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Hearth & Home IntelliFire Plus Troubleshooting Manual

Ignition system
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Troubleshooting
Guide
IntelliFire Plus Ignition System
*For authorized gas technicians use
only.
9/15/2011
Hearth & Home Technologies ©
Page1

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Summary of Contents for Hearth & Home IntelliFire Plus

  • Page 1 Troubleshooting Guide IntelliFire Plus Ignition System *For authorized gas technicians use only. 9/15/2011 Hearth & Home Technologies © Page1...

  • Page 2: Table Of Contents

    IntelliFire Plus Troubleshooting Guide Table of Contents Introduction…………………………………………………………………. 3 Tools and Instruments……………………………………………………... 5 System Basics……………………………………………………………… 6 Problem Scenario #1………………………………………………………. Problem: Pilot wont’ light, no noise and no spark Problem Scenario #2………………………………………………………. Problem: The module makes noise, but no spark Problem Scenario #3……………………………………………………….

  • Page 3: Introduction

    Introduction IntelliFire Plus Troubleshooting Use of this Guide This troubleshooting guide provides an overview of the IntelliFire Plus system, reviews problem scenarios, provides a system’s checklist and frequently asked questions. The purpose of this guides is to provide a tool:...
  • Page 4 Introduction IntelliFire Plus Troubleshooting Technical Assistance—Distributors & Dealers Heat & Glo—877-228-5012 Heatilator—877-943-2848 Quadrafire—866-804-7783 For technical assistance call the appropriate branded number, which is dedicated to trade channel partners. Please do not give these numbers to homeowners, builders, etc. Be prepared to provide the following information:...

  • Page 5: Tools And Instruments

    Tools and Instruments IntelliFire Plus Troubleshooting You will need the following tools and equipment to execute troubleshooting outlined in this guide. Required Tools: Required Testing Equipment: Open end wrenchs, 3/8‖, 7/16‖, 9/16‖ Multi-meter (must measure millivolts) Adjustable end wrenches: 8‖ and 10‖...

  • Page 6: System Basics

    System Basics IntelliFire Plus Troubleshooting The IntelliFire Plus IPI (intermittent pilot ignition) Ignition System and Wireless Con- trols is a total control system, from the components under the fireplace to the re- mote control in your hand. HHT Hearthville offers Sales and Product Knowledge Training modules as companions to this troubleshooting guide.
  • Page 7 System Basics IntelliFire Plus Troubleshooting Wireless Controls Eliminate wireless controls from the system when troubleshooting system by “unlearning remote. ON/OFF/REMOTE switch on module must be in REMOTE position for wireless con- trols to operate the remote and optional wired wall switch.
  • Page 8 System Basics IntelliFire Plus Troubleshooting IPI Ignition Control Module (see labeled diagram below) w/ remote receiver 1—Igniter sparks when commanded via wall switch, wireless control or control module switch to turn on main burner. Voltage through the wire to igniter on pilot assembly creates spark to ignite gas released to pilot assembly.
  • Page 9 System Basics IntelliFire Plus Troubleshooting IPI Gas Valve w/ Stepper Motor 2. Inlet 3.Manifold 4. Stepper Pressure Pressure Motor 1. Pilot Regulator 5. Main Burner Regulator 1. Pilot regulator is stamped as Nat or LP, designating the factory set- ting. If converted the main burner...
  • Page 10 System Part Numbers IntelliFire Plus Troubleshooting IPI valve Pilot Assembly Control Module (Sold complete) Battery Backup Transformer with 1 amp fuse 2166-305 2166-323 Jumper Wire * Refer to specific unit service parts list for correct part number. 9/15/2011 Hearth & Home Technologies ©...
  • Page 11 System Part Numbers IntelliFire Plus Troubleshooting Main Components of Wireless Controls RC100 control RC100—Wall mounted control w/ cover plate. RC200—Control, docking station and AUX200 module to control fan kit. RC300—Control, docking station and AUX300 module to control fan kit and 2 auxiliary func- tions.
  • Page 12 System Checklist IntelliFire Plus Troubleshooting Diagnose Root Cause Going into a service call with a conclusion prior to checking the complete system can lead to replacing unnecessary parts, multiple service calls and wasted time and money for you, the customer and HHT. When servicing any HHT product the complete sys- tem needs to be checked to diagnose the cause.

  • Page 13: Problem Scenario #1

    Problem Scenarios #1 IntelliFire Plus Troubleshooting Problem: Pilot wont’ light, no noise and no spark* Go to page 29 to familiarize yourself with ** Notice ** module diagnostic codes. Disconnect power to the system The problem may be: prior to disconnecting any compo- nents by switching the ON/OFF/ 1.
  • Page 14 Problem Scenarios #1 continued... IntelliFire Plus Troubleshooting Problem: Pilot wont’ light, no noise and no spark * 1. Loose or improper wiring. System not grounded. 2. Control Module selector switch NOT set properly. * Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system.
  • Page 15 Problem Scenarios #1 continued... IntelliFire Plus Troubleshooting Problem: Pilot wont’ light, no noise and no spark * 3. No power to junction box x 4. No power from junction bo 5. No power from 6Volt DC transformer If the module does not...
  • Page 16 Problem Scenarios #1 continued... IntelliFire Plus Troubleshooting Problem: Pilot wont’ light, no noise and no spark * 6. Wired wall switch not wired properly. The wiring to the wall switch may not be correct if fireplace does not turn on...
  • Page 17 Problem Scenarios #1 continued... IntelliFire Plus Troubleshooting Problem: Pilot wont’ light, no noise and no spark * 7. LP/NG switch on module damaged or not fully engaged into LP or NG setting. 8. Faulty Module If the NG/LP selector switch is not turned com-...

  • Page 18: Problem Scenario #2

    Problem Scenarios #2 IntelliFire Plus Troubleshooting Problem: The module makes sparking noise, but no spark * ** The problem may be: ** Notice ** Go to page 29 to familiarize yourself with Disconnect power to the system module diagnostic codes.

  • Page 19: Problem: The Module Makes Noise, But No Spark

    Problem Scenarios #2 continued IntelliFire Plus Troubleshooting Problem: The module makes noise, but no spark 1. Loose or improper wiring 2. Pilot assembly is not grounded * Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system.

  • Page 20: Problem: The Module Makes Noise, But No Spark

    Problem Scenarios #2 continued IntelliFire Plus Troubleshooting Problem: The module makes noise, but no spark 3. Igniter is disconnected, loose or shorted to fireplace. 4. Improper gap between igniter and pilot hood If igniter is shorted it will at- tempted to light for 60 sec- onds before module times out.

  • Page 21: Problem Scenario #3

    Problem Scenarios #3 IntelliFire Plus Troubleshooting Problem: Pilot sparks, but pilot will not light. The problem may be: ** Notice ** 1. Gas supply Disconnect power to the system 2. Faulty module voltage to valve prior to disconnecting any compo- 3.
  • Page 22 Problem Scenarios #3 continued IntelliFire Plus Troubleshooting Problem: Pilot sparks, but pilot will not light. 1. Gas supply * Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system. To do this the remote must be ―unlearned‖ from the system.
  • Page 23 Problem Scenarios #3 continued IntelliFire Plus Troubleshooting Problem: Pilot sparks, but pilot will not light. 2. Faulty module voltage to valve 3. Faulty valve (pilot solenoid) * Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system.

  • Page 24: Problem Scenario #4

    Problem Scenarios #4 IntelliFire Plus Troubleshooting Problem: Pilot lights, but continues to spark and main burner will not ignite. The problem may be: ** Notice ** 1. Gas Supply Disconnect power to the system 2. Sensor rod shorted or disconnected.
  • Page 25 Problem Scenarios #4 continued IntelliFire Plus Troubleshooting Problem: Pilot lights, but continues to spark and main burner will not ignite. 1. Gas supply 2. Sensor rod shorted or disconnected. * Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system.
  • Page 26 Problem Scenarios #4 continued IntelliFire Plus Troubleshooting Problem: Pilot lights, but continues to spark and main burner will not ignite. 3. Poor flame rectification or contaminated sensor 4. Faulty Valve (Burner Solenoid) If contaminated sensor wire prevents continuity the system will time out after 60 seconds and go into lockout mode.

  • Page 27: Problem Scenario #5

    Problem Scenarios #5 IntelliFire Plus Troubleshooting Problem: Pilot lights, stops sparking, and pilot remains lit. Burner will not light. The problem may be: ** Notice ** 1. Faulty module Disconnect power to the system 2. Faulty valve prior to disconnecting any compo-...
  • Page 28 Problem Scenarios #5 continued IntelliFire Plus Troubleshooting Problem: Pilot lights, stops sparking, and pilot remains lit. Burner will not light. 1. Faulty module (burner solenoid) 2. Faulty valve (burner solenoid) * Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system.

  • Page 29: Problem Scenario #6

    Problem Scenarios #6 IntelliFire Plus Troubleshooting Low pressure reading on manifold side when set to high flame position. Problem: ** Notice ** 1. Stepper motor lost power during operation and must be reset. Disconnect power to the system 2. Gas Supply prior to disconnecting any compo- 3.

  • Page 30: Flame Position

    Problem Scenarios #6 cont... IntelliFire Plus Troubleshooting Low pressure reading on manifold side when set to high flame position. Problem: 3. Module is programmed to remote and using module HI/LOW switch. Remote control has been programmed to module, which overrides the HI/LOW switch on the module.

  • Page 31: Diagnostic Codes

    Diagnostic Codes IntelliFire Plus Troubleshooting Diagnostic Codes are listed below and should be used as a additional tool to help di- agnose failure modes. Use the troubleshooting guide to check all possible failures be- fore changing any component parts. CODE...

  • Page 32: System Checklist

    System Checklist IntelliFire Plus Troubleshooting Visual Inspection 9/15/2011 Hearth & Home Technologies © Page32...
  • Page 33 System Checklist IntelliFire Plus Troubleshooting Electrical System Electrical System Refer to appropriate installation and operation manual for all areas 1. Proper Wiring a. Control Module ON/OFF/ ―OFF‖ – Module is dead. REMOTE Setting ―ON‖ – Used during set up or testing without learned remote ―REMOTE‖...
  • Page 34 System Checklist IntelliFire Plus Troubleshooting Electrical System continued... b. Optional Wired Wall Switch Overrides remote. Must be in OFF position for remote to work. c. Proper Gap between pilot hood and igniter 3. System Ground 9/15/2011 Hearth & Home Technologies ©...
  • Page 35 System Checklist IntelliFire Plus Troubleshooting Electrical System continued... 4. Voltage a. 120 VAC to and from Junction Box 9/15/2011 Hearth & Home Technologies © Page35...
  • Page 36 System Checklist IntelliFire Plus Troubleshooting Electrical System continued... c. To valve pilot solenoid d. To valve burner solenoid 9/15/2011 Hearth & Home Technologies © Page36...
  • Page 37 System Checklist IntelliFire Plus Troubleshooting Electrical System continued... 5. Continuity a. Wiring Harness 9/15/2011 Hearth & Home Technologies © Page37...
  • Page 38 System Checklist IntelliFire Plus Troubleshooting Gas System Area/System Proper Readings/Reference Info/Items to be checked: Gas Supply Refer to appropriate installation and operation manual for all areas 1. Inlet Pressure 2. Manifold Pressure 3. Orifice Size a. Burner Refer to conversion matrix or service parts list in owner & installation manual.
  • Page 39 System Checklist IntelliFire Plus Troubleshooting Gas System continued.. 6. Valve Fuel type marked on pilot solenoid. a. Ohms If converted the main burner regu- lator has LP stamped along the side, indicating the conversion. *valve pictured to left is factory supplied as natural gas.
  • Page 40 9/15/2011 Hearth & Home Technologies © Page40...

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