Travis Industries Deerfield, Service & Troubleshooting Manual

Page 1: ...Deerfield Foxfire Troubleshooting ServiceGuide Copyright 2017 Travis Industries Certified Factory Training Program ...

Page 2: ...nd Block Removal 34 Chisel Removal 34 Horizontal Rotating Disk HRD Component 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 volta...

Page 3: ...re 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 headScrewdrivers Wir...

Page 4: ...on Blower Left 250 04440 Right 250 04439 Combustion Blower 250 03636 Flow Switch 90 0791 Snap Disk aka System Disk or Proof of Fire 250 02966 Igniter 250 02613 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 ...

Page 5: ...Left Convection Blower 3 Exhaust Box 4 Combustion Blower 5 Push Auger Motor 6 Metering Motor 7 System Disk 8 HRD High Limit Disk 9 Hopper High Limit Disk 10 Flow Switch 11 Power Control Board 12 Fuse Holder 13 Thermostat Connectors 14 HRD 15 Air Intake 1 11 3 5 9 8 2 6 10 4 7 12 13 14 15 ...

Page 6: ...rical 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 r...

Page 7: ...platform see section Visual Deflector and Burn Platform 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 bottom of the panel from the notches in the firebox Guide the bottom of the panel forward until it can be lowered into ...

Page 8: ...me process for the other side fireback 6 The rear fireback is between the back of the fireback and the mounting studs for the visual deflector Lift the 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 ...

Page 9: ...ucting service Unplug the 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 disengage the bottom of the panel from the floor of the stove Set the screws aside for reinstallation ...

Page 10: ...ear 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 If 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 Retaining Screw D Shaped part of Shaft Collar ...

Page 11: ...oder wires from the motor Carefully use a flat screwdriver to separate the white connector see below 6 Slide the push auger motor straight back to disengage 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 ...

Page 12: ...ay 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 through the shield behind the board The board is held in place by a clip in each corner 3 Press the 2 tabs on the sides of the 10 pin Molex plug supplies AC power to the PCB and disconnect it from the board Pull forward to disengage the PCB from clips ...

Page 13: ... the tab back on the Molex from the User Interface and disconnect it 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 ...

Page 14: ...e connectors have the same type of tab on it as the User Interface 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 nut driver to remove the 2 screws at the bottom of the shield When reinstalling the shield make sure that the green gr...

Page 15: ...s at the quick connects 5 Depending on where the retaining screw ends up in the rotation of the HRD you may need to remove the left convection blower see section Convection Blower Removal 6 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 and spacer will stay in place making for easier re installatio...

Page 16: ...a nut driver remove the zip tie anchor from the back of the stove The anchor is located just below 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 th...

Page 17: ...Page 17 17602010 12 15 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 ...

Page 18: ...ow the left hand convection blower Removal of the left blower is not required but the fans removal will give better access to the Flow Switch see section Blower Removal 3 Use a 3 8 nut driver to remove the two locknuts that mount the switch to the stove set aside for reinstallation The nuts are located on the side nearest the rear of the stove 4 Disconnect the two wires from the wiring harness at ...

Page 19: ...Page 19 17602010 12 15 17 5 Remove the vacuum hose from the flow switch ...

Page 20: ...e left blower is being removed remove the PCB and shield first see section PCB removal 1 Remove the side rear panel see section Rear Panel Removal 2 Remove the 4 screws that mount the blower to the mounting 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 disconn...

Page 21: ...ver plate by removing the wingnut 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...

Page 22: ... 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 it will fit If you pre...

Page 23: ...connections in the 10 o clock position with the exhaust box outlet on the left like shown in the picture below 10 Carefully remove the fan from the exhaust box by lifting it straight up Take care not to damage or bend the exhaust blower impellers 11 Remove the circular white gasket from the fan Install the exhaust blower into the new exhaust box make sure the exhaust blower gasket is in position a...

Page 24: ...er Motor Removal 3 Remove the Visual Deflector and Burn Platform see section Visual 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 nut driver to remove the 2 screws that mount the bushing plate to the Mounting brackets on the HRD set the screws aside for reinstallation 6 Use a T20 Torx bit to remov...

Page 25: ... of the plate from the notch in the auger tube see below 8 Remove the bushing block by sliding it straight back 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 Push shaft flush with bushing Lift up on plate so tab on plate releases from the notch in the tube ...

Page 26: ...o prevent electrical shock 1 Remove all pellets from the hopper 2 Using a nut driver remove the 6 screws that secure the HRD access panel to the hopper set aside for reinstallation 3 Remove the HRD access panel This will expose the top of the HRD assembly NOTE You may want to use gloves when removing the plate to protect yourself from sharp edges ...

Page 27: ...7 17602010 12 15 17 4 Use a 1 8 Allan wrench to remove the 2 20 x 1 2 screws 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 ...

Page 28: ... assembly to help ensure that the installation order is maintained 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 the auger flight If you can you have changed the orientation of some of the internal components Contact Travis Industries Technical Support for assistance 1 Remove all pellets from the hopper ...

Page 29: ...op 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 the HRD set aside for reinstallation 7 Remove the top fuel metering disk has the chisel attached Remove screws ...

Page 30: ...ve 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 ...

Page 31: ...r 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 screws removed Exploded View of the HRD Assembly ...

Page 32: ...Page 32 17602010 12 15 17 User Interface UI Removal The process is the same as the Foxfire see section User Interface UI Removal on pg 46 ...

Page 33: ...ion Blower 3 Combustion Blower 4 Push Auger Motor 5 Metering Motor 6 System Disk 7 HRD High Limit Disk 8 Hopper High Limit Disk 9 Flow Switch 11 Power Control Board 12 HRD 13 Fuse Holder 11 4 8 2 9 3 7 12 1 5 6 Behind blower shroud 13 Right Side facing front of stove Left Side facing front of stove ...

Page 34: ...l 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 ...

Page 35: ...estrictor 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 slightly to 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 Remove the fastener S...

Page 36: ...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 o...

Page 37: ...2010 12 15 17 4 Disconnect the two wires on the motor from the wire harness at the quick connects 5 Disconnect encoder wires from the motor Carefully use a flat screwdriver to separate the white connector see below ...

Page 38: ...Slide the push auger motor straight back to disengage 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 ...

Page 39: ...e instructions for removal of the Power Control Board PCB The 2 blowers have different orientations and different 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 Side Panel Removal 2 Disconnect the wiring orientation of the wires does not matter when re connecting 3 Remove the 3 3 8...

Page 40: ...Page 40 17602010 12 15 17 4 Remove the blower and shroud from the stove and remove the 4 screws that secure the blower to the mounting bracket set aside for reinstallation ...

Page 41: ...nel 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 nut driver to remove the screws that secure the access plate at the bottom rear of the stove as shown below set aside fo...

Page 42: ...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 impellers are clear of the exhaust housing and remove the blower from the stove Take care not to damage or bend the exhaust blower impellers Top three screws accessed from top Bottom three screws accessed from rear access ...

Page 43: ... Side Panel 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 mount the switch to the rear panel of the stove set aside for reinstallation 4 Disconnect the two wires from the wiring harness at the quick connects orientation d...

Page 44: ...Page 44 17602010 12 15 17 5 Remove the vacuum hose from the flow switch ...

Page 45: ... to gain access to the retaining screw 3 Disconnect the two wires on the motor from the wire harness at the quick connects 4 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 and spacer will stay in place making for easier re installation of the auger motor NOTE When re installing the auger motor make...

Page 46: ...ee section Rear Panel Removal 8 Pull the PCB forward to release it from the shield see PCB removal 9 Disconnect the AC power harness from the upper left corner 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 stove behi...

Page 47: ...cures the right hopper hinge to the stove see below Move the UI to the right and it will disengage from the 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 Remove nut ...

Page 48: ...cal shock Our new generation of pellet stoves is equip with a unique control system that simplifies the troubleshooting process Each stove has a Power Control Board PCB that 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 ...

Page 49: ...ontal Rotating Disk assembly HRD Follow the steps above in the OTemp Hopper status section for this disk as well d Proof of Flame 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 the disk proves to the PCB that the stove has actually lit by sensing the temperature change on the firebox If the s...

Page 50: ...or and ash pan door for leaks 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 ri...

Page 51: ...ht 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 voltage 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 continuit...

Page 52: ...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 AC power pins Combustion Blower AC Neutral Igniter Push Auger Meter Auger Convection Blower AC Line ...

Page 53: ...e 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 You 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 sure the push auger is turning If it is check the encoder wire connections to the PCB an...

Page 54: ...your meter that will vary based on the temperature at the sensor See illustration and example below 10mV 1 Celsius Example 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...

Page 55: ...ects at the Combustion Blower Use a test cord to power the blower directly to outlet power Check pressure Status light Check wires for damage YES NO Check the PCB for Push Auger status light 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 YES Status Light is flashing 1 flash sec Does Combustion Blower c...

Page 56: ... 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 YES Depending on environmental conditions cleanliness of the stove fuel quality and condition of gasket material this process may take between 4 15 minutes NO Check the quality of the fuel Check for gasket leaks around door Check for gasket leaks...

Page 57: ...s imperative that service is done by a professional on an annual basis This section will cover areas of the stove that need to be serviced but it does not address proper methods for protecting the customer s home from dust and soot that get disrupted while performing service It is the responsibility of the person performing this maintenance to properly utilize drop cloths soot vacuums other forms ...

Page 58: ...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 opera...

Page 59: ...sing compressed air can damage the diaphragm 3 Remove the vacuum tube from the barbed nipple on the exhaust housing 4 Use a crescent wrench or box wrench to remove the barbed nipple and clean any debris out of the interior portion Clean the firebox liners and burn platform The firebox ashpan liners and burn platform will likely be one of the dirtiest parts of the system Cleaning this portion of th...

Page 60: ...from the burn platform Brush it clean and set aside for reinstallation Vacuum 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 for reinstallation Vacuum the ignitor area below the burn platform ...

Page 61: ...iners 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 ...

Page 62: ... the firebox and sweep the heat exchanger Sweep the sides and back of the firebox 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 the ashpan sits below the firebox ...

Page 63: ...ing the left side forward 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 Remove wingnut Foxfire Deerfield Remove wingnut ...

Page 64: ...ers the then vacuum the debris Check gaskets Leaking gaskets can cause poor performance in pellet appliances If air is able to enter the firebox through a leak then it is not being pulled through the burn platform and burning fuel Leaking gaskets can also cause an ignitor to not light the pellets properly as well The following gaskets should be checked annually Door Gasket Glass Gasket Ashpan Door...

Page 65: ... be opened and cleaned annually For details on how to access and open the HRD see section Horizontal Rotating Disks HRD Components Removal Make sure to vacuum out the following areas on the HRD assembly Take care to reassemble the HRD with all components in the same order AND make sure not to turn any of the components upside down Improper reassembly could cause performance issues and could be a s...

Page 66: ...Page 66 17602010 12 15 17 Appendix A Wiring Diagram ...

Page 67: ...Page 67 17602010 12 15 17 Appendix B Control Timing ...

Page 68: ...5 100 6 105 7 110 8 110 9 110 10 110 95 100 103 105 110 112 115 120 120 120 95 100 105 110 115 120 120 120 120 120 148 124 100 80 63 49 35 22 18 12 Use CONV LOWwhen heat level is 5 or less use CONV HIGH otherwise METERTIMINGS areinseconds andrepresenttheOFFtime On time is 45 seconds Voltagesassume120Vacpowersource measuredusingaTrue RMS voltmeter under load and are approximate ...

Page 69: ...Page 69 17602010 12 15 17 Appendix C Power Control Board Pinout ...