Travis Industries AGP Troubleshooting Manual

AGP

(All Grade Pellet)

Troubleshooting Guide

Document 176-01795

Travis Industries Certied Factory Training Program

AGP™ Pellet Troubleshooting

The unit has been programmed to evacuate smoke in case of a power failure. When 110V is introduced to the unit the exhaust fan will start and operate approximately 15 minutes, and the

RED stop light will illuminate.

To START Manually

IF CONTROL BOARD IS FLASHING EITHER A RED LIGHT OR BLUE LIGHT, OR HAS CONSTANT RED AND GREEN, REFER TO DIAGNOSTIC CHART.

Press the START button on the control panel. The stove will enter the start-up sequence for approximately 22 min.

• 1. Green light will start to ash in start up mode.

• 2. Exhaust blower will come on.

• 3. Push Auger will turn.

Plug

stove into

outlet. Does

YES

convection fan

come

on?

• 4. Meter System will turn.

• 5. Pellets will start to feed the system.

• 6. Igniter will come on.

1. Check system disc for continuity.

NO

Green

light will

start to ash in

START-UP

mode

YES

Exhaust

Blower Comes

On?

YES

NO

GREEN

LIGHT

NO

1. If no power, check fuses on control board and the inline fuse on the back of the unit. (See Diagram 4).

2. If there is power to the board and GREEN light does not come on when the start button is depressed. Replace the control board.

1. Check continuity of exhaust blower or connect power directly to the blower. If blower does not function and there are no obstructions in the blower housing, replace blower.

2. Check wiring connection. (See Diagram 1). Check

pathway for continuity from pin #4 to the end of the Black wire and pin #7 to White wire.

3. Is the blower getting power? If not receiving power

check fuses on control board and power supply. If fuses are good you will see the ashing GREEN light, if not replace board. (See Diagram 4).

SEE NEXT PAGE.

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AGP™ Pellet Troubleshooting

1. Check vacuum and brass barb tube for blockage, kinks, or cracks.

2. Check ow switch for continuity. No continuity through ow switch when actuated, replace ow switch.

Push

Auger

Turning?

YES

Meter Motor

Turning

(HRD)?

NO

3. Check continuity of motor.

4. Check jumper wire between ow switch and push auger for continuity. Check continuity from pin #7 to White wire. If no continuity replace wiring.

5. Check for power to motor, this should be a constant power supply (See Diagram 2).

6. Connect power direct to motor to determine if operational. If not turning replace motor.

7. Check auger ight for jam.

8. If the ow switch is good and still no power to motor, replace control board.

1. Push auger must be operational for meter motor to operate.

2. Is the Start light ashing?

3. Are there pellets in the hopper?

4. If push auger is turning and Stop light on control board is ashing, Check encoder for proper voltage to and from control board and if Molex is connected to the control board.

(See Diagram 3). Check continuity of metering motor.

5. Check for power to the meter motor, this will be an intermittent

YES

SEE NEXT PAGE.

power supply. (See Diagram 2).

6. Is hopper lid closed and lid switch actuated?

7. Connect power direct to motor to determine if operational. (If slight movements check for jam)

8. Check Hopper lid switch for continuity.

9. Check Horizontal Rotating Disc (HRD) assembly for

fouling or jam.

10. Check pathway (with hopper CLOSED) from pin #6 to the end

of the RED wire pin #7 to WHITE wire.

11. Check to see if encoder molex is plugged in at board.

12. Remove pellets from the hopper; disconnect metering

motor to determine if HRD is spinning freely.

NOTE: Do not use a wrench or socket drive on 7/16”

retaining bolt on HRD to free a jam. Serious damage can occur or bolt can be broken. If this happens the stove must be returned for repair.

2

AGP™ Pellet Troubleshooting

1. Check to see if the wires are connected?

Igniter

Comes On

YES

Pellets

Ignite

NO

2. Check igniter for continuity. Ohms should be (57Ω +10/-5) (If ohms not in range replace igniter).

(See Diagram 2).

3. Check for voltage to the Igniter? No voltage, check fuse. Check that unit is in start mode with ashing green light. Not working? Replace control board.

4. Check pathway continuity from pin #1 to the end of

the BLACK wire and pin #7 to the WHITE wire.

NOTE: Igniter is accessed through combustion chamber and behind burn platform.

(See Diagram 5).

1. Pellets should ignite between 5-15 minutes from the time the start button is pushed.

2. Check the gaskets on the door, the ash door and that both are latched.

3. Ensure exhaust access panel behind ash pan is in place.

3

AGP™ Pellet Troubleshooting

RUN MODE

Convection

Blower Comes

On

YES

Green

Light Goes

to Constant

Glow?

NO

1. Check Systems disc for continuity. If no continuity when hot replace System disc.

2. Jumper Systems disc and check power supply to convection blower. If no power when systems disc is jumped, replace control board.

3. Check continuity or connect power direct to blower. If there is no continuity or blower does not function with direct power, replace blower.

1. If the green light does not stay on and the red light comes on, this indicates the unit has gone into shut down.

2. Check the systems disc for continuity when heated. If no continuity, replace systems disc.

SHUT DOWN MODE

Press the STOP button on the control panel. The stove will begin the shut-down process, which takes approximately 45 minutes.

1. The metering auger will stop feeding pellets, but the push auger stays running.

2. When the unit gets cool the convection blower will shut off while the combustion

2. blower stays running for another 15 minutes.

3. The unit is now off and waiting to be started.

4

AGP™ Pellet Troubleshooting

THERMOSTAT MODE

Tstat calls for heat.

1. Unit will go into start mode. Unit will start same as manually. See manual start.

The stove will enter the start-up sequence for approximately 22 min. See manual start.

Changing the TSTAT Program

This heater comes with three TSTAT programs built in. Each program is unique and allows you to modify your thermostat setting to your preference. The stove is shipped pre-programmed in TSTAT program 1.

How to Tell Which TSTAT Program You Are In

When you press the “STOP” and “TSTAT” button simultaneously while the unit is cold the blue Auto-Fan LED light will ash. It will ash once for Program 1, twice for Program 2, and three times for Program 3. Flashes are quick.

Switching Between Program 1, 2, and 3

Each time you press the “STOP” and “TSTAT” button simultaneously while the unit is cold, the TSTAT program will toggle to the next program. Continue to press these two buttons until the blue Auto-Fan LED light ashes the program you wish to use.

Thermostat Program 1

When the thermostat stops calling for heat (the thermostat is open) the feed rate “steps down” to a lower heat setting. The heater will stay at this setting for 15 minutes. If the thermostat does not call for heat, the feed rate will “step down” again to a lower setting (or off).

At any time if the thermostat calls for heat (thermostat is closed) during this cycle, the heater will resume at the HEAT output setting set at the control board.

If it switches to off and there is a call for heat it will switch to start up mode for the 22 min. cycle before returning to its board setting.

5

AGP™ Pellet Troubleshooting

THERMOSTAT MODE

THERMOSTAT PROGRAM 2

In Thermostat Mode Program 2 when the thermostat stops calling for heat (the thermostat is open) the following happens:

The burn rate decreases to Level 1 (low) for 15 minutes. If there is no call for heat during that time…

The unit turns off. If there is a call for heat by the thermostat (the thermostat is closed) at any point during this cool-down period then the burn rate resumes corresponding with the setting on the control panel.

THERMOSTAT PROGRAM 3

In Thermostat Mode Program 3 when the thermostat stops calling for heat (the thermostat is open) the following happens:

The burn rate decreases to Level 1 (low) and remains at this level until there is a call for heat by the thermostat (the thermostat is closed), then resumes corresponding with the setting on the control panel.

Run mode. Same as manual mode.

Shut Down. Same as manual mode.

6

AGP™ Pellet Troubleshooting

7

AGP™ Pellet Troubleshooting

Stove - Diagram 1

System Snap Disc

Exhaust/Combustion

Blower

Flow Switch

8

AGP™ Pellet Troubleshooting

Stove - Diagram 2

Grey Wires

go to

Hopper Snap

Disc

Push Motor

with Encoder

Safety Snap

Disc

Meter Motor

(HRD)

Igniter

Encoder

Molex

Wires

Convection Blower

9

AGP™ Pellet Troubleshooting

INSERT - Diagram 1

Meter Motor

Cooling Fan

Push Motor

with Encoder

Exhaust

Blower

Cooling

Fan Fuse

Encoder

Molex

(HRD)

Flow Switch

Push Auger

Igniter

Convection

Wires

Fan

10

AGP™ Pellet Troubleshooting

Insert - Diagram 2

Cooling Fan Cooling

Fan Fuse

0.5 AMP/125 v

Control Panel Light Molex

Control

Panel

Light

Micro

Switch

Encoder Molex

Hopper Lid

Switch

Connection

Inline

Fuse

11

AGP™ Pellet Troubleshooting

Diagram 3 - Encoder Voltage Test

Take measurements from the Molex Connector (either side)

Voltage DC

5

To Red and Black Wires

If no power check molex connection at control board. If good replace control board.

5 VDC

Set To DCV

Voltage DC

2.5

2.5 VDC

If not 2.5 VDC and you are reading 5 VDC through the RED and BLACK wires, replace the Pusher Auger.

Set To DCV

To White and Black Wires

12

AGP™ Pellet Troubleshooting

Diagram 4

5amp/125v Fuse

5amp/250v Fuse

STOVE

Encoder Molex

Back Of Unit

INSERT

5amp/250v Fuse

Bottom of

Control Board

13

AGP™ Pellet Troubleshooting

Diagram 5 - Ignitor

Burn Platform

Igniter

14

AGP™ Pellet Troubleshooting

15

AGP™ Pellet Troubleshooting

AGP™ Pellet Insert

16