Travis Industries Avanti PS, Heritage Bay PI, Avanti PI, Heritage Bay PS Service Manual

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Page 1

Pellet Stove

Service Guide

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This manual addresses the following models:

· Avanti PS

· Avanti PI

· Heritage Bay PS

· Heritage Bay PI

Page 2

Table of Contents

Introduction

Models Addressed in This Guide..................... i

Who should use this guide............................. i

Precautions............................................... i

How to Use this Service Guide....................... i

Items to Bring on Service Calls....................... ii

Eliminating False Fixes................................ iii

Warranty Procedure.................................... iv

Flowcharts Ð (Section 1)

Stove WonÕt Start................................... 1 - 1

Pellets Don't Feed.................................. 1 - 2

Stove Burns Poorly................................. 1 - 3

Stove Goes Out......................................1 - 4

Stove Doesn't Heat................................. 1 - 5

Stove is Noisy....................................... 1 - 6

Glass is Dirty......................................... 1 Ð 7

Troubleshooting Steps (Section 2)

Cleaning

Clinkers.................................................2 - 1

Firebox and Exhaust System Cleaning.........2 - 2

Blocked Vent..........................................2 - 5

Vent

Restrictor Adjustment..............................2 - 5

Air Leak

Air Leaks...............................................2 - 6

Checking the Door Seal.........................2 - 6

Replacing the Door Gasket.....................2 - 6

Adjusting the Door................................2 - 7

Checking the Ash Pan Seal....................2 - 8

Air Inlet Blocked......................................2 - 8

Electrical

Faulty Exhaust Blower..............................2 - 9

Fuse Blown............................................2 - 9

Circuit Board Faulty...............................2 - 10

Faulty Igniter........................................2 - 11

Auger

Clearing the Auger.................................2 - 12

Auger Motor Defective............................2 - 13

Auger Circuit Faulty...............................2 - 14

Pellet Quality........................................2 - 15

Noise

Noisy Stove.........................................2 - 16

Convection Blower

Faulty Convection Blower........................2 - 17

Convection Blower Circuit Faulty..............2 - 18

Removal Instructions (Section 3)

Panel Removal

Side Panel Opening (Stoves Only)............. 3 - 1

Rear Panel Removal (Stoves Only)............. 3 - 1

Surround Panel Removal (Inserts Only)....... 3 - 2

Door and Glass Assembly

Door Removal.........................................3 - 3

Glass Removal........................................3 - 4

Electrical Components

Circuit Board Removal ..............................3 - 5

Wiring Harness Removal ...........................3 - 6

System Snap Disk Removal ......................3 - 7

Hopper Snap Disk Removal .......................3 - 8

Flow Switch Removal ...............................3 - 8

Igniter Removal ......................................3 - 9

Auger Components

Auger Motor Removal .............................3 - 10

Auger Flight Removal .............................3 - 11

Blowers

Exhaust Blower Removal ........................3 - 12

Convection Blower Removal ....................3 - 13

Parts List

Parts List............................Inside Back Cover

Index

Index..........................................Back Cover

Page 3

Introduction i

Models Addressed in This Guide

This guide addresses the Avalon Avanti and Lopi Heritage Bay pellet stoves and inserts. For earlier Avalon 900 and Lopi FoxFire and 400 models, refer to the 1994 Pellet Troubleshooting Guide.

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 all local building codes. Bring an owner's manual for the heater being serviced in case any installation or maintenance questions arise.

Precautions

This heater becomes very hot during operation - use care to prevent burns or property damage while servicing.

Make sure the appliance is unplugged before conducting 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 flyash and other debris from staining the carpet or other flooring. On inserts, lay down a piece of cardboard on the hearth to prevent scratches.

How to Use this Service Guide

This guide uses several sections to address pellet stove service. The flowchart section (section 1) details the troubleshooting process from start to finish. Section 2 addresses each troubleshooting step individually (if you know the problem, you may wish to go directly to the troubleshooting step). Section 3 is dedicated to removal and replacement instructions. Section 4 contains technical specifications.

When this troubleshooting guide refers to a side or direction, use the diagram to the right to determine direction.

When this troubleshooting guide refers to a electrical connectors, use the following diagram to determine the type of connector.

Key to Quick

Left

Front

Above

Back

Right

Connects

Male

Below

Female

Page 4

ii Introduction

Items to Bring on Service Calls

Tools

¥ Nutdrivers, open end & socket wrenches in 1/4", 5/16", 11/32", 3/8", 7/16", 1/2", 7/8", 1" ¥ Door Tool (1/4Ó Allen Wrench) ¥ Multimeter ¥ Standard and Phillips-head Screwdrivers ¥ Wire with a male quick-connect attached to each end (called a jumper wire)

Hot 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 flyash entering home.

Jumper Wire

Spare Components

¥ Circuit Board ¥ Auger Motor ¥ Exhaust Blower ¥ Snap Disks (System & Hopper) ¥ Wiring Harness ¥ Exhaust Motor & Blower Gasket ¥ Power Cord

¥ Convection Blower ¥ Heater Fuses (5 Amp Quick - 1/4" x 1-1/4") ¥ Circuit Board Fuses (6 Amp 5 mm x 20 mm) ¥ Burn Pot ¥ Door Gasket Kit (includes cement) ¥ Igniter ¥ Flow Switch

3 Bags of High-Quality Pellets

Many pellet stove problems are due to poor quality pellets. Burning high quality pellets on-site often convinces the pellet heater owner to switch to a higher quality fuel.

Silicone Sealant

RTV 500° Silicone must be used to seal the joints between vent sections.

Page 5

Introduction iii

Eliminating False Fixes

Unfortunately, many service calls provide only a temporary solution. Unless the true problem is found, conducting service may only provide a slight performance increase. Often, when a part is exchanged with a new part, the stove's performance will improve enough to operate at a low performance level. For example, if you install a new exhaust blower you may improve performance enough to let the stove burn. But unless you clean the stove and show the customer how to maintain a clean stove, you will not fix the real problem. This stove with a "false fix" may work for several months, only to fail again. To eliminate false fixes and help make correct diagnosis, keep in mind these principles when diagnosing pellet stoves:

Treat the Pellet Stove as an Entire System

Air leaking through the door seal will decrease performance; a dirty stove will decrease performance; poor pellets will decrease performance: before you leave a service call, make sure all aspects of the pellet stove are working correctly. Just because you fixed a door leak does not mean that you should not check for flyash buildup.

Test Components Individually

Before replacing a component, test it against a new component. This is especially important for blowers and auger motors. Simply plug them in directly to a hotwire and compare performance.

Test the Stove Thoroughly

Before leaving a customer's home, make sure to operate the stove for at least one-half hour. Use the time to clean up or finish paperwork. Furthermore, test the stove on various burn rates to ensure proper operation.

Know the Stove's Performance Level

Become familiar with how a brand new stove performs. Check the flame quality (on high and low), heat output, blower noise, blower cfm, air wash, normal ash buildup, and door seal. Everything should be noted. With a new stove as a benchmark, you can test a customer's stove for relative performance.

The 5 Most Common Problems

Before leaving a service call, make sure the following items have been checked:

¥ Air Leaks ¥ Dirty Stove ¥ Jammed Auger ¥ Poor Pellets ¥ Blocked Vent

Page 6

iv Introduction

Warranty Procedure

Most components inside Travis Industry stoves are warranted. To receive credit for a component covered on the warranty, follow the PRA ( P roduct R eturn A uthorization) procedure below:

1) Fill out a PRA form (white, pink, & gold carbon paper form) - keep the gold copy for your records.

2) Send the form, along with the component, to Travis Industries, Attn: PRA Returns, 15530 Woodinville Redmond Road, Suite # 300, Woodinville, WA 98072.

3) When it is tested defective, you will receive full credit.

4) Order a new component (if needed to replace existing stock).

NOTE:

The items must be defective and under warranty to receive credit. If the component is tested and found to be workable, or if it is not under warranty, it will be returned to you at your expense. The items must be accompanied by a PRA form with all the information completed.

Page 7

Stove WonÕt Start

Flowcharts 1 - 1

Re-start the stove by moving the mode switch to “OFF” then “MANUAL” and pressing the “MANUAL START” button (press this button firmly).

Plug in a lamp or other appliance to verify the power outlet is supplying power.

There are two fuses on the stove - one on back of the heater near the power cord, one on the back of the circuit board.

To check the circuit board, replace it and check operation.

AUTO

MANUAL

Yes

Does

ÒMANUALÓ

Light Come

On?

Has

Household

Breaker

Blown?

Has

Either

Fuse

Blown?

Is the

Circuit

Board

Faulty?

Yes

Check the Power Outlet

Make sure the household breaker

(or fuse) is operational.

Replace the Fuse

See ÒFuse BlownÓ on page 2-9 for

inspecting and replacing the fuse(s).

Replace the Circuit Board

See ÒCircuit Board FaultyÓ on page 2-10 for

diagnosing and replacing the circuit board.

Start the stove and check for pellets feeding into the burnpot.

Pellets

Feed?

Yes

Igniter is Faulty

If the stove does not start after 10 minutes,

see the section ÒFaulty IgniterÓ on page 2-11.

Pellets ArenÕt Feeding

See the flowchart ÒPellets ArenÕt

FeedingÓ on page 1-2.

Page 8

1 - 2 Flowcharts

Pellets DonÕt Feed

Make sure the hopper has pellets. If the stove recently ran out of pellets, it will take approximately 10 minutes for new pellets to feed.

Re-start the stove by moving the mode switch to “OFF” then “MANUAL” and pressing the “MANUAL START” button (press this button firmly).

Empty the hopper of pellets and carefully look at the auger. If it moves slightly back and forth during operation, the auger is most likely jammed.

Listen to the auger motor to detect if it is working (see “Auger Motor Defective” for more details).

MANUAL

AUTO

AUGER

Pellets

in Hopper &

Auger

Primed?

Yes

Does

Auger Light

Come

On?

Is the

Auger

Jammed?

Is Auger

Motor

Working?

Yes

This is Normal

Fill the hopper and start the heater.

It should start in 7 to 10 minutes.

Stove Does Not Start

See the flowchart ÒStove Does

Not StartÓ on page 1-1.

Clear the Auger

See ÒClearing the AugerÓ on page 2-12

for details on un-jamming the auger.

Auger Motor Defective

See ÒAuger Motor DefectiveÓ on page 2-13 for

details on diagnosing and fixing auger motors.

The auger circuit is used to disable the auger in cases where the flue becomes hot or the hopper overheats.

To check the circuit board, replace it and check operation.

Yes

Is Auger

Circuit

Faulty?

Replace the Circuit Board

See ÒCircuit Board FaultyÓ on page 2-10 for details

on diagnosing and replacing the circuit board.

Yes

Auger Circuit Faulty

See ÒAuger Circuit FaultyÓ on page 2-14 for

details on diagnosing and fixing auger circuits.

Page 9

Stove Burns Poorly

A poorly burning stove will have a dark, sooty flame. Often the burnpot will fill up with smoldering pellets.

Flowcharts 1 - 3

Look for dark “clinkers” inside the burnpot.

Air leaks are the most over-looked area when troubleshooting pellet stoves.

Check for blockage where the flue turns upwards and at the cap.

Burnpot

Clean?

Yes

Air Leaking

into the

Firebox?

Has

Stove Been

Cleaned?

Yes

Is Vent

Blocked?

Yes

Clean the Burnpot

See ÒClinkersÓ on page 2-1 for

details on what causes clinkers.

Check for Air Leaks

See ÒAir LeaksÓ on page 2-6 for details

on diagnosing and fixing air leaks.

Clean the Stove

See ÒFirebox and Exhaust System

CleaningÓ on page 2-2 for details on

cleaning the stove.

Clean the Flue

See ÒBlocked VentÓ on page 2-5 for details

on diagnosing and fixing blocked flues.

The vent may have a maximum of two 90° elbows, must not be higher than 35’, must not run horizontally more than 10’, and in some cases, must be 4” in diameter.

Make sure the air inlet cap is not blocked and the flex tube is not crushed.

The restrictor is only for stoves that over-draft .

Vent

Installed

Correctly?

Is Air Inlet

Blocked?

Restrictor

Fully

Open?

Faulty Exhaust Blower

See ÒFaulty Exhaust BlowerÓ on page 2-9 for

details on diagnosing and fixing exhaust blowers.

Yes

Re-Install the Vent

See the ownerÕs manual for a complete list

of venting requirements.

Clear the Air Inlet

See ÒAir Inlet BlockedÓ on page 2-8

for details on the air inlet.

Open the Restrictor

See the section ÒRestrictor

AdjustmentÓ on page 2-5.

Page 10

1 - 4 Flowcharts

Stove Goes Out

Start the stove momentarily and check to see if pellets feed into the burnpot.

Does

Hopper

Have

Pellets?

Yes

Has power

gone out

recently?

Are

Pellets

Feeding?

Yes

This is Normal

Re-fill the hopper and start the

heater. The heater should start in 7

to 10 minutes.

This is Normal

A power outage may disable the

heater - simply re-start the heater.

Pellets ArenÕt Feeding

See the flowchart ÒPellets

ArenÕt FeedingÓ on page 1-2.

Was the fire bright with an occasional pellet jumping out of the firepot before the stove went out?

What was the burn rate when the stove when out.

HEAT OUTPUT

Does the

Stove Burn

Well?

Yes

What was

the Burn

Rate?

Unit may be over-drafting

“High” Burn

“Low” Burn Rate

See the section ÒRestrictor

AdjustmentÓ on page 2-5.

Rate

Stove Burns Poorly

See the flowchart ÒStove

Burns PoorlyÓ on page 1-2.

Double-check the items above. If

the unit is still going out, call Travis

Industries for more information.

Page 11

Stove Doesn't Heat

Flowcharts 1 - 5

The convection air blows heated air above the door.

Yes

Does

Convection

Blower Come

On?

Stove up to

Temperature?

Yes

Convection

Blower

Faulty?

Convection Circuit is Faulty

See ÒConvection Blower Circuit FaultyÓ on page

2-18 for details on the convection blower circuit.

Yes

This is Normal

The fan will come on once the stove is hot

(5 to 15 minutes after start-up).

Replace the Convection Blower

See ÒFaulty Convection BlowerÓ on page 2-17

for details on the convection blower.

Look for dark “clinkers” inside the burnpot.

To check draft, inspect the pellets inside the burnpot while on “Low”. If un-burned pellets jump out of the burnpot, you may wish to adjust the restrictor (watch for several minutes).

Are Heat

Exchangers

Clean?

Yes

Is Burnpot

Clean?

Yes

Is Vent

Drafting Too

Fast?

Is Heating Need too Large?

This heater produces approximately 20,000 BTUÕs on ÒHIGHÓ - it may not be

suitable for all home heating needs. Check the homeÕs size, insulation level

and the outside temperature to verify that 20,000 BTUÕs per hour is adequate.

Heater location may also be a consideration: heaters located in a corner or

one side of a room may not distribute heat to other rooms.

Yes

Clean the Heat Exchangers

With the stove cool, move the heat exchange

cleaner up and down (see ÒClean the Heat

Exchange TubesÓ in the ownerÕs manual).

Clean the Burnpot

See ÒClinkersÓ on page 2-1 for

details on what causes clinkers.

Adjust the Restrictor

See ÒRestrictor AdjustmentÓ on page 2-5

for details on the adjusting the restrictor.

Page 12

1 - 6 Flowcharts

Stove is Noisy

Try pressing down on various points around the base of the heater to see if it decreases noise.

Try pressing down on the surround panels and decorative trim to see if it decreases noise.

Is Noise

Coming From

Hearth?

Are

Surround

Panels

Noisy?

Is the

Exhaust

Blower

Noisy?

Is the

Convection

Blower

Noisy?

Yes

Dampen the Hearth

See ÒNoisy StoveÓ on page 2-16

more details on fixing noisy stoves.

Inspect Surrround Panels

See ÒNoisy StoveÓ on page 2-16

more details on fixing noisy stoves.

Inspect Exhaust Blower

See ÒNoisy StoveÓ on page 2-16

more details on fixing noisy stoves.

Inspect Convection Blower

See ÒNoisy StoveÓ on page 2-16

more details on fixing noisy stoves.

Is the

Auger Motor

Noisy?

Inspect the Stove

Loose components may create noise if allowed to vibrate. Locate the

source of the noise and tighten it connection. See ÒNoisy StoveÓ on

page 2-16 more details on fixing noisy stoves.

Yes

Inspect the Auger Motor

See ÒNoisy StoveÓ on page 2-16

more details on fixing noisy stoves.

Page 13

Glass is Dirty

Flowcharts 1 - 7

The door seal can be checked by closing the door on a piece of paper. If the paper slides out easily, the door seal is not tight enough.

The lower airwash gap, located next to the burnpot, may become plugged with ash. Look for ash piling up in the area directly behind the glass on the bottom.

Burnpot

Clean?

Yes

Is Door

Gasket

Leaking?

Airwash Gap

Plugged?

Try a Different Brand of Pellets

Poor quality pellets may lead to dirty glass. Try a new brand of pellets

and monitor glass cleanliness. See ÒPellet QualityÓ on page 2-15 for

details on diagnosing poor pellets.

Yes

Clean the Burnpot

A plugged burnpot will create creosote and

excessive flyash, dirtying the glass. See

ÒClinkersÓ on page 2-1 for details on what

causes clinkers.

Check for Air Leaks

Air Leaksl decrease the amount of air coming

through the airwash. See ÒAir LeaksÓ on page

2-6 for details on what causes clinkers.

Clean the Airwash Gap

Use a vacuum or brush to dislodge any

flyash caught in the airwash gap area.

Page 14

1 - 8 Flowcharts

Page 15

Troubleshooting Steps 2 - 1

Clinkers

If the flames are coming only from the sides, or are orange and black, turn the stove off and check for clinkers. Clinkers are hardened clumps that form over the air holes inside the firepot.

The most likely causes are:

¥ Poor pellet quality

¥ The door or glass has an air leak

¥ The stove or vent requires cleaning

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

Cleaning the Firepot

To clean the firepot, open the door (see page 23) and knock away any debris on the firepot with a screwdriver. If severely clogged, remove the firepot to gain better access. Use a screwdriver, or other tool, to fully dislodge any clinkers on the firepot.

Page 16

2 - 2 Troubleshooting Steps

Stove Cleaning

Ash buildup is the leading cause of poor performance. Excessive buildup can even lead to stove failure. Regular cleaning is required to keep pellet stoves operating. Whenever service is conducted, consider cleaning the stove in front of the homeowner to display how this process is conducted. The four sections of stove cleaning, and the appropriate cleaning frequency are displayed below:

Section Frequency

Clean the Firebox Twice a Week Ð or Every 10 Bags

Clean the Vertical Exhaust Duct Once a Year Ð or Every 2 Tons

Clean the Horizontal Exhaust Duct Once a Year Ð or Every 2 Tons

Clean the Exhaust Box and Exhaust Blower Once a Year Ð or Every 2 Tons

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

A shop vacuum with a drywall filter (available at most hardware stores) will remove flyash well. The drywall filter prevents the fine ash particles from entering the air.

Clean the Firebox

Swing the side ash trap door up. Lift it up and away from the firebox.

Repeat for the opposite side.

Lift the firepot out of its holder.

Slide the ash pan trap door forward

to expose the ash dumps.

Brush all flyash into the ash dumps, including

the flyash inside the firepot holder.

Replace the ash trap doors and firepot.

Slide the ash pan trap door forward.

Page 17

Troubleshooting Steps 2 - 3

Stove Cleaning (continued)

Clean the Vertical Exhaust Duct

The following models have vertical exhaust ducts welded in place.

Heritage Bay PS serial # below 211650 Heritage Bay PI serial # below 410650 Avanti PS serial # below 121700 Avanti PI serial # below 320525

To clean, follow the directions below.

Vertical Exhaust Duct

Use a hammer to tap against the fireback in front of the vertical exhaust ducts (not too hard). This should dislodge loose flyash.

Remove the flyash by removing the ash trap doors and sweeping into the ashpan.

NOTE: If the flyash does not dislodge, use a bottle brush or other device to scrape the flyash from the ducts.

More recent models use the cast-iron fireback as the front of the vertical exhaust duct. To clean, follow the directions below.

Remove both refractory side clips.

Clean this area behind where the refractory rests (both sides).

Remove the refractory.

Remove these doors to remove fallen flyash and soot (see ÒBi-Weekly Maintenance for detailsÓ)

Page 18

2 - 4 Troubleshooting Steps

Stove Cleaning (continued)

Clean the Horizontal Exhaust Duct

Open the hopper lid and remove the two

screws holding the side doors in place.

Phillips Screwdriver

Clean the Exhaust Box, Exhaust Blower

Open the hopper lid and remove the screw hlding the left door in place. Swing the left side panel open.

Cover Plate

Swing the side panels open.

Remove the cover plates over the exhaust

duct (both sides)

Remove the six screws holding the

exhaust blower motor in place.

11/32" Socket

Use a vacuum or bottle brush to remove all flyash from the exhaust duct.

5/16" Nutdriver

Phillips Screwdriver

Pull the motor out (be careful not

to damage the gasket or wiring).

Blower Blades

Exhaust Motor

Clean the blower blades, blower housing, and exhaust box. You may wish to use a

vacuum to pull ash out of the vent system.

Gasket

Exhaust Box

Blower Housing

Page 19

Troubleshooting Steps 2 - 5

Blocked Vent

Flyash that has been expelled by the exhaust blower will accumulate in the vent sections. Check the locations shown below for flyash buildup, and, if necessary, clean the entire vent system.

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

Make sure the cap is free of debris (especially if it has a screen that could become blocked).

Check the vent sections for creosote accumulation (indicating a poorly burning stove). Accumulation over 1/4Ó must be removed.

Flyash will deposit along sections that are horizontal.

On vertically vented systems, the dirtiest portion is often the point where the vent turns upwards (i.e. the "Tee"). Fortunately, the "Tee" has a built-in clean out cover. Remove the cover and vacuum out. While open, use a flashlight to look up the pellet vent to check for build-up.

Restrictor Adjustment

In some cases the vent will produce too much draft for the stove. This leads to an inefficient burn, and in some cases, the flame going out. Excessive draft typically happens in tall vertical installations or very short horizontal installations. The factory restrictor setting is wide open.

When to Adjust the Restrictor

¥ If un-burned pellets are expelled from the firepot often (make sure they are un-burned, not just cylindrical

embers), the restrictor needs adjustment.

¥ If on LOW the pellets burn too quickly and the flame goes out, the restrictor needs adjustment.

How to Adjust the Restrictor

NOTE: You will not notice much change in the flame after

Use these index marks to gauge restrictor movement. Move the restrictor

one position, then inspect the stoveÕs performance over a long period of time.

Turn this bolt counter-clockwise to push the restrictor in, increasing restriction.

adjusting the restrictor. Check stove performance over a long period of time.

Air Inlet

Restrictor

7/16" Wrench

WARNING: The stove must be completely cool and unplugged

prior to beginning this procedure.

Loosen this nut several turns.

TIghten the nut down (turn it counter-clockwise).

Combustion

Air

Page 20

2 - 6 Troubleshooting Steps

Air Leaks

Air leaks can come from the door or ash pan. Follow the directions below to diagnose and fix any air leaks.

Checking the Door Seal

Close the door on a dollar bill (or a piece of paper). Then try pulling the bill out. If it comes out easily, the door gasket is not forming a seal. Repeat this process around the perimeter of the door to ensure a complete seal. If the seal is inadequate, check the door gasket. If it is flattened, or does not protrude at least 3/16" from the door frame, replace the door gasket. If the gasket is adequate the door will require adjustment.

To check the glass seal, press on each panel of glass. If the glass moves easily, the glass gasket has become displaced or damaged. To fix the glass seal, disassemble the door and re-assemble, ensuring the glass gasket is properly placed.

Replacing the Door Gasket

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

Use only Travis Industries gasket when replacing the door gasket.

1 Remove the decorative trim above the door by opening the hopper and removing the two screws holding

it in place (use a phillips-head screwdriver).

2 Remove the door by unlatching it, opening it wide open and lifting it straight up off the hinge mounts. You

may need to swing the door back and forth to loosen the hinge pins.

3 Place the door on a flat, soft surface with the inside of the door facing upwards (do not scratch the gold).

Find the beginning of the gasket, usually near a corner, and pull it away from the door assembly. Prepare the surface for the new gasket by scraping off any large pieces of debris with a flat-head screwdriver, scraper, or wire brush. Remove any loose particles.

4 Apply a liberal amount of the gasket cement around the area where the new gasket will lie.

5 Apply the new gasket onto the gasket cement. Start in the bottom corner near the hinge. Be careful not

to bunch or stretch the gasket. Make sure the corners lie flat. The gasket is cut to fit the door - there should be little or no excess length (at most 3Ó).

Start the gasket in the bottom corner near the hinge.

Make sure the gasket is flat around the corners.

New Gasket

NOTE: Do not bunch or stretch the gasket - this will make the gasket uneven, or too thin - leading to air leaks.

Gasket Cement

6 Wipe any excess adhesive off all free surfaces and let the adhesive set about 30 minutes.

7 Re-attach the door assembly and decorative trim Close the hopper lid.

Page 21

Troubleshooting Steps 2 - 7

Air Leaks (continued)

Door Adjustment

The door latch plate and hinge plate are adjustable, allowing the door to be pulled in closer to the stove. These plates have notches that line up with dimples on the side of the stove. To adjust the door, loosen both plates and move them back 1/16". Use the notch and dimple to ensure correct alignment (so the door does not tilt up or down). Recheck the door seal after each adjustment. If you notice the door is tight against one side, but loose against the other, tighten only the side that is loose.

HINT:

Open the hopper and look down at the door from above. Make sure the door is properly aligned and is evenly spaced away from the face of the heater.

Dimple & Notch (used for alignment)

Hinge Adjustment

Door

Plate

7/16Ó

Socket

Loosen these bolts and slide the hinge adjustment plate back approximately 1/16Ó. Then re-tighten the bolts.

Open the hopper lid and remove the two

screws holding the side doors in place.

Dimple & Notch (used for alignment)

Door

Phillips Screwdriver

Swing the side panels open.

Open the door.

Loosen these bolts and slide the door latch adjustment plate back approximately 1/16Ó. Then retighten the bolts.

7/16Ó

Socket

Door Latch Adjustment Plate

Page 22

2 - 8 Troubleshooting Steps

Air Leaks (continued)

Ash Pan Seal

The trap door above the ash pan seals air from entering the firebox. Check the items below to ensure the trap door is sealing.

Clean the trap door and underside of firebox. Slide the trap door back in place.

Trap Door

Pull the trap door out. Carefully inspect it to make sure it is not warped.

The trap door is pressed against the firebox with this pressure plate. If the trap door does not press firmly against the firebox, tighten the four

nuts on the pressure plate appropriately.

Air Inlet Blocked

In rare cases the air inlet becomes blocked. Snow or debris can clog the opening. The flexible aluminum duct can be flattened.

To verify the air inlet is functional, remove the air inlet hose from the stove. If stove performance improves dramatically, the air inlet may be restricted or blocked.

Page 23

Troubleshooting Steps 2 - 9

Faulty Exhaust Blower

The exhaust blower pulls air through the air inlet, burnpot, and exhaust ducts. If these channels are blocked or restricted, performance will decrease. Therefore, before checking the exhaust blower, make sure the stove is clean.

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

The only way to check the exhaust blower is to remove it from the stove, hotwire it, and compare it to a new exhaust blower. See the directions below.

Use a hot-wire to check blower performance (you should do this outside to prevent stray flyash from entering the home).

Be careful to not touch the impeller.

Gauge the airflow leaving the blower.

Fuse Blown

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

There are two fuses on the pellet stove. An in-line fuse is found at the rear, near the power cord.

A circuit board fuse is found on the back of the circuit board. See the section ÒCircuit Board FaultyÓ for details.

The fuse is located at the back of the stove near the location where the power cord connects. There are two different types of fuse holders:

Fuse (part # 93-0695)

Fuse Holder

This type unscrews with your fingers. Press in slightly while turning the fuse holder counter-clockwise to release.

Small Standard

Screwdriver

Use a small standard screwdriver for this type. Press in slightly while turning the fuse counter-clockwise to release.

Blown fuses will have a break in the element. In rare cases the fuse may have a loose cap replace the fuse if uncertain.

Fuse (part # 93-0695)

Fuse Holder

Page 24

2 - 10 Troubleshooting Steps

Circuit Board Faulty

The circuit board is not serviceable (with the exception of the circuit board fuse Ð see below). Test this component by replacing it and checking operation of the stove.

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

Access the back of the circuit board.

On stoves, open the right side panel. On inserts, remove the surround panel trim, the top panel, and right side panel.

Check the circuit board fuse. If the element inside the fuse is broken, replace it and check operation (in rare cases the fuse cap detaches from the element - replace the fuse if uncertain).

Circuit Board Fuse (part # 93005019)

Detach the wiring harness from

the circuit board.

Pinch these tabs to remove the wiring harness.

Attach the wiring harness to the new circuit board and test

operation.

If using a thermostat, detach the thermostat wires.

For more details on circuit board operation, see ÒCircuit BoardÓ in the technical specifications section of this guide.

Wiring Harness

Page 25

Troubleshooting Steps 2 - 11

Faulty Igniter

During the start-up sequence the igniter receives electricity for 10 minutes under normal circumstances. To check the igniter, access the right side of the stove and connect a hot wire to the two igniter leads.

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

Locate the two wires leading from the igniter (they are white fiberglass

sheathed wires - you may need to cut the lock ties holding them in place replace the lock ties after service).

Disconnect the

leads and attach to a hot wire.

Open the door and remove the burnpot.

Look into the area behind the

burnpot. Within two to three minutes of hot wiring the igniter, you should see it start to glow red. If it does not, the igniter is faulty.

If the igniter does glow red, the igniter is functional. Next, check the wires leading to the igniter.

Locate the two quick-connects leading from the wiring harness to the igniter

(one has a black wire, one has a pair of white wires).

Set the stove to "MANUAL" and press the "MANUAL START" button. Watch the multimeter to see if it displays 120 Volts. If it does not, the wires are damaged or the

circuit board is not providing electricity to the igniter.

VOLTS

Igniter Wires

Attach a multimeter set to volts AC to

these two quick-connects.

Page 26

2 - 12 Troubleshooting Steps

NOTE:on pellet i

Clearing the Auger

Several different factors can cause the pellets inside the auger to compress and jam the auger. Pellets, left over the summer, can absorb water, expand, and jam the auger. Pellets piling up inside the burnpot can fill the drop tube and then jam the auger. Foreign objects left in the hopper can jam the auger. To remove the auger flight inspection plate and clear any items jamming the auger, follow the directions below.

conducting the following steps.

nserts, remove the hopper cover before

Remove all pellets in the hopper.

Remove the silicone shown here (the silicone

shown in gray need not be removed).

Remove any debris and pellets from the auger flight. If the auger had been jammed,

you would probably notice pellets lodged firmly between the auger flights.

Bearing Cover

Unscrew the six screws holding the auger flight

inspection cover in place.

5/16" Nutdriver

Remove the bearing cover and auger flight

inspection plate.

Auger Flight Inspection Plate

Before re-assembly, you may wish to re-start the stove and verify the auger turns. Make sure to

apply high-temperature silicone to the bearing cover (see step ÒbÓ above), this keeps pellet fines from contacting the upper auger flight.

Page 27

Troubleshooting Steps 2 - 13

Auger Motor Defective

The auger motor can be checked while it is still installed inside the stove. Follow the directions below to check the auger motor.

Unplug the stove to prevent electrical shock.

Plug in the hotwire and watch to see if the

auger turns. NOTE: watch the auger for a couple minutes to verify that it is turning over repeatedly Ð a jammed auger may turn slightly.

Unplug the stove. Disconnect the

auger motor leads. Attach a hotwire to the auger motor (orientation does not matter).

If the auger does not turn over, remove the auger

motor, attach a hotwire, and check the output shaft.

If the auger motor is working correctly, the auger may have been incorrectly connected to the auger shaft. Use the illustration below to verify the auger motor connection.

Make sure the lock screw goes through the auger shaft and contacts the dimple on the output

Hopper

Auger Flight Inspection Cover

Lower Auger Bushing

Auger Flight

Auger Shaft

Drive Collar

Lock Screw

Motor Stop

3/16" Allen

Auger Motor

shaft of the auger motor.

Lock Screw

Auger Shaft

NOTE:

If the output shaft on the auger motor does not light up with the auger shaft hole, you may hotwire the auger motor to turn the shaft until it lines up.

Drive Collar

Output Shaft

Auger Motor

Page 28

2 - 14 Troubleshooting Steps

Auger Circuit Faulty

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

Hopper Snap Disk

The auger circuit consists of the auger motor, flow switch, hopper snap disk, and the wiring between. If the auger motor is not receiving electricity during normal operation, you should check the auger circuit for malfunctions. The first step is to check the wiring. Make sure no wires have been pulled loose, severed, or melted.

Check the four red wires leading to the hopper snap disk and flow switch. Check the red and white wires leading to the auger motor. Disconnect each quick-connect and re-connect, making sure full contact is made.

Flow Switch

Auger Motor

Next, check the flow switch and hopper snap disk. These safety components were designed to disable the auger motor in the event of a malfunction. The hopper snap disk disables the circuit if the hopper becomes too hot. The flow switch disables the circuit if the vent becomes blocked. Follow the directions below to test the flow switch.

Unplug the stove.

Disconnect the

two wires leading to the flow switch.

Back of Flow Switch

Attach a jumper

wire to the two wires removed.

Turn the stove on and test operation. If

the stove still does not work, replace the wires and test the hopper snap disk (see the directions below). If the stove does work, the flow switch is not working. Make sure the vacuum hose is attached at both ends and in good shape. Replace the flow switch if the hose is correct.

Vacuum Hose

Follow the directions below to test the hopper snap disk.

Unplug

the stove.

Hopper Snap Disk (on the right side of the hopper near the top)

Disconnect the two wires leading to the hopper snap disk.

Attach a jumper

wire to the two wires removed.

Turn the stove on and test operation. If

the stove works normally, the hopper snap disk is malfunctioning and should be replaced. If the stove still does not work, see the section for testing the circuit. board.

CONTINUITY

If you do wish to test the snap disk, heat the back side of the snap disk with a lighter. It should show continuity until it is warmed to 200¡ (3 to 10 seconds under a lighter) - you can also listen for a ÒclickÓ.

Page 29

Troubleshooting Steps 2 - 15

Pellet Quality

With the surge in popularity of pellet heaters came the tremendous increase in pellet demand. Because pellets are made from wood by-products, pellet manufacturing is dependent upon the supply of these by-products and the quality found therein. Unfortunately, this surge in pellet manufacturing has led to a decline in the quality of the raw materials used to produce the pellets. Ideally, pellets should have a very low moisture, ash, dirt, and salt content. Some pellets do not. Pellets should have a consistent diameter of 1/4", 5/16", or 7 mm. Pellets should also be no longer than 1 1/2" long. Some pellets are longer. There is no real pellet monitoring agency, so you must monitor pellet quality yourself. Pellets left outside in damp conditions may absorb water, decreasing performance. Poor pellets may lead to the symptoms listed below.

oor quality pellets may lead to clinkers in the firepot (look for dark spots on the burn grate while the stove is burning)

oor quality pellets may lead to dirty glass, especially if it is black and sooty

Poor quality pellets may lead to excessive flyash, making the stove require more frequent cleaning

oor quality pellets may lead to the auger jamming frequently

Recommendation:

Bring 3 bags of pellets that you have tested and are high quality. Let the customer burn the pellets and check for these signs of bad pellets: clinkers develop in the air holes on the bottom of the firepot; the auger jams for no apparent reason, and when the hopper is cleaned out, the auger runs again; there is more than one-half cup of sawdust in the bottom of the bag of pellets; or, the pellets don't burn well on a low burn rate. It is best to check one brand of pellets versus another to see the difference first-hand. The Association of Pellet Fuel Manufacturers has set the following standards for pellets: density of at least 40 lbs. per cubic foot; 1/4" to 5/16" diameter; length no greater than 1 1/2"; 8200 BTU's/lb.; moisture under 8% by weight; ash under 1% by weight; and, salt under 300 parts per million.

Page 30

2 - 16 Troubleshooting Steps

If the noise

Noisy Stove

Normal Operating Sounds

Exhaust Blower

Before conducting a service call for a noisy stove, try to quantify the amount of sound coming from the stove. Pellet stoves have several components with moving parts that will create noise. You may wish to go over the normal operating sounds with the customer before conducting a service call.

The flow of exhaust gases may create a low-pitched hum. This sound will change as the FEED RATE is altered.

Heat Exchanger Tubes

You may hear the heated air being forced through these tubes by the convection fan.

Firepot

As pellets are fed into the firepot, a light clicking sound may be heard.

Auger Motor

When feeding pellets, you may hear the intermittent buzz of this motor running.

Covection Fan

The modern high efficiency fan may produce a low hum, particularly on "HIGH". This sound will change as the FAN dial is turned.

Diagnosing Stove Noises

Noise may be created by several factors. Moving components (blowers or auger motors) may create noise or a vibration that leads to a rattle. The process of eliminating a noise is to identify which component is creating the noise and either securing it better, placing a piece of gasket to dampen the rattle, or replacing the component. Use the illustrations to the right to help diagnose stove noises.

Listen carefully for screws, bolts, or nuts that have become loose. If they are not tight, rattling may occur.

If a blower is creating noise, try loosening its connection, realigning the blower (& gasket), and re-tightening the connection. Any vibration can lead to noise.

The hearth may ampify any vibration on the stove, especially on uneven or irregular hearth surfaces. If you hear any noise from this area, try attaching gasket tape to the bottom corners of the pedestal.

Inserts

is moving, remove the pellets and check the auger flight to see if anything is caught.

Make sure the top panel is not rattling against the facing. Use gasket tape to dampen any sound, if necessary.

Check the base of the insert. Sometimes, especially on irregular shaped hearths, the hearth can transmit sound from the insert. Wedge a small piece of gasket tape under the insert to eliminate the sound.

Make sure the double-back tape holds the trim firmly against the surround panels.

occurs only when the auger

If the auger motor "clicks" , check to see if it is knocking against the motor stop. There are two rubber bumpers built into the motor stop designed to stop this noise - make sure they are in place.

On stoves, make sure the side panels are attached.

Make sure nothing has fallen into the convection blower.

Surround

Surround Panel

Double-back tape

Panel Brass Trim

Page 31

Troubleshooting Steps 2 - 17

Faulty Convection Blower

The convection blower pushes air through the heat exchanger tubes located along the top of the firebox, transferring heat from the firebox to the room. It also performs a necessary cooling function for internal components*. To check the convection blower, follow the steps below.

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

Unplug the

stove.

Check for air blowing out of the heat exchanger tubes.

Air Comes Out - Blower is okay, check the convection blower circuit.

Air Does Not Come Out - Blower is faulty. Go to step ÒeÓ.

Disconnect the two

wires leading to the convection blower.

Convection Blower

Attach a a hotwire

to the convection blower.

Convection Blower (shown here removed)

With the blower unplugged, check

the inside of the squirrel cage thoroughly. Make sure the squirrel cage turns. Debris or pellets can jam the blower. If nothing is found, replace the blower.

* If the convection blower does not work, the stove may overheat, causing the hopper snap disk to disable the auger. Replace the convection blower if it does not work correctly Ð see the instructions on page 3-13.

Page 32

2 - 18 Troubleshooting Steps

Convection Blower Circuit Faulty

The convection blower is controlled directly by the circuit board. . Follow the directions below to check the convection blower circuit.

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

Start the stove and let it

reach normal operating temperature (10 to 15 minutes).

Attach the multimeter leads, set to voltage AC, to the

two posts on the convection blower (there is enough bare metal on the post to get a good reading).

VOLTS

Convection Blower

Convection Blower (shown removed)

Convection Blower Wires (Brown & White)

The voltage should read approximately 70 volts on low

blower speed, approximately 115 volts on high blower speed.

If No Voltage is Detected

Check the brown and white wires leading to the blower for breaks or damage. Replace the wiring harness if damage is found. Othewise, the circuit board (or system snap disk) is faulty. Replace these components and re-test the stove.

Page 33

Removal Instructions 3 - 1

Side Panel Opening (Stoves Only)

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

Open the hopper lid and remove the screw holding the door in place (this works for both sides).

Phillips Screwdriver

Rear Panel Removal (Stoves Only)

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

Loosen the six screws holding the rear panel in place.

1/4" Nutdriver

Slide the panel up and away from the stove.

Page 34

3 - 2 Removal Instructions

Surround Panel Removal (Inserts Only)

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

Trim Removal

Top Panel

Pull the bottom of the trim outwards slightly to peel it away from the double-back tape holding it in place. Replace the double-back tape after installing the trim this keeps the trim from rattling or flaring at the bottom.

Top Panel Removal

Lift the top panel upwards off the joggle clips to remove.

NOTE: When installed, the panels must be 3/8Ó off the fireplace face.

Double-Back Tape

Side Panel Removal

Each side panel has two slots that accept clips attached to the sides of the insert. Lift the panels up and away from the insert.

Slot

Tab

Wiring Harness

The wiring harness is attached to the circuit board, which is attached to the right side panel. You may wish to disconnect the wiring harness

Back Side of Circuit Board (attached to right side panel)

Pinch these tabs to remove the wiring harness.

Wiring Harness

If using a thermostat, detach the thermostat wires at this time.

Page 35

Door Removal

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

Door

Removal Instructions 3 - 3

Phillips

Screwdriver

Open the hopper lid and remove the grill.

Door Hinge

Hinge Adjustment Bracket (attached to side of stove).

Open the door. Grasp the door with both hands. Swing the door back and forth while lifting up. The door should lift off the hinges.

Page 36

3 - 4 Removal Instructions

Glass Removal

Remove the door and place it face down on a soft surface. To disassemble the door, follow the directions below.

· Remove the door from the stove (see page 3-3) and place it face down on a soft surface.

· Peel the door gasket away from the door, noting how it is positioned. Remove the upper and lower airwash brackets

(see the illustration below).

11/32" Nutdriver

Airwash Brackets

Door Gasket (note

how it loops in the

bottom corners)

· The three pieces of glass are held in place with eight glass clips. Remove the glass clips to access the glass.

· Before replacing the glass, make sure the

glass gasket is in place, forming a seal around the perimeter of the glass. Place the center glass first. Place the side glass up against the center glass, making sure

Side Glass

(note gasket on

three sides)

the center piece is centered in the door frame. Re-attach the glass clips from the center outwards. Replace the airwash brackets and door gasket (see page 2-6).

Gold Door

Door Frame

11/32" Nutdriver

Attachment

Nuts

Airwash

Opening

Glass

(with channel gasket)

Door Gasket

Glass Clip

Airwash Bracket

Center Glass

Glass Clips

Page 37

Removal Instructions 3 - 5

Circuit Board Removal

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

1 For stoves, open the right side panel (see page 3-1). For inserts, remove the surround panels (see page

3-2).

2 Remove the circuit board following the directions below.

Detach the wiring harness (and

Pinch these tabs to remove the wiring harness.

Wiring Harness

thermostat wires, if used) from the circuit board.

Back Side of Circuit Board (attached to right side panel)

If using a thermostat, detach the thermostat wires at this time.

Remove the four screws

holding the circuit board in place.

Phillips Screwdriver

Page 38

3 - 6 Removal Instructions

Wiring Harness Removal

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

Make sure no wires contact the exhaust box or other high-temperature surface. Furthermore, make sure no wires come near the auger lock screw or convection blower intake (the wires may become snagged in these areas). Use lock-ties to secure the wiring harness away from these areas where they may become damaged.

1 For stoves, open the both side panels (see page 3-1). For inserts, remove the surround panels (see page

3-2).

2 The wiring harness connects to every electrical component inside the stove. If the wiring harness does

require removal, disconnect all of the wiring and replace. If only one wire is damaged, you may wish to attach a new wire to replace it (use the appropriate connectors and replacement wire). After installing the wires, make sure to lock-tie any loose wiring to prevent contact with hot or moving components.

Wiring Diagram

Avanti PS & PI

Heritage Bay PS & PI

Exhaust Blower

Key to Quick

Connects

Power Cord

Common

Hot (fuse)

Ground

1 3 5 7

Male

Female

White

Green

Screwed

Baseplate

2 4 6 8

Pinch these tabs to remove the wiring harness.

Protective Sheath around Wiring Harness

White

Black

Brown

White

Black

Auger Motor Flow Switch

Igniter

Convection

Blower

Brown

Red

Brown

Hopper

Snap Disk

Red Red

Black

Brown

System Snap Disk

NOTE: some models use quick-connects.

Back Side of Circuit Board

Red

Black

Page 39

Removal Instructions 3 - 7

System Snap Disk Removal

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

1 For stoves, open the left side panel (see

page 3-1). For inserts, remove the surround panels and pull the insert out to access the left side (see page 3-2).

2 The system snap disk is located on the

exhaust duct, just in front of the exhaust blower.

3 Remove the snap disk following the

directions below.

There are two types of system snap disks. Both operate in the same manner. If replacing the snap disk, the ceramic snap disk should be used (if the phenolic type failed, Travis will replace free of charge).

Phenolic (older type) Ceramic (newer type)

Disconnect the wires leading to the snap disk. Some models use wiring harnesses with quickconnects. When replacing the snap disk, use the connector wires included with the replacement system snap disks (discard the wires for wiring harness with ring connectors).

Standard Screwdriver

The snap disk is held in place with two screws.

Snap Disk Bracket

Phillips Screwdriver

Connector Wires (for older wiring harnesses)

Phillips Screwdriver

Newer wiring harnesses use ring connectors.

Standard Screwdriver

Page 40

3 - 8 Removal Instructions

Hopper Snap Disk Removal

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

1 For stoves, open the right side panel (see page 3-1). For inserts, remove the surround panels and pull

the insert out to access the right side (see page 3-2).

2 The hopper snap disk is located on the hopper, near the top.

3 Remove the snap disk following the directions below.

Hopper Snap Disk

Disconnect the two wires leading to the hopper snap disk.

Unscrew the two screws holding the snap disk to the bracket.

Snap Disk Bracket

Phillips Screwdriver

Flow Switch Removal

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

1 For stoves, open the right side panel (see page 3-1). For inserts, remove the surround panels and pull

the insert out to access the right side (see page 3-2).

2 The flow switch is located at the rear left of the appliance near the baseplate.

3 Remove the flow switch following the directions below.

Flow Switch

Disconnect the two red wires leading to the flow switch (orientation does not matter when re-installing). Disconnect the vacuum hose.

Back of

Vacuum Hose

The flow switch is attached to the stove with two screws.

Flow Switch

1/4" Nutdriver

Page 41

Removal Instructions 3 - 9

Igniter Removal

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

1 For stoves, open the right side panel (see page 3-1). For inserts, remove the surround panels and pull

the insert out to access the right side (see page 3-2).

2 Remove the convection blower (see page 3-10)

3 Remove the igniter following the directions below.

Remove this screw

Remove the igniter

5/16" Nutdriver

Disconnect the two wires leading to the igniter

Page 42

3 - 10 Removal Instructions

Auger Motor Removal

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

1 For stoves, remove the rear panel (see page 3-1). For inserts, remove the surround panels and pull the

insert out to access the rear (see page 3-2).

2 Disconnect the two wires leading to the auger motor. Unscrew the lock screw (see the illustration below).

With the lock screw removed, the auger will slide out.

When re-installing, make sure the lock screw goes through the auger

Hopper

Auger Flight

Drive Collar

Lock Screw

3/16" Allen

shaft and contacts the dimple on the output shaft of the auger motor.

Lock Screw

Output Shaft

Auger Flight Inspection Cover

Lower Auger Bushing

Auger Shaft

Motor Stop

Auger Motor

NOTE:

If the lock screw is not accessible, remove the two nuts on the motor stop (they are accessed from the right side). With the motor stop removed, the auger motor, with auger flight attached, can be rotated to better access the lock screw.

NOTE:

If the output shaft on the auger motor does not light up with the auger shaft hole, you may hotwire the auger motor to turn the shaft until it lines up.

Auger Motor

Drive Collar

7/16Ó

Socket

Motor Stop

Page 43

Removal Instructions 3 - 11

Auger Flight Removal

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

1 For stoves, remove the rear panel (see page 3-1). For inserts, remove the surround panels and pull the

insert out to access the rear (see page 3-2).

2 Remove the auger motor following the directions on the previous page.

3 Remove the lower auger bushing plate following the directions below. The auger flight can now be slid

out of the auger (on inserts you will need to lift the rear edge of the appliance slightly).

Remove the four bolts holding the lower auger bushing plate in place.

Hopper

Lower Auger Bushing Plate

7/16Ó

Socket

Motor Stop (attached to lower auger bushing plate)

Auger Flight

Page 44

3 - 12 Removal Instructions

Exhaust Blower Removal

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

1 For stoves, open the left side panel (see page 3-1). For inserts, remove the surround panels and pull the

insert out to access the left side (see page 3-2).

2 Remove the exhaust blower following the directions below.

Remove the four screws holding the exhaust duct to the exhaust blower. Cut the silicone where the duct

attaches to the blower (note: when replacing the duct, use high-temperature silicone to seal the duct air-tight). Remove the exhaust duct.

Exhaust Duct

Phillips Screwdriver

Remove the three

nuts holding the exhaust blower in place.

7/16" Nutdriver

Exhaust Blower

Exhaust Box

Page 45

Removal Instructions 3 - 13

Convection Blower Removal

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

1 For stoves, open the right side panel (see page 3-1). For inserts, remove the surround panels and pull

the insert out to access the right side (see page 3-2).

2 Disconnect the wiring from the convection blower following the directions below (orientation of the wires

does not matter when re-connecting).

Disconnect the two wires leading to the convection blower.

2 Disconnect the right side of the convection blower following the directions below.

Remove the two nuts holding the right side of the blower mount.

11/32" Nutdriver

Remove the stud bracket

Page 46

3 - 14 Removal Instructions

3 Remove the blower following the directions below.

Thread the blower out of the heater. You will need to rotate the blower slightly.

NOTE: Be careful not to damage wiring.

4 When replacing the blower, make sure the blower mounts correctly (see below).

View from Rear of Heater

Side View of

Blower Mounting

Auger Motor

Blower Mounting Plate

When replacing the blower, make sure the slots on the blower mounting plates slide into the groove on the rubber grommets.

Blower Mounting Plate

Stud Plate

Mounting Bracket (attached to base of heater)

Bushing

Nut

Rubber Grommet

Page 47

Parts List

Air Control Restrictor 93005061 Ash Door, Stove & Insert 93005051 Ash Dump Seal Plate, Spring Loaded 93005052 Ashpan, Pellet Freestanding Stove 93005050 Ashtrap Clean-Out Doors 93005054 Auger Assembly 93005092 Auger Bushing, Lower 93005094 Auger Bushing, Upper 93005093 Auger Flight 93005091 Auger Motor, 90-0191 Brush, Bottle Brush Style 93005531 Brush, Broom Style 93005530 Burn Pot 99300170 Circuit Board 93005000 Convection Blower 98900755A Convection Blower Knob, for Rheostat 99300657 Convection Blower Mounting Grommets, Rubber with Spacers 93005017 Convection Blower Mounting Plate 93005016 Convection Snap Disk, 120 Degree - 2 Prong 98900720 Door Gasket 93005085 Door Gasket 91001300 Door Gasket, 7/8Ó Multi-use, Black, 120Ó Long 99900402 Door Latch Hook 93005011 Door Latch Tool 93005010 Door Roller Plate Assembly 93005012 Exhaust Adapter, Vertical 99300137 Exhaust Blower 90-0391 Exhaust Blower Gasket (between Blower & stove) 90-0392 Exhaust Blower Gasket (between motor & housing) 99300135 Fireback, Cast Steel, Brick Pattern 93005057 Flow Switch 93005060 Flow Switch Tubing, 1/4Ó dia, High Heat 99300164 Fuse Holder, Pellet 99300570 Fuse, 5-Amp In-line fuse, Pkg of 5 93-0695 Fuse, 6 Amp Circuit Board, Pack of 5 93005019 Glass Gasket, 7/8Ó X 50 Ft, 302-B 99900401 Glass Gasket, 7/8Ó X 54Ó 99900408 Glass, Front 93005080 Glass, Side 93005081 Grill, Black 93005035 Grill, Gold 93005034 Handle, Hopper Lid, 1997 93005040 Hinge Plate Assembly 93005082 Hopper Snap Disk, 200 Deg. 91-1791 Igniter 99300148 Motor Stop, Stove & Insert 93005095 Power Cord 93005015 System Snap Disk, Ceramic, 120 Degree, 2 Prong 93005018 Thermostat, Remote 99300653 Thermostat, Wall Mounted, All Gas, 1997 Pellet 99300650 Wiring Harness 93005013

Page 48

Index

Air Inlet Blocked......................................2 - 8

Air Leaks...............................................2 - 6

Ash Pan Seal (Checking) ..........................2 - 8

Ash Removal (FireboxÉ Cleaning) .............. 2 - 2

Auger (clearing a jammed auger).................2-12

Auger Circuit Faulty ............................... 2 - 14

Auger Flight Removal ............................. 3 - 11

Auger Motor Defective............................ 2 - 13

Auger Motor Removal ............................ 3 - 10

Blocked Vent..........................................2 - 5

Circuit Board Faulty (& circuit board fuse)... 2 - 10

Circuit Board Removal .............................3 - 5

Cleaning (FireboxÉ Cleaning)....................2 - 2

Clearing the Auger ................................. 2 - 12

Clinkers.................................................2 - 1

Control Board Faulty (Circuit Board) ............2-10

Control Board Removal (Circuit Board).........3 - 5

Convection Blower Circuit Faulty .............. 2 - 18

Convection Blower Faulty........................ 2 - 17

Convection Blower Removal ....................3 Ð 13

Door Adjustment .....................................2 - 7

Door Gasket (replacement) .......................2 - 6

Door Removal ......................................... 3 - 3

Door Seal (checking the door seal)..............2 - 6

Electrical Connector (Key to Quick Connects.....I

Electrical Harness Removal.......................3 - 6

Electronic Circuit Board Faulty...................2-10

Electronic Circuit Board Removal................. 3-5

Eliminating False Fixes ................................ iii

Exhaust Blower Faulty..............................2 - 9

Exhaust Blower Removal ........................ 3 - 12

Firebox and Exhaust System Cleaning.........2 - 2

Firepot Clogged (Clinkers) ......................... 2 - 1

Flow Switch Removal ............................... 3 - 8

Fuse Blown (in-line fuse) ........................... 2 - 9

Glass is Dirty Flowchart ........................... 1 - 7

Glass Removal........................................3 - 4

Hopper Snap Disk Removal .......................3 - 8

How to Use this Service Guide........................ i

Igniter Faulty ........................................2 - 11

Igniter Removal ......................................3 - 9

Items to Bring on Service Calls...................... ii

Loud Stove............................................ 2-16

Models Addressed in This Guide..................... i

Noisy Stove..........................................2 - 16

Panel Removal (inserts).............................3-2

Panel Removal (stoves).............................3-1

Parts List............................Inside Back Cover

Pellet Quality........................................2 - 15

Pellets Don't Feed Flowchart..................... 1 - 2

Precautions................................................ i

Rear Panel Removal (Stoves Only)............. 3 - 1

Restrictor Adjustment...............................2 - 5

Side Panel Opening (Stoves Only) ............. 3 - 1

Stove Burns Poorly Flowchart ................... 1 - 3

Stove Doesn't Heat Flowchart ................... 1 - 5

Stove Goes Out Flowchart.........................1 - 4

Stove is Noisy Flowchart.......................... 1 - 6

Stove WonÕt Start Flowchart...................... 1 - 1

Surround Panel Removal (Inserts Only)....... 3 - 2

System Snap Disk Removal ......................3 - 7

Vent Blockage ........................................2Ð 5

Warnings (Precautions) ................................ I

Warranty Procedure.................................... iii

Who should use this guide ............................. i

Wiring Harness Removal ...........................3 - 6