Travis Industries GreenSmart 2 User manual

GreenSmartTM!2!!
Parts!Overview!&!Troubleshooting!
176-01796 GS2 GAS TROUBLE-SHOOTING GUIDE

Table&of&Contents&
Section! ! Page&Number(s)!
Parts!Overview!! 1-3!
Tools!Needed! ! 4!
Recommended!Service!Parts! 4!
Troubleshooting!Flow!Chart!! 5-8!
Reference!Diagrams! ! 9-12!
Wiring!Diagrams!13-15!
Quick&Start&Information!
•If!the!issue!is!pilot!ignition!or!flame!rectification,!check!the!pilot!assembly
first.!!The!appliance!should!have!either!the!SIT!pilot!assembly!with!ground
upgrade!kit!(250-02736)!installed!or!a!PSE!pilot!assembly.!!Both!of!these
assemblies!will!improve!pilot!ignition!and!flame!rectification.
•Next,!identify!the!version!of!IFC!before!you!begin!troubleshooting.!!The!IFC
will!be!marked!with!a!silver!numeral!on!both!ends.!!An!updated!IFC!will
provide!the!necessary!power!for!the!spark!electrode!and!flame!sensor.
Base!IFC’s!(shown!on!left)!should!be!a!number!3&or!higher
Remote!IFC’s!(shown!on!right)!should!be!a!number!4a!or!higher

"#$%&'!()*+',#&-'.!()/0!1!2344!5$#67+#!87&),-!9:%*0!;<!1!=+>&:,-7.!<?!@3ABC!
Gas!Control!Valve!–!(250@01422)!
•D'-*!7)!$::!E#--);F$#,!$GG:&$)/-'
•?::7H'!I7#!J$'!,7!6-/7F-!G#-'-),!$,!G&:7,!$)*!6+#)-#
•8&:7,!$*K+',F-),!'/#-H
•8#-''+#-!,$G'!L&)/7F&)J!$)*!7+,J7&)JM
•N:-/,#&/$:!'G$*-'!I7#!%7:,$J-!,-',&)J!L7#$)J-.!J#--)M
•=$)+$:!5&JOPQ7H!#-J+:$,7#!I7#!G#-''+#-!$*K+',F-),'
o!"#$%&'()*'(+&,&-.-,&-.-&'/,&012,&3-0&45,&6-0&45
7.&89(&:";$&<#=>?=@?&AB#C&!D&<#$EE$@&;"#"@
Split!Flow!(Comfort!Control)!Valve!–!(250@01423)!
•D'-*!7)!$::!E#--);F$#,!$GG:&$)/-'!L$F:$E#&-.-&'/M
•?::7H'!7)P7II!/7),#7:!7I!$!G7#,&7)!7I!,O-!6+#)-#
•()!$!6$'-!'R',-F.!6$,,-#&-'!)--*-*!,7!I+)/,&7)
Pilot!Assembly!
•D'-*!7)!$::!E#--);F$#,!$GG:&$)/-'
•;("!8&:7,!?''-F6:R
oASH$R!$''-F6:R!LAC4S4TC@TM
oUSH$R!$''-F6:R!LAC4S4AAT4M!'(),&11'(G&H&IJE@$<<&">KJ
o;G$#>!V7*!LAC4S4A4@TM!&J)&,-'!J$'
o8&:7,!;-)'7#!LAC4S4A4@AM!/7)I&#F'!G&:7,!&'!:&, !!!!!!!!!!PSE!Pilot!
oE#7+)*!DGJ#$*-!W&,!LAC4S4ABUXM
•8;N!8&:7,!?''-F6:R
oASH$R!$''-F6:R!LAC4S4ABXTM
oUSH$R!$''-F6:R!LAC4S4ABXAM!'(),&11&'(G
6-0 &45&H&IJE@$<<&">KJ
oUSH$R!$''-F6:R!LAC4S4AB@UM!-.-&=>?&-.-&'/&">KJ
o;G$#>!V7*!LAC4S4ABBBM
Base!Integrated!Fireplace!Control!(IFC)!
(250@02664)!
•Y-),#$:!G#7/-''7#!L6#$&)M!I7#!$::!6$'-!E#--);F$#,!$GG:&$)/-'
•8#7%&*-'!,O-!'G$#>!$)*!F7)&,7#&)J!7I!,O-!G&:7,
•Y7),#7:'!7G-#$,&7)!7I!,O-!J$'!%$:%-
•Y7),$&)'!#-*!:-*!:&JO,!I7#!*&$J)7',&/'
•8#7,-/,-*!6R!U0TC!$FG!I+'-
SIT!Pilot!
Copyright © 4/8/2013 - Travis Industries Certified Factory Training Program Page 1

"#$%&'!()*+',#&-'.!()/0!1!2344!5$#67+#!87&),-!9:%*0!;<!1!=+>&:,-7.!<?!@3ABC!
Main!Burner!Switch!–!(250@02013)!
•D'-*!,7!,+#)!F$&)!6+#)-#!Z[PZ\\
•;H&,/O!O$'!A!F$:-!'G$*-'.!+'-!7)-!,7G!$)*
7)-!67,,7F!$'!&::+',#$,-*
•D'-*!7):R!&)!6$'-!'R',-F'
•]&'/$#*-*!HO-)!+)&,!&'!+GJ#$*-*!,7!E;!#-F7,-
Comfort!Control!Switch!–!(250@01569)!
•ZG-)'!$)*!/:7'-'!,O-!'G:&,!I:7H!L/7FI7#,!/7),#7:M
%$:%-!I7#!#-$#!7#!7+,'&*-!6+#)-#!I+)/,&7)'
•D'-*!7):R!&)!6$'-!'R',-F'
•]&'/$#*-*!HO-)!+)&,!&'!+GJ#$*-*!,7!E;!#-F7,-
IPI/CPI!Switch!–!(250@01578)!
•;H&,/O-'!6-,H--)!',$)*&)J!G&:7,!$)*!/7),&)+7+'!G&:7,
•D'-*!7)!6$'-!E#--);F$#,!'R',-F'
•]&'/$#*!HO-)!+)&,!&'!+GJ#$*-*
Main%Burner%
Copyright © 4/8/2013 - Travis Industries Certified Factory Training Program Page 2

"#$%&'!()*+',#&-'.!()/0!1!2344!5$#67+#!87&),-!9:%*0!;<!1!=+>&:,-7.!<?!@3ABC!
Remote!Integrated!Fireplace!Control!(IFC)!
(250@02662)!
•()/7F&)J!87H-#!/7))-/,-*!,7!67$#*
•V-/-&%-#!6+&:,!&)
•?//-),!:&JO,'!$)*!9:7H-#!/7),#7:
•;,-GG-#!=7,7#!$)*!Y7FI7#,!Y7),#7:!/7))-/,!,7!67$#*
•8#7,-/,-*!6R!U0TC!$FG!I+'-
Remote!Transmitter!(250@02711)!
•;-)*'!'&J)$:!,7!#-/-&%-#
•Z)PZII!6+,,7)
•"O-#F7',$,!6+,,7)
•DG!$)*!]7H)!$##7H!>-R
•=7*-!6+,,7)
•(8(PY8(!$/,&%$,&7)
•9:7H-#!$)*!Q&JO,!F7*+:$,&7)
•?F6-#!9$/>!Q&JO,
•D'-*!&)!+GJ#$*-*!E#--);F$#,!#-F7,-!+)&,'
•U!???!6$,,-#&-'
Stepper!motor!
•Natural!Gas!(NG)!–!(250@01566)
•Liquid!Propane!(LP)!–!(250@01463)
•D'-*!&)!E;!#-F7,-!+GJ#$*-!>&,
•N:-/,#7)&/$::R!F7*+:$,-'!6+#)-#!+G!$)*!*7H)
•<7#>'!&)!/7)K+)/,&7)!H&,O!#-F7,-!,#$)'F&,,-#
o!"#$%&'()*'(+&,&-.-,&-.-&'/,&012,&3-0&45,&6-0&45
7.&89(&:";$&<#=>?=@?&AB#C&!D&<#$EE$@&;"#"@
Battery!Holder!(250@02663)!
•9$,,-#R!9$/>!+G
•2!??!6$,,-#&-'
•Z)PZIIPV-F7,-!'H&,/O
•ZG-#$,-'!6+#)-#!HO-)!)7!#-F7,-
•^8VE_!6+,,7)!I7#!G#7J#$FF&)J!,O-!#-F7,-
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"#$%&'!()*+',#&-'.!()/0!1!2344!5$#67+#!87&),-!9:%*0!;<!1!=+>&:,-7.!<?!@3ABC!
Tools!needed:!
T0 =+:,&F-,-#
A0 E$'!G#-''+#-!J$+J-
U0 E$'!:-$>!*-,-/,7#
20 8O&::&G'!'/#-H*#&%-#`A
C0 ;F$::!I:$,!6:$*-!'/#-H*#&%-#
X0 TP2_!a!CPTX_!)+,!*#&%-#'
B0 [--*:-!)7'-!G:&-#'
30 ;:&G!K7&),!G:&-#'
@0 Z+,:-,!$)$:Rb-#
T40 UP2_!a!BP3_!7G-)!-)*!H#-)/O-'
TT0 `A4!,7#c+-!*#&%-#
TA0 "-',!/7#*!I7#!:&JO,'!$)*!I$)!LAC4S44UTXM
Recommended!Parts!List!for!GreenSmart2!service:!
T0 ;("!8&:7,!E#7+)*!DGJ#$*-!W&,!LAC4S4ABUXM
A0 8;N!8&:7,!?''-F6:R!LASH$R!AC4S4ABXT.!USH$R!AC4S4ABXA.!$)*!XTX!1!USH$R!AC4S4AB@UMM
U0 9$'-!(\Y!LAC4S4AXX2M.!V-F7,-!(\Y!LAC4S4AXXAM
20 9$,,-#R!57:*-#!LAC4S4AXXUM!$)*!2S??!6$,,-#&-'
C0 V-F7,-!"#$)'F&,,-#!LAC4S4ABTTM!$)*!US???!6$,,-#&-'
X0 ;H&,/O-'
•=$&)!6+#)-#!LAC4S4A4TUM
•Y7FI7#,!Y7),#7:!LAC4S4TCX@M
•(8(PY8(!LAC4S4TCB3M
B0 V-J+:$,7#![E!LAC4S4T2UXM!a!Q8!LAC4S4T2ABM
30 ;,-GG-#!=7,7#![E!LAC4S4TCXXM!a!Q8!LAC4S4T2XUM
@0 ;&,!E$'!d$:%-!LAC4S4T2AAM
T40 <&#&)J!O$#)-''-'
•AC4S4AXXC!=$&)!O$#)-''!+'-*!7)!$::!E;A!+)&,'!L-e/-G,!2U4PXTXM
•AC4S4AXBC!!!=$&)!O$#)-''!I7#!2U4PXTX
•AC4S4AXBT!!!;O7#,!87H-#!;+GG:R!O$#)-''!+'-*!7)!]d;PUT]d(.!XTX.!$)*!AT"Vd
•AC4S4AXBA!Q7)J!87H-#!;+GG:R!O$#)-''!+'-*!7)!$::!E;A!+)&,'!-e/-G,!,O7'-!)7,-*!$67%-
•AC4S4AXX3!!!V-F7,-!DGJ#$*-!O$#)-''!+'-*!7)!$::!+GJ#$*-*!E;A!+)&,'
•AC4S4AXX@!!!\$)PQ&JO,!O$#)-''!,O$,!G:+J'!&),7!(\Y
TT0 A0C!?FG!I+'-'!I7#!:&JO,'!$)*!I$)!LAC4S4AB@2!1!C!G$/>M
TA0 U0C!?FG!I+'-'!I7#!(\Y!LAC4S4AB@3!1!C!G$/>M
Copyright © 4/8/2013 - Travis Industries Certified Factory Training Program Page 4

Turn Main Burner
Switch To ON, Wait
10-30 Seconds.
DOES
THE PILOT
LIGHT?
IS
SPARK
SEEN AT
PILOT?
DOES
PILOT BURN
BUT IGNITOR
CONTINUES
TO SPARK?
SEE NEXT PAGE.
NO
Copyright © 4/8/2013 - Travis Industries Certied Factory Training Program
1. Check voltage to ON/OFF switches on Green and
White wire. You should have 3+ volts DC with switch in
the OFF position (BASE ONLY). If no, replace IFC.
2. Check ON/OFF switch for continuity. No continuity, 3.
replace switch (Base Only).
3. Check voltage to Continuous pilot switch. Blue and
White wire should have 3+ volts DC with the switch in
IPI position. On upgrade, unplug jumper to test. If no
voltage, replace IFC.
4. Check continuity of continuous pilot switch. Continuity,
switch is good, No Continuity, replace switch.
5. Verify main harness connection to IFC (X5).
(See Diagram K)
6. Check to see if igniter wire connected to IFC (X2).
(See Diagram K)
7. Check continuity of the pilot coil. Continuity within range =
good value. No continuity or outside of range = bad value.
Replace valve. (See Diagram C)
8. Check that the orange wire is connected to the pilot coil.
9. Check voltage at the pilot coil. Should be 5 volts
12. DC for 1 sec. After 1 sec. voltage will drop to .9 volts.
12. No voltage. Replace IFC. (See Diagram D)
10. Check incoming gas pressure. Is gas turned on?
(See Diagram H)
NOTE: IFC can continue to spark up to 60 seconds after pilot
is lit. This can be normal as pilot establishes.
1. Is ame sensor being hit by pilot ame? If not, adjust pilot.
2. Is the ame sensor wire connected to the IFC and
grounded? If not, connect it (X3). (See Diagram K)
3. Check log placement.
4. Check continuity of ame sensor.
1. Is the Intergrated Fireplace Control (IFC) in lockout -
3 RED FLASHES every few seconds. Turn off for 2
seconds and back on.
2. Does stove have pilot upgrade kit (sku 250-02736)?
If not install kit.
3. Check spark rod. Is spark seen at the base? If so
porcelain is cracked. Replace ignitor.
4. Check ignitor wire at IFC. Is spark seen there? If so check
to make sure insulation tube is down all the way on the wire.
5. Check to see if batteries are in properly.
6. Check battery voltage at the battery molex. If voltage is
below 4.8 replace the batteries. RED and Black Wires
(See Diagram B)
7. Verify appliance is connected to grounded circuit properly
(use outlet analyzer).
8. Check inline voltage - Black to L
and polarity. - White to N
(See Diagram A) - Green to ground unit.
- Check Fuse (3.15 amp) on IFC
9. Check to see if the unit is grounded on IFC to base.
5
GreenSmart2™ Troubleshooting
PILOT IGNITION
YES
YES
NO
NO
YES

1. Identify if the pilot activity is turbulance or
starvation. Adjust Intake and Exhaust
Restrictors as needed.
2. Does the pilot have the right orice installed?
DOES
THE
BURNER
COME
ON?
1. Flame is too blue = adjust the air shutter
closed to make the ame more yellow.
2. Flame is orange and sooty = adjust the air
shutter open to make the ame more yellow.
3. Sooty tall ame = was the unit converted to
3. LP? Check if the orices are correct and
3. the regulator is the correct one.
4. Short blue ame = check the input gas
4. pressure.
DOES THE
PILOT FLAME
ACT
NORMAL?
1. Check that the green wire is connected to the
gas valve main burner coil, if not, connect it.
2. Check to see if the IFC is grounded to the gas
valve. If not, connect it.
3. Do continuity test of the main burner coil in the
gas valve. Continuity within range = valve good.
If no continuity or outside of range, replace the gas
valve. (See Diagram C)
4. Check voltage to the main burner coil. It should
be 5 volts DC for 1 sec. After 1 sec. voltage will
drop to .9 volts. If no voltage replace IFC.
(See Diagram D)
5. Check outgoing gas pressure. (See Diagram H)
DOES
THE FLAME
LOOK
GOOD?
SYSTEM IS WORKING
PROPERLY
GreenSmart2™ Troubleshooting
YES
YES
YES
NO
NO
NO
6
Copyright © 4/8/2013 - Travis Industries Certied Factory Training Program
BURNER IGNITION
WILL
THE REAR
BURNER
SHUT OFF
(if applicable)
NO
YES
1. Check battery voltage.
2. Check continuity of split ow valve.
If no continuity replace split ow valve.

1. Identify if the pilot activity is turbulance or
starvation. Adjust Intake and Exhaust
Restrictors as needed.
2. Does the pilot have the right orice installed?
DOES
THE
BURNER
COME
ON?
1. Flame is too blue = adjust the air shutter
closed to make the ame more yellow.
2. Flame is orange and sooty = adjust the air
shutter open to make the ame more yellow.
3. Sooty tall ame = was the unit converted to
3. LP? Check if the orices are correct and
3. the regulator is the correct one.
4. Short blue ame = check the input gas
4. pressure.
DOES THE
PILOT FLAME
ACT
NORMAL?
1. Check that the green wire is connected to the
gas valve main burner coil, if not, connect it.
2. Check to see if the IFC is grounded to the gas
valve. If not, connect it.
3. Do continuity test of the main burner coil in the
gas valve. Continuity within range = valve good.
If no continuity or outside of range, replace the gas
valve. (See Diagram C)
4. Check voltage to the main burner coil. It should
be 5 volts DC for 1 sec. After 1 sec. voltage will
drop to .9 volts. If no voltage replace IFC.
(See Diagram D)
5. Check outgoing gas pressure. (See Diagram H)
DOES
THE FLAME
LOOK
GOOD?
SYSTEM IS WORKING
PROPERLY
GreenSmart2™ Troubleshooting
YES
YES
YES
NO
NO
NO
6
Copyright © 4/8/2013 - Travis Industries Certied Factory Training Program
BURNER IGNITION

1. Is the battery box switch OFF? If yes, turn it to
REMOTE or ON position. (See Diagram E)
2. Is the remote transmitter turned off or out of
sync? If yes, turn it on or re-sync.To sync Press
“PRG” button on battery box (See Diagram E) or
listen for recognition tones. remote (Amber light
is “ON” in program mode).
3. Is the remote in regular or “Smart” themostate
mode? If yes, adjust set temperature higher than
room temperature.
DOES
THE FLAME
MODULATE
HIGH TO
LOW?
GREENSMART2™
REMOTE
DOES
THE
BURNER
COME
ON?
DOES
THE FAN
COME
ON?
SEE NEXT PAGE.
1. Check remote. Is the “Smart” thermostat on?
1. Change the remote thermostat to off or on
thermostat to make the ame so it will change.
(See Diagram F)
2. Check to see if the Stepper Motor on the gas
valve has been installed.
3. Check Stepper Motor for continuity. There are
two parts to the motor to check continuity between.
The Yellow and Orange wires resistance should
be 26 - ohms. Also check continuity between the
Black and Brown wires. Continuity should be
26 ohms resistance. If no continuity on either
circuit replace motor.
1. Is there power to the unit? Check fuse on control
board (2.5 amp fuse).
2. Check remote in manual mode. Is it set for the
fan to come on? If not, turn it on.
3. Check to see that the fan is plugged into the
IFC where it is marked fan (10X). (See Diagram K)
4. Check to see if the fan motors are getting
power.
5. GSB units have a snap disc (jump if applicable)
6. Check the fan rheostat for continuity if
applicable.
7. Check the fan motors for continuity. If no
continuity, replace motors.
GreenSmart2™ Troubleshooting
YES
YES
YES
NO
NO
NO
Copyright © 4/8/2013 - Travis Industries Certied Factory Training Program 7

1. Is there power to the unit?
2. Check fuse on control board (2.5 amp)
3. Check the remote.
Is the light turned on?
4. Check that the light bulb is good.
5. Check the wiring to see if it is
connected correctly.
6. Check continuity of light wires to ground to
check for short.
7. Check light xture (base).
1. Check to see if the unit has a split ow
valve. If no split ow valve the back burner
will not turn off.
2. Check the remote transmitter.
Is it turned on?
3. Check battery voltage. If below 4.8
voltage, replace batteries.
4. Check that the wires to the split ow valve
are connected.
GREENSMART2™
REMOTE (Cont.)
DO
THE
LIGHTS
COME
ON?
Does
Back Burner
Function
Properly
ON/OFF?
SYSTEM IS WORKING
PROPERLY
GreenSmart2™ Troubleshooting
YES
YES
NO
NO
8
Copyright © 4/8/2013 - Travis Industries Certied Factory Training Program

Voltage
6.0
Set To
DCV
Voltage
120
Set To
ACV
GreenSmart2™ Troubleshooting
(1.) Voltage Testing
(B)
Battery Molex
(A)
Power In Molex
9
Copyright © 4/8/2013 - Travis Industries Certied Factory Training Program
Power In Molex + Battery Molex
Diagram A
Diagram B
ON REMOTE OFF
Battery Box

(2.) Continuity Testing Gas Valve
(A) Pilot
(B) Main
(3.) Voltage Testing Gas Valve
1. Pilot Coils Side 2. Main Coil Side
(A) (B)
Set To
OHMS
Set To
DCV
340
GreenSmart2™ Troubleshooting
10
Copyright © 4/8/2013 - Travis Industries Certied Factory Training Program
+15
_
Disconnect Wires For Continuity
Diagram D
Diagram C
(C) Ground
5 volts for
1 second.
Stabilizes
at about
0.9 volts.

ON REMOTE OFF
A = Power
B = Thermostat
C = Mode
GreenSmart2™ Troubleshooting
4. Battery Holder
5. Transmitter
11
Copyright © 4/8/2013 - Travis Industries Certied Factory Training Program
Diagram E
Diagram F
“PRG” Button

Programming Remote
GreenSmart2™ Troubleshooting
12
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Gas Pressure
Test For Incoming Pressure
Test For Manifold Pressure
Diagram H
Diagram G

GreenSmart2™ Troubleshooting
13
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GreenSmart2™ Basic Wiring (No Remote)
Diagram I

GreenSmart2™ Remote Wiring
14
GreenSmart2™ Troubleshooting
Copyright © 4/8/2013 - Travis Industries Certied Factory Training Program
Diagram J
ON REMOTE OFF

GreenSmart2™ IFC Guide
15
GreenSmart2™ Troubleshooting
Copyright © 4/8/2013 - Travis Industries Certied Factory Training Program
Diagram K