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11
Troubleshooting
With proper installation, operation and maintenance your gas appliance will provide years of trouble-free service. If you do
experience a problem, this troubleshooting guide will assist a qualified service person in the diagnosis of a problem and the
corrective action to be taken. This troubleshooting guide can only be used by a qualified service technician.
A. Intellifire Ignition System
Symptom
1.
The ignitor/module makes
noise, but no spark.
2.
Pilots won't light, there is
no noise or spark.
3.
Pilot lights but continues
to spark, and main burner
will not ignite. (If the pilot
continues to spark after
the pilot flame has been
lit, flame rectification has
not occurred.)
4.
Pilot sparks, but pilot will
not light.
Outdoor Lifestyles by Hearth & Home Technologies • Dakota 42-B/Dakota 42H-B • 4036-909 • Rev P • 11/4/13
Possible Causes
A.
Incorrect wiring.
B.
Loose connections or
electrical shorts in the
wiring.
C.
Ignitor gap is too large.
D.
Faulty module.
A.
Transformer installed
incorrectly.
B.
A shorted or loose
connection in wiring
configuration or wiring
harness.
C.
Improper wall switch
wiring.
D.
Module not grounded.
E.
Faulty module.
A.
A shorted or loose
connection in sensor rod.
B.
Poor flame rectification or
contaminated sensor rod.
C.
Module is not grounded.
D.
Damaged pilot assembly
or dirty sensor rod.
E.
Faulty module.
A.
Correct gas supply.
B.
Ignitor gap is too large.
C.
Module is not grounded.
D.
Module voltage output/
valve/pilot solenoid ohms
readings.
Corrective Actions
Verify "S" wire (white) for sensor and "I" wire (orange) for ignitor are connected to the
correct terminals on the module and the pilot assembly. Reversed wires at the module
may cause the system to make a sparking noise, but the spark may not be present at
pilot hood.
Verify there are no loose connections or electrical shorts in wiring from module to
pilot assembly. The rod closest to the pilot hood should be ignitor. Verify connections
underneath pilot assembly are tight; also verify the connections are not grounding out
to the metal chassis, pilot burner, pilot enclosure, mesh screen if present, or any other
metal object.
Verify gap of ignitor to pilot hood. The gap should be approximately .17 in. or 1/8 in.
Turn ON/OFF rocker switch or wall switch to OFF position. Remove ignitor wire "I"
from module. Place ON/OFF rocker switch or wall switch in ON position. Hold ground
wire about 3/16 in. away from "I" terminal on module. If there is no spark at "I" terminal,
module must be replaced. If there is a spark at "I" terminal, module is fine. Inspect pilot
assembly for shorted sparker wire or cracked insulator around electrode.
Verify that transformer is installed and plugged into module. Check voltage of
transformer under load at space connection on module with ON/OFF switch in ON
position. Acceptable readings of a good transformer are between 3.2 and 2.8 volts AC.
Remove and reinstall the wiring harness that plugs into module. Verify there is a tight
fit. Verify pilot assembly wiring to module. Remove and verify continuity of each wire in
wiring harness.
Verify wall switch is wired correctly.
Verify black ground wire from module wire harness is grounded to metal chassis of
appliance.
Turn ON/OFF rocker switch or wall switch to OFF position. Remove ignitor wire "I"
from module. Place ON/OFF rocker switch or wall switch in ON position. Hold ground
wire about 3/16 in. away from "I" terminal on module. If there is no spark at "I" terminal
module must be replaced. If there is a spark at "I" terminal, module is fine. Inspect pilot
assembly for shorted sparker wire or cracked insulator around electrode.
Verify all connections to wiring diagram in manual. Verify connections underneath pilot
assembly are tight. Verify connections are not grounding out to metal chassis, pilot
burner, pilot enclosure or screen if present, or any other metal object.
Verify flame is engulfing sensor rod. If the pilot assembly does not have a ground
strap, consider installing one to increase flame rectification. Verify correct pilot orifice
is installed and inlet gas specifications are met. Flame carries rectification current, not
the gas. If flame lifts from pilot hood, the circuit is broken. A wrong orifice or too high
an inlet pressure can cause pilot flame to lift. The sensor rod may be contaminated.
Clean sensor rod with emery cloth.
Verify that module is securely grounded to metal chassis of appliance. Verify that the
wire harness is firmly connected to module.
Verify that ceramic insulator around the sensor rod is not cracked, damaged, or loose.
Verify connection from sensor rod to white sensor wire. Clean sensor rod with emery
cloth to remove any contaminants that may have accumulated on sensor rod. Verify
continuity with a multimeter with ohms set at lowest range.
Turn ON/OFF rocker switch or wall switch to OFF position. Remove ignitor wire "I"
from module. Place ON/OFF rocker switch or wall switch in ON position. Hold ground
wire about 3/16 in. away from "I" terminal on module. If there is no spark at "I"
terminal, module must be replaced. If there is a spark at "I" terminal, module is fine.
Inspect pilot assembly for shorted sparker wire or cracked insulator around electrode.
Verify that incoming gas line ball valve is "open". Verify that inlet pressure reading is
within acceptable limits, inlet pressure must not exceed 14 in. w.c.
Verify that spark gap from ignitor to pilot hood is .17 in. or 1/8 in.
Verify module is securely grounded to metal chassis of appliance.
Replace module.
23
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