14 Troubleshooting
With proper installation, operation, and maintenance your gas appliance will provide years of
A. IntelliFire Ignition System
Symptom | Possible Cause | Corrective Action | |
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1. The ignitor/module | a. Incorrect wiring. | Verify “S” wire (white) for sensor and “I” wire (orange) for ignitor | |
makes noise, but no |
| are connected to correct terminals on module and pilot assembly. | |
spark. |
| Reversed wires at the module may cause system to make sparking | |
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| noise, but spark may not be present at pilot hood. | |
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| b. Loose connections or electrical | Verify no loose connections or electrical shorts in wiring from mod- | |
| shorts in the wiring. | ule to pilot assembly. Rod closest to pilot hood should be ignitor. | |
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| Verify connections underneath pilot assembly are tight; also verify | |
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| connections are not grounding out to metal chassis, pilot burner, | |
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| pilot enclosure, mesh screen if present, or any other metal object. | |
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| c. Ignitor gap is too large. | Verify gap of igniter to pilot hood. The gap should be approximately | |
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| .17 inch or 1/8 inch. | |
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| d. Faulty module. | Turn ON/OFF rocker switch or wall switch to OFF position. Remove | |
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| ignitor wire “I” from module. Place ON/OFF Rocker switch or wall | |
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| switch in ON position. Hold ground wire about 3/16 inch away from | |
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| “I” terminal on module. If there is no spark at “I” terminal module | |
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| must be replaced. If there is a spark at “I” terminal, module is fine. | |
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| Inspect pilot assembly for shorted sparker wire or cracked insulator | |
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| around electrode. | |
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2. Pilot won’t light, | a. Transformer installed correctly. | Verify that transformer is installed and plugged into module. Check | |
there is no noise or |
| voltage of transformer under load at spade connection on module | |
spark. |
| with ON/OFF switch in ON position. Acceptable readings of a good | |
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| transformer are between 3.2 and 2.8 volts AC. | |
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| b. A shorted or loose connection in wir- | Remove and reinstall the wiring harness that plugs into module. | |
| ing configuration or wiring harness. | Verify there is a tight fit. Verify pilot assembly wiring to module. | |
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| Remove and verify continuity of each wire in wiring harness. | |
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| c. Improper wall switch wiring. | Verify that 110/VAC power is “ON” to junction box. | |
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| d. Module not grounded. | Verify black ground wire from module wire harness is grounded to | |
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| metal chassis of appliance. | |
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| e. Faulty module. | Turn ON/OFF rocker switch or wall switch to OFF position. Remove | |
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| ignitor wire “I” from module. Place ON/OFF Rocker switch or wall | |
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| switch in ON position. Hold ground wire about 3/16 inch away from | |
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| “I” terminal on module. If there is no spark at “I” terminal module | |
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| must be replaced. If there is a spark at “I” terminal, module is fine. | |
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| Inspect pilot assembly for shorted sparker wire or cracked insulator | |
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| around electrode. | |
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3. Pilot lights but con- | a. A shorted or loose connection in | Verify all connections to wiring diagram in manual. Verify connec- | |
tinues to spark, and | sensor rod. | tions underneath pilot assembly are tight. Verify connections are | |
main burner will not ig- |
| not grounding out to metal chassis, pilot burner, pilot enclosure or | |
nite. (If the pilot contin- |
| screen if present, or any other metal object. | |
ues to spark after the |
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b. Poor flame rectification or contami- | Verify that flame is engulfing sensor rod. If the pilot assembly does | ||
pilot flame has been lit, | |||
flame rectification has | nated sensor rod. | not have a ground strap, consider installing one to increase flame | |
| rectification. Verify correct pilot orifice is installed and inlet gas | ||
not occurred.) |
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| specifications. Flame carries rectification current, not the gas. If | ||
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| flame lifts from pilot hood, the circuit is broken. A wrong orifice or | |
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| too high an inlet pressure can cause pilot flame to lift. The sensor | |
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| rod may be contaminated. Clean sensor rod with emery cloth. | |
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