Hearth & Home IntelliFire Plus User manual

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Troubleshooting
Guide
IntelliFire Plus Ignition System
*For authorized gas technicians use
only.

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Introduction…………………………………………………………………. 3
Tools and Instruments……………………………………………………... 5
System Basics……………………………………………………………… 6
Problem Scenario #1……………………………………………………….
Problem: Pilot wont’ light, no noise and no spark
13
Problem Scenario #2……………………………………………………….
Problem: The module makes noise, but no spark
18
Problem Scenario #3……………………………………………………….
Problem: Pilot sparks, but pilot will not light.
21
Problem Scenario #4……………………………………………………….
Problem: Pilot lights, but continues to spark and main
burner will not ignite.
24
Problem Scenario #5……………………………………………………….
Problem: Pilot lights, stops sparking, and pilot remains lit.
Burner will not light
27
Problem Scenario #6
Problem: Low pressure reading on outlet side when set to high
flame position.
29
Diagnostic Codes………………………………………………………….. 31
System Checklist ………………..………………………………………… 32
IntelliFire Plus Troubleshooting Guide
Table of Contents

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Introduction IntelliFire Plus Troubleshooting
Use of this Guide
This troubleshooting guide provides an overview of the IntelliFire Plus system, reviews
problem scenarios, provides a system’s checklist and frequently asked questions.
The purpose of this guides is to provide a tool:
To educate
To aid in proper diagnosis for accurate parts replacement
To reduce multiple service calls
To gather necessary information to assist with proper diagnosis of problems
Qualified Service Technicians Only
This troubleshooting guide is for use by qualified service technicians only. It is de-
signed to help qualified service technicians troubleshoot gas fireplace with IntelliFire
Plus ignition systems.
Warning: Do not attempt to service appliances which you are not qualified to service.
Service attempted by unqualified persons could result in risk of bodily injury and prop-
erty damage.
Obligation of Service Professionals
Service technicians must be attentive to appropriate codes, understand and follow
manufacturer’s installation instructions, and use the proper parts and materials when
servicing and installing gas appliances. One of the most important tools you bring to a
service call is the installation manual.
Communicating with the Owner
Ask the owner a few simple questions prior to service:
Has What are the symptoms?
When does the problem occur?
How long has the appliance been installed?
Model Number
Serial Number
Operating Gas—LP or NG

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Introduction IntelliFire Plus Troubleshooting
Technical Assistance—Distributors & Dealers
Heat & Glo—877-228-5012
Heatilator—877-943-2848
Quadrafire—866-804-7783
For technical assistance call the appropriate branded number, which is dedicated to
trade channel partners. Please do not give these numbers to homeowners, builders,
etc. Be prepared to provide the following information:
Fireplace model and serial number
Previous service history if with previous HHT reference number, if any
Detailed problem description
Technical Service will assign a reference number to troubleshooting calls when infor-
mation is provided. To ensure a more timely repair and processing of claims involving
multiple service calls, HHT expects a dealer to contact Technical Service after 2 failed
attempts to repair a product. A completed checklist may be requested to assist with
diagnosis.

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Tools and Instruments IntelliFire Plus Troubleshooting
You will need the following tools and equipment to execute troubleshooting outlined in
this guide.
Required Tools:
Open end wrenchs, 3/8‖, 7/16‖, 9/16‖
Adjustable end wrenches: 8‖ and 10‖
1/4‖, 5/16‖ nut driver
Straight screwdrivers (including small 1/8‖
blade for pressure check and stubby
straight.
Phillips screwdrivers #1 and #2 and
stubby Phillips
Plastic straight screwdriver (Rhino style)
Electrical pliers
Needle nose pliers
Flashlight
Numbered drill index
T-20 tamper resistant Torx bit HHT part
#810-225
Soft-bristle toothbrush
Soft 1‖ paint brush
Electric drill 1/4‖ - 3/8‖
Required Testing Equipment:
Multi-meter (must measure millivolts)
Manometer
Leak detection fluid
2 to 4, 12‖-14‖ jumper wires
―flame stick‖ lighter wand
Miscellaneous:
Smoke Match
Drop Cloth/Tarp
Glass cleaner/towels
Vacuum
Personal Protection Equipment
ALL TOOLS AND TEST EQUIPMENT
SHOULD BE PROPERLY STORED AND
MAINTAINED.

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System Basics IntelliFire Plus Troubleshooting
The IntelliFire Plus IPI (intermittent pilot ignition) Ignition System and Wireless Con-
trols is a total control system, from the components under the fireplace to the re-
mote control in your hand. HHT Hearthville offers Sales and Product Knowledge
Training modules as companions to this troubleshooting guide. Taking Hearthville
modules is recommended. HHT dealers and distributors can go to
www.hearthville.com.
Ignition Control Components
Ignition Control Box (includes receiver for wireless remotes)
6 DC Volt Transformer
Wiring Harness
IPI Valve with Stepper Motor
IPI pilot assembly
Battery Backup *
Wireless Controls*
RC100, RC200 & RC300 wireless controls w/ batteries
* This guide assumes the wireless controls and battery backup components have been elimi-
nated and ―unlearned‖ from the system for purposes of troubleshooting the ignition system.

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System Basics IntelliFire Plus Troubleshooting
#1
#2
#3
#1
#2
#3
ON/OFF/REMOTE switch on module must
be in REMOTE position for wireless con-
trols to operate the remote and optional
wired wall switch.
The wireless control and receiver (housed
in the control module) communicate to and
from each component via radio frequency.
They must remain within 30 feet of each
other.
For the RC300, when in thermostat mode,
transmission of information happens every
60 seconds. For optimum operation you
may need to try different locations for the
wireless control when in thermostat mode.
If a wired wall switch is installed and in the
ON position, it will override the commands
of the wireless controls. Must be OFF to
use remote.
#4
#4 AUX200 & 300 module controls the
FAN and incorporates timer and
rheostat functionality.
AUX300 module also controls 2
auxiliary functions. AUX1 offers
high/med/low settings
AUX2 offers ON/OFF control.
From the wireless control commands, data
signals are transmitted to the AUX200 &
300 modules. Voltage is sent to igniter,
stepper motor, pilot regulator and main
burner regulator.
Eliminate wireless controls
from the system when
troubleshooting system by
“unlearning remote.
Wireless
Controls

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System Basics IntelliFire Plus Troubleshooting
1
2
3
4
5
6
7
8
9
10
IPI Ignition Control Module (see labeled diagram below)
w/ remote receiver
1—Igniter sparks when commanded via wall switch, wireless control or control module switch
to turn on main burner. Voltage through the wire to igniter on pilot assembly creates spark to
ignite gas released to pilot assembly.
2—Sensor rod acknowledges pilot flame is present before releasing gas to the main burner for
ignition. When a pilot flame engulfs the sensor rod it conducts electrical current from the sen-
sor through the flame to ground in one direction, which acts as a switch to the control module
at this connection. Gas flows to the main burner 4-8 seconds after continuity happens via
flame rectification.
3—Sends commands from the wireless controls to the AUX200/300 modules, controlling fan
kits (AUX200&300) and 2 additional auxiliary functions (AUX300).
4—Fuel setting is factory set, but must be adjusted if fireplace is converted. Switch does not
regulate gas pressure to valve, but it does allow for appropriate variability settings for flame
modulation. Take care when adjusting this switch. We recommend using a small, straight ce-
ramic/anti-static screwdriver, which is supplied by electrical supply companies.
5—Learn Button is used to program up to 3 wireless controls to fireplace. Instructions pro-
vided in controls instructions.
6—Diagnostic light assists with troubleshooting. Error code chart provided page 30.
7—ON/OFF/REMOTE Switch
Ignition Control Connections and Functions
Warning: DO NOT CONNECT 120V AC TO CONTROL
MODULE.
8—Manual HI/LOW flame switch is
operable with RC100 use only with
ON/OFF/REMOTE switch in RE-
MOTE setting. Modulates 2 flame
settings.
9—Power from battery pack, wall
switch connection, and connection to
valve pilot and burner regulators.
10—Flame Modulation (stepper mo-
tor) connection
11—Power supply connection to 6
Volt DC adapter, plugged into the
junction box.
11

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System Basics IntelliFire Plus Troubleshooting
IPI Gas Valve w/ Stepper Motor
Important gas supply information provided in
HHT gas fireplace Owner’s Manual, Installa-
tion and Operation.
1. Pilot regulator is stamped as Nat
or LP, designating the factory set-
ting. If converted the main burner
regulator has fuel type stamped
along the side, indicating the con-
version. The orange wire from the
ipi ignition module is connected to
the pilot regulator.
2. Test the inlet pressure at this tap.
3. Test the manifold pressure at this
tap.
4. The stepper motor is not a replace-
able as a separate part, only available
assembled to the main burner regulator.
It’s function is to modulate the flame.
There is no reliable field voltage test for
the stepper motor. Valve will function
without functioning stepper motor, but
flame will not modulate. *** Note: An
audible noise will be heard when the
stepper motor is modulating flame dur-
ing flame adjustment, in thermostat
mode and when flame is turned off.***
5. Main burner regulator is changed
when unit is converted and comes with
stepper motor installed. The green wire
from the ipi ignition module is connected
to the main burner regulator.
1. Pilot Regulator
5. Main Burner Regulator
2. Inlet
Pressure
Tap
3.Manifold
Pressure
Tap
4. Stepper
Motor

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System Part Numbers IntelliFire Plus Troubleshooting
IPI valve
Control Module
Pilot Assembly
(Sold complete)
Battery Backup
with 1 amp fuse
2166-323
Transformer
2166-305
* Refer to specific unit service parts list for correct part number.
Jumper Wire

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System Part Numbers IntelliFire Plus Troubleshooting
RC100 control
RC200 Control & AUX200 Control
RC300 Control & AUX300 Control
Main Components of Wireless Controls
RC100—Wall mounted control w/ cover plate.
RC200—Control, docking station and AUX200
module to control fan kit.
RC300—Control, docking station and AUX300
module to control fan kit and 2 auxiliary func-
tions.
AUX200—Powers and controls voltage for
variable fan speeds.
AUX300—Powers and controls volt-
age for variable fan speeds, high/
medium/low (AUX1) and on & off
(AUX2) .
AUX300
AUX200

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System Checklist IntelliFire Plus Troubleshooting
Diagnose Root Cause
Going into a service call with a conclusion prior to checking the complete system can
lead to replacing unnecessary parts, multiple service calls and wasted time and money
for you, the customer and HHT. When servicing any HHT product the complete sys-
tem needs to be checked to diagnose the cause.
Using the checklist to document the diagnos-
tic information will...
Instills consumer confidence
Consistent service performance
Provides unit history for future service
calls
Improves communication when seeking
technical assistance
Areas to be checked:
Visual Inspection for proper installation
and condition of installation
Electrical
Gas Supply
Area/System Proper Readings/Reference Info/Items to be checked:
Visual Inspection Refer to appropriate installation and operation manual for all areas
1. Proper Installation/Condition
a. Vent System Does the installation meet venting requirements for…
rise to run ratio?
vent cap type?
vent cap location?
venting size?
b. Gas Supply Components Gas line sizing and components must meet ANSI Z223.1 and local
codes requirements.
Supply pipe must be ½‖ minimum.
Note all appliances supplied inline with fireplace.
Locate all shut off valves. What position are they in?
Complete system checklist is provided at the back
of the guide. Sections of the system checklist are
duplicated and used with specific problem scenar-
ios.
HHT Technical Service may request a complete
checklist for units in the field that have not been
repaired after 2 or more service calls.
Example

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Problem Scenarios #1 IntelliFire Plus Troubleshooting
Problem: Pilot wont’ light, no noise and no spark*
The problem may be:
1. Loose or improper wiring. System not
grounded.
2. Control Module selector switch NOT set
properly.
3. No power to junction box
4. No power from junction box
5. No power from 6Volt DC transformer
6. Wired wall switch not wired properly.
7. LP/NG switch on module damaged or not
fully engaged into LP or NG setting.
8. Faulty module
*Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system.
To do this the remote must be ―unlearned‖ from the system. .
** Notice **
Disconnect power to the system
prior to disconnecting any compo-
nents by switching the ON/OFF/
REMOTE module switch to the
OFF position. Interrupting power to
stepper motor can freeze motor po-
sition (see page 29).
It is not recommended to operate
the ignition control module with
disconnected wire connections. A
short could cause permanent dam-
age.
Introducing the pilot sensor rod with
a false flame, such as from a flame
stick, will cause the module to go
into lock-out mode. This is due to a
Go to page 29 to familiarize yourself with
module diagnostic codes.

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Problem Scenarios #1 continued... IntelliFire Plus Troubleshooting
Problem: Pilot wont’ light, no noise and no spark *
1. Loose or improper wiring. System not grounded.
2. Control Module selector switch NOT set properly.
*Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system.
To do this the remote must be ―unlearned‖ from the system.
1
2

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Problem Scenarios #1 continued... IntelliFire Plus Troubleshooting
Problem: Pilot wont’ light, no noise and no spark *
3. No power to junction box x
4. No power from junction bo
5. No power from 6Volt DC transformer
*Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system.
To do this the remote must be ―unlearned‖ from the system.
3 4
5
If this is no power from
junction box, trace electri-
cal supply to junction box
including proper wiring at
junction box.
If the module does not
flash, trace power supply to
junction box, from junction
box and from 6 Volt trans-
former.
Pulling and re-connecting the power supply cord from transformer
does not serve as the same test as turning switch from OFF to ON.

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Problem Scenarios #1 continued... IntelliFire Plus Troubleshooting
Problem: Pilot wont’ light, no noise and no spark *
6. Wired wall switch not wired properly.
*Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system.
To do this the remote must be ―unlearned‖ from the system.
6
The wiring to the wall
switch may not be correct if
fireplace does not turn on
when the switch on the
module is in the REMOTE
position.
AND/OR….the optional
wired wall switch is in the
ON position.
Red and Brown wire con-
nect to wall switch.
Diagram to the bottom/
right reviews proper switch
operation when wired wall
switch and wireless con-
trols are both installed.

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Problem Scenarios #1 continued... IntelliFire Plus Troubleshooting
Problem: Pilot wont’ light, no noise and no spark *
7. LP/NG switch on module damaged or not fully engaged into LP or NG setting.
8. Faulty Module
*Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system.
To do this the remote must be ―unlearned‖ from the system.
8
If the NG/LP selector
switch is not turned com-
pletely to NG or LP set-
ting, the fireplace will not
ignite and will go into
lockout mode.
If the selector switch
spins freely and does not
engage into NG or LP
position the switch is
damaged and the mod-
ule go into lockout mod-
ule. Damaged switch
requires module replace-
ment.
7

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Problem Scenarios #2 IntelliFire Plus Troubleshooting
Problem: The module makes sparking noise, but no spark * **
The problem may be:
1. Loose or improper wiring
2. System is not grounded
3. Igniter wire is loose or disconnected
4. Improper gap between igniter and pilot hood
*Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system. To do
this the remote must be ―unlearned‖ from the system.
** IntellifFire Plus IPI ignition module emits beeps during operation. The noise referred to in this section is noise
from the module ignition coil which creates voltage for pilot igniter.
Go to page 29 to familiarize yourself with
module diagnostic codes.
** Notice **
Disconnect power to the system
prior to disconnecting any compo-
nents by switching the ON/OFF/
REMOTE module switch to the
OFF position. Interrupting power to
stepper motor can freeze motor po-
sition (see page 29).
It is not recommended to operate
the ignition control module with
disconnected wire connections. A
short could cause permanent dam-
age.
Introducing the pilot sensor rod with
a false flame, such as from a flame
stick, will cause the module to go
into lock-out mode. This is due to a

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Problem Scenarios #2 continued IntelliFire Plus Troubleshooting
Problem: The module makes noise, but no spark
1. Loose or improper wiring
2. Pilot assembly is not grounded
*Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system.
To do this the remote must be ―unlearned‖ from the system.
1
2

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Problem Scenarios #2 continued IntelliFire Plus Troubleshooting
Problem: The module makes noise, but no spark
3. Igniter is disconnected, loose or shorted to fireplace.
4. Improper gap between igniter and pilot hood
*Troubleshooting assumes the wireless controls & battery backup have been eliminated from the system.
To do this the remote must be ―unlearned‖ from the system.
3
4
If igniter is shorted it will at-
tempted to light for 60 sec-
onds before module times
out.
It will flash green 3 times and
go into lockout.
Voltage shorted to ground
may cause damage to mod-
ule, resulting in damaged
module.