Travis Industries Deerfield, Foxfire Service & Troubleshooting Manual

Download

Page 1

Deerfield™/Foxfire™

Troubleshooting

Service Guide

Travis Industries Certified Factory Training Program

Page 2

Models Addressed in this Guide ............................................3

Who should use this guide .....................................................3

Precautions ........................................................................3

Items to Bring on Service Calls ..............................................3

Tools ..................................................................................3

Spare Parts ........................................................................3

Parts Identification and Part Numbers ...................................4

Deerfield - Location of Components ......................................5

Deerfield - Removal of Components ......................................6

Visual Deflector and Burn Platform Removal .....................6

Fireback Removal ..............................................................7

Rear Panel Removal ..........................................................9

Push Auger Motor Removal .............................................10

Power Control Board (PCB) Removal ..............................12

Metering Motor Removal ..................................................15

Igniter Removal ................................................................16

Flow Switch Removal .......................................................18

Convection Blower Removal ............................................20

Combustion Blower Removal ...........................................21

Auger, Bushing Plate and Block Removal ........................24

Chisel Removal ................................................................26

Horizontal Rotating Disks (HRD) Components Removal ..28

User Interface (UI) Removal .............................................32

Foxfire - Location of Components ........................................33

Foxfire - Removal of Components .......................................34

Visual Deflector and Burn Platform Removal ...................34

Fireback Removal ............................................................34

Igniter Removal ................................................................34

Auger, Bushing Plate and Block Removal ........................34

Chisel Removal ................................................................34

Horizontal Rotating Disk (HRD) Com ponent Removal .....34

Side Panel Removal .........................................................35

Push Auger Motor Removal .............................................36

Convection Blower Removal ............................................ 39

Combustion Blower Removal .......................................... 41

Flow Switch Removal ...................................................... 43

Metering Motor Removal ................................................. 45

User Interface (UI) Removal ............................................ 46

Troubleshooting the Appliance ............................................ 48

Sensor Status Lights........................................................ 49

AC Status Lights .............................................................. 51

Testing AC Power at the Board ....................................... 52

Testing DC voltage from the Push Auger E ncoder. ......... 53

Testing DC voltage from the Temperature Sensor .......... 54

Normal Operation Flow Chart .......................................... 55

Annual Service .................................................................... 57

Introduction ...................................................................... 57

Recommended Tools for Service .................................... 57

Recommended Supplies for Service................................ 57

Clean the Venting System ............................................... 58

Clean convection blowers ................................................ 58

Clean and Inspect Vacuum Tube .................................... 59

Clean the firebox, liners and burn platform ...................... 59

Clean the horizontal exhaust passage ............................. 63

Clean the Exhaust Blower Impellers and Housing ........... 64

Check gaskets ................................................................. 64

Clean fines out of the HRD .............................................. 65

Appendix A .......................................................................... 66

Wiring Diagram ................................................................ 66

Appendix B .......................................................................... 67

Control Timing ................................................................. 67

Appendix C .......................................................................... 68

Fan Voltages and Metering Motor Timing ........................ 68

Appendix C .......................................................................... 69

Power Control Board Pinout ............................................ 69

17602010 - 12/15/17

Page 3

This heater becomes very hot during operation - us e car e t o prev ent burns or property damage while

Test Cord

Jumper Wire

Models Addressed in this Guide

This guide addresses the Lopi Deerfield™ and Foxfire™ S toves.

Who should use this guide

This guide was developed for service personnel and those selling Travis Industries products. Because of the inherent danger involved with heating appliances, all work must be done by qualified personnel only. The heater must be installed in accordance with the owner’s manual and al l l ocal building codes. Bring an owner’s manual for the heater being serviced in case any installation or maintenance questions arise.

Precautions

servicing.

Make sure the appliance is unplugged before cond ucting service or replacing a component. Some procedures may require the heater to be plugged in while diagnosing the problem. In these cases, use caution to prevent arcing or electrical shocks.

Before conducting service, lay down a drop cloth to prevent fly ash and other debris from staining the carpet or other flooring. On inserts, lay down a piece of cardboard on the hearth to prevent scratches.

Items to Bring on Service Calls

Tools

• Nut drivers

• open end & socket wrenches in 1/4", 5/16", 11/32", 3/8", 7/16", 1/2", 7/8", 1"

• Allen Wrenches

• Torx bits or drivers

• Multimeter

• Standard and Phillips-head Screwdrivers

• Wire with a male quick-connect attached to each end (called a jumper wire)

• Power cord with female quick-connects attached to the hot and common wires (called a hot wire)

• Ash Vacuum (or shop vacuum with drywall filter) and bottle brush for cleaning the stove

• Lock Ties (for keeping all wires from contacting hot portions of the stove)

• Cleaner, paper towels, drop cloth, cardboard & other supplies to clean any fly ash entering home.

Spare Parts

• Circuit Board

• Metering Auger Motor

• Push Auger Motor

• Exhaust Blower

• Snap Disks (System & Hopper)

• Combustion Blower & Blower Gasket

• Convection Blower

• Heater Fuses (5 Amp Fast Acing - 1/4" x 1-1/4")

• Circuit Board Fuses (6 Amp 5 mm x 20 mm)

• Door Gasket and Gasket Cement

• Igniter

• Flow Switch

17602010 - 12/15/17

Page 4

Chisel 250

Parts Identification and Part Numbers

-04138

Convection Blower

Left 250-04440 Right 250-04439

Flow Switch 90-0791

Igniter

250-02613

Power control Board

250-04443

Combustion Blower 250-03636

Snap Disk (aka - System Disk or Proof of Fire)

250-02966

Snap Disk (aka - High Limit Disk - Hoper Safety Disk - Safety Disk)

250-00314

Push Auger Motor (with encoder)

250-04442

High Torque Metering Motor (aka – HRD motor)

250-03633

17602010 - 12/15/17

Page 5

Right Convection Blower

Left Convection Blower

Exhaust Box

Combustion Blower

Push Auger Motor

Metering Motor

System Disk

HRD High Limit Disk

Hopper High Limit Disk

Flow Switch

Power Control Board

Fuse Holder

Thermostat Connectors

HRD

Air Intake

Deerfield - Location of Components

17602010 - 12/15/17

Page 6

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the

Deerfield - Removal of Components

Visual Deflector and Burn Platform Removal

stove to prevent electrical shock.

1. Grab the front, middle of the visual deflector and lift up slightly to release the hooks from the pins on the side of the housing (see below).

2. Lift the locking key up to release the burn platform from the stove (see below).

3. Grab the upper portion of the Burn Platform and pull forward. Once the hole in the back of the burn platform clears the auger tube, you can angle the platform up and remove it from the stove.

17602010 - 12/15/17

Page 7

stove to prevent electrical shock.

Fireback Removal

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the

1. Remove the visual deflector and burn platform (see section “Visual Deflector and Burn Platf orm Removal”).

2. Lift the top center panel of the fireback up to release it from the notches on the lower panels. Lower one side and guide the panel out of the firebox.

3. Lift up on one of the side panels to release the (2) tabs on the bot tom of the panel from the notches in the firebox. Guide the bottom of the panel forward until it can be lowered into the ashpan area.

17602010 - 12/15/17

Page 8

4. Tip the top edge of the side panel forward and guide the panel out of the firebox..

5. Repeat the same process for the other side fireba ck.

6. The rear fireback is between the back of the fireback and the mounting studs for the visual deflector. Lift t he rear fireback straight up until the legs of the fireback can clear the mounting studs. Tilt it forward and guide it out of the firebox.

7. The back of the firebox is now visible

17602010 - 12/15/17

Page 9

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the

Rear Panel Removal

stove to prevent electrical shock.

1. Remove the (3) 5/16” screws along the top and (3) additional screws along the bottom of the back panel. Lift up on the panel using the handle on the top edge to disengag e t he bottom of the panel from the floor of the stove. Set the screws aside for reinstallation.

17602010 - 12/15/17

Page 10

Retaining Screw

“D” Shaped part of Shaft

Collar

Auger Motor

Auger Shaft

Push Auger Motor Removal

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the stove to prevent electrical shock.

1. Remove the rear panel (see section “Rear Panel Removal”).

2. The push auger motor is the motor that is directly above the air intake of the stove and is facing horizontally.

3. Use a 3/16” Allan wrench to loosen the retaining screw. I f you only remove the screw enough to allow the

shaft of the motor to become free, the collar will stay in place making for easier re installation of the auger motor.

17602010 - 12/15/17

Page 11

4. Disconnect the two power wires on the motor from th e wire harness at the quick connects.

5. Disconnect encoder wires from the motor. Car efully use a flat screwdriver to separate the white con nector

(see below).

6. Slide the push auger motor straight back to disenga ge it from the auger shaft.

NOTE: When re-installing the auger motor make sure that the retaining screw is seated against the flat portion of the “D” shaped portion of the auger shaft.

17602010 - 12/15/17

Page 12

Pull forward to PCB from clips.

Power Control Board (PCB) Removal

Unplug the stove to prevent electrical shock.

1. Remove the rear panel (see section “Rear Panel Removal”).

2. Gently pull the PCB away from the metal shield that surrounds it to gain access to the back of the board. You

may need to assist some of the wire harnesses throu gh t he shield behind the board. The board is held in place by a clip in each corner. .

disengage the

3. Press the (2) tabs on the sides of the 10 pin Molex plu g (su ppl i es AC power to the PCB) and disconnect it from

the board.

17602010 - 12/15/17

Page 13

4. With a flat head screwdriver, gently pry the tab back on the Molex from the User Interface and disconnect i t

from the board. NOTE: Be careful not to bend the tab further than needed to release if from the board.

5. Press the tab on the safety circuit Molex on the board to release it. Disconnect it from the board.

17602010 - 12/15/17

Page 14

Ground Wire

6. The long flat Molex at the bottom of the board is actual ly two separate connectors. The smaller of the two is

from the encoder on the push auger motor. The large r con nector is from the external thermostat. These connectors have the same type of tab on it as the User Interf ace connector. Pry the tab back slightly and disconnect the connectors from the board.

7. If you are removing the board in order to gain access to other components, you will now want to remove the

metal heat shield Using a ¼” nut driver to remove the (2) s crews at the bottom of the shield. When reinstalling the shield make sure that the green ground wire is reconnected.

17602010 - 12/15/17

Page 15

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the

Auger

Auger Shaft

Retaining Screw

“D” Shaped part of Shaft

Spacer

Collar

Metering Motor Removal

stove to prevent electrical shock.

1. Remove the rear panel (see section “Rear Panel Removal”).

2. Remove the Power Control Board and heat shield (see section “Power Contr ol B oard Removal”).

3. Remove the Exhaust Box (see section “Exhaust Box Removal”).

4. Disconnect the two wires on the motor from the wire harness at the quick conn ects.

5. Depending on where the retaining screw ends up in the rotation of the HRD, you may need to remove the left conv ec tion

blower (see section “Convection Blower Removal”).

6. Use a 3/16” Allan wrench to loosen the retaining screw. If you only remove t he s crew enough to allow the shaft of the

motor to become free, the collar and spacer will stay in place making for easier re installation of the auger motor.

NOTE: When re-installing the auger motor make sure that the retaining screw is seated against the flat portion of the “D” shaped portion of the auger shaft.

17602010 - 12/15/17

Page 16

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the

Zip tie anchor

Igniter Removal

stove to prevent electrical shock.

1. Remove the rear panel of the stove (see rear panel re m oval).

2. Using a ¼” nut driver remove the zip tie anchor from the back of the stove. The anchor is located just bel ow and to the left of the right blower (facing the back).

3. Disconnect the two white wires from the wiring harness at the quick connects.

4. Open the front door of the stove and remove the visual deflector and the burn platform (see section “Visual Deflector and Burn Platform Removal”). .

5. Locate the igniter to the left of the push auger tube.

17602010 - 12/15/17

Page 17

6. Remove the 3/8” bolt that secures the igniter to the firebox (set bolt aside for reinstallation).

7. Pull the igniter forward and work the wires through the hole.

17602010 - 12/15/17

Page 18

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the

Disconnect Wires

Flow Switch Removal

stove to prevent electrical shock.

1. Remove the rear panel of the stove (see rear panel re m oval).

2. The Flow Switch is located directly below the lef t hand convection blower. Removal of the left blower is n ot required but the fans removal will give better acces s t o t he Fl ow Switch (see section “Blower Removal”).

3. Use a 3/8” nut driver to remove the two locknuts that m ount t he switch to the stove (set aside for reinstallation). The nuts are located on the side nea rest the rear of the stove.

4. Disconnect the two wires from the wiring harness at t he quick connects (orientation does not matter for reinstallation).

17602010 - 12/15/17

Page 19

5. Remove the vacuum hose from the flow switch

17602010 - 12/15/17

Page 20

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the

Both blowers remove the same way. If the left blowe r is being removed, remove the PCB and shield first

Convection Blower Removal

stove to prevent electrical shock.

(see section “PCB removal”)

1. Remove the side rear panel (see section “Rear Pane l Removal”)

2. Remove the (4) screws that mount the blower to the m ounting bracket (set aside for reinstallation). NOTE: The rear two screws can be removed with a nut driver. The front (2) will require a small ratchet or

box wrench.

3. Remove the fan from the stove and disconnect the wires from motor.

17602010 - 12/15/17

Page 21

Make sure the stove has fully cooled (approxim at el y 25 minutes) before conducting service. Unplug the

Remove bolts

Combustion Blower Removal

stove to prevent electrical shock.

2. Disconnect the venting from the stove.

3. Open the ash pan door and remove the ash pan from the appliance.

4. Remove the exhaust cover plate by removing the win gnut on the left side and pulling the left side of the plate forward and pulling the plate free of the stove. Set the wing nut and plate aside for reinstallation.

5. Locate the 6 bolts around the exhaust port in the rear of the ash pan cavity. Depending on the amount of use the

stove has had, you may want to apply penetrating oil and allow it to sit for a few minutes before removing the bolts. Use a 3/8” nut driver or ratchet for removal. Set the bolts aside for reinstallation.

17602010 - 12/15/17

Page 22

Air Box

6. Remove the (3) 5/16” screws along the top and (3) additional screws along the bottom of the back panel. Lift up

on the panel using the handle on the top edge to disengag e t he bottom of the panel from the floor of the stove. Set the screws aside for reinstallation.

7. Locate the two wires that power the fan motor (orange and grey). Disconnect the wires from the motor. Make sure

not to damage the connectors on the wires while removing.

8. The exhaust box is now loose in the stove. Lift the box up and gently remove it from the stove.

NOTE: It is a tight fit for the fan motor to fit between the push auger motor and the stove but i t will fit. If you prefer, you can remove the push auger motor to allow more room.

17602010 - 12/15/17

Page 23

10 o’clock

9. Disconnect the exhaust blower from the exhaust box by removing the (6) bolts shown below. Us e a 5/16” nut

driver. Set bolts, washers and orange spacers aside for reinstallation.

NOTE: Pay attention to the orientation of the blower to the exhaust box. When reinstalling the blower back into the exhaust box, it will need to be oriented with the electrical connections in the 10 o’clock position (with the exhaust box outlet on the left) like shown in the picture below.

Oriented to

10. Carefully remove the fan from the exhaust box by lifting it straight up. Take care not to damage or ben d the

exhaust blower impellers.

11. Remove the circular white gasket from the fan. Install the exhaust blower into the new exhau st box (make sure the

exhaust blower gasket is in position) and secure it with the six bolts, washers and spacers removed from t he ol d box. Make sure the blower is oriented to 10 o’clock whe n reinstalling (See step 8).

17602010 - 12/15/17

Page 24

Auger, Bushing Plate and Block Removal

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the stove to prevent electrical shock.

1. Remove the rear panel (see section “Rear Panel Removal”).

2. Remove the Push Auger Motor (see sectio n “Push Auger Motor Removal”).

3. Remove the Visual Deflector and Burn Platform (see section “Visu al Deflector and Burn Platform”)

4. Reach into the auger tube and hook your finger around the auger flight. Pull the auger flight assembly forward.

5. Use a ¼” nut driver to remove the (2) scr ews that mount the bushing plate to the M ounting brackets on the HRD (set the screws aside for reinstallation).

6. Use a T20 Torx bit to remove the (4) screws that mount the bushing plate to t he bushing block (set the screws aside f or reinstallation).

17602010 - 12/15/17

Page 25

Push shaft flush with bushing

Lift up on plate

notch in the tube

7. Push the auger shaft forward so that it is flush with the outer edge of the brass bushing. Slide the bushing plate up to disengage the tab on the bottom of the plate from the notch in the auger tube (see below).

so tab on plate releases from the

8. Remove the bushing block by sliding it straight ba ck, out of the end of the auger tube.

9. Go around to the front of the stove. Reach into the end of the push auger tube, pull the auger flight forward and remove it from the tube.

17602010 - 12/15/17

Page 26

Chisel Removal

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the stove to prevent electrical shock.

1. Remove all pellets from the hopper.

2. Using a ¼” nut driver remove the (6) ¼” screws that secure the HRD access panel to the hopper (set aside for reinstallation).

3. Remove the HRD access panel. This will expose th e top of the HRD assembly. NOTE: You may want to use gloves when removing the plate to protect yourself from sharp edges.

17602010 - 12/15/17

Page 27

4. Use a 1/8” Allan wrench to remove the (2) ¼-20 x 1/2” scre ws that secure the chisel to the disk and remove the chisel.

NOTE: The chisel is very sharp. Handle with care.

5. Remove the chisel spacer.

17602010 - 12/15/17

Page 28

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the

It is very important that all of the internal components of the HRD assembly be reinstalled in the same

ensure that the installation order is maintained.

assistance. .

Horizontal Rotating Disks (HRD) Components Removal

stove to prevent electrical shock.

order as they were removed and in the same orientation.. We recom m end that you create a space where you can lay the parts out in order as you dismantl e the HRD and clean the assembly to help

When the HRD is reinstalled, make sure that when you look down through the HRD assembly you can not see all the way through the assembly, into t he auger f l i ght. If you can, you have changed the orientation of some of the internal component s. Contact Travis Industries Technical Support for

1. Remove all pellets from the hopper.

2. Using a ¼” nut driver remove the (6) ¼” screws that secure the HRD access panel to the hopper (set aside for reinstallation).

3. Remove the HRD access panel. This will expose th e top of the HRD assembly. NOTE: You may want to use gloves when removing the plate to protect yourself from sharp edges.

17602010 - 12/15/17

Page 29

Remove screws

4. Remove the three ¼” screws on the top of the HRD assembly (set aside for reinstallation)

5. Remove the cover from the HRD assembly.

6. Use a 7/16” wrench to remove the bolt from the center of t he HRD (set aside for reinstallation).

7. Remove the top fuel-metering disk (has the chisel at tached).

17602010 - 12/15/17

Page 30

8. Remove the thin metal spacer from the auger shaft (set aside for reinstallation).

9. Remove the (2) fuel cup slide plates

10. Remove the thin metal spacer from the auger shaft (set aside for reinstallation).

11. Remove the bottom fuel-metering disk

17602010 - 12/15/17

Page 31

Exploded View of the HRD Assembly

12. Remove the thin metal spacer from the auger shaft (set aside for reinstallation).

13. Remove the (2) fuel meter spacers. NOTE: The spacers can be removed without removing the snap disk bracket on the left side of the HRD but it is

much easier to remove them with the bracket screw s removed.

17602010 - 12/15/17

Page 32

User Interface (UI) Removal

The process is the same as the Foxfire (see section “User Interface (UI ) Removal” on pg.46.

17602010 - 12/15/17

Page 33

Right Convection Blower

Left Convection Blower

Combustion Blower

Push Auger Motor

Metering Motor

System Disk

HRD High Limit Disk

Hopper High Limit Disk

Flow Switch

Power Control Board

HRD

Fuse Holder

2 9

6 (Behind blower shroud)

Right Side (facing front of stove)

Left Side (facing front of stove)

Foxfire - Location of Components

17602010 - 12/15/17

Page 34

Foxfire - Removal of Components

Visual Deflector and Burn Platform Removal

The process is the same as the Deerfield ( see section “Visual Deflector and Burn Platform Removal” on pg. 6.

Fireback Removal

The process is the same as the Deerfield ( see section “Fireback Removal” on pg. 7

Igniter Removal

The process is the same as the Deerfield ( see section “Igniter Removal” on pg.16

Auger, Bushing Plate and Block Removal

The process is the same as the Deerfield ( see section “Auger, Bushing Plate and Block Removal” on pg. 24

Chisel Removal

The process is the same as the Deerfield ( see section “Chisel Removal” on pg. 26

Horizontal Rotating Disk (HRD) Component Removal

The process is the same as the Deerfield ( see section “Horizontal Rotat i ng Disk (HRD) Component Rem ov al ” on pg. 28

17602010 - 12/15/17

Page 35

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the

Remove the fastener

Slide tab out of slot on rear of stove

Slide front tabs out of slot on side of stove

Side Panel Removal

stove to prevent electrical shock.

1. (Left panel only) Push the air rest rictor rod all the way in and unscrew the k nob from the end of the restrictor rod (set aside for reinstallation).

2. Remove the fastener on the back edge of the side panel. There is one screw for each panel.

3. Slide the panel backwards slightl y t o release the small tab on the upper rear portion of the panel from the slot on the stove.

4. Slide the panel back further to disengage the front tabs from the stove. The panel is now free and can be set aside.

17602010 - 12/15/17

Page 36

Retaining Screw

“D” Shaped part of Shaft

Collar

Auger Motor

Auger Shaft

Push Auger Motor Removal

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the stove to prevent electrical shock.

1. Remove the both side panels (see section “Side Panel Removal”). Locate the set screw and locking collar between the bushing plate and the Push Auger Motor (whichever way the set screw is facing is the side you want to perform the rest of the procedure from (in the example below it is being shown from the right side of the stove)..

2. The push auger motor is the motor that is directly above the air intake of the stove and behind the HRD assembly. The auger motor is oriented horizontally.

3. Use a 3/16” Allan wrench to loosen the retaining screw. If you only remove the screw enough to allow the shaft of the motor to become free, the collar will st ay in place making for easier re inst all ation of the auger motor.

17602010 - 12/15/17

Page 37

4. Disconnect the two wires on the motor from the wire h arness at the quick connects.

5. Disconnect encoder wires from the motor. Car efully use a flat screwdriver to separate the white con nector (see below).

17602010 - 12/15/17

Page 38

6. Slide the push auger motor straight back to disenga ge it from the auger shaft.

NOTE: When re-installing the auger motor make sure that the retaining screw is seated against the flat portion of the “D” shaped portion of the auger shaft.

17602010 - 12/15/17

Page 39

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the

Convection Blower Removal

stove to prevent electrical shock.

The removal steps are the same for both blowers howev er t here are additional steps to gain access to the blower on the left hand side of the stove. If you are only removing the right hand blower, see the instructions for removal of the Power Control Board ( PCB).

The (2) blowers have different orientations and dif ferent part numbers. Make sure you are ordering the correct part. The fans are named “Left” or “Right” based on facing the front of the stove.

1. Remove the side panel (see section “S ide Panel Removal).

2. Disconnect the wiring (orienta tion of the wires does not matter when re-connecting)

3. Remove the (3) 3/8” screws that mount the blower and shroud to the stove body (set aside for reinstallation). The side (2) can be removed with a nut driver; the top ( 1) wi l l require a small ratchet or a box wrench.

17602010 - 12/15/17

Page 40

4. Remove the blower and shroud from the stove and remove the (4) ¼” screws that secure the blower to the mounting bracket (set aside for reinstallation).

17602010 - 12/15/17

Page 41

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the

Combustion Blower

Combustion Blower Removal

stove to prevent electrical shock.

1. Remove the left side panel (see section “Side Panel Removal”).

2. Locate the combustion blower just inside the side opening of the stove, beside the exhaust plenum (see below)

3. Locate the two wires that power the fan motor. Disconnect the wires from the motor. Make sure not to damage the connectors on the wires while removing.

4. Use a ¼” nut driver to remove the screws that secur e t he access plate at the bottom, rear of the stove as shown below (set aside for reinstallation).

17602010 - 12/15/17

Page 42

Top three screws accessed from top

Bottom three screws accessed from rear access.

5. Disconnect the exhaust blower from the stove by removing the (6) bolts with a 5/16” nut driver.. The top three are accessible from above and the bottom three can be re ached through the access that was uncovered in the step above. Set bolts, washers and orange spacers aside for reinstallation.

6. Carefully move the blower backward until the im pel lers are clear of the exhaust housing and remove the blo wer from the stove. Take care not to damage or bend the exhaust blower impellers.

17602010 - 12/15/17

Page 43

Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug t he

Flow Switch Removal

stove to prevent electrical shock.

1. Remove the left side panel of the stove (see section “Side P anel Removal”).

2. The Flow Switch is located behind the PCB. Removal of the PCB is not required but its removal will give better access to the Flow Switch (see section “PCB Removal”).

3. Use a 3/8” nut driver to remove the two locknuts that m ount t he switch to the rear panel of the stove (set

aside for reinstallation).

4. Disconnect the two wires from the wiring harness at t he quick connects (orientation does not matter for reinstallation).

17602010 - 12/15/17

Page 44

5. Remove the vacuum hose from the flow switch

17602010 - 12/15/17

Page 45

Make sure the stove has fully cooled (approximately 25 mi nutes) before conducting service. Unplug the

Auger

Auger Shaft

Retaining Screw

“D” Shaped part pf Shaft

Spacer

Collar

Metering Motor Removal

stove to prevent electrical shock.

1. Remove the left side panel (see secti on “ Side Panel Removal”).

2. Remove the Power Control Board and heat shield (see section “Power Contr ol Board Removal”).

Remove the blower (see section “Blower Removal”) to gain access to the retaining screw.

3. Disconnect the two wires on the motor from the wire harness at the quick conn ects.

4. Use a 3/16” Allan wrench to loosen the retaining screw. If you only remove t he s crew enough to allow the shaft of the motor to become free, the collar and spacer will stay in place making for easier re installation of the auger mot or .

NOTE: When re-installing the auger motor make sure that the retaining screw is seated against the flat portion of the “D” shaped portion of the auger shaft.

17602010 - 12/15/17

Page 46

Make sure the stove has fully cooled (approximat el y 25 minutes) before conducting service. Unplug the

Remove Rubber Grommet

User Interface (UI) Removal

stove to prevent electrical shock.

7. Remove the left side panel (see section “Side Panel Removal”) or the rear panel on a Deerfield (see s ection “Rear Panel Removal”).

8. Pull the PCB forward to release it from the shield (se e “P CB removal”).

9. Disconnect the AC power harness from the upper left cor ner of the board so you can tilt the board forward and gain access to the back of it.

10. Disconnect the UI board harness from the back of the DCB.

11. Remove the rubber grommet where the harness enters the hopper, on the back side of the sto ve behind the left hopper door hinge (set aside for re-installation).

17602010 - 12/15/17

Page 47

Remove nut

12. Pull the wire up into the hopper.

13. Use a 3/8” ratchet to remove the nut, inside the hopper, that secures the right hopper hinge to the stov e (see below). Move the UI to the right and it will disengage from t he bracket on the stove.

NOTE: Make sure to not drop the nut or washer into the hopper, it could possibly jam the HRD. NOTE: When re-installing the UI make sure the washer is in place between the hinge and the bracket.

17602010 - 12/15/17

Page 48

Troubleshooting the Appliance

Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock.

Our new generation of pellet stoves is equip with a unique control system that simplifies the troubleshooti ng process. Each stove has a “Power Control Board” (PCB ) t hat has indicator lights that indicate the status for all of the safety control sensors on the unit (see below). It also indicates the status of power being distributed to the AC powered components in the appliance.

17602010 - 12/15/17

Page 49

Sensor Status Lights

When starting the troubleshooting process, the first thing to check the User Interface (UI) board, (t ouch controls on the hopper lid) and see if there are any fault codes. M ake note of the codes and clear them by pressing the power switch 2 times. The display should say “Clearing” and then the stove will go into cool down mode. Press the start button again to begin the startup process and pay close a ttention to the AC components in the appliance. Make note of what runs and what does not before the fault code reappears on the control board. Armed with this information, follow the steps below to narrow down where the p roblem lies.

1. Locate the PCB and check the System status light. The status light should be blinking at a rate of (1) flash per second. If it is flashing faster, you may be having an issue with the UI board or the wires going to it. Check the wire for damage and check the connection to t he PCB. If you cannot resolve the fast flashing code, replace the UI board.

2. Check the status lights of the sensors. If all sensor s are w orking properly and the stove is cold the status should be as follows:

a) TStat Status – This light indicates whenever the thermostat is calling for heat. Light on i ndicates

a call for heat, light off indicates a no call for heat. The li ght will function the same way if you are using the internal or external TStat.

b) OTemp Hopp er status– This light indicates the status of the Hopper High Li m it Disk or Overtemp

Disk. Since this disk is a “Normally Closed” or NC disk, this light should be lit. If i t is not then a continuity test should be done on the disk. Disconnect the wires from the disk and use the “tone”

setting or measure resistance in Ohms (Ω). If you measure resistance or get tone when touching

the two posts on the disk then the disk is not the problem . Check the wires for damage and

3. Pressure Switch Status – This light shows that status of the Pressure or Flow switch. The flow switch has a diaphragm inside of it. When vacuum is supplied to one side of the diaphragm, the diaphragm moves and completes the electrical circuit, which sends an el ect rical signal to the PCB and proves that the fan is operating. If the appliance is running, the switch should be on. Whenever the Combustion fan is operating, the light should be on.

When a COLD stove is trying to run but the Pressure switch is not activated, the PCB will provide power to the combustion blower and the push auger for 15min as pa rt of the “Fault Post Purge”. The push auger is always in operation when the exhaust blo wer is on. The PCB will not distribute power to any other AC powered component during this purge.

When a HOT stove has an APS fault, the same process will o cc ur but there will be one additional step. The HOT stove will go into a “Fault Cool down” mode until the system disk (aka Proof of Fire) closes. A t that point, the stove will enter the “Fault Purge” mode for 15min. After the 15min, the stove will enter a “Fault Idle” mode (power light will alternate between Red and Green. An error code will show on the UI board and will need to be manually cleared before the stove will attempt to operate again. To clear the code, press the power button once. Press the power button one more time to restart the stove.

continuity.

c) OTemp HRD status – This disk operates the same as the OTemp Hopper disk but it sensing the

temperature on the Horizontal Rotating Disk ass em bly (HRD). Follow the steps above in the OTemp Hopper status section for this disk as well.

d) Proof of Fl ame status – This indicates the status of the “System Disk” aka the “Proof of Fire Disk”.

This disk is a “Normally Open” or NO disk. When the stove reaches temperature, t he disk proves to the PCB that the stove has actually lit by sensing the temperature change on the firebox. If the stove is cold, the light should not be on. If the light is on, the PCB believes that the stove has fire in it and will start to feed pellets into the burn platform. The Convection blowers will also be on. Symptoms of this disk being stuck on would be:

• Overflowing pellets off the burn platform.

• Convection blower coming on as soon as power is suppl ied t o the stove.

• Combustion blower that does not shut off at all.

17602010 - 12/15/17

Page 50

Ground

Touch each of the pins

If the pressure switch seems to be the issue, use a jumpe r t o bypass the switch and see if the stove runs (make sure not to leave the stove with the jumper in pl ace. This is a troubleshooting step only). If the jumper resolves the fault and allows the stove t o run, check the following:

• Check for an obstruction in the venting.

• Check the vacuum hose for cracks and/or obstructions.

• Check the barbed nipple that is threaded into the exhaust plenum. Sometimes debris

gets in the nipple and obstructs the vacuum. Clean the Barbed nipple and reinstall.

• Check the gasket on the door and ash pan door for le aks

• Check the glass gasket for leaks

• Check the gasket on the exhaust blower for leaks.

4. If a component is working but there is no indication on the status lights, you can check the board to see if the lights are working properly. To check the safety sensors status lights on the PCB, preform the following test.

• Disconnect the (8) pin Molex connector from the back of the lower right of the board (see section “Removal of PCB”).

• On the front side of the board, use a jumper to touch the lower right pin (ground) and touch the other end of the jumper to each of the (4) left hand pins. One l ight should light up with each of the pins being touched. If status lights do n ot light during this test, replace the board.

on the left side and the ground w/ jumper

17602010 - 12/15/17

Page 51

AC Status Lights

The status lights for the AC components tell you when the board is sending power to the component, not if the component is working properly. If you find that a particular component is not working (i.e. the push auger motor is not turning), check the status light for the component and see if the board is sending power. If the light is on, use a Multimeter to test the power at the AC Pins on the board that corresponds to the component in question (see section “Testing AC Power at the Board“). If the appropriate power is present at the pins on the PCB, test volt age at the component and see if power is reaching it. If power is not present at the component, the stove most likely has a wiring harness issue and you should test continuity between the board and the component. If power is present , the component is likely bad. Use a test cord to supply power directly to the component to verify your findings.

17602010 - 12/15/17

Page 52

This portion of the PCB discussed in this section deals with high voltage. Only qualified personnel should test

AC power pins

Combustion Blower

AC Neutral

Igniter

Push Auger

Meter Auger

Convection Blower

AC Line

Testing AC Power at the Board

this portion of the board.

To test the AC power leaving the PCB us a Multimeter at the pins indicated below.

Touch the AC Neutral pin with the black lead from your Multimeter and use the red to touch the other pins to verify the voltage that is actually being sent to the component.

17602010 - 12/15/17

Page 53

5VDC

2.5VDC

PCB

Encoder Wire Connections

Testing DC voltage from the Push Auger Encoder.

The push auger is equipped with a device called an e ncoder. It receives a voltage signal from the PCB (5VDC) and sends a (2.5VDC) back to the PCB to prove to the PCB that it is operating properly. If the PCB does not get the correct signal from the encoder, it will not allow the metering auger to turn. T o test the DC power that is going to the encoder and the voltage being sent back to the PCB set your Multimeter to read DC volts.

1. Touch one lead to the left pin and the other to the right pin. You should read approximately 5VDC at this point.

2. Touch one lead to the left pin and the other to the center pin. Y ou should read 2.5VDC. (See illustration below).

3. If you measure 5VDC going from the board but do not measure 2.5VDC coming from the encoder, make sur e the push auger is turning. If it is, check the encoder wire connections to the PCB and the connector where the wires connect to the push auger motor.

• If 5VDC is present but the 2.4VDC is not and wires and connections are not the issue, this would indicated a faulty encoder and the push auger motor should be replaced.

• If 5VDC is not present – Replace the PCB.

17602010 - 12/15/17

Page 54

Example:

PCB

5VDC

10mV per degree C

Temp. Sensor Pins

Testing DC voltage from the Temperature Sensor

The temperature sensor functions by receiving vol t age from the PCB and returning a smaller voltage signal back to the PCB. The amount of voltage that the sensor sends bac k to the board is a direct relationship to the temperature at the sensor (10mV = 1°Celsius). The temperature sensor can be checked for proper operat i on by testing the DC voltage at the appropriate pins on the board. To test the temperature sensor follow the steps below:

1. Touch one lead to the left pin and the other to the right pin. You should read approximately 5VDC at this point. The 5VDC is the voltage that the PCB is sending out to the sensor. If 5VDC is not present then replace the board.

2. Touch one lead to the center pin and the other to the right pin. You should get a mV reading on your meter that will vary based on the temperature at the sensor (See illustration and example below). 10mV = 1°Celsius.

1. You take a reading between the center pin and the right pin and get a reading of 210mV.

2. 10mV = 1°Celsius so divide the 210mV by 10mV and you get 21°Celsius

3. To convert Celsius to Fahrenheit you multiply the Celsius reading by 1.8 and then add 32 to the total so:

21°C x 1.8 = 37.8

37.8 + 32 = 68.9°F

NOTE: The temperature reading is the temperature at the sensor, which is in close proximity to the stove, so it may read differently than another thermometer somewhere else in the room. If you are trying to det er mine if the sensor is reading correct ly you should use another thermometer near the loc ation of the stoves sensor to compare the reading.

NOTE: If the board is showing a readin g of 32°F it would indicate a disconnect ed or grounded sensor. If the board is showing a reading of around 140°F it would possibly indicat e the 5VDC shorted on the sensor.

17602010 - 12/15/17

Page 55

YES

YES YES

Press Start:

Continue on next page

Normal Operation Flow Chart

Status Light is flashing –

1 flash/sec.

• If it is flashing (2) flashes /sec then check the UI connection to the PCB.

• Check if the UI board is lit up.

If still not working, replace UI.

•

• Check Exhaust Fan status light on

the PCB.

Does

Combustion

Blower

come on

• Check Power at quick connects at the Combustion Blower.

• Use a test cord to power the blower directly to outlet power.

• Check pressure Status light

• Check wires for damage.

Does the

push auger

come on?

17602010 - 12/15/17

• Check the PCB for Push Auger

• Check The voltage at the AC power

• Use a test cord to power the blower

• Check wires for damage

status light. pins (see testing AC power) directly to outlet power.

Page 56

YES

• Check the quality of the fuel.

YES

Enjoy the Fire!!!!

• Check the PCB for Push Auger status light.

Does

Metering

Motor Cycle

On/Off

• Check The voltage at the AC power pins (see testing AC power)

• Use a test cord to power the blower directly to outlet power.

• Check wires for damage Check Encoder voltages (see section Testing DC voltage from encoder”)

• Check to see if HRD is jammed.

• Check the PCB Igniter status light.

If it is on, the unit is sending power to the igniter.

• Check The voltage at the AC power

Is the Igniter

getting hot?

pins (see testing AC power)

• Check voltage at the quick connects to the igniter.

• Check wires for damage.

• Disconnect wires from the igniter

and test resistance. Should be 52Ω

to 67Ω (out of range = replace)

Depending on environmental conditions, cleanliness of the stove, fuel quality and condition of gasket material this process may take between 4-15 minutes.

Are the

Pellets

Lighting?

17602010 - 12/15/17

• Check for gasket leaks around

• Check for gasket leaks at

• Look for obstructions in intake air.

• Check for buildup on the burn

• Make sure the burn platform is in

door. glass. combustion blower

platform. place properly.

Page 57

The following section details exten sive maintenance procedures. W e st r ongly suggest these items be carried out

stove to prevent electrical shock.

Annual Service

by a trained service technician. NOTE: Pellet quality may vary by supplier. The maintenance schedule may need to be revised to acco mm odate the

pellets used.

Make sure the stove has fully cooled (approximat el y 45 minutes) before conducting service. Unplug the

Introduction

Pellet stoves are inherently complicated devices. They work on precisely metered full and air and the movement of those two things, as well as the heat produced by the appliance, require each of the components of the st ove to be operating as designed. The biggest obstacle to that occurring is the lack of regular maintenan ce.

The owner of the stove, on a weekly basis, should perf orm m ai ntenance. If this maintenance is not preformed, the stove will burn less efficiently, create more parti culate matter, produce less heat, and have a shorter component life. Whether or not the regular maint enance is being performed, it is imperative that service is done by a professional on an annual basis.

This section will cover areas of the stove that need t o be serviced but it does not address proper methods for protecting the customer’s home from dust and soot t hat get disrupted while performing service. It is the responsibility of the person performing this maintenance to properly utilize drop cloths, soot vacuums, other forms of dust control, and personal protective gear while dealing with the byproducts of the combustion process.

Below are the steps that we would recommend for an annu al service:

• Clean the venting system

• Clean convection blowers

• Clean vacuum tube to the flow switch (including barbed nipple)

• Clean the firebox, liners and burn platform

• Clean the horizontal exhaust passage

• Clean the Exhaust Blower Impellers and Housing

• Check gaskets

• Clean fines out of the HRD

Recommended Tools for Service

• Pellet brushes and flexible rods

• Ash vacuum

• Drop cloths

• Magnetic drop light

• Variety of small brushes for inside the firebox and blowers (small paint brushes and bottle brushes work well)

• Personal protective gear

• Nut drivers and screwdrivers

• Calk gun

Recommended Supplies for Servic e

• RTV silicone calk

• Aluminum Tape

• Replacement Gasket

• Replacement Exhaust Box Cleanout Gas ket (Deerfield)

17602010 - 12/15/17

Page 58

• Door and Glass Gasket Material and Gas k et Cement

Clean the Venting System

1. Inspect the venting system prior to performing a ny cleaning. Check for loose or unsealed joints to help ensure that dust does not escape when the venting is being swept down. Make note of caps on cleanout tees.

2. Go to the termination of the vent system and remove the cap. Clean the cap thoroughly. This part of the system accumulates a lot of soot because it is the coldest part of the vent system.

3. Use a properly sized pellet brush for the vent and sweep the pipe all the way down to the cleanout tee.

4. Remove the cap on the cleanout tee and vacuum the debris out of the pipe. Replace the cap and reseal with aluminum tape.

5. Clean horizontal sections of pipe back to the stove.

Clean convection blowers

Cleaning the convection blowers improves their ability to move air efficiently. Cleaning the blowers helps move more heat into the house, prolongs the life of the blower, and keeps the area that contains other electronic components cooler during operation.

1. Use a brush to remove debris from the impellers of the blower. Use one hand to keep the impeller from turning while brushing the scooped area of the impeller blades.

NOTE: Handle the impellers gently. If an impeller becomes bent or damaged, it will no longer be balanced and will caus e noise during operation and will need t o be r eplaced.

2. Vacuum the blower area and the blower motor. Removing debris from the mot or will allow the blower to run cool er.

17602010 - 12/15/17

Page 59

Clean and Inspect Vacuum Tube

The vacuum tube is communicates the negative pressur e of t he exhaust blower to the pressure switch. An obstruction of tube, the barbed nipple that connects the tube to the exhaust housing or a cracked tube can cause the f low switch not to function properly.

1. Remove the left side panel (Foxfire) or the rear panel (Deerfield) to gain access to the flow switch.

2. Remove the Vacuum tube from the stitch and blow com pressed air through the hose back toward the exhaust housing.

NOTE: DO NOT blow air into the flow switch. The switch runs on very small amounts of pressure, blowing air or using compressed air can damage the diaphragm .

3. Remove the vacuum tube from the barbed nipple on the ex haust housing.

4. Use a crescent wrench or box wrench to remove the barb ed ni pple and clean any debris out of the interior portion.

Clean the firebox, liners and burn plat form

The firebox, ashpan, liners, and burn platform will l i kely be one of the dirtiest parts of the system. Cleaning this portion of the appliance stirs up a lot of dust and you will need to pul l di rt y components out of the firebox so use plenty of drop cloths. Brush soot off the firebox components before completely removing them from the firebox in order to help contain dust

NOTE: We recommend keeping an ash vacuum running and put the hose right at the door to the firebox while performing cleaning in the firebox area. This will help control the dust while cleaning.

17602010 - 12/15/17

Page 60

1. Open the door of the stove and vacuum the air wash just insi de the door opening (see below).

2. Remove the visual deflector from the burn platfo rm. Brush it clean and set aside for reinstallation. V acuum off the burn platform, scrap it clean with the stove tool provided with the stove or other scraper. Make sure all the holes are free from obstruction.

3. Remove the burn platform from the firebox and set aside f or reinstallation. Vacuum the ignitor area below the burn platform.

17602010 - 12/15/17

Page 61

4. Start at roof of the firebox and sweep the soot off the liners, top, sides and rear. You can either vacuum up the debris as you go or just sweep everything down into the ash pan area or remove it at the end.

5. Remove the fireback liners from the firebox (see section “Fireback Removal”). Sweep the backside of each piece as you remove it from the stove.

17602010 - 12/15/17

Page 62

6. With the Firebacks removed, the cast iron heat exchanger and the metal firebox are now exposed. Start at the ceiling of the firebox and sweep the heat exchanger. Sweep the sides and back of the fir ebox as well.

7. Reach in and vacuum up the dislodged debris.

8. Open the ashpan door and remove the pan from the stove. NOTE: Vacuum the ashpan as you remove it to help dust and soot entering the home.

9. Vacuum the area below and around where t he ashpan sits below the firebox.

17602010 - 12/15/17

Page 63

left side forward.

Remove wingnut

Foxfire

Deerfield

Remove wingnut

Clean the horizontal exhaust passage

Remove the access cover by removing the wing nut on the left of the cover and pulling the

Slide the cover out of the stove.

Locate the exhaust port on the right side. Vacuum up all loose debris

Remove the access coverby lifting up in the top center and guiding it out of the stove. Remove the circular coverplate by removing the wingnut

Vacuum the horizontal chanel

17602010 - 12/15/17

Page 64

Deerfield

Foxfire

Clean the Exhaust Blower Impellers and Housing

A thorough cleaning of the Exhaust Blower Impellers and Housing is vital ly important to the stoves ability to burn cleanly and efficiently.

Remove the access plate and gasket from the side of the exhaust box

NOTE: You will need to have a replacement gasket for reinstallation. SKU# 250-04450

Gently brush the impellers the then vacuum the debris

Check gaskets

Leaking gaskets can cause poor perfor mance in pellet appliances. If air is able to enter the firebox through a leak then it is not being pulled through the burn platfor m and burning fuel. Leaking gaskets c an al so cause an ignitor to not light the pellets properly as well. The following gaskets should be checked annually:

• Door Gasket

• Glass Gasket

• Ashpan Door Gasket

• Exhaust Blower Gasket

Door and glass gasket will often show leaks easily if you know what to look for. Generally, a leak in either of these two places will cause a clean streak on the glass where the air is entering.

17602010 - 12/15/17

Page 65

Take care to reassemble the HRD with al l components in the same order AND make sure not to turn any of the hazard.

Vacuum

Here

Top View

HRD

Clean fines out of the HRD

Fines or sawdust debris from pellet s can accumulate in the HRD over time. H umidity in the air can cause the fines to swel l and can impede the movement of the disks. We rec ommend the HRD be opened and cleaned annually.

For details on how to access and open the HRD, see section “Horizontal Rotati ng Disks (HRD) Components Removal”. Make sure to vacuum out the following areas on the HRD assembly:

components upside down. Improper reassembly could cause performance issues and could be a saf ety

17602010 - 12/15/17

Page 66

Appendix A

Wiring Diagram

17602010 - 12/15/17

Page 67

Appendix B

Control Timing

17602010 - 12/15/17

Page 68

Appendix C

Fan Voltages and Metering Motor Timing

Voltages and Timings for v1.1.7 FW

LEVEL

1 2 3 4

5 6 7 8 9

CONV

LOW

90 92 93

95 100 105 110 110 110 110

CONV

HIGH

95 100 103 105 110 112 115 120 120 120

EXHAUST

95 100 105 110 115 120 120 120 120 120

METER

TIMINGS

148 124 100

80 63 49 35 22 18 12

Use CONV LOW when heat level is 5 or less; use CONV HIGH otherwise. METER TIMINGS are in seconds, and represent the OFF time. On time is 45 seconds. Voltages assume 120Vac power source, measured using a True RMS voltmeter under load, and are approximate.

17602010 - 12/15/17

Page 69

Appendix C

Power Control Board Pinout

17602010 - 12/15/17