11 Troubleshooting
With proper installation, operation and maintenance your gas appliance will provide years of
A. Intellifire Ignition System
| Symptom |
| Possible Causes | Corrective Actions |
1. | The ignitor/module makes | A. | Incorrect wiring. | Verify “S” wire (white) for sensor and “I” wire (orange) for ignitor are connected to the |
| noise, but no spark. |
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| correct terminals on the module and the pilot assembly. Reversed wires at the module |
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| may cause the system to make a sparking noise, but the spark may not be present at |
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| pilot hood. |
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| B. | Loose connections or | Verify there are no loose connections or electrical shorts in wiring from module to |
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| electrical shorts in the | pilot assembly. The rod closest to the pilot hood should be ignitor. Verify connections |
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| wiring. | underneath pilot assembly are tight; also verify the connections are not grounding out |
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| to the metal chassis, pilot burner, pilot enclosure, mesh screen if present, or any other |
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| metal object. |
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| C. | Ignitor gap is too large. | Verify gap of ignitor to pilot hood. The gap should be approximately .17 in. or 1/8 in. |
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| D. | Faulty module. | Turn ON/OFF rocker switch or wall switch to OFF position. Remove ignitor wire “I” |
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| from module. Place ON/OFF rocker switch or wall switch in ON position. Hold ground |
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| wire about 3/16 in. away from “I” terminal on module. If there is no spark at “I” terminal, |
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| module must be replaced. If there is a spark at “I” terminal, module is fi ne. Inspect pilot |
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| assembly for shorted sparker wire or cracked insulator around electrode. |
2. | Pilots won’t light, there is | A. | Transformer installed | Verify that transformer is installed and plugged into module. Check voltage of |
| no noise or spark. |
| incorrectly. | transformer under load at space connection on module with ON/OFF switch in ON |
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| position. Acceptable readings of a good transformer are between 3.2 and 2.8 volts AC. |
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| B. | A shorted or loose | Remove and reinstall the wiring harness that plugs into module. Verify there is a tight |
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| connection in wiring | fi t. Verify pilot assembly wiring to module. Remove and verify continuity of each wire in |
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| confi guration or wiring | wiring harness. |
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| harness. |
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| C. | Improper wall switch | Verify wall switch is wired correctly. |
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| wiring. |
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| D. | Module not grounded. | Verify black ground wire from module wire harness is grounded to metal chassis of |
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| appliance. |
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| E. | Faulty module. | Turn ON/OFF rocker switch or wall switch to OFF position. Remove ignitor wire “I” |
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| from module. Place ON/OFF rocker switch or wall switch in ON position. Hold ground |
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| wire about 3/16 in. away from “I” terminal on module. If there is no spark at “I” terminal |
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| module must be replaced. If there is a spark at “I” terminal, module is fi ne. Inspect pilot |
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| assembly for shorted sparker wire or cracked insulator around electrode. |
3. | Pilot lights but continues | A. | A shorted or loose | Verify all connections to wiring diagram in manual. Verify connections underneath pilot |
| to spark, and main burner |
| connection in sensor rod. | assembly are tight. Verify connections are not grounding out to metal chassis, pilot |
| will not ignite. (If the pilot |
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| burner, pilot enclosure or screen if present, or any other metal object. |
| continues to spark after | B. | Poor fl ame rectifi cation or | Verify fl ame is engulfi ng sensor rod. If the pilot assembly does not have a ground |
| the pilot fl ame has been | |||
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| contaminated sensor rod. | strap, consider installing one to increase fl ame rectifi cation. Verify correct pilot orifi ce | |
| lit, fl ame rectifi cation has |
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| is installed and inlet gas specifi cations are met. Flame carries rectifi cation current, not | |
| not occurred.) |
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| the gas. If fl ame lifts from pilot hood, the circuit is broken. A wrong orifi ce or too high | |
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| an inlet pressure can cause pilot fl ame to lift. The sensor rod may be contaminated. |
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| Clean sensor rod with emery cloth. |
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| C. | Module is not grounded. | Verify that module is securely grounded to metal chassis of appliance. Verify that the |
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| wire harness is fi rmly connected to module. |
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| D. | Damaged pilot assembly | Verify that ceramic insulator around the sensor rod is not cracked, damaged, or loose. |
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| or dirty sensor rod. | Verify connection from sensor rod to white sensor wire. Clean sensor rod with emery |
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| cloth to remove any contaminants that may have accumulated on sensor rod. Verify |
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| continuity with a multimeter with ohms set at lowest range. |
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| E. | Faulty module. | Turn ON/OFF rocker switch or wall switch to OFF position. Remove ignitor wire “I” |
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| from module. Place ON/OFF rocker switch or wall switch in ON position. Hold ground |
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| wire about 3/16 in. away from “I” terminal on module. If there is no spark at “I” |
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| terminal, module must be replaced. If there is a spark at “I” terminal, module is fi ne. |
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| Inspect pilot assembly for shorted sparker wire or cracked insulator around electrode. |
4. | Pilot sparks, but pilot will | A. | Correct gas supply. | Verify that incoming gas line ball valve is “open”. Verify that inlet pressure reading is |
| not light. |
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| within acceptable limits, inlet pressure must not exceed 14 in. w.c. |
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| B. | Ignitor gap is too large. | Verify that spark gap from ignitor to pilot hood is .17 in. or 1/8 in. |
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| C. | Module is not grounded. | Verify module is securely grounded to metal chassis of appliance. |
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| D. | Module voltage output/ | Replace module. |
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| valve/pilot solenoid ohms |
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| readings. |
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