STORED AND MAINTAINED INTELLIFIRE Component Parts Valves Variable 705 500 NG 705 501 LP Non Variable 593 500 NG 593 501 LP Module Transformer 593 592 593 593A Wire Harness Battery 593 5940 593 590 INTELLIFIRE Component Parts Continued Pilot Assemblies 385 510A NG 11A LP 593 510A NG 11ALP 4021 025 NG 26 LP Shown wo mounting tracket TOW Site no ge used zten wi Grand Strap Main Burner Solenoids Regulators NGICDXF ng or LPK DXF FIXED NON ADJUSTABLE SOLENOID NGK DXV ng or LPK DXV Ip ADJUSTABLE REGULATOR SOLENOID Intermittent Pilot Basics A reliable multimeter is required to properly troubleshoot this system When troubleshooting an Intellifire system it is important to distinguish it from a standing pilot system A standing pilot system is a thermal system heat is used to generate Millivalts within the thermocouple and thermopile to open and close the gas valve However the Intellifire system is not a thermal system The intellifire system should be treated as an electrical circuit When the fireplace is turned ON the pilot lights and a rectified current passes through the pilot bumer flame to the sensor rod and th
5. Replace necessary component recommend in Solution 4 on Page 14 Ground srap not Problem Pilot lights stops sparking and pilot remains but burner will not turn on If the pilot lights and stops sparking but the burner doesn t engage the problems may be 1 Wiring Connection 2 Wiring hamess 3 Cabin Kit installed incorrectly 4 Module or Valve Valve regulator Solution 1 Inspect all the wires ensure good tight connections Verify that all wiring is installed exactly as specified in the installation manual s wiring diagram If you don t have the installation manual refer to a generic wiring diagrams included in the back of this trouble shooting guide Verify that the green male spade on the valve see picture below is not bent it should not touch the metal valve This green connection is insulated from the valve by the green mounting plate Solution 2 Inspect the wiring harness and verify that the harness is tightly connected to the module Verify that you have 7 wires and they are in the correct order See Picture Figure Below Solution 2 Solution 1 Black Ground Orange Plot valve Green Main Bumer valve pn Brown Switch fed Positive battery Black Negative battery Wiring Harness Solution 3 Verify installation of the Cabin Kit make sure the cold climate switch is wired correctly Refer to Cabin Kit Wiring on Page 23 Problem
6. is turned to OFF 6 Never use component that is not in a conversion kit Specifically never use material RTV or silicone sealant on the regulator portion of the gas valve 7 Upon completion of a gas conversion verify all connections are leak free with a soapy water solution or a NGILP gas detector This should be done before and after an initial fire up of a fireplace o RON When performing a gas conversion never install a damaged Regulator or Valve If a Valve or Regulator is dropped ora technician suspect s damage or unauthorized modification to a valve component may have occurred do not install that component Please contact Heat N Glo technical Service Heal N Glo Tech we will issue an RMA Relurn Merchandise Authorization to have that Valve or Regulator retumed the Heat N Glo for inspection When the RMA is returned to Heat N Glo the distribulor s account will be credited the distributor purchase price 19 Illas Inlet and Manifold Pressure Specifications INTELLIFIRE Inlet Gas Pressure Check Inlet Gas Pressure Requirements NG LP Captive Slotted Screws Will Not Come Out of Towers INTELLIFIRE Manifold Gas Pressure Check Manifold or Output Gas Pressure Requirements NG 358 WC Be Sure to Tighten After Testing to Prevent Gas Leaks at Towers our E Intellifire Conversion Components and Required Tools Conversion Kit will contain EET Conversi
7. open the pilot solenoid pilot is stil sparking Upon proof of pilot flame rectification on the sensor probe the pilot assembly pilot is and is not sparking the orange wire voltage drop to 0 49 volts and the green wire from the module to the regulator solenoid is a minimum of 1 17 volts during main burner operation Ohms Readings With no wires attached to the valve typical Ohms readings on a functioning valve are Pilot solenoid is 37 Ohms Bumer Solenoid is 55 Ohms These Ohms readings will vary upon temperature ja Ne Problem Burner Lights but Burner will Cycle Off and Oi The problem may be attributed to Over drafling or Over frring gas pressure too high Poor flame rectification Remote Wall switch or Thermostat Low batteries or bad transformer Cold Climate Start up Solution 1 Refer to the installation manual and verify if an exhaust restrictor is required Ifthe installation manual suggests a restrictor plate for given installation verify that the restrictor plate has been properly installed Verify the burner orifice size to the orifice listed on the rating plate Ifthe fireplace is installed over 2 000 feet above Sea Level verify that the fireplace has been de raled accordingly Check the manifold pressure to ensure the fireplace is at 3 5 W C on high for NG and 10 W C on high for LP Proper manifold settings and orifice sizes are critical the more fuel put into a fireplace mea
8. pilot flame extends over the burner for immediate ignition and secondly conserves energy when the appliance is not in operation Service Experience This troubleshooting guide is for use by QUALIFIED SERVICE TECHNICIAN ONLY Itis designed to help QUALIFIED SERVICE TECHNICIANS troubleshoot gas appliances This troubleshooting guide is not to be used by the appliance owner builders who are familiar with gas appliances WARNING Do not attempt to service gas appliances which you are not qualified to service Service attempted by UNQUALIFIED PERSONS could result in the risk of bodily injury and property damage Obligations of Service Professionals Service technicians must be attentive to appropriate codes understand and follow the manufacturer s installation and service instructions and use the proper parts and materials when servicing or installing gas appliances One of the mast important tools you can bring to a service call is the installation manual for wiring diagrams venting applications clearances to combustibles and part reference If you do not have of the installation instructions before you go on a Service call check with the customer to see if they have the original copy which was left with the appliance Note Remember that unit designs and corresponding installation manuals change occasionally Be sure you are referencing the current manual for the serial and model you are working C
9. C votage from transformer and will automatically flip over to the DC vollage from the battery backup With the CABIN KIT batteries can remain in the backup harness without the worries of having premature battery drain Wiring Diagram Page 23 Cold Climate Switch Relay Switch for Battery Pack FAQs Ground Strap Intellifire cycling fireplace at startup recent reliability testing we have found a small percentage of Intellifire systems cycling as if the burner is being turned on and intermittently This is caused by occasional pilot instability during startup Although the occurrences of this problem are seldom our engineers have developed a grounding strap 385 512 to greatly improve the rectification of the Intellifire system In the near future this ground strap will become a component of every Intellifire system If you would like more information regarding the Intellfire system or lo order the ground strap 385 512 please contact Heat N Glo Technical Service Model and serial number is required for all no charge orders Sensor Ground strap is screwed into a vertically mounted Intellifire pilot assembly CMe FAQs Gas Fuel Type Conversions Intellifire IPI Conversion Instructions As with other gas ignition systems such as DSI and Standing Pilot IPI systems are field convertible provided the appropriate conversion kit is being used Although
10. en the module will engage the main burner A glowing red sensor rod does not indicate that the system is working properly Always verify that the sensor wire is not shorted to ground fireplace chassis or pilot bracket and is continuous from the sensor terminal on the module to the sensor rod by means of a multimeter set on ohms The intellifire system operates on an external power source 120 VAC hard wired to the junction box where the 120VAC is stepped down to 3 volt transformer which delivers 3 volts AC to the Module The 3VAC is converted by the module to DC power 120 VAC is not to be connected to the module valve or ignition system at any time OR Two D 1 5 Volt batteries When both the batteries and the transformer are installed the Intelifire system will use the battery power before the 3VAC transformer unless Cabin Kit is installed Other operational features The Pilot will spark for 60 seconds If rectification has not occurred within the 60 seconds the system will lock aut To reset wait 5 minutes for gas to dissipate and then turn the main switch and then back Orr The main burner should never engage when the pilot is sparking When the fireplace is turned off both the pilot light and the main burner will shut down Note If Cabin Kit or DBK Kit is installed the pilot will remain Flame Rectification Flame is a conductor of electricity and will preferentially carry an elect
11. he ceramic insulator around the sensor rod is not crack damaged or loose Verify the connection from the sensor rod lo the white sensor wire Clean the sensor rod with an emery cloth to remove any containment that may have accumulated on the sensor Verify continuity with a multimeter with ohms set at lowest range See following page for instructions Problem Pilot Lights but Continues to Spark and Main Burner will Ignite Continued Note There different models of pilot assembly The Sensor Rod and ignitor locations may vary ert or Continuity Test Verify that the sensor wire white wire is not shorting out to the pilot bracket or another metal area of the fireplace 1 Set Multimeter to Ohm 2 Place one lead on the sensor rod Make sure sensor or the lead from your multimeter does not touch the ground strap or another metal part of the pilot assembly 3 Place the other lead on the pilot hood pilot base or pilot bracket Make sure this lead has a good connection to ground paint may insulate and cause a false reading 4 Some multimeters may have an audible beep to indicate continuity The multimeter pictured above does not have an audible beep so we read the LED display The reading of 1 is an infinite number which indicates no continuity exists between the pilot hood and the sensor rod Any other reading other than 1 such as 078 depend
12. ights but Continues to Spark Main Burner will not Ignite If the pilot continues to spark after the pilot flame has been Iit lame rectification has not occurred The problem may be shorted or loose connection in the sensor rod Poor flame rectification or contaminated sensor rod see ground strap on page 18 Module is not grounded Damaged pilot assembly or dirty sensor rod Module arona Solution 1 Solution 1 Verify all connections to wiring diagram in manual Verify the connections underneath the pilot assembly are tight also verify these connections are not grounding out to the metal chassis pilot burner pilot enclosure or screen if present or any other metal object Solution 2 Verify that the flame is engulfing the sensor rod If the pilot assembly does not have a ground strap you may want to consider installing one This will increase the flame rectification Verify correct pilot orifice is installed and inlet gas specifications to page 10 Remember the flame carries the rectification current not the gas If the flame from the pilot hood the circuit is broken A wrong orifice or too high of an inlet pressure can cause the pilot flame to lit The sensor rod may be contaminated Clean the sensor rod with an emery cloth Solution 3 Verify that that module is securely grounded to the metal chassis of the fireplace Verify that the wire hamess is firmly connected to the module Solution 4 Verify that t
13. ing on the ohms setting would indicate continuity There should not be any continuity between the sensor rod and the pilot hood pilot base or pilot bracket If continuity is present this would indicate that there is short At some point the sensor wire is shorted out to an area of the metal chassis of the fireplace A simple continuity test can be used to verily the integrity of a single wire or any wiring connection When a wire connection is insulated with a rubber boot a continuity test is the only way to verify the connection because one can t visually see the bad connection refer to above picture Insulated connections are very common on the Intellifire system these connections need to be verified when troubleshooting Solution 45 The final solution is to replace the module nellie Problem Pilot sparks but Pilot will not light The problem may be 1 Gas supply 2 Spark gap 3 Module is not grounded 4 Module voltage output Valve Pilot solenoid ohms readings Solution 1 Verify that the incoming gas line ball valve is open Verify that the inlet pressure reading is within acceptable limits inlet pressure must not exceed 14 W C See Page 20 Solution 2 Verify that the spark gap form the ignitor to the pilot hood is 17 or 1 8 Solution 3 Verify module is securely grounded to the metal chassis of the fireplace Solution 4 See Solution 4 on Page 14 Test the orange wire while pilot is sparking
14. it is possible to convert a unit without a conversion Kit by simply ordering the necessary orifices burner regulator or logs if required only authorized Heat N Glo conversions kits are approved The conversion kit will not only ensure that all necessary correct components are being replaced to convert to another fuel type but the kit will also include detailed instructions and conversion labels to certify the gas conversion to local building code To convert a fireplace without the Heat N Glo conversion kit will void the fireplace warranty Furthermore only certified gas technicians are permitted to perform a conversion Conversions are not to be completed by a non gas certified homeowner or service person Tips for converting a Fireplace 1 Refer to the installation guide or Gas Matrix to get the correct conversion kit part number Serial Number is often required Use only the Heat N Glo conversion kit specifically designed for each fireplace Do nat combine conversion kits Read the instructions carefully all conversions require the diaphragm or regulator gasket must be replaced Verify both inlet and manifold gas pressures refer to conversion instructions for proper manifold pressure Upon completion of a conversion for IPI systems verify that both the pilot burner and main burner shut off when power is removed to the module For Standing pilot systems verify that the pilot burner and main burner shut off when the pilot knob
15. limates a pilot light may lessen cold surface transfer through the glass when the fireplace is not in use it may also reduce the amount of condensation that may appear on the glass Additionally pilot light may help the main burner of the fireplace light more easily on those extra cold Minnesota type winter mornings more more detailed of the Cabin Kit turn to page 17 FAQs Wall Switch Installation Intellifire Installation much too frequent installation error occurs when an electrician has wired an ON OFF switch such as a wall switch before the junction box of the fireplace The theory behind this is that the ON OFF rocker switch on the valve plate shall always remain in the ON position and controlling the 120 Volt supply to the junction box via the wall switch would control the burner flame This is incorrect an Intellifire system will not work properly with this type of wall switch wiring It is designed to operate on a constant supply of 3 AC 3 volt transformer or 3 Volt battery backup The wall switch can then be used in conjunction with the Wall Switch Remote Control leads coming off the back of the fireplaces ON OFF rocker switch Wat site To 120 Volt Supply YES Incorrect Wal Switch o Correct Val Switch wring FAQs Cabin Kit Cold ClimatelCabin Kit A new feature of the 6000TRXI IPI is that it now comes standard with the
16. ns more oxygen is required for proper combustion An over drafting or over fring fireplace can translate into an increase in air turbulence inside the firebox that cause the pilot flame to blow out or pull away from the sensor rod resulting in a cycling effect Solution 2 Whenever the pilot is sparking there is no flame rectification and when there is no flame rectification the main burner should never light The problem could be a result of over drafting pulling the pilot flame off the sensor Oxygen starvation pilot flame shrinks due to blockage in venting gas supply problems or improperly installed venting Verify all wiring connections Verify that the module is grounded Verify that the sensor rodiwire is grounding out to the pilot bracket or any piece of the metal fireplace chassis A short in a wire may have appeared after the fireplace had been operating for a given period Solution 3 Bypass the any optional accessories that are being used to turn the fireplace On and Troubleshoot the system with the manual On Off rocker switch bad wall switch thermostat or remote may be the root cause of the problem Solution 4 Verify output under load of the transformer See Solution 1 Page 9 If batteries are being used verify output of the battery pack is at least 2 6 volts DC Solution 5 Cold Climate feature enables the pilot flame to remain even when the main burner flame 8 In colder c
17. ommunicating with the CustomerlPrevious Service Asking the customer a few simple questions can help you service the appliance in a careful and safe manner Has the fireplace ever been serviced Who and When Have you tried to operate the appliance before arrived How long ago What are the symptoms when does the problem occur How long has the appliance been installed in your home Technical Assistance Tools and Instruments To properly adjust service or troubleshoot gas appliances the service technician must have the proper tools and test equipment Required Tool wrenches 3 87 The 9 16 Adjustable end wrenches 8 and 10 1 4 5 16 inch nut driver Straight screwdrivers including small 1 8 blade for pressure check also stubby Straight Phillips screwdrivers 1 and 2 stubby Phillips 3 16 hex key or set T handle needed in some cases Electrical pliers Needle Nose Pliers Pipe wrenches 8 m Tin snips Flashlight Numbered drill index Tubing cutter 20 tamper resistant Torx bit HHT Part 810 225 Flaring tool Softbristled Tooth brush Soft 1 paint brush Electric drill 1747 3187 Required Testing Equipment Mult meter must measure millivolts Manometer LP or NG Gas sniffer or leak detection fluid 2104 12 47 jumper wires Flame Stick lighter wand Miscellaneous Pipe joint compound Smoke match
18. on Components Required Tools TR 20 Tamper Torx HHT 810 225 Instructions Conversion Labels Burner Orifice s Styles may vary Pilot Orifice Styles may vary Regulator Solenoid New Gasket Bumer if required Manometer or Magnehelic Leak Detection Fluid OR LP or NG Gas Detector Melie Basic IPI Wiring Diagram teemonwoouus nor SV TRANSFOR nm WA f rem Dem UE E mellig IPI Wiring with power exhaust B Vent PVK 80 d 527 E mei a em pes Wiring with PVK 80 NOTES
19. ric current from the sensor rod through the flame to ground in only one direction SENSOR Flame Rectification Problem Ignitor Module makes Noise but No Spark The problem may be 1 Wiring 2 Loose connection 3 Ignitor Gap 4 Module Solution 1 Verify that the S wire white for the sensor and the 7 wire orange wire for the ignitor are connected to the correct terminals on the module and on the pilot assembly If these wires were reversed at the module it may cause the system to make the noise of sparking but the spark not be present at the pilot hood Solution 2 Verify no loose connections or electrical shorts in the wiring from the module to the pilot assembly The rod closet to the pilot hood should be the ignitor Verify the connections underneath the pilot assembly are tight also verify these connections are not grounding out to the metal chassis pilot bumer pilot enclosure mesh screen if present or any other metal object See Continuity test on page 11 Solution 3 Verify gap of the igniter to the pilot hood The gap should be approximately 17 or 1 8 Solution 1 Solution 4 Verify Spark Module Spark Test Turn the On Off rocker switch or wall switch to the OIT position Remove the ignitor wire I from the module Place the ON OFF Rocker switch or wall switch in the On position Hold ground wire about 3 16 away from the terminal on the module If there is no
20. spark at the I terminal the module must be replaced If there is a spark at the I terminal the module is fine Next inspect the pilot assembly for a shorted sparker wire or cracked insulator around the electrode See Continuity Test on Page 11 Problem Pilot won t Light No Noise or Spark The problem may be Transformer A shorted or loose connection in the wiring configuration or wiring harness Improper wall switch wiring Module is not grounded Faulty module Solution 1 Verify that the transformer is installed and plugged into the module Check voltage of transformer under load at the spade connection on the module with the ON OFF switch in the position Acceptable readings of a good transformer are between 3 2 and 2 8 volts AC Red Lead from Multimeter Black Lead fram Multimeter Solution 1 Solution 2 Remove and reinstall the wring harness that plugs into the module Verify that there is a tight fit Verify the pilot assembly wiring to the module Remove and verify the continuity of each wire in the wiring harness See Continuity Test on Page 11 Solution 3 See FAQs Wall Switch on page 16 Troubleshoot the system with the simplest On Off switch Solution 4 Verify the black ground wire from the module wire harness is grounded to the metal chassis of the fireplace Solution 5 Solution 84 on page 8 If spark replace module Problem Pilot L
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