Gas Appliance Troubleshooting Guide

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Gas Appliance Troubleshooting Guide
TRAVIS INDUSTRIES TRAINING
YOUR SUCCESS IS OUR BUSINESS
Gas
Appliance
Troubleshooting
Guide
Copyright © 2008
Travis Industries, Inc.
Required & Recommended
Diagnostic Tools
Diagnostic Equipment
MUST HAVE
IMPORTANT TO HAVE
Digital Air
Pressure Gauge
Multimeter
Gas
Pressure
Gauge
CO Analyzer
Thermocouple
Adaptor
Gas Leak Dectector
Copyright © 4/20/2006
1
Travis Industries, Inc.
Diagnostic Equipment
NICE TO HAVE
Multimeter
Temperature
Adaptor
Test Cord
Volt Stick
Laser Targeted
Thermometer
Outlet
Analyzer
Test Wires
Laser Center Locator
Copyright © 4/20/2006
2
Travis Industries, Inc.
Gas Leaks
!'Gas~
I
I
I
lIII'
..
•
__
•
Checking For Gas Leaks
1. Turn on leak detector
2. Adjust to most sensitive setting
3. Check incoming gas connections
4. Light pilot
5. Check gas valve and pilot tubing connections
6. Turn on burner
7. Check gas valve and burner tubing connections
IMPORTANT!
As a professional, you must ensure all gas
connections are free of any gas leaks
Copyright © 4/20/2006
1
Travis Industries, Inc.
SIT Gas Control Valve
Gas Control Knob
Adjustable
Regulator
(Flame Adjustments)
Pilot Gas
Adjustment
Screw
Switch
Terminal
Thermopile
Terminal
Inward Gas
Port
Switch &
Thermopile
Terminal
IN
OUT
Outward Gas
Port
Thermocouple
Socket
Pilot Gas
Outlet
Gas Inlet
Gas Flow
Indicator
Burner Gas Outlet
SIT Gas Control Valve
Troubleshooting Flow Chart
Page A - C
SIT Gas Control Testing Diagram
Page D
SIT Gas Control
Page E
Purging Air
Page 1
Pilot Adjustment
Page 2
Measuring Incoming Gas Pressure
Page 3
Thermocouple Testing
Page 4 - 5
EPU Testing
Page 6
Thermopile Testing (Voltage Test 1)
Page 7
Operator Head Test (Voltage Test 2)
Page 8
Operator Head Continuity Test
Page 9
Thermostat Circuit Test (Voltage Test 3)
Page 10
Thermostat/Switch Circuit Continuity Test
Page 11
Measuring Outgoing Gas Pressure
Page 12
SIT
Gas Troubleshooting Flow Chart
Push The Piezo Igniter
Spark is
seen at
Pilot Hood
• Check wire connections on the end of piezo
¥ igniter
NO
• Check the electrode positioning - adjust as
¥ necessary
• Check for pinched or broken ignition wire
¥ (as it comes through floor)
• Check for a broken spark electrode base
¥ (porcelain)
YES
• Replace piezo igniter
Turn gas control knob to
pilot, push in and push
piezo igniter
• Realign control knob-push in and try again
• With gas off - Hold a flame wand at
¥ Pilot Hood - Push in Pilot Control Knob
Flame Bends Away - Air in lines
- Purge air through inlet pressure port
(see page 1)
Pilot Lights
NO
Flame Does Not Bend Away No Gas Flow
- Check if Pilot Adjustment Screw is closed
- Check for closed gas shut off(s)
- Verify gas inlet supply
(see page 1& 3)
YES
• Check pilot orifice for blockage
• Check pilot tube for blockage
• Replace valve
Copyright ' 4/20/2006
A
Travis Industries, Inc.
PILOT
FLAME
CORRECT
• Adjust pilot gas (see page 2 of testing section)
NO
• Check Pilot Orifice
- Size
- Partial Blockage
• Check incoming pressure (see page 3)
YES
• Re-light and hold Control Knob in for 30 seconds
Release
Control Knob
Pilot Stays
Lit
NO
• Check thermocouple voltage production (see
pages 4 to 5)
• Check EPU of gas control valve (see page 6)
YES
• Is the control knob turned to ON?
• Check - Is there a wall thermostat and is it calling
Turn Gas
Control Knob ON
Turn Unit Switch ON
Burner Comes
ON
¥ for heat?
• Is the wiring proper?
NO
• Conduct thermopile voltage test #1 (see page 7)
• Conduct valve operator head voltage test #2 (see ¥
¥ page 8)
• Conduct thermostat/switch circuit voltage test #3 ¥
¥ (see page 10)
YES
Burner
Comes
On
Copyright ' 10/6/2003
BLOCKAGE
NO
B
• Check out going pressure
(see page 12)
Travis Industries, Inc.
• Check regulator to to make sure it is appropriate
¥ for type of fuel
Proper
Burner
Flame
• Check proper orifice size
NO
• Check incoming pressure (see page 3)
• Check outgoing pressure (see page 12)
• Check for partial blockage of burner
• Replace gas control valve (bad diaphragm)
YES
END
Copyright ' 10/6/2003
C
Travis Industries, Inc.
Copyright ' 10/6/2003
D
Travis Industries, Inc.
6
3
6
1
5
Continuity
Continuity
5 - 4
Disconnect 6 - 6
and Test Wire
SWITCH CIRCUIT
CONTINUITY
Minimum 6 MV
11
6
4-5
10
145 MV or Greater-But Not Equal To
1 - 1
EPU
3 - 3
THERMOSTAT
CIRCUIT
8
Minimum 225 MV - But Not Equal
or Greater than Test 1 - 1
4 - 4
2 - 2
INTERNAL VALVE
REFERENCE
PAGE
7
READINGS
300 MV or Greater
Pilot Hood
Spark Electrode
Orange
Piezo Igniter
THERMOCOUPLE
1 - 1
3
THERMOPILE
2
4a
Thermopile
TEST LEAD
PLACEMENT
1
White
Red
Copper Co-Axial
Wire
*
Thermocouple
TESTING
4
Optional Remote
Control
Brown
2
On/Off Switch
Jumper Wire
Adaptor
* Thermocouple
Red
Optional
Thermostat
Wiring Diagram
Testing Direct Vents Using A SIT Gas Control
SIT Gas Control Valve
• Millivolt gas valve
• Used on newer Travis
¥ gas appliances
• Not used with any older
¥ B-Vented appliances
• Is modulating remote
¥ compatible
• Contains a pilot side and
¥ burner side operation
• Operation head coil resistance
2.25 OHMS
+ .5 OHMS
• EPU coil resistance
.018 OHMS
+ .003
Copyright ' 10/6/2003
E
Travis Industries, Inc.
Pilot
Does Not
Light
Purging Air From
Gas Supply Lines
SIT Gas Control Valve
• Loosen inward pressure tap 2-3 turns
• Leave open until air is purged
• Tighten pressure tap
• Loosen pressure tap 2-3 turns
(No cover cap)
Copyright ' 10/6/2003
1
Travis Industries, Inc.
Pilot
Flame Size
Is Not
Correct
SIT Pilot Flame
Adjustment
• No cover cap screw (Uses Double O Ring)
• Turn Adjustment Screw
SMALLER
FLAME
LARGER
FLAME
• Pilot Flame Should Be A Soft Blue Flame With
¥ Good Themocouple/Thermopile Engagement
To adjust the pilot flame, turn this screw
clockwise to lower the flame/counterclockwise to raise the flame.
Standard
Screwdriver
The pilot flame must contact
the thermocouple and
thermopile. Adjust the pilot
flame up or down as
necessary.
Copyright ' 10/6/2003
2
Travis Industries, Inc.
Burner
Does Not
Have Proper
Flame
Measuring Incoming
Gas Pressure
Gas Inlet Pressure
- Test Port
Pilot
Flame Not
Correct
Gas Outlet
Pressure
- Test Port
SIT Control Valve
Digital Pressure Gauge
1) Zero out digital pressure gauge
2) Loosen input pressure tap (about two or three turns)
3) Slip pressure hose over the inlet port
4) Light the pilot
5) Turn control knob to ON
6) Turn ON the main burner (high)
7) Read pressure (see chart)
NG
Then
Min. Input
Pressure
7 W.C.
8) Turn OFF burner
9) Turn control knob to OFF
10) Remove pressure hose
11) Tighten pressure port screw
Copyright ' 10/6/2003
LP
11
W.C.
With Main Burner ON
3
Travis Industries, Inc.
Pilot
Does Not
Stay
Lit
Testing
Thermocouple
Voltage On A SIT or RobertShaw Gas
Control Valve
Testing MV Production
SIT Gas Control
Minimum 6 MV
Screw
thermocouple
into the gas
control valve
Thermocouple
Adaptor MUST
BE USED
Copyright ' 10/6/2003
4
Travis Industries, Inc.
Pilot
Does Not
Stay
Lit
Testing
Thermocouple
Voltage On A SIT Gas Control
Minimum 6 MV
To Valve Body
To Solder
Joint
Brown Wire
Delivering TC
Voltage to the EPU
Copyright ' 10/6/2003
Back of SIT Gas
Control
5
EPU
Electromagnetic
Power Unit
Travis Industries, Inc.
Pilot
Does Not
Stay
Lit
Testing Pilot Coil (EPU)
for Continuity
1. Socket Center to any ground
point*
SIT
Control
Valve
or
2. Ground to solder joint on the
bottom of the valve**- Disconnect
Thermocouple from valve
1. EPU Coil
Continuity
Test*
* Make sure your test lead does
not touch the side of the socket
2. EPU Coil
Continuity
Test*
** Disconnect
Thermocouple
From Unit
To Valve
Body
To Solder
Joint
Back of SIT Gas Control
Copyright ' 10/6/2003
6
Travis Industries, Inc.
Burner
Does Not
Light
Voltage Testing
Thermopile Test 1
Control Knob In Pilot Position
1. Pilot Lit for
1. Approximately
1. 3 Minutes
2. Disconnect All
2. Wires EXCEPT 2.
2. the Thermopile
2. Wires
300 or More MV
If Not, Adjust Pilot
or Replace
Thermopile
Thermopile
Wires
Copyright ' 10/6/2003
DCV
7
Travis Industries, Inc.
Burner
Does Not
Light
Voltage Testing
Operator Head Test 2
Control Knob In Pilot Position
Place Jumper
Wire
225* MV or Greater
* NOTE: Voltage should not
be equal to or greater than
the voltage in Test # 1
If it is, you have an open
(defective) Operator Head and
the Valve needs replacing
DCV
Thermopile
Wires
* If less than 225 MV, this indicates Operator Head
* has too much resistance - replace Gas Control Valve
(Conduct a resistance test on page 9)
Copyright ' 10/6/2003
8
Travis Industries, Inc.
Coil Operator Head Test
for Continuity
SIT
Control
Valve
• TP to
TH
Terminals
Head Coil
Continuity
Test
2.25 OHMS
+ .5 OHMS
NOTE: If the
voltage on Test
#2, page 8, is less
than 225 MV
AND the gas
control operating
head does not
meet the above
OHMS
specification, it
should be
replaced
Copyright ' 10/6/2003
9
Travis Industries, Inc.
Burner
Does Not
Light
Voltage Testing
Thermostat Circuit Test 3
Control Knob In Pilot Position
Remove Jumper Wire and
Connect Thermostat Circuit
Wires - Turn Burner Switch ON
145 MV or Larger
If = to or greater than Test
#1 there is a
switch circuit problem Conduct a continuity
test on the thermostat switch
circuit (see page 11)
Thermopile
Wires
Copyright ' 10/6/2003
DCV
10
Travis Industries, Inc.
Thermostat/Switch Circuit
Continuity Test
Burner
Does Not
Light
Remove
thermostat
switch
circuit
wires
Remove
thermostat
switch
circuit
wires
• Test continuity of the thermostat switch circuit
• Turn rocker switch to ON or make sure thermostat
¥ contacts are closed
• NO Continuity - Bad wires or defective thermostat/switch
Copyright ' 10/6/2003
11
Travis Industries, Inc.
Measuring Outgoing Gas
Pressure
Burner
Does Not
Light
Gas Inlet Pressure
- Test Port
Gas Outlet
Pressure Test Port
Digital Pressure Gauge
1) Loosen output pressure tap (about two
or three turns)
2) Zero out digital pressure gauge
3) Slip pressure hose over the outlet port
4) Light the pilot (knob on pilot)
5) Turn control knob to ON
SIT Control Valve
No
Outgoing Pressure
Replace Regulator
Body - Then if
Neccessary, Gas
Control Valve
Outgoing Pressure
But Still No Flame
• Check Burner Orifice
for Blockage
• Check Burner Supply
Tube
6) Turn ON the main burner (high)
7) Read pressure (see chart)
Output Pressures
Then
8) Turn OFF burner
9) Turn control knob to OFF
10) Remove pressure hose
11) Tighten pressure port screw
Copyright ' 10/6/2003
12
NG
1.8
LP
2.7
3.5
W.C.
11
W.C.
Travis Industries, Inc.
Gas Control Valve
RobertShaw
Millivolt Valve
Adjustable Regulator
Flame Height
Adjustment
Gas Outlet
(manifold)
Pressure
Test Port
Gas Control
Knob
Switch Terminal
Gas Outlet to
Manifold
(3/8” NPT)
LO
TP
TH
OUT
I
H
FF
O
IN
PI L OT
Pilot
Tube
TH
TP
O
N
VENT
Gas Inlet
(3/8” NPT)
IN
PILOT ADJ
Thermocouple
Port
Switch and
Thermopile
Terminal
Pilot
Thermocouple Adjustment
Port
Cover Screw
Gas Inlet
Pressure
Test Port
RobertShaw
Millivolt Valve
Troubleshooting Flow Chart
Page A - C
RobertShaw Gas Control Testing Diagram
Page D - E
RobertShaw Gas Control
Page F
Purging Air
Page 1
Pilot Adjustment
Page 2
Measuring Incoming Gas Pressure
Page 3
Thermocouple Testing
Page 4
EPU Testing
Page 5
Voltage Testing
Test 1 (Thermopile)
Test 2 (Operator Head)
Test 3 (Thermostat/Switch Circuit)
Page 6
Measuring Outgoing Gas Pressure
Page 7
Thermostat/Switch Circuit Continuity Test
Page 7
RobertShaw
Gas Troubleshooting Flow Chart
Push The Piezo Igniter
Spark is
seen at
Pilot Hood
• Check wire connections on the end of piezo
• igniter
NO
• Check the electrode positioning - adjust as
• necessary
• Check for pinched or broken ignition wire
• (as it comes through floor)
• Check for a broken spark electrode base
• (porcelain)
YES
• Replace piezo igniter
Turn gas control knob to
pilot, push in and push
piezo igniter
• Realign control knob-push in and try again
• With gas off - Hold a flame wand at
• Pilot Hood - Push in Pilot Control Knob
Flame Bends Away - Air in lines
- Purge air through inlet pressure port
(see page 1)
Pilot Lights
NO
Flame Does Not Bend Away No Gas Flow
- Check if Pilot Adjustment Screw is closed
- Check for closed gas shut off(s)
- Verify gas inlet supply
(see page 1)
YES
• Check pilot orifice for blockage
• Check pilot tube for blockage
• Replace valve
Copyright © 4/20/2006
A
Travis Industries, Inc.
PILOT
FLAME
CORRECT
• Adjust pilot gas (see page 2 of testing section)
NO
• Check Pilot Orifice
- Size
- Partial Blockage
• Check incoming pressure (see page
3 of Gas Testing Section)
YES
• Re-light and hold control knob in for 30 seconds
Release
Control Knob
Pilot Stays
Lit
NO
• Check thermocouple voltage production (see
page 4 of testing section)
• (B-Vent) Check spill switch circuit test: 4A-5,
4A-7, 4A-8 (B-Vent wiring diagram - Section E)
• Check EPU of gas control valve (see page 5 of
testing section)
YES
• Is the control knob turned to ON?
Turn Gas
Control Knob On
Turn Unit Switch ON
Burner Comes
On
• Check - Is there a wall thermostat and is it calling
• for heat?
• Is the wiring proper?
NO
• Conduct thermopile voltage test #1 (see page 6)
• Conduct valve operator head voltage test #2 (see •
• page 6)
• Conduct thermostat/switch circuit voltage test #3 •
• (see page 6)
YES
Burner
Comes
On
Copyright © 4/20/2006
BLOCKAGE
NO
B
• Check outgoing pressure
(see page 9)
Travis Industries, Inc.
• Check regulator to to make sure it is appropriate
• for type of fuel
Proper
Burner
Flame
• Check proper orifice size
NO
• Check incoming pressure (see page 3)
• Check outgoing pressure (see page 9)
• Check for partial blockage of burner
• Replace gas control valve (bad diaphragm)
YES
END
Copyright © 4/20/2006
C
Travis Industries, Inc.
Copyright © 4/20/2006
D
Travis Industries, Inc.
Brown
Optional
Thermostat
Jumper Wire
(Manual
Operation)
4
Optional
Remote
Control
Green
terminal
EPU
EPU
Terminal
5
*
Gas Control Valve
RobertShaw Valve
Wiring Diagram
6
3
2
2
3
SWITCH
CIRCUIT
EPU
1
Copper Co-Axial Wire
Disconnect 6 - 6
and Test Wire
5
4a
TEST LEAD
PLACEMENT
4a
6
4
Less than 80 MV - Pilot and
burner switch ON
Using a thermocouple adaptor 13 MV - minimum
Continuity
9
5
6
More than 100 MV - Pilot burner switch ON,
but not = to or greater than test 1 - 1
Continuity
6
REFERENCE
PAGE
250 MV - Pilot ON Only
READINGS
Thermocouple
Orange
Piezo Igniter
= Thermocouple Adaptor
White
Red
1
Thermopile
THERMOCOUPLE
THERMOSTAT
CIRCUIT
INTERNAL
VALVE
THERMOPILE
TESTING
On/Off
Switch
Red
6
Testing Direct Vents Using A RobertShaw Control
Copyright © 4/20/2006
E
Travis Industries, Inc.
5
8
EPU
Terminal
7
*
Interrupter Block
4
RobertShaw Valve
Wiring Diagram
6
1
SWITCH
CIRCUIT
EPU
13MV - Minimum
SPILL CIRCUIT
Continuity
Continuity
8
Disconnect 6 - 6
and Test Wires
13MV - Minimum
8
13MV - Minimum
4
13MV - Minimum
THERMOCOUPLE
7
6
Less than 80MV - Pilot and
burner switch ON
THERMOSTAT
CIRCUIT
9
5
E
E
E
6
More than 100MV - Pilot and burner switch
ON but not = to or greater than 1 - 1
INTERNAL VALVE
REFERENCE
PAGE
6
READINGS OR GREATER
4a
250 MV - Pilot ON only
TEST LEAD
PLACEMENT
Wires must be disconnected
to test switch circuit continuity
1
TESTING
6
3
2
2
THERMOPILE
3
Testing B-Vents Using A RobertShaw Gas Control
LO
TP
TH
OUT
FF
O
IN
I
H
TH
TP
O
N
VENT
RobertShaw Gas
Control Valve
PI L OT
IN
PILOT ADJ
• Millivolt gas valve
• Used on all older Travis gas appliances
• Used on some current Travis gas appliances
• All old Travis B-Vented appliances utilize this gas control
• Is not compatible with modulating remote
• Contains a pilot side and burner side operation
• Operation head coil resistance
1.5 - 1.7 OHMS
+ .5
• EPU coil resitance
.037 OHMS
+ .002
Copyright © 4/20/2006
F
Travis Industries, Inc.
Purging Air
From Gas Supply Lines
RobertShaw Gas Control Valve
• Remove pilot adjustment screw
Use 1/8” Quick
Wedge
Screwdriver
Needle Valve
Cover Screw Gasket
Cover Screw
The cover screw and
gasket must be
replaced to prevent
gas from leaking
Remove Pilot
Adjustment
Screw
1/4” Quick
Standard
Screwdriver Wedge Screwdriver
• Turn to "Pilot" and HOLD IN until all air is
• purged
• Replace pilot adjustment screw
- Gently turn it all the way closed
- Then back out 3 1/2 full turns
Copyright © 4/20/2006
1
Travis Industries, Inc.
Pilot Flame Adjustments
RobertShaw Gas Control Valve
ADJUSTING A PILOT
• Remove the protective cap screw
• Turn the pilot adjustment screw clockwise to reduce
• the pilot flame, counterclockwise to increase the
• pilot flame (do not turn all the way).
• Replace the protective cap screw and washer
• Note: The pilot flame should be a steady blue
• flame which has contact with the upper 3/8” of
the thermopile or thermocouple.
LO
TP
TH
OUT
FF
O
IN
I
H
TH
TP
O
N
VENT
SAFETY NOTE:
Keep face, body parts, clothing, etc. from being in
direct line of the pilot adjustment port
PI L OT
IN
PILOT ADJ
Pilot Adjustment Cover Cap
Copyright © 4/20/2006
2
Travis Industries, Inc.
Burner
Does Not
Have Proper
Flame
Measuring Incoming
Gas Pressure
1) Light the pilot (keep control knob on pilot)
Measuring Gas
Pressure
2) Loosen input pressure tap (about two or
three turns)
3) Zero out digital pressure gauge
RobertShaw
4) Slip pressure hose over the inlet port
Gas Outlet
(Manifold)
Pressure Test Port
5) Turn control knob to ON
7) Read pressure (see chart)
TP
TH
OUT
Then
LO
FF
O
IN
I
H
TH
TP
O
N
VENT
6) Turn ON the main burner (high)
PI L OT
IN
PILOT ADJ
8) Turn OFF burner
9) Turn control knob to OFF
Gas Inlet
Pressure Test Port
NEW- #0 Phillips
OLD - Small Straight Screwdriver
10) Remove pressure hose
11) Tighten pressure port screw
Min. Input
Pressure
LP
7”
W.C.
11”
W.C.
With Main Burner ON
Digital Pressure Gauge
Copyright © 4/20/2006
NG
3
Travis Industries, Inc.
Pilot
Does Not
Stay
Lit
Testing the
Thermocouple
Voltage On A SIT or RobertShaw Gas
Control Valve
Testing MV Production
RobertShaw Gas Control
Minimum 13 MV
Thermocouple
Adaptor MUST
BE USED
Gas Control
Valve EPU
Screw thermocouple
into gas control valve
Copyright © 4/20/2006
4
Travis Industries, Inc.
Pilot
Does Not
Stay
Lit
Testing Pilot Coil (EPU)
for Continuity
RobertShaw
Valve
Make contact to
bottom of opening
- NOT SIDES
EPU Coil
Continuity Test
Copyright © 4/20/2006
Place one test lead into socket
center of EPU and the other test
lead to the valve body.
5
Travis Industries, Inc.
Burner
Does Not
Light
Voltage Testing 1, 2, 3
RobertShaw Valve
TESTING OPERATOR HEAD
Pilot Burning - Burner Switch On
More than 100 MV
Test
#2
If = 0 Volts, there is a switch circuit problem. Conduct
continuity test on Page 8 to locate problem.
LO
TP
TH
OUT
FF
O
IN
I
H
TH
TP
O
N
VENT
DCV
* Voltage should not be equal to or greater
than voltage in Test #1. If equal to Test #1, conduct
continuity test of operator head (see page 7).
PI L OT
IN
PILOT ADJ
Test
#3
TESTING SWITCH
CIRCUIT
Pilot and Burner Switch On
Reading should be less than 80
MV . If not, shorten switch wires
and check switch or wall
thermostat.
If voltage = Test #1 go back and
Test #2 again
Copyright © 4/20/2006
Test
#1
TESTING THERMOPILE
Pilot Only On , Burner Switch Off
250 MV - Minimum
If not, adjust pilot or replace
thermopile
* Indicates Operator Head has too much
* resistance - Replace Gas Control Valve
6
Travis Industries, Inc.
Continuity Test
Operation Head
LO
TP
TH
OUT
FF
O
IN
I
H
TH
TP
N
O
VENT
• Continuity test Operation Head
PI L OT
IN
PILOT ADJ
Copyright © 4/20/2006
7
Travis Industries, Inc.
Measuring Outgoing Gas
Pressure
Burner
Does Not
Come On
1) Light the pilot (keep control knob on pilot)
Measuring Gas
Pressure
2) Loosen output pressure tap (about two or
three turns)
3) Zero out digital pressure gauge
RobertShaw
4) Slip pressure hose over the outlet port
Gas Outlet
(Manifold)
Pressure Test Port
5) Turn control knob to ON
6) Turn ON the main burner (high)
Then
LO
PI L OT
IN
PILOT ADJ
TP
TH
OUT
FF
O
IN
I
H
TH
TP
O
N
VENT
7) Read pressure (see chart)
8) Turn OFF burner
9) Turn control knob to OFF
10) Remove pressure hose
Gas Inlet
Pressure Test Port
NEW- #0 Phillips
OLD - Small Straight Screwdriver
11) Tighten pressure port screw
No
Outgoing Pressure
Replace Regulator
Body - Then if
Neccessary, Gas
Control Valve
Outgoing Pressure
But Still No Flame
• Check Burner Orifice
for Blockage
• Check Burner
Output Pressures
NG
High 3.5”
W.C.
LP
11”
W.C.
.9”
W.C.
2.7”
W.C.
Low
Digital Pressure Gauge
Copyright © 4/20/2006
8
Travis Industries, Inc.
IPI Gas Control Valve
(For Revolution & 1080 Gas
Fireplaces)
Troubleshooting Flow Chart
Page 1-13
IPI Gas Control Valve Diagram
Page 15
Remote Control
Page 16
Wall Switch
Page 17
Electronic Ignition System
START
1. Check the remote and make sure the 8.
8. batteries are good. If not, replace them.
PUSH H/L BUTTON
ON REMOTE
2. Check batteries in battery pack and make
8. sure they are good. If not, replace them.
8. (see figure 1)
3. Check to see if the battery pack is connected
8. to the module. If not, connect it.
DOES
THE PILOT
LIGHT COME
ON?
4. Check leads from pilot assembly to 8. 8.
8. module ignition “I” terminal on module
8. & sensor on the “S” terminal on the 8.
8. module. (see figure 2)
NO
5. Check to see if the remote has been 8.
8. programmed. If not, see Programming
8. Remote.
YES
6. Check that the switch on the side of the
8. module is in the Remote position. If not,
8. switch to Remote position.
PILOT IS
BURNINING
BUT IGNITOR
CONTINUS TO
SPARK
7. Check continuity of pilot coil. Continuity
8. good, no continuity bad, replace valve.
8. (see figure 3)
YES
8. Check voltage to pilot coil voltage.
8. Should be 1.5 volt DC if not, replace 8.
8. module. (see figure 4)
NO
DOES
THE PILOT
FLAME LOOK
BLUE?
1. Is flame sensor being hit by pilot flame?
1. If not adjust pilot. Is flame sensor wire 1.
1. connected to module and grounded?
1. If not connect it.
2. Check continuity of sensor. (see figure 5)
If sensor has continuity replace module.
NO
1. Does the unit have the right pilot
orifice installed?
YES
2. Has the unit been converted to
the right fuel? If not, convert it.
See next page.
1
1. Does the remote show CP in
1. the display? If yes, child proof
1. is on.
DOES
THE BURNER
COME
ON?
2. Check to see if the flame 2.
4. sensor rod is being touched
2. by the pilot flame. If not, 2.
2. adjust pilot flame.
NO
3. Check that the green and 2.
2. white wire is connected to 2.
2. the module and the gas valve
2. main burner coil. If it isn’t, 2.
2. connect it.
YES
4. Check to see if the module
2. is grounded to the valve. If it
4. is not, connect it.
5.
5.
2.
2.
2.
Do a continuity test of the 2.
main burner coil in the gas
valve. Continuity it is good.
If no continuity it is bad, 2.
replace the valve.(see figure 6)8.
6. Check voltage to the main 4.
4. burner coil. It should be 1.5
4. volts DC. If no voltage, 4. 4.
4. replace module. (see figure 7)
See next page.
2
DOES
THE FLAME
LOOK
GOOD?
1. Flame is too blue =
1. Adjust the air shutter closed
1. to make the flame more 1. 1.
1. yellow
NO
2. Flame is orange & sooty =
2. Adjust the air shutter open to
2. make the flame more yellow
YES
3. Sooty tall flame =
2. Was unit converted to LP?
2. Check valve is in right position
2. and the orifices are correct.
4. Short blue flame =
2. Check for regulation in natural
2. gas position and check the 2.
2. gas pressure. Make 2. 2. 2.
2. adjustments if needed.
DOES
THE BURNER
STAY
ON?
1. Is the remote set to manual or
1. auto? If in auto is room showing
1. on remote? If yes, is temperature
1. set to low? If yes, set 1. 1.
1. temperature higher.
NO
2. Check pilot flame sensor is
2. touching the pilot flame.
3. Check ground wire to receiver.
YES
4. If receiver beeps, replace 1. 1.
2. batteries in the remote.
See next page.
3
DOES
THE FLAME
MODULATE
HIGH TO
LOW?
1. Is modulating motor 6. 6.
6. connected to the battery 6.
6. pack? If not, connect it.
NO
2. Check switch on battery pack.
6. Is it in DC motor drive, if not,
6. change it. (see figure 8
3. Does flame go down when it
6. shows HI and does it go up
6. when it shows LO? If so, 6.
6. reverse black and red power
6. wires to motor.
YES
4. Test again to see of flame 6.
6. modulates high to low. If not,
6. check voltage to motor (see
6. figure 9) No voltage - replace
6. battery pack
5. Check continuity of motor. 6.
6. No continuity
- Bad, replace valve.
- Continuity Good,
(see figure 10)
END
6. If everything is good, replace
6. module.
ELECTRONIC IGNITION
SYSTEM IS WORKING
PROPERLY
4
Figure 1
Must be checked
here to test all 4
batteries
Should be 6 volt DV
+
+
6.00
-
5
Contacts
inside of
box
Figure 2
Verify wiring from pilot to module is correct.
6
Figure 3
Check continuity on pilot head coil
Continuity - Good
No continuity - Bad, replace valve
Unplug Molex with
orange/white
wires to test head
coil on valve.
Continuity
Test
OL
7
Figure 4
With pilot turned ON
1.5
1.5 volts DC
Pilot will continue to spark for 1 minute and
shut down if pilot does not light.
Put test leads into
Molex while pilot is
sparking to test.
1. Voltage is good
if meter displays a
constant 1.5 .
2. If numbers
displayed are
randomly cycling to
different numbers
there is no voltage
- replace module.
8
Figure 5
Perform A Continuity Test
Test Continuity
If you have continuity,
the part is GOOD
If No continuity, the part
is BAD - Replace
002
9
Figure 6
Test Continuity
Continuity - GOOD
No Continuity - BAD/Replace
000
10
Figure 7
Pilot Must Be ON To Perform Test
1.5
1.5 volts DC
Make sure Molex
is connected to
the valve and put
leads into the
Molex with pilot
burning.
11
Figure 8
12
Figure 9
Burner Must Be ON
5.5
Should have 5.0 volts as a minimum
No voltage - replace battery box
H/L Button needs to be pressed on
remote to perform test
Pilot Assembly
a
Igniter ("I") Wire
(Orange - with
fiberglass
insulation)
Receiver
Module
Battery Box
Sensor ("S")
Wire (White)
Battery Box Wires (DC Motor Drive) - 12' Length
Black, Brown, Red, and Orange wires
NEPO OT SSERP
Le
ar
n
AU
I
X
W
PO
S
J
ER
DCMD Wires (DC Motor Drive) - 12' Length
Red and Black/Red wires (w quick connects)
c
Gas Control Valve
AD
ff
O
us
uo
tin lot n
on Pi f/O
C
f
O
Not
Used
/
te
o
em
R
b
Make sure continuous pilot
is set to "OFF" and remote
is set to "REMOTE".
Main Burner Control Wires
White
Green
Orange
White
Pilot Flame Control Wires
Figure 12
13
Figure 10
002
Check motor for continuity
If no continuity, replace valve
14
Electronic Ignition Gas Valve
15
Revolution Remote Control
16
Revolution Wall Switch
17
RING OF FIRE™
Electrical Troubleshooting
Guide
RING OF FIRE™
Troubleshooting
Guide
Troubleshooting Flow Chart
Page A - D
Wiring Diagram
Page E
Gas Ignition Control Module
Page F
Component Location Identification
Page G
AC Voltage Testing
Page H
Continuity Testing
Page I
Low Level Water Switch Testing
Page 1
High Temperature Water Snap Switch Testing
Page 2
Safety Relay Testing (Early Models Only)
Page 3
Master Control Module Testing (Input Side Only)
Page 4
Remote Switch Testing
Page 5
Master Control Module Testing (Output Side)
Page 6
Lighting Testing
Page 7
Water Pump Testing
Page 8
Purging Air
Gas Control (Pilot Side/Burner Side)
Page 9
Incoming Voltage Testing
Gas Control Pilot Operator and Burner
Page 10
Operation Continuity Testing
Page 11
Incoming Gas Pressure Testing
Page 12
Outgoing Gas Pressure Testing
Page 13
Flame Rectification
Page 14 -15
RING OF FIRE
ROF TROUBLESHOOTING FLOW CHART
Simultaneously
depress light and
water button.
• Check for 110 AC incoming voltage
• Check for low water (fill if needed)
Hold for
approximately
5 seconds,
then release.
• Check low water switch (see page 1)
• Check for over heated water snap disk
• Test high water temperature snap disk (see page 2)
Switch
pad lights
up
NO
• Disconnect power from master control module and • • •
• continuity test transformer - Black and White wires
(see page 4)
• Disconnect Blue wires output side of Master Control and
conduct test #4 on page 6)
• Disconnect switch pad wires from master control module
• and conduct Tests 1, 2, 3. (see page 5)
YES
Rope
lights come on
NO
• Check control module output side - (Red & White
wires) for 110 v AC (See Test #1 page 6)
• Test lighting components (see page 7)
YES
Water
Comes
on
• Check control module output side (Yellow and
• White wires) (See test #2 on Page 6)
NO
• Check water pump (See page 8)
NEXT PAGE
Copyright © 4/20/2006
A
Travis Industries, Inc.
RING OF FIRE
ROF TROUBLESHOOTING FLOW CHART
Push and Hold
Flame Button
Then Enter Code
Light, Light, Water
Switch
pad lights
up
NO
• Conduct test # 3 on Test Page #3
YES
Ignition
starts to
click
• Verify AC voltage on output of master control module
• - Grey wires (See test #3 on Test Page #6)
NO
• If all of above check out good - replace the gas •
ignition control module
NEXT PAGE
Copyright © 4/20/2006
B
Travis Industries, Inc.
RING OF FIRE
ROF TROUBLESHOOTING FLOW CHART
• Check gas shut offs- main shut off- gas control valve
• Check fuel supply (LP)
• Check wiring to make sure ignition control module is
• properly wired (see Wiring Diagram pages E & F)
Pilot flame
comes on
NO
• Check orifice for blockage
• Purge air (see Test Page #9 for procedure)
• Check that 30 VAC is present at the P & C terminals
• of the wiring harness that connects to the valve
(see Test Page #10) see pilot side test
YES
• NO VOLTAGE - Replace the ignition control module
• Continuity check the pilot side of the gas control valve
• (see Test Page #11)
• CONTINUITY - Good
• NO CONTINUITY - Replace gas control valve
• Test incoming gas valve pressure (See Test Page #12)
• Check pilot tube for blockage
• Replace the gas control valve
No Flame Rectification
Ignition spark
turns off
NEXT PAGE
Copyright © 4/20/2006
NO
• Check pilot flame for proper contact with spark electrode
(see Page #14)
• Check all ground connections (valve & ignition control)
(see Page #15)
• If all of the above are good - replace the ignition control
• module
C
Travis Industries, Inc.
RING OF FIRE
ROF TROUBLESHOOTING FLOW CHART
• Check burner orifice for blockage
• Check that 30 VAC is present at the M & C terminals
of the wiring harness that connects to the valve
(see Test Page #10)
Burner
comes
on
NO VOLTAGE - Replace the ignition control module
NO
• Continuity check the burn side of the gas control valve
(see Test Page #11)
• CONTINUITY - Good
• NO CONTINUITY - Replace gas control valve
YES
• Test incoming gas valve pressure (see Test Page #12)
• Check outgoing pressure (see Test Page #13)
• IF NO PRESSURE - Replace gas control valve
• IF PRESSURE IS PRESENT - Blockage is in burner
supply tube, burner orifice or burner
• Did you exceed automatic 2 hour shut down?
Burner stays on
for desired time
NO
• Wind interruption - ROF will lose flame rectification
and automatically relight
YES
END
Copyright © 4/20/2006
D
Travis Industries, Inc.
Light
Water
E
Power
Source
Flame
Copyright © 4/20/2006
Green
Brown
Black
Red
White
Yellow
Orange
Remote Control Panel
White
Black
Green
White
Black
Green
Brown (Ground)
Ground
White
Brown
Orange
Brown
Orange
Blue (Common)
Red
Yellow
Red
Yellow
Black
Remote
Cable
Brown (Hot)
Wiring Diagram
Ring of Fire
Control Module
White
Yellow
White
Red
Gray
Gray
Blue
Blue
White
Black
GND
TH 24V
Float
Switch
Water
Pump
M
C (M/P)
P
GND
Gas Valve
Valve
Gas
Robert Shaw 20001PERC
RobertShaw 20001PERC
Flexible Rope Light
30FT, 110VAC, 1/2” DIA, 5.52W/FT
M
C (M/P)
P
IgnitionControl
ControlUnit
Unit
Ignition
Robert Shaw780-715
780-715 U
U
RobertShaw
Water Temp
Switch
RING OF FIRE
Travis Industries, Inc.
RING OF FIRE
Gas Ignition Control Module
I.P.I.
TH
Grey-Power Wire
PV
Blue-Pilot Valve
OPT Sensor
Accessory Term.
MV
MV PV
TR
Copyright © 4/20/2006
Not Used
Not Used
Red-Main Valve (Burner)
Shared
White Common
Between Pilot & Burner
Not Used
Ground
Green-Ground
Igniter
Orange-Igniter
F
Travis Industries, Inc.
RING OF FIRE
Total Components
Master
Control
Module
Safety
Relay
Water
Connection
Remote
Switch
Terminal
Gas Ignition
Control Module
Low Level
Water Switch
Newer Models
Have This Built
Into the Circuitry of
Master Control Module
Copyright © 4/20/2006
G
Electronic
Gas Control
Valve
N. C. High
Temperature
Snap Disk
140˚
Travis Industries, Inc.
RING OF FIRE
When Testing ROF Components
for AC Voltage
AVC
• The ROF contains 110 VAC circuits (caution-shock potential)
• The ROF contains low voltage circuits 24-30 volts AC
Copyright © 4/20/2006
H
Travis Industries, Inc.
RING OF FIRE
When Testing ROF Components
for Continuity
A. Disconnect all power - No live voltage
B. Isolate the component being tested by
disconnecting it from the electrical circuit
Use this scale
setting
Do not use audible
beep scale
Copyright © 4/20/2006
I
Travis Industries, Inc.
RING OF FIRE
TEST Page #1
TESTING ROF COMPONENTS
TESTING LOW WATER
LEVEL SWITCH - N.O. Switch
No Continuity
Has Continuity - Good
No Continuity - Replace
Disconnect Wires
Disconnect Wires
Copyright © 4/20/2006
1
Travis Industries, Inc.
RING OF FIRE
TEST Page #2
TESTING ROF COMPONENTS
TESTING THE WATER
TEMPERATURE SNAP DISK
Disconnect all wires
to snap disk
N.C. 140˚ F Snap Disk
Continuity Test
CHECK
COLD = Continuity
WARM = No Continuity
COOLED = Continuity
• If the snap disk does not perform as described
• in the above box, it is defective and should be
• replaced.
Copyright © 4/20/2006
2
Travis Industries, Inc.
RING OF FIRE
TEST Page #3
TESTING ROF COMPONENTS
Testing Master Control Module - Incoming
Side
Incoming 110v
Power Wires
Master Control
Module
Continuity Test
CONTINUITY Transformer is
good
NO CONTINUITY
- Transformer is
defective. Replace
the Master Control
Module
• Disconnect the BLACK and WHITE wires from the
• incoming power.
• Continuity test the incoming side of the step down transformer.
Copyright © 4/20/2006
3
Travis Industries, Inc.
RING OF FIRE
TEST Page #4
TESTING ROF COMPONENTS
TESTING REMOTE SWITCH
LIGHT
Disconnect Green wire
from the terminal block
before testing
WATER
GREEN
YELLOW
FLAME
RED
BROWN
Remote
Switch
Test
#
Test
Test
Points
1
Continuity
2
Continuity
1
3
3
Flame
1
4 hold in FLAME
Circuit
Push and
Copyright © 4/20/2006
1
2 hold in LIGHT
button
Push and
hold in
WATER
button
Push and
button
4
1
2
3
Test
points
4
Continuity No Continuity
YES
GOOD
NO
Replace Remote
Switch
YES
GOOD
NO
Replace Remote
Switch
YES
GOOD
NO
Replace Remote
Switch
Travis Industries, Inc.
RING OF FIRE
TEST Page #5
TESTING ROF COMPONENTS
TESTING CONTROL MODULE - Output Side
RED
1
WHITE
2
YELLOW
3
WHITE
Master
Control
Module
4
BLUE
5
BLUE
6
GREY
ACV
7
GREY
8
Test Points
Ground
• Testing AC voltage output of control module
• Disconnect each set of wires as you test them
• With power ON and the light, water and flame buttons pushed ON,
• conduct the following test
Test
Points
Test
#
Test
1
AC Volts
1
2
2
AC Volts
3
4
Water Pump 110 - 125 VAC Replace Module
3
AC Volts
7
8
Gas Control
Unit
30 VAC
Replace Module
4
AC Volts
Water
Safety
30 VAC
Replace Module
5
6
Copyright © 4/20/2006
Circuit
Lighting
5
Reading
Low or No
Voltage
110 - 125 VAC Replace Module
Travis Industries, Inc.
RING OF FIRE
TEST Page #6
TESTING ROF COMPONENTS
TESTING LIGHTING CONNECTOR
Jumper
Wire
110 Volts Present: Connection is good
No Voltage: Connection is bad
TESTING ROPE LIGHTING
Continuity: Good
No Continuity: Defective - Replace
Copyright © 4/20/2006
6
Travis Industries, Inc.
RING OF FIRE
TEST Page #7
TESTING ROF COMPONENTS
TESTING WATER PUMP
Continuity Test
Continuity: Pump is Good
No Continuity: Defective - Replace Pump
Copyright © 4/20/2006
7
Travis Industries, Inc.
RING OF FIRE
TEST Page #8
TESTING ROF COMPONENTS
PURGING AIR
• To purge air, loosen the inlet gas pressure port.
• When gas is present, re-tighten.
Purge Air
Through Inlet
Gas Pressure
Tap (3/16” Hex)
ON/OFF
Gas Cock
Copyright © 4/20/2006
Incoming
Gas Port
8
Travis Industries, Inc.
RING OF FIRE
TEST Page #9
TESTING ROF COMPONENTS
24-30 VAC
Pilot Side
Test
Molex Connector
Pilot Burner Coil
24-30 VAC
M
CP
Va
lve
Top
Common
Terminal
Main
Burner Coil
Main Burner
Side Test
Copyright © 4/20/2006
9
Travis Industries Inc
RING OF FIRE
TEST Page #10
TESTING ROF COMPONENTS
TESTING THE
ROBERTSHAW GAS VALVE
Main Burner &
Pilot Burner
Operator
Electrical Connections
Ground
Connections
NOTE: DO NOT
CONDUCT
CONTINUITY
TEST USING
THE AUDIBLE
TONE SCALE
Continuity
Test of Pilot
Operator
M
Continuity
Test of Burner
Operator
CP
Top of Operator
Disconnect all wires
to the gas valve
Copyright © 4/20/2006
10
Travis Industries, Inc.
RING OF FIRE
TEST Page #11
TESTING ROF COMPONENTS
TESTING GAS PRESSURE
INCOMING PRESSURE TESTING
1. Turn off gas to Ring of Fire
2. Remove inward pressure plug (3/16” Hex)
3. Screw barbed adapter into pressure port
4. Zero out pressure gauge
5. Slip hose over barbed connector
6. Turn on gas, turn on fountain and flame
7. Read pressure
8. Turn fountain off, turn gas off
9. Disconnect hose
10. Remove barbed connector and replace hex plug
11. Test for gas leak at replaced plug
Inlet Gas
Pressure Tap
(3/16 ” Hex)
ROF Incoming
Gas Pressure
NG = 7” W.C.
ON/OFF Gas Cock
Incoming Gas Port
• If incoming gas pressure is incorrect,
LP = 13” W.C.
check for adequate pipe sizing and/or
•
call your gas supplier.
Copyright © 4/20/2006
11
Travis Industries, Inc.
RING OF FIRE
TEST Page #12
TESTING ROF COMPONENTS
TESTING GAS PRESSURE
OUTGOING PRESSURE TESTING
1. Turn off gas to Ring of Fire
2. Remove outward pressure plug (3/16” Hex)
3. Screw barbed adapter into pressure port
4. Zero out pressure gauge
5. Slip hose over barbed connector
6. Turn on gas, turn on fountain flame
7. Read pressure
8. Turn fountain off, turn gas off
9. Disconnect hose
10. Remove barbed connector and replace hex plug
11. Test for gas leak at replaced plug
Reversible (NG & LP
Gas) Regulator Body
Burner Outgoing Gas
Pressure Tap (3/16” Hex)
ROF Outgoing
Gas Pressure
NG = 3.5” W.C.
Pilot Outlet to
Pilot Burner
Gas Outlet To
Main Burner
LP = 11” W.C.
•
Copyright © 4/20/2006
12
Travis Industries, Inc.
RING OF FIRE
TEST Page #13
TESTING ROF COMPONENTS
Flame Rectification
Proper Flame
Electrode Contact
Flame completely
immerses electrode tip
Results in good flame
rectification keeping the ROF
burning
Improper Flame
Electrode Contact
Flame lifts up and is too far
away from electrode tip
Results in no flame rectification
shutting down the ROF
Improper Flame
Electrode Contact
Flame is too small to reach
electrode tip
Results in no flame rectification
shutting down the ROF
Copyright © 4/20/2006
13
Travis Industries, Inc.
RING OF FIRE
TEST Page #14
TESTING ROF COMPONENTS
• Make sure the ground on the valve and the ground
on the ignition control are sound
Ground
Connections
Copyright © 4/20/2006
14
Travis Industries, Inc.
Switches, Remotes &
Thermostat Testing
Switch Testing
Page 1
Thermostat Testing
Page 2
Thermostat Wire Sizing
Page 3
110 V Remote Testing
Page 4-6
Battery Powered Remote Testing
Page 7-9
Continuity Testing Switches
Rocker Style Switch
Used on older
configuration
Switch Continuity
Test: Remove at least
one wire; jumper
must be in place
Wall Switch
Rocker Style Switch
New configuration
Switch Continuity
Test: Disconnect
one wire
Copyright © 4/20/2006
1
Travis Industries, Inc.
Testing the Thermostat Circuit
1 Jumper Wire
2
Checking
Thermostat
Disconnect wires
from thermostat
With thermostat
contacts
Closed: Continuity
Open: No Continuity
3
Checking Wires
Continuity test
across the wire
ends
OFF - No
continuity
* If connected to
switch terminals
(old units switch
must be turned
to ON)
Copyright © 4/20/2006
1
Jumper Wire Test
Jumper turns on fire
- Replace thermostat
Jumper wire does not
turn on fire
- Bad wire
- Replace wire
2
Travis Industries, Inc.
Thermostat Wire Gauge Sizing
WIRE SIZE
MAXIMUM “RUN” LENGTH*
21 GAUGE
16 Feet - 8 Feet Linear
20 GAUGE
25 Feet - 12 1/2 Feet Linear
18 GAUGE
40 Feet - 20 Feet Linear
16 GAUGE
64 Feet - 32 Feet Linear
14 GAUGE
100 Feet - 50 Feet Linear
12 GAUGE
150 Feet - 75 Feet Linear
*RUNS MEASURE FROM
FIREPLACE TO CONTROLLER AND BACK
Copyright © 4/20/2006
3
Travis Industries, Inc.
Continuity Testing
Battery Powered Remote Control
1
Check Wiring
Screws to
connect wire
REAR OF
RECEIVER
Wire
Connectors
(2)
PUSH
3 Receiver Continuity Test
• Hook up meter
• With the switch (1) in the remote
• position PUSH (2)
- Continuity - OK
- No continuity - Defective
sensor or receiver
(1)
2 Check Batteries
• Move position switch (1) to the
• ON position
- Continuity - OK
- No continuity - Defective
sensor or receiver
In sender (see page 5)
& receiver (see page 6)
Check that dip (see page
5) switches in sender
and receiver match (see
page 6)
Copyright © 4/20/2006
4
Travis Industries, Inc.
Testing 110 Volt Remote Controls
1
Check Wiring
(see page 7)
(1) PUSH
2
(2)
PUSH
Copyright © 4/20/2006
Sender
Continuity Test
• Push (2)
- Continuity - OK
- No Continuity - Defective
- receiver
5
Receiver
Continuity Test
• Plug 110 cord in
outlet
• Hook up meter
• Push (1) override •
button
- Continuity - OK
- No Continuity - Defective receiver
Travis Industries, Inc.
Copyright © 4/20/2006
6
Travis Industries, Inc.
c
Connect the red & brown wire
(removed in step “a”) to each
gas stove connector wire.
“Y” Jumper Wires
d
e
Connect the “Y” jumper
wires to the left side of the
on/off switch.
Connect each thermostat wire to
each gas stove connector wire.
Red & brown
wires leading to
gas control valve
Thermostat
Wires
NOTE: Failure to use the “Y” jumpers will result in an inoperable stove should
the 110 Volt supply fail
b
Remove the jumper
wire and discard.
Remove the
red & brown
wires
leading to
the gas
control
valve.
a
Back of
on/off switch
Fireplace Remote Control
Requires 4
AA Batteries
Copyright © 4/20/2006
7
Travis Industries, Inc.
Fireplace Remote Control
• Burner ON/OFF
- Remote option (Fireplace) - Child Proof Code (UD DUD)
- Requires
- Remote ON/OFF
3 AAA Batteries
- Remote Thermostat
4 AA Batteries
- Timed OFF Remote
Copyright © 4/20/2006
8
Travis Industries, Inc.
Remote Fireplace Thermostat
• TWO - Wires to ON/OFF
NOTE: Switch MUST BE ON for the remote to work.
Copyright © 4/20/2006
9
Travis Industries, Inc.
Blower Circuit
Troubleshooting
110 VAC
Troubleshooting Flow Chart
Page A
Incoming AC Voltage
Page 1
Rheostat Continuity Testing
Page 2
Blower Snap Disk Testing
Page 3
Blower Snap Disk Testing
Page 4
Blower Speed Testing and Adjustment
Page 5 - 6
TURN ON BLOWER
• Verify incoming power 110 VAC (see page 1)
Blower
Comes
ON
NO
• Test rheostat for continuity (see page 2)
• Test snap disk for continuity (see page 3)
• Test blower for continuity (see page 4)
YES
Moves
From High To
Low Speeds
NO
• Readjust rheostat (see page (5-6)
YES
END
Copyright ' 4/20/2006
A
Travis Industries, Inc.
Testing Incoming Voltage
Chassis
Ground
Blower
Motor
Black
Green
120 Volt
Grounded AC
Power Supply
White
Black
Black
120 Volt
Grounded A.C.
Power Supply
Black
Black
White
Black
ACV
Blower
Thermodisk
Blower
Rheostat
Measure 110 Volts AC
CAUTION (Electrical Shock)
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Travis Industries, Inc.
Continuity Testing
Rheostat Control
• Disconnect power 110 VAC
• Continuity test rheostat
Make sure to turn rheostat ON
(High blower setting)
Note: Only test with selector switch
of multimeter in the OHMS position
- Do not use the audible tone
position
Continuity - GOOD
No Continuity - Replace Rheostat
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2
Travis Industries, Inc.
Testing Blower Snap Disks
N. O. (Normally Open)
No Continuity Until
Temperature Rise
• Test COLD
• Remove snap disk ¥
¥ and gently heat with
¥ a flame wand
• Test HOT
• Upon being heated ¥
¥ there should be ¥ ¥ ¥
¥ continuity
• Test Again When It
¥ Has Cooled
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Travis Industries, Inc.
Continuity Testing Blowers
CAUTION
110 POWER
OFF
Continuity Test
Continuity - Good
No Continuity - Replace
Convection Blower
(shown removed)
Disconnect
Convection Blower
Wires (Brown and
White)
POWER OFF
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Travis Industries, Inc.
Voltage Testing Blowers
High to Low Speeds
Set to voltage AC.
Attach the
multimeter leads to
the two post on the
convection blower
(there is enough
bare metal on the
post to get a good
reading).
ACV
AC Voltage
65-70V - Low
115V - High
Convection Blower
(shown removed)
Keep wires
connected for
this test
See page 6 for re-setting rehostat
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Travis Industries, Inc.
Rheostats
DIRECTIONS
A) Unplug the heater
B) Disconnect the rheostat so the potentionmeter on the top may be
accessed. Keep the wiring attached.
C) Set the blower to low (all the way clockwise).
D) Make sure no wiring is loose. Plug the heater in.
E) Turn the potentionmeter all the way clockwise.
F) Turn the potentionmeter counter-clockwise until the blower starts to
run (approximately 65 volts).
G) Unplug the heater. Reinstall the rheostat.
New Style Rheostat
Old Style Rheostat
INCREASE VOLTAGE
(on low setting)
Potentiometer
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INCREASE VOLTAGE
(on low setting)
DECREASE VOLTAGE
(on low setting)
DECREASE VOLTAGE
(on low setting)
Potentiometer Micro (1/16”) Standard
Screwdriver (or
phillips)
Micro (1/16”)
Standard
Screwdriver
6
Travis Industries, Inc.
Gas Troubleshooting Check List
PILOT SIDE
Pilot
Won t
Light
Poor
Pilot
Flame
Page
1 to 3
Page
15 to 17
Pilot
Won t
Stay
Lit
Page
4 to 12
Delayed
Pilot
Ignition
BURNER SIDE
Remote
Does
Not
Turn
On
Burner
APPLIANCE
Sooting
Noise
Smells
and
Odors
Page
28 to 30
Page 40
Page
41 to 44
Blower
Doesn t
Work
Page
33 to 34
Page
13 to 14
Page 39
Burner
Won t
Light
Delayed
Burner
Ignition
Page
18 to 21
Page 31 to 32
Burner
Won t
Stay
Lit
Poor Flame
Appearance
Page
25 to 27
Thermostat
Doesn t
Turn On
Burner
Page
22 to 24
Page 35-37
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A
Travis Industries, Inc.
PROPER
OPERATION
PROCEDURE
FUEL
Pilot
Will Not
Light
OXYGEN
• Gas Shuts Off
• Gas Supply
• Blockage
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HEAT
• Spark
¥ Electrode
• Pizeo Ignitor
¥ and Wire
¥ Connections
1
Travis Industries, Inc.
Copyright ' 4/20/2006
2
Travis Industries, Inc.
Spark Is Seen But
Not Lighting
No Gas Flow
No Gas Flow
No Spark
No Spark
Is Seen
Spark Is Seen But
Not Lighting
No Spark
No Spark
Is Seen
No Spark
No Spark
Is Seen
B-Vent
Direct V
Application
Replace
Pizeo Ignitor
Fill
Tank
Turn ON
Look for
Multiple Shut-Offs
Defective
Pizeo Ignitor
LP Tank
Empty
Gas
Turned OFF
Tighten Pizeo
Lock Nut
Poorly Grounded
Pizeo
Replace Pilot
Assembly/or
Electrode
Adjust Electrode
1/8 From Pilot Hood
Poor or Misaligned
Spark
Cracked Electrode
Ceramic
Connect, Tighten
Loose Piezo
Wire
Solution
Follow Lighting
Instructions
Possible Cause
Improper Lighting
Procedure
PILOT WILL NOT LIGHT
Light Up
Light Up
Light Up
Light Up
Light Up
Light Up
Light Up
No Spark
No Spark
Is Seen
No Spark
Light Up
Operational
Knowledge
Pilot Does
Not Light
No Spark
Is Seen
Occurrence
Timing of
Problem
Area of Focus
Symptoms
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Travis Industries, Inc.
No Gas Flow
No Gas Flow
Spark Is Seen
But Not
Lighting
No Gas Flow
Spark Is Seen
But Not
Lighting
Spark Is Seen
But Not
Lighting
No Gas Flow
Spark Is Seen
But Not
Lighting
No Gas Flow
No Gas Flow
Spark Is Seen
But Not
Lighting
Spark Is Seen
But Not
Lighting
Area of Focus
Symptoms
B-Vent
Direct V
Application
Blockage in Valve
Blockage in
Pilot Tube
Blockage in
Pilot Orifice
Pilot Hood Misshaped
Creating Poor Air/Fuel/Heat
Relationship
Pilot Adjustment
Turned Closed
Air in the
Supply Line
Possible Cause
PILOT WILL NOT LIGHT
Light Up
Light Up
Light Up
Light Up
Light Up
Light Up
Occurrence
Timing of
Problem
Replace
Valve
Clean
or Replace
Clean
or Replace
Reshape or Replace
Pilot Assembly
Open to
Proper Setting
Purge Air
Solution
PROPER
OPERATION
PROCEDURE
Pilot
Will Not
Stay Lit
MILLIVOLT
PRODUCTION
PILOT
FLAME
VENTING
• Thermocouple
• Pilot
¥ Adjustment
¥ Setting
• Drafts in or
¥ Around Pilot
¥ Flame
• Gas Pressure
• Vent Spillage
¥ (B-Vent Only)
• Thermopile
Old/Old Units
• Gas Control
¥ Safety Magnet
(EPU)
• Spill Switch
¥ and Spill
¥ Switch Circuit
Copyright ' 4/20/2006
• Orifice Size
• Pilot Flame
¥ Positioning
4
Travis Industries, Inc.
Copyright ' 4/20/2006
5
Travis Industries, Inc.
Pilot Flame
Pilot Flame
Pilot Flame
Small Pilot Flame and
Pilot Will Not Stay Lit
Misplaced Logs or
Thick Application of
Ember-Fyre“
Pilot Flame
Pilot Flame is Not in
Upper 1/3 of
Thermocouple
Heavy Yellow Tipped
Pilot Flame
Pilot Flame
Small Pilot Flame and
Will Not Stay Lit
Pilot Flame
Operational
Knowledge
Accidentally Turned
Unit OFF Now Pilot
Will Not Stay Lit
Small Pilot Flame
Light Up
Operational
Knowledge
Pilot Lights Then
Goes Out
B-Vent
Direct V
Application
Possible Cause
Rearrange Logs and Ember
Materials Away From
Pilot Assembly
Replace With Correct
Pilot Orifice Size
Pilot Orifice
Too Small
Ember or Log Placement
Interferes With
Pilot Operation
Lower Pilot Tube
and/or Straighten
Pilot Retainer
Increase Pilot Size
and/or Increase Incoming
Pressure
Realign Pilot Hood or
Replace Pilot Assembly
Turn Up Pilot Flame
Wait Approximately
30 Seconds for Safety
Pilot to Engage
Retry By Holding Pilot Knob
in Long Enough to Heat the
Thermocouple
Solution
Pilot Tube Pushing
Up Pilot Bracket
Low Gas Pressure
Poor Pilot Hood
Alignment
Pilot Flame Too Small
Pilot Came On
(Safety Lock-Out Engaged)-SIT
Then Pilot Went Out
Not Holding Pilot Knob in for
at Least 15 Seconds When
Lighting
PILOT WILL NOT STAY LIT
Light Up
Light Up
Light Up
Light Up
Light Up
Light Up
Light Up
Occurrence
Timing of Problem
Area of Focus
Symptoms
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Travis Industries, Inc.
Area of Focus
Millivolt
Production
Millivolt
Production
Millivolt
Production
Millivolt
Production
Millivolt
Production
Symptoms
Pilot Flame Looks
Good But Pilot
Will Not Stay Lit
Pilot Flame Looks
Good But Pilot
Will Not Stay Lit
Pilot Flame Looks
Good But Pilot
Will Not Stay Lit
Pilot Flame Looks
Good But Pilot
Will Not Stay Lit
Pilot Flame Looks
Good But Pilot
Will Not Stay Lit
B-Vent
Direct V
Application
Defective EPU
(Gas Safety Control)
Defective Spill Switch
or Circuit (B-Vent)
Weak or Defective
Thermocouple
Loose Thermocouple
Connection
Sooted Up Thermocouple
Causing Poor
Millivolt Production
Possible Cause
PILOT WILL NOT STAY LIT
Light Up
Light Up
Light Up
Light Up
Light Up
Timing
Diagnose and Replace
Valve as Necessary
Diagnose and Replace as
Necessary
Verify and Replace
Tighten Thermocouple
Connection
With Fine Abrasive,
Clean Thermocouple Surface
- Then Set Pilot Flame
to Proper Flame
Solution
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Travis Industries, Inc.
Venting
Pilot Flame
Lights and
Fades Out
Pilot Flame
Lights and
Fades Out
Pilot Flame
Lights and
Fades Out
Venting
Venting
Venting
Venting
Pilot Flame
Blowing About
Pilot Flame
Lights and
Fades Out
Venting
Pilot Flame
Blowing About
Venting
Venting
Pilot Flame
Blowing About
Pilot Flame
Lights and
Fades Out
Area of Focus
Symptoms
B-Vent
Direct V
Application
Pilot Shield Improperly Set
(Pan Style Burner)
Add/Adjust
No Incoming Air Restrictor
on older DVS Inserts
Downward Slope of
Horizontal Flue
Vent Mixing Flue Gases
Vent Blockage
Adjust to 1/8
Dimension
Add Slide Plate Restrictor
Add Screen Diffuser
Reinstall With At
Least 1/4 Rise Per Foot
of Horizontal Run
Check Inner Liners and Seal
and/or Check for Proper Cap
Installation
Locate and Remove
Replace With
High Wind Cap
Adjust Air Restrictor
and Observe
Air Restrictor
Not Adjusted
Properly
Improper
Vent Cap
Refer to
Installation Directions
and Correct
Solution
Improper
Venting
Configuration
Possible Cause
PILOT WILL NOT STAY LIT
Light Up
Light Up
Light Up
Light Up
Light Up
Light Up
Light Up
Light Up
Occurrence
Timing of
Problem
Log Shelf & Pilot Shield Alignment
In an effort to fully diagnose any problem that may lead to the pilot flame
going out, we recommend checking the log shelf and pilot shield on the
models shown below. With the log shelf installed correctly, the pilot shield
should protect the pilot flame from air disturbances, keeping the flame pointed
directly at the thermocouple (see the illustration below). An improperly placed
log shelf or a slight misalignment of the pilot shield may cause intermittent
pilot dropout when the flame is blown away from the thermocouple. Use the
illustration below to check the log shelf and pilot shield. If the log shelf is
out of alignment, remove it and reinstall. If the pilot shield is out of alignment,
follow the directions on the following page to fix the problem.
Check the pilot
flame to see if it is
deflected forward (it
may be intermittent
- watch for at least
30 seconds) NOTE:
The
the pilot flame is
exaggerated in this
illustration.
Models Affected:
• Avalon 700 B-Vent
• Avalon 700 DV
• Avanti DV
• Avanti B-Vent
• Lopi Spirit B-Vent
Copyright ' 4/20/2006
• Lopi Spirit DV
• Lopi Spirit Insert
• Lopi Heritage Bay Insert
• Travis DVS Insert
• Travis DVS Fireplace
8
Travis Industries, Inc.
Copyright ' 4/20/2006
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Travis Industries, Inc.
Check the pilot shield.
Pilot
Hood
With the log shelf correctly
aligned, the pilot shield should
look like this. The right edge
should be 1/8” to the left of the tip
of the thermocouple. Mis-placed
pilot shields may lead to pilot
outage. See the directions on the
following page to align the pilot
shield.
b
Pilot Shield
a
1/8”
Rear Log Shelf
The two tabs slide over the
side of the burner pan on
both sides.
Thermocouple
When positioned correctly,
the rear log shelf has a
parallel 3/8” gap to the
burner pan.
Check rear log shelf alignment:
Rear
Log
Shelf
Burner Pan
Assembly
How to Check the Log Shelf and Pilot Shield
Log Shelf & Pilot Shield Alignment
Position the
shelf so the
back edges
of the shelf
and burner
pan are
flush.
Log Shelf & Pilot Shield Alignment
How to Fix Pilot Shield Alignment:
Older Models (Built Before January 1999)
Older models used round holes with rivets. To realign the pilot shield on these
models, follow the directions below.
a
Note how far, and to which direction,
the pilot shield is out of alignment.
b
Remove the log shelf and drill
out these two rivets to remove
the pilot shield.
c
Make new holes (or enlarge the
existing holes) to accommodate
the incorrect alignment. Then reattach the pilot shield with two
screws or rivets.
Newer Models (Built After January 1999
Newer models utilize a shield with oblong holes and are fastened with screws,
allowing adjustment at the factory. If the pilot shield requires adjustment,
simply loosen the two screws and move the pilot shield to the left or right to
achieve the correct position.
To adjust the pilot shield, loosen these screws
and move the pilot shield to the correct
position. Re-tighten the screws.
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Travis Industries, Inc.
Pilot Mounting Bracket Check
In an effort to fully diagnose any problem that may lead to the pilot flame
going out, we recommend checking the pilot assembly bracket on the models
listed below. This bracket was originally made with an inadequate mounting
hole for the pilot assembly (it has since been fixed). This caused one of the
screws on the quick-change pilot assembly to interfere with the bracket,
creating a small warp on the pilot assembly. The warp may tilt the pilot
flame away from the thermocouple, causing the pilot to go out intermittently.
It does not create a safety hazard.
Models Affected:
- Avalon 700 B-Vent with Quick-Change Pilot Assemblies (starting with serial # 70390)
- Avalon 700 DV with Quick-Change Pilot Assemblies (starting with serial # 52263)
- Avanti DV with Quick-Change Pilot Assemblies (starting with serial # 34538)
- Lopi Spirit B-Vent with Quick-Change Pilot Assemblies (starting serial # 6933)
- Lopi Spirit Insert with Quick-Change Pilot Assemblies (starting with serial # 27137)
- Lopi Heritage Bay Insert with Quick-Change Pilot Assemblies (starting with
¥ serial # 111622)
- Travis DVS Inserts with Quick-Change Pilot Assemblies (starting with serial # 88892)
- Travis DVS Fireplaces with Quick-Change Pilot Assemblies (starting with serial # 103887)
Copyright ' 4/20/2006
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Travis Industries, Inc.
Pilot Mounting Bracket Check
How to Check for This:
Check the front edge
of the pilot assembly
to see if it is warped
upwards. You may
notice a slight gap
between the pilot
assembly gasket and
the pilot mounting
bracket.
Pilot Assembly
Pilot Assembly
Gasket
Pilot
Mounting
Bracket
How to Fix this Problem:
The end of this screw may interfere
with the pilot mounting bracket.
To fix this problem, use a
file or drill to remove a
small amount of the bracket
at this location (be careful
not to damage the pilot
tube or wires)
3/4”
Copyright ' 4/20/2006
1/4" Nutdriver
1/8”
12
Travis Industries, Inc.
PROPER
OPERATION
PROCEDURE
FUEL/AIR/HEAT
RELATIONSHIP
• Spark Electrode
• Pilot Hood
Copyright ' 4/20/2006
Delayed
Pilot
Ignition
FUEL
• Partial
¥ Blockage
• Proper
¥ Fuel
¥ Pressure¥
13
LOG/EMBER
PLACEMENT
• Correct
¥ Placement
¥ and
¥ Position
Travis Industries, Inc.
Copyright ' 4/20/2006
14
Travis Industries, Inc.
Area of Focus
Fuel
Fuel
Log Ember
Placement
Miniature Puff As
Pilot Lights
Miniature Puff As
Pilot Lights
Relationship
Miniature Puff As
Pilot Lights
Miniature Puff As
Pilot Lights
Air/Fuel/Heat
Miniature Puff As
Pilot Lights
Miniature Puff As Lack of Operational
Pilot Lights
Knowledge
Symptoms
B-Vent
Direct V
Application
Clean/Replace
Check Incoming
Pressure and Adjust as
Necessary
Correct Placement
Improper Gas
Pressure
Improper Application of
Ember Material
Reshape/Replace
Realign for Proper
Balance
Follow Lighting
Instructions
Solution
Partially Plugged
Pilot Orifice
Pilot Hood
Mishaped
Spark/Gas
Alignment
Not Waiting Between
Attempts to Light
Possible Cause
DELAYED PILOT IGNITION
Light Up
Light Up
Light Up
Light Up
Light Up
Light Up
Occurrence
Timing of
Problem
POOR
PILOT
FLAME
LOW GAS
FLOW
HIGH GAS
FLOW
PILOT
ASSEMBLY
• Pilot
¥ Adjustment
• Pilot
¥ Adjustment
• Pilot
¥ Retainer
• Increasing Gas
¥ Pressure
• Increasing Gas
¥ Pressure¥
• New/Old
Assemblies
• Pilot Orifice Size
• Pilot Orifice Size
• Partial Blockage
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Travis Industries, Inc.
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Travis Industries, Inc.
Light Up
Light Up
Low Gas
Flow
Low Gas
Flow
Low Gas
Flow
High Gas
Flow
High Gas
Flow
High Gas
Flow
Small
Poor Pilot
Small
Poor Pilot
Small
Poor Pilot
Small
Poor Pilot
Large
Overfiring Pilot
Large
Overfiring Pilot
Large Pilot
Lifting Off of
Burner
B-Vent
Direct V
Application
POOR PILOT FLAME
Light Up
Light Up
Light Up
Light Up
Light Up
Low Gas
Flow
Symptoms
Occurrence
Timing of
Problem
Area of Focus
Check Pipe Sizing
and/or Supply System
Regulator
Adjust Pilot
Flame Down
Change to
Proper Size
Low Incoming
Pressure
Improper Pilot
Adjustment
Improper Size
Orifice
Check Incoming
Pressure and Notify
Supplier
Change to
Proper Size
Improper Size
Orifice/or Gas Type
High Incoming
Pressure
Clean/Replace
Adjust Pilot
Flame Up
Solution
Partially Plugged
Orifice
Improper Pilot
Adjustment
Possible Cause
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Travis Industries, Inc.
Light Up
Light Up
Pilot
Assembly
Pilot
Assembly
Pilot
Assembly
Pilot
Assembly
Large Yellow
Tipped Pilot
Large Yellow
Tipped Pilot
Large All Yellow
Candle Like Flame
Large Target
Poorly Located
B-Vent
Direct V
Application
POOR PILOT FLAME
Light Up
Light Up
Area of Focus
Symptoms
Occurrence
Timing of
Problem
Reshape or Replace
Pilot Hood
Replace Missing
Pilot Retainer
Pilot Retainer
Missing
Misshaped
Pilot Hood
Replace Pilot
Retainer
Loosen Pilot Tube Nut,
Push Pilot Assembly
Down and Retighten Nut
Solution
Pilot Retainer
Bent Up
Pilot Retainer
Pushed Up
Possible Cause
PROPER
OPERATION
PROCEDURE
GAS
FLOW
• Blockage
• Gas Pressure
Burner
Will Not
Light
MILLIVOLT
PRODUCTION
• Pilot
¥ Flame
• Electrical
¥ Connections
¥ & Circuits
• Thermopile
DEFECTIVE
COMPONENTS
• Rocker Switch¥
• Remote Control
¥ or Thermostat
• Operator Head
¥ Gas Valve
• Proper Wiring
Copyright ' 4/20/2006
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Travis Industries, Inc.
Copyright ' 4/20/2006
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Travis Industries, Inc.
Defective Regulator
Light Up
of Burner
Gas
Flow
Burner
Does Not Light
BURNER WILL NOT LIGHT
Incoming Gas
Pressure/Orifice
Too Small
Light Up
of Burner
Gas
Flow
Burner
Does Not Light
Replace
Regulator
Adjust
Pressure/Replace
Clean Burner Ports
Blocked Burner Ports
(Paint/Foreign Material)
Light Up
of Burner
Burner
Does Not Light
Gas
Flow
Operational
Knowledge
Burner
Does Not Light
Turn Control
Knob to ON
Solution
Not Enough Time for the Allow More Time for the
Thermopile to Warm Up Thermopile to Warm Up
Control Knob Not
Turned to ON
Possible Cause
Rocker Switch OFF or
Turn ON Rocker
Switch
or Turn Up the
Thermostat is Not Closed
Thermostat
(Calling for Heat)
Light Up
of Burner
Operational
Knowledge
Burner
Does Not Light
B-Vent Direct V
Application
Light Up
of Burner
Light Up
of Burner
Operational
Knowledge
Burner
Does Not Light
Occurrence
Timing of
Problem
Area of Focus
Symptoms
Copyright ' 4/20/2006
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Travis Industries, Inc.
Light Up
of Burner
Gas
Flow
Gas
Flow
Millivolt
Production
Burner
Does Not Light
Burner
Does Not Light
Burner
Does Not Light
Burner
Does Not Light
Burner
Does Not Light
Appliance
Components
Burner
Does Not Light
BURNER WILL NOT LIGHT
Weak Thermopile From
Switch Wire Length
Weak or Defective
Thermopile
Light Up
of Burner
Millivolt
Production
Burner
Does Not Light
Light Up of Burner After A Couple of Years
of Working Well
Loose/Bad
Thermopile Connections
Light Up
of Burner
Millivolt
Production
Burner
Does Not Light
Replace Thermopile or
Shorten or Increase
Wire Gauge Size
Replace if Less
Than 250-300 MV
Tighten/Replace
Connections
Straighten Floor and
Eliminate Contact
Tube Style Burner Floor Bent
and Touching Top of the
Thermopile Causing Low
Millivolt Production
Light Up
of Burner
Replace Gas
Control Valve
Clean/Replace Burner
Tube
Clean/Replace
Orifice
Millivolt
Production
Blockage in the
Gas Valve
Burner Tube Blockage
Orifice Blockage
Solution
Adjust to Proper
Location and Size
Direct V
Possible Cause
Misaligned or too
Small Pilot
B-Vent
Application
Light Up
of Burner
Light Up
of Burner
Light Up
of Burner
Gas
Flow
Symptoms
Occurrence
Timing of
Problem
Area of Focus
Copyright ' 4/20/2006
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Travis Industries, Inc.
Defective Wall
Thermostat/Switch
BURNER WILL NOT LIGHT
Light Up
of Burner
Defective
Components
Burner
Will Not Light
Defective
Rocker Switch
Light Up
of Burner
Defective
Components
Burner
Will Not Light
Test/Replace
Test/Replace
Replace Gas
Control Valve
Defective
Operator Head Coil
Light Up
of Burner
Defective
Components
Burner
Will Not Light
Shorten/Replace
Thermostat Wire
Too Long
or Broken
Light Up
of Burner
Millivolt
Circuit
Burner
Will Not Light
Wire
Correctly
Mis-wired Wall Switch,
Remote Thermostat
Light Up
of Burner
Millivolt
Circuit
Burner
Will Not Light
Wire
Properly
Mis-wired
Gas Valve
Light Up
of Burner
Millivolt
Circuit
Burner
Will Not Light
Turn Rocker
Switch ON
Replace Jumper
Solution
Series Wired Thermostat,
Remote, Wall Switch and
Rocker Switch
Possible Cause
Light Up
of Burner
Direct V
Green Jumper Wire on
Rocker Switch Missing
B-Vent
Application
Light Up
of Burner
Occurrence Timing
of Problem
Millivolt
Circuit
Millivolt
Circuit
Area of Focus
Burner
Will Not Light
Burner
Will Not Light
Symptoms
Copyright ' 4/20/2006
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Travis Industries, Inc.
• Mixing Flue
¥ Gases
• Blockage
• Lack of High
¥ Wind Cap
• Venting
¥ Parameters
VENTING
• Air Restrictor
APPLIANCE
ADJUSTMENT
• Spill Switch/
ACircuit
• Thermopile
APPLIANCE
COMPONENTS
BURNER
WILL NOT
STAY LIT
• Uninstalled
¥ Outside Chase
¥ Termination
• Termination
¥ Location
Stack Effect
• Negative
¥ Pressure
HOUSE
EFFECT
Copyright ' 4/20/2006
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Travis Industries, Inc.
Venting
Venting
Venting
Normal Looking
Burner Flame &
Then Just Goes Out
Ghosting Flame
Flame Disruption
or Ghosting
Ghosting Flame
BURNER WILL NOT STAY LIT
Mixing Exhaust Gases
With Fresh Air
Immediate to
Within a
Few Minutes
Venting
Blockage
Immediate to
Within a
Few Minutes
Downward Slope on
Horizontal Run
Lack of a
High Wind Cap
Immediate to
Within a
Few Minutes
Immediate to
Within a
Few Minutes
Exceeding Venting
Parameters
Immediate to
Within a
Few Minutes
Venting
Spill Switch Caused By
Spilling Flue Gases
Possible Cause
Immediate to
Within a
Few Minutes
Direct V
Restrictor
Adjustment
B-Vent
Application
Immediate to
Within a
Few Minutes
Occurrence
Timing of
Problem
Ghosting Flame
Venting
Appliance
Adjustment
Fire Lifts Off Burner Flame Gets Ghostly
Blue & Disappears
Ghosting Flame
Area of Focus
Symptoms
Re-Seal Inner
Lining/Reinstall Cap
Correctly
Raise So There is at
Least 1/4 Rise Per Foot
Locate and Remove
Blockage
Install a High
Wind Cap
Correct Size, Height Run,
Rise before Elbowing, # of
Elbows, Etc. (Refer to
Installation Manual)
Identify Venting
Problem & Fix
Readjust
Restrictor
Solution
Copyright ' 4/20/2006
24
Travis Industries, Inc.
House Depressurization
of More Than 5 pa
(B-Vent) or 20 pa (DV)
High Pressure at Vent
Termination Due to
Surrounding Roof Line or
Other Elements
Uninsulated Chase/Vent
Area - Flue Gases Cool
Too Quicky
House Stack
Effect
Determined By
Other House
Appliances
Determined By
Weather
Patterns
Determined By
Weather
Patterns
Determined By
House and Weather
Patterns
House
Environment
House
Environment
House
Environment
Burner Will Not
Stay Lit
Burner Will Not
Stay Lit
Burner Will Not
Stay Lit
Burner Will Not
Stay Lit
House
Environment
Overheated
Thermopile
Immediate to
Within a
Few Minutes
Burner Will Not
Stay Lit
Appliance
Components
Possible Cause
Defective Spill
Switch/Circuit
BURNER WILL NOT STAY LIT
Direct V
Immediate to
Within a
Few Minutes
B-Vent
Appliance
Components
Application
Burner Will Not
Stay Lit
Occurrence
Timing of
Problem
Area of Focus
Symptoms
Relocate Stove to a
Taller Part of
the House
Insulate/Heat
Chase Area
Raise/Move
Termination
Bring in Adequate
Make Up Air
Wire Diameter
Remove Ember/Log
Heat Transfer
Test and Replace as
Necessary
Solution
Copyright ' 4/20/2006
25
Travis Industries, Inc.
• Air Shutter
• Air Shutter
• Gas Pressure
• Placement¥
• Ember-Fyre
¥ Shutter
¥ Adjustment
SHORT
BLUE
FLAME
LIFTING
BLOWING
FLAME
POOR
EMBER
GLOW
POOR BURNER
FLAME
APPEARANCE
• Gasket Leak
¥Adjustment
• Air
FLAME
NEVER
YELLOWS UP
• Venting
• Adjustment
ORANGE
GHOSTLY
BLUE FLAME
Copyright ' 4/20/2006
26
Travis Industries, Inc.
When Lit
After About
15 Minutes of
Burn Time
Ember Material
Air & Gas
Settings
Air
Restrictor
Air
Shutter
Air Shutter &
Gasketing
No or Poor Ember
Glow
Lifting
Flame
Active
Blowing Flame
Short Blue
Flame
Flame
Never Yellows Up
B-Vent
Ember-Fyre
Direct V
Application
FLAME APPEARANCE
When Lit
When Lit
After About
15 Minutes of
Burn Time
Ember Material
No or Poor Ember
Glow
Occurrence
Timing of
Problem
After About
15 Minutes of
Burn Time
Area of Focus
Symptoms
Close Air Shutter Thus
Creating More Glow
Refer to
Placement Guide
Solution
• Fire Chamber Gasket
• Glass Gasket Leaks
• Air Restrictor Adjustment
• Air Shutter
Air Shutter Open too Far
Air Restrictor Adjustment
is Open too Far
• Excessive Air
Check Settings and
Gaskets
Adjust According to
Flame Pictorial in
Installation Manual
Reduce Restrictor
Opening
Check and Properly
Adjust Air Shutter and
• Excessive Gas Pressure
Gas Pressure
Air Shutter
Too Open
Poor Placement Not
Giving BEST
Ember Look
Possible Cause
Copyright ' 4/20/2006
27
Travis Industries, Inc.
Flame Changes
Color to Orange and
Then Ghostly Blue
Symptoms
Short Time
After Start Up
Air Restrictor &
Venting
B-Vent Direct V
Application
FLAME APPEARENCE
Occurrence
Timing of
Problem
Area of Focus
• Clean
• Change
• Provide 1/4 Rise Per Foot
• Relocate Vent Exit
• Blocked Flue
• Rise To Run Parameters
¥ Not Followed
• Downhill Horizontal Runs
• Vent Terminations Too
¥ Close to Adjacent
¥ Surfaces or Structures
¥
• Inner Flue Co-Linear Not
¥ Sealed With High
¥ Temperature Sealant
Exhaust
Only
• Check and Repair
• Ensure No Unauthorized
¥ Modifications Have Taken
¥ Place
DVS & DVL Exhaust
& Intake
• Reconnect
• Disconnected Flues
• Seal
• Readjust
Solution
• Air Restrictor
Possible Cause
SOOTING
LACK OF
COMBUSTION
AIR
LOG EMBER
MATERIAL
FUEL
• Air Shutter
• Log Placement
• Air Restrictor
• Ember Material • Fuel Type
• Venting
• Orifice Size
• Non-Commercial
¥ Grade Propane
• Gas Pressure
Copyright ' 4/20/2006
28
Travis Industries, Inc.
Copyright ' 4/20/2006
29
Travis Industries, Inc.
Area of Focus
Lack of
Combustion Air
Lack of
Combustion Air
Lack of
Combustion Air
Log Ember
Placement
Log Ember
Placement
Symptoms
Carbon & Soot On
Logs - Glass and/or
Outside of House
Carbon & Soot On
Logs - Glass and/or
Outside of House
Carbon & Soot On
Logs - Glass and/or
Outside of House
Carbon & Soot On
Logs - Glass and/or
Outside of House
Carbon & Soot On
Logs - Glass and/or
Outside of House
Over
Time
Over
Time
Over
Time
Over
Time
Over
Time
B-Vent
Direct V
Application
SOOTING
Occurrence
Timing of
Problem
Improper
Application of
Ember Material
Log/Flame
Impingment
Venting Fresh
Air Restriction
Improper Restrictor
Setting
Air Shutter
Closed Too Far
Possible Cause
Replace With Proper
Amount and Correct
Placement
Re-Set Logs
Open Up-Clean Out
Blockage
Readjust
Restrictor
Adjust
Properly
Solution
Copyright ' 4/20/2006
30
Travis Industries, Inc.
Area of Focus
Fuel
Fuel
New Fill Up of
Propane
Long Extended
Cold Spell
Symptoms
Carbon & Soot On
Logs - Glass and/or
Outside of House
Carbon & Soot On
Logs - Glass and/or
Outside of House
Carbon & Soot On
Logs - Glass and/or
Outside of House
Carbon & Soot On
Logs - Glass and/or
Outside of House
Over
Time
Over
Time
Over
Time
Over
Time
Occurrence
Timing of
Problem
Direct V
SOOTING
B-Vent
Application
Change to a Commercial
Grade of Propane
No Fix Other Than Wait
for Warmer Weather
and the Discontinued
Use of Propane Air Mix
Propane Air Mix Added
to Natural Gas to Meet
Demand
Check and Adjust to
Proper Fuel Pressure
Replace With Correct
Orifice
Solution
Non-Commercial
Grade of Propane
Improper Fuel
Pressure
Wrong Orifice
Possible Cause
DELAYED
BURNER
IGNITION
OPERATIONAL
PROCEEDURES
PARTIAL
BLOCKAGE
FUEL/AIR/HEAT
RELATIONSHIP
• No Wait Between
¥ Attemps to Light
• Burner Ports
• Air Shutter
¥ Setting
• Burner Tube
• Ember
¥ Placement
• Orifices
Copyright ' 4/20/2006
31
• Flame Gas
¥ Alignment
• Carry Over
¥ Gas Ports
Travis Industries, Inc.
Copyright ' 4/20/2006
32
Travis Industries, Inc.
At Light Off
At Light Off
At Light Off
At Light Off
At Light Off
Fuel/Air/Heat
Relationship
Fuel/Air/Heat
Relationship
Fuel/Air/Heat
Relationship
Partial
Blockage
Partial
Blockage
Partial
Blockage
Partial
Blockage
Small Explosion As
Burner Lights
Small Explosion As
Burner Lights
Small Explosion As
Burner Lights
Small Explosion As
Burner Lights
Small Explosion As
Burner Lights
Small Explosion As
Burner Lights
Small Explosion As
Burner Lights
Small Explosion As
Burner Lights
B-Vent Direct V
Application
Follow Lighting
Directions
Realign for
Proper Balance
Adjust to
Minimum Opening
Per Travis Instruction
Add Burner Ports
Clean
Ports
Clean
Correct Placement
Clean/Replace
Pilot Flame/Gas
Alignment
Air Shutter
Totally Closed
No
Flame Travel
on Burner
Partially
Plugged Burner
Ports
Burner
Tube
Blockage
Improper
Application of Ember
Material
Partially Plugged
Pilot/Burner
Orifice
Solution
Not Waiting Between
Attempts to Light
Possible Cause
DELAYED BURNER IGNITION
At Light Off
At Light Off
At Light Off
Lack of Operational
Knowledge
Symptoms
Occurrence
Timing of
Problem
Area of Focus
Remote
Does Not
Turn On
Main
Burner
PROPER
OPERATION
PROCEDURE
REMOTE
• Batteries
• Frequencies
• Deffective
¥Sensor
¥ Reciever
Copyright ' 4/20/2006
33
ELECTRICAL
• Wiring
¥ Pattern
• No Electricity
¥ (110 Volt
¥˚Receivers)
• Loose Wiring
¥ Connections¥
Position
Travis Industries, Inc.
Copyright ' 4/20/2006
34
Travis Industries, Inc.
Remote Does Not
Activate Burner
Reset Breaker or
Replace Fuse
Tighten or Replace as
Necessary
Loose Wiring
Connections
Wire in Accordance
With Installation
Directions
Replace
Replace Batteries
No 110 Volt Power
Source
Mis-Wired
REMOTE DOES NOT TURN ON BURNER
Throughout Life of
Product
At Start Up
Electrical Supply
Source
Electrical
At Start Up
Defective Sending or
Receiving Unit
Electrical
Remote Does Not
Activate Burner
Turn Unit Switch ON
Unit Switch OFF
(Series Wired)
Match Frequencies By
Sender and Receiver
Matching
ON or OFF of
Frequencies Not Matched
Dip Switches
Read and Follow
Remote Use
Instructions
Solution
Improper Use of Remote
Functions
Possible Cause
Throughout Life of
Product
Direct V
Weak or Dead AA or AAA
Batteries
B-Vent
Application
Throughout Life of
Product
Remote Does Not
Activate Burner
Remote
Remote Does Not
Activate Burner
At Start Up
Remote
Remote
Remote Does Not
Activate Burner
At Start Up
At Start Up
Occurrence
Timing of
Problem
Remote Does Not
Activate Burner
Operational
Operational
Remote Does Not
Activate Burner
Remote Does Not
Activate Burner
Area of Focus
Symptoms
OPERATIONAL
PROCEDURE
Thermostat Doesn t
Turn ON Main
Burner
THERMOSTAT
LOCATION
MILLIVOLT
FLOW
• Other
¥ Heat Sources
• Loose
¥ Electrical
¥ Connections
• Rated for
¥ Millivolt
¥ Operation
• Thermopile
¥ Electrical
¥ Production
• Defective ¥
Thermostat
• Location
¥ in the House
• Wire Length
• Properly Wired
Copyright ' 4/20/2006
35
THERMOSTAT
• Dirty Contacts
• Improperly Set
Heat Anticipator
Travis Industries, Inc.
Copyright ' 4/20/2006
36
Travis Industries, Inc.
Mis-Wired
Too Long of
Length of Wire
At Start Up
At Start Up and
Throughout Life of
Product
Throughout Life of
Product
Electrical Flow of
Millivolt
Electrical Flow of
Millivolt
Electrical Flow of
Millivolt
Thermostat Doesn t
Activate Burner
Thermostat Doesn t
Activate Burner
THERMOSTAT DOES NOT TURN ON MAIN BURNER
Broken Wire
Replace Wire
Shorten or Increase
Wire Gauge Size
Wire in Accordance of
Installation Instructions
Increase Millivolt
Production or Replace
Thermopile
Weak Millivolt Production
(Pilot/Thermopile)
Thermostat Doesn t
Activate Burner
Throughout Life of
Product
Electrical Flow of
Millivolt
Thermostat Doesn t
Activate Burner
Tighten Connections
Solution
Loose Connections at
Thermostat or Switch
At Start Up
Electrical Flow of
Millivolt
Possible Cause
Thermostat Doesn t
Activate Burner
B-Vent Direct V
Area of Focus
Symptoms
Application
Occurrence
Timing of
Problem
Copyright ' 4/20/2006
37
Travis Industries, Inc.
Thermostat Doesn t
Activate Burner
Throughout Life of
Product
Throughout Life of
Product
At Start Up
At Start Up
Through Out Life of
Product
At Start Up
Occurrence
Timing of
Problem
B-Vent
Direct V
Application
Dirty
Controls
Defective
Non-Millivolt
Thermostat
Wrong Location in the
House
Heat Source Close to
Thermostat I.E. Lamp,
TV, Etc.
Unit ON/OFF Switch Not ON
(Thermostat Wired in Series
Possible Cause
THERMOSTAT DOES NOT TURN ON MAIN BURNER
Thermostat
Thermostat
Thermostat
Thermostat Doesn t
Activate Burner
Thermostat Doesn t
Activate Burner
Installation
Location of
Thermostat
Thermostat Doesn t
Activate Burner
Thermostat Doesn t
Activate Burner
Installation
Location of
Thermostat
Operational Error
Symptoms
Thermostat Doesn t
Activate Burner
Area of Focus
Clean
Replace
Replace
Move Location to
Better Sense the
Need for Heat
Remove Heat Source or
Relocate Thermostat
Turn Unit ON/OFF
Switch ON
Solution
APPLIANCE
BLOWER
DOES NOT
WORK
• Operational
¥ Procedures
• Electrical
• Defective
¥ Rheostat
NOISES
SMELLS &
ODORS
• Metal Expansion
• Gas Leaks
• Pilot Related
• First Firing
• Burner
• Construction
¥ Related ON/OFF ¥ Materials
• Blower Related
• Defective Blower
• Dust, Dirt, Lint,
¥ Pet Hair
• Defective Snap
¥ Disk
Copyright ' 4/20/2006
38
Travis Industries, Inc.
Copyright ' 4/20/2006
39
Travis Industries, Inc.
At Start Up
Operational
Knowledge
No 110V
Supply
Low
Voltage
Defective
Components
Defective
Components
Defective
Components
Symptoms
Blower Not
Coming On
Blower Not
Coming On
Blower Not
Coming On
Blower Not
Coming On
Blower Not
Coming On
Snap DiskBlower ON Before
Stove Heats Up
¥ With a N.O. ¥˚Snap Disk
• Wrong Snap Disk N.C.
BLOWER DOES NOT WORK
• Test and Replace
Test and
Replace
Replace
Blower
Adjust POT on the
Rheostat
Reset Breaker
or Replace Fuse
¥ Wait for Stove to Reach
¥ Temperature
¥ Turn on Rheostat
Solution
• Defective Snap Disk
Defective Blower
Anytime
Throughout Life of
Blower
Anytime
Throughout Life of
Blower
Too Low of Voltage
on Low Speed
Breaker/Fuse
¥ Stove Not Up to
¥ Temperature
¥ Rheostat Switch OFF
Possible Cause
Anytime
Throughout Life of
Blower
Direct V
No 110 Volt
Power Supply
B-Vent
Application
Anytime
Throughout Life of
Blower
At Start Up
Occurrence
Timing of
Problem
Area of Focus
Copyright ' 4/20/2006
40
Travis Industries, Inc.
Burner
APPLIANCE NOISES
At Shut
Down
Burner
Baffling
Replace With
Updated Burner
Air Shutter
Extension Pop After
Burner Turns Off
Extension Pop After
Burner Turns Off
Close Down
Air Shutter
Air Shutter
Open Too Far
Shutter Opening
Roaring Noise
At Shut
Down
Turn OFF Burner and
Close Down Primary
Air Shutter
Excess Air/or Burn
Back at Burner Orifice
At Light
Off
Turn Pilot
Down
Close Primary Air/Turn
Down Gas Pressure
Too Strong
of a Pilot
Replace Defective
Blower
Scrapping/Grinding
Sound
Excess Air - Too Much
Gas Pressure
During
Burn
When Blower is
Operating
Adjust POT
See Adjustment Page
Dragging Sound
(Too Low Voltage)
At Light
Off
Blower
Scraping
Squeeling Sound
When Blower is
Operating
Turn
Rheostat Down
Loud
Air Flow
Burner
Blower
Growing
Grinding Noise
When Blower is
Operating
Release Stress on
Subject Part
Solution
Stress Expansion in Metal
Heating and Cooling (Minimal)
Possible Cause
Hissing/Roaring
Noise at Burner
Blower
Air Flow
Noise
At Start Up and
Cool Down
Direct V
Pilot
Metal Expansion
(Tin Canning)
Clicking
Bong Noise
B-Vent
Application
Hissing
Sound
Area of Focus
Symptoms
Occurrence
Timing of
Problem
Copyright ' 4/20/2006
41
Travis Industries, Inc.
Consistent or After
Insert Comes Up to
Heat
During Start Up or
During Burn
Occurrence
Timing of
Problem
B-Vent Direct V
Application
• Check With An
Solution
• Rain Moisture Entrance
¥ on Masonry Firebox,
¥ Smoke Chamber or
¥ Chimney
• Creosote/Soot Build Up
• Gas Leak Around Gas
¥ Control Valve
• Install Rain Cap
¥ Smoke Chamber
• Purge Firebox and
• Remove Tile and
¥ Reline
¥ Creosote
• Clean Out 3rd Degree
• Better Face Seal
• All Leaks MUST Be
¥˚Located and Fixed
¥ Appliances Gas Tubing ¥ Electric Gas Leak
¥˚Detector
¥ Connections
• Gas Leaks At One of the
Possible Cause
SMELLS AND PERSISTENT ODORS
Rotten Egg Gas
Smell
Chimney
Gas Leak
Symptoms
Stinky Creosote
Smell
Area of Focus
Copyright ' 4/20/2006
42
Travis Industries, Inc.
Burner/Convection
Chamber
Consistent Odor After
First Few Months or
First Summer
First Burn Through
Some Duration of
Time
Building Material
Waste Such as
Sawdust, Dry Wall
Dust, Adhesives,
Plastic Coatings. Etc.
There Might Be a
Sawdust or Burnt
Wood Odor
First
Firing
NEW Appliance
Odor/Smoke and
Fumes
Area of Focus
B-Vent
Direct V
Application
May be Distributing Dust
Due to a Poor filter
• Vacuums - Your Vacuum
Contaminated Combustion
Air or Air Flow Through
Contaminated Convection
Chambers - i.e. Cat, Dog,
Pet Dander, Carpet Fiber,
Bed, Clothing Lint, House
Dust, Insects.
• Aldehydes Caused By
Burning Off Any Building
Material, Dirt, Dust and
Debris
Paint Curing - Logs
Burning Gases Off
Oil Burning Off
Possible Cause
SMELLS AND PERSISTENT ODORS
NOTE: When Aldehydes Are Produced,
Carbon Monoxide is Always Present
Pungent Odor or
Burnt
Dust/Plastic Smell
Sawdust or Burnt
Wood Odor
Odor/Smoke/
Fumes
Symptoms
Occurrence
Timing of
Problem
Convection Chambers
Frequently
• Clean Stove Surfaces and
on Central Heating System
• Put in Electrostatic Filter
Frequency in the Room the
Appliance is Located in
• Increase Cleaning
Convection Chamber With
Denatured Alcohol
• Clean Entire Stove and
Clean All Accessible
Areas and Remove any
Inappropriate Building
Material Contact
Will Burn Off With Heat
and Time
Open Doors and
Windows to Ventilate
Solution
Copyright ' 4/20/2006
43
Travis Industries, Inc.
Mildew/Mold Smell
Once Appliance
Comes Up to Heat
After Some
Considerable Time
Occurrence
Timing of
Problem
B-Vent Direct V
Application
Heat Reaction to Finish
and or Trim
Applications and Floor
Coverings I.E. Varnish,
Paints, Urethanes,
Carpet, Wood, Drywall
Etc.
Water Leakage Creating
Mildew, Mold From
Flashing, Chimney
Possible Cause
SMELLS AND PERSISTENT ODORS
Finish of Trim,
Flooring, and
Surroundings
Chase/Fireplace
Enclosure
Symptoms
Hot Smell, Plastic
Smell,
Discoloration of
Finished Materials
Area of Focus
Replace Materials
With Heat Resistant
Materials or Shield
From Heat
Off Gassing of NEW
MATERIALS I.E. Vinyls,
Carpets - Will
Dissipate With Time
¥ Open Mildew Area
¥ and Kill With Lysol
¥ Spray and Clean
¥ Find Leaks and
¥ Correct
Solution
Copyright ' 10/6/2003
44
Travis Industries, Inc.
Venting
Flue Gas Smell
(Note: Odor Will
Not Always Be
Present)
Spillage Switch
Turns OFF
Appliance
Shortly After Start
Up or anytime
During Burn
Occurrence
Timing of
Problem
B-Vent
Direct V
Application
Solve House Problems
By Providing House
Make Up Air
• Negative House
¥ Pressure
Install a High Wind
Cap
Unblock Venting
Correct Vent
Configuration
Solution
• Down Drafts
• Blocked Venting
¥ Configuration
• Improper Vent
• B-Vent Spillage
Possible Cause
SMELLS AND PERSISTENT ODORS
Venting
Symptoms
House Effect
Area of Focus
SIT Gas Control Ember-Fyre Units
Copyright ' 4/20/2006
45
Travis Industries, Inc.
Copyright ' 1/15/2004
Red
Optional
Thermostat
On/Off Switch
Jumper Wire
Brown
Thermocouple
46
White
Red
Copper Co-Axial
Wire
Optional Remote
Control
Thermopile
Pilot Hood
Spark Electrode
Orange
Piezo Igniter
Direct Vent SIT Gas Control
Travis Industries, Inc.
Old B-Vent
RobertShaw Gas Control Units
Wiring Diagram
Thermopile
Spill Switch
Thermodisk
Piezo Igniter
Orange
Gas Control Valve
Brown
Thermocouple
Red
Red
Red
EPU
terminal
White
Red
Jumper Wire
(Manual
Operation)
Green
Copper Co-Axial Wire
On/Off
Switch
Chassis
Ground
Blower
Motor
Black
Green
White
Black
Optional
Thermostat
Optional
Remote
Control
Black
White
Black
120 Volt
Grounded A.C.
Power Supply
White
Black
Blower
Thermodisk
Copyright ' 1/15/2004
47
Blower
Rheostat
110 V.
Blower
Circuit
Travis Industries, Inc.
Copyright ' 1/15/2004
Brown
48
Optional
Thermostat
Jumper Wire
(Manual
Operation)
Optional
Remote
Control
Green
EPU
terminal
Gas Control Valve
Wiring Diagram
On/Off
Switch
Red
White
Red
Thermocouple
Orange
Piezo Igniter
Copper Co-Axial Wire
Thermopile
Old Direct Vent
RobertShaw Gas Control Units
Travis Industries, Inc.
Thermostat
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Copyright ' 1/15/2004
49
Travis Industries, Inc.
Remote Fireplace
Thermostat
Wire to ON/OFF Switch
Back of
on/off switch
Red & brown wires
leading to the gas
control valve.
a
Remove the jumper
wire and discard.
b
Connect the thermostat wires to back of the
on/off switch (orientation does not matter).
NOTE: Switch Must Be ON for the Remote to Work
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Travis Industries, Inc.
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Travis Industries, Inc.
a
c
Connect the red & brown wire
(removed in step “a”) to each
gas stove connector wire.
“Y” Jumper Wires
d
e
Connect the “Y” jumper
wires to the left side of the
on/off switch.
Connect each thermostat wire to
each gas stove connector wire.
Red & brown
wires leading to
gas control valve
Thermostat
Wires
NOTE: Failure to Use the Y Jumpers Will Result in an Inoperable Stove
Should the 110 Volt Supply Fail
b
Remove the jumper
wire and discard.
Remove the
red & brown
wires
leading to
the gas
control
valve.
Back of
on/off switch
¥ THREE - Wire Switch
Gas/Pellet Stove and Insert Remote
Thermostat
Blower Wiring Diagram
Chassis
Ground
Blower
Motor
Black
Green
White
Black
Black
120 Volt
Grounded A.C.
Power Supply
Black
Black
White
Black
Blower
Thermodisk
Copyright ' 1/15/2004
Blower
Rheostat
52
Travis Industries, Inc.
Optional Power Heat Duct
Wiring to the Fireplace
a
Remove the cover from the
fireplace junction box.
1/4" Nutdriver
Note: you may need to loosen this cable
clamp to ease removal of the cover plate.
Power
Source
for
Fireplace
b
Standard
Screwdriver
Copyright ' 1/15/2004
Pry out and discard
this knock-out.
53
Travis Industries, Inc.
54
Common
(white)
Ground
(green)
Common
(white)
Ground
(green)
Molex
Connector
Fireplace
Blower
Hot
(black)
Hot
(black)
Fireplace
Fireplace
Rheostat
Blower
Snap Disk
Molex
Connector
Ground
(green)
Common
(white)
Hot
(black)
Ground
(green)
Common
(white)
Hot
(black)
Ground
(green)
Common
(white)
Hot
(black)
Ground
(green)
Common
(white)
Hot
(black)
Ground
(green)
Common
(white)
Hot
(black)
Blower
Junction
Box
Optional Second Heat
Duct (same rheostat and
blower wiring as above)
Rheostat
Junction
Box
Heat Duct
Rheostat
Optional Power Heat Duct
Wiring Diagram
Wiring Diagram
Power Supply
Copyright ' 1/15/2004
Travis Industries, Inc.
Grounded
to Blower
Heat Duct
Blower
Optional Power
Duct Wiring
a
b
Remove the cover from
the blower box.
Standard
Screwdriver
Phillips
Screwdriver
Insert sheathed cable through the cable clamp.
After the wires have been connected tighten the
clamp to secure the cable.
c
Attach the hot (black) and common (white) wires to the
leads coming from the wires (use wire nuts).
d
Secure the ground wire to the ground stud inside the
blower box by tightening the included nut over the
ground wire. Re-attach the cover removed in step
"a".
Ground Wire
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Travis Industries, Inc.
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Travis Industries, Inc.
b
NOTE:Two junction
boxes are included use the best box for
your installation.
Force the sheathed cable through
one of the locking flaps on the
junction box (repeat for the other
cable). Some force is needed.
The flap will lock the cable in place.
To
Fireplace
From
Blower Box
a
Attach the common (white) wires
together. Attach the ground
(exposed or green) wires together.
Then attach each of the hot (black)
wires from the cables to the two
wires on the rheostat (orientation
does not matter). Carefully pack
the wires into the junction box.
Attach the cover plate
(either white or beige) with
the included screws. Slide
the knob (either white or
beige) over the rheostat
shaft.
Standard
Screwdriver
c
Follow the directions below to wire the rheostat. NOTE: There are two types of junction boxes, use the
appropriate junction box for your installation.
Optional Power Duct Wiring
57
Power
Source
Green
Brown
Black
Red
White
Yellow
Orange
White
Black
White
Black
Ground
White
Brown (Ground)
Blue (Common)
Green
Brown
Orange
Brown
Orange
Green
Red
Yellow
Red
Yellow
Black
Remote
Cable
Brown (Hot)
Wiring Diagram
Ring of Fire
Control Module
White
Yellow
White
Red
Gray
Gray
Blue
Blue
White
Black
GND
TH 24V
Float
Switch
Water
Pump
M
C (M/P)
P
GND
Gas Valve
Robert Shaw 20001PERC
Flexible Rope Light
30FT, 110VAC, 1/2” DIA, 5.52W/FT
M
C (M/P)
P
Ignition Control Unit
Robert Shaw 780-715 U
Water Temp
Switch
Ring of Fire Wiring Diagram
Remote Control Panel
Light
Water
Flame
Copyright ' 1/15/2004
Travis Industries, Inc.

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