Go to Main Menu Pellet Stove Service Guide AAAA AA AAA AAAAAAAAA A AAA AAA AA AA AAA AA AA AAA AA AAA A A A A AA AA AA AA A A This manual addresses the following models: © 1998 Travis Industries, Inc.
Go to Main Menu Table of Contents Introduction Models Addressed in This Guide..................... i Who should use this guide............................. i Precautions ............................................... i How to Use this Service Guide ....................... i Items to Bring on Service Calls....................... ii Eliminating False Fixes ................................ iii Warranty Procedure.................................... iv Flowcharts Ð (Section 1) Stove WonÕt Start ..............
Go to Main Menu Introduction i Models Addressed in This Guide This guide addresses the Avalon Avanti and Lopi Heritage Bay pellet stoves and inserts. For earlier Avalon 900 and Lopi FoxFire and 400 models, refer to the 1994 Pellet Troubleshooting Guide. Who Should Use this Guide This guide was developed for service personnel and those selling Travis Industries products. Because of the inherent danger involved with heating appliances, all work must be done by qualified personnel only.
Go to Main Menu Introduction ii Items to Bring on Service Calls Tools ¥ ¥ ¥ ¥ ¥ Nutdrivers, open end & socket wrenches in 1/4", 5/16", 11/32", 3/8", 7/16", 1/2", 7/8", 1" Door Tool (1/4Ó Allen Wrench) Multimeter Standard and Phillips-head Screwdrivers Wire with a male quick-connect attached to each end (called a jumper wire) Hot Wire ¥ ¥ ¥ ¥ Jumper Wire Power cord with female quick-connects attached to the hot and common wires (called a hot wire) Ash Vacuum (or shop vacuum with drywall filter) and b
Go to Main Menu Introduction iii Eliminating False Fixes Unfortunately, many service calls provide only a temporary solution. Unless the true problem is found, conducting service may only provide a slight performance increase. Often, when a part is exchanged with a new part, the stove's performance will improve enough to operate at a low performance level. For example, if you install a new exhaust blower you may improve performance enough to let the stove burn.
Go to Main Menu iv Introduction Warranty Procedure Most components inside Travis Industry stoves are warranted. To receive credit for a component covered on the warranty, follow the PRA (P roduct R eturn A uthorization) procedure below: 1) Fill out a PRA form (white, pink, & gold carbon paper form) - keep the gold copy for your records. 2) Send the form, along with the component, to Travis Industries, Attn: PRA Returns, 15530 Woodinville Redmond Road, Suite # 300, Woodinville, WA 98072.
Go to Main Menu Flowcharts 1-1 Stove WonÕt Start Re-start the stove by moving the mode switch to “OFF” then “MANUAL” and pressing the “MANUAL START” button (press this button firmly). AUTO MANUAL Yes Does ÒMANUALÓ Light Come On? No Has Household Breaker Blown? Plug in a lamp or other appliance to verify the power outlet is supplying power. Yes Check the Power Outlet Make sure the household breaker (or fuse) is operational.
Go to Main Menu Flowcharts 1-2 Pellets DonÕt Feed Make sure the hopper has pellets. If the stove recently ran out of pellets, it will take approximately 10 minutes for new pellets to feed. Pellets Pellets Re-start the stove by moving the mode switch to “OFF” then “MANUAL” and pressing the “MANUAL START” button (press this button firmly). A AAA AAA A AUTO MANUAL AUGER ON in Hopper & Auger Primed? No This is Normal Fill the hopper and start the heater. It should start in 7 to 10 minutes.
Go to Main Menu Flowcharts 1-3 Stove Burns Poorly A poorly burning stove will have a dark, sooty flame. Often the burnpot will fill up with smoldering pellets. Clean the Burnpot Is AA AA Look for dark “clinkers” inside the burnpot. No Burnpot See ÒClinkersÓ on page 2-1 for Clean? details on what causes clinkers. Yes Air leaks are the most over-looked Air Leaking area when troubleshooting pellet Check for Air Leaks Yes into the stoves.
Go to Main Menu Flowcharts 1-4 Stove Goes Out Does Pellets A AAA A AAA AAA No Hopper Have This is Normal Re-fill the hopper and start the heater. The heater should start in 7 Pellets? to 10 minutes. Yes Has power Yes gone out This is Normal A power outage may disable the heater - simply re-start the heater.
Go to Main Menu Flowcharts 1-5 Stove Doesn't Heat Yes The convection air blows heated air above the door. Does Convection Blower Come On? No Is Stove up to Temperature? No This is Normal The fan will come on once the stove is hot (5 to 15 minutes after start-up). Yes Is Convection Blower Faulty? Yes Replace the Convection Blower See ÒFaulty Convection BlowerÓ on page 2-17 for details on the convection blower.
Go to Main Menu Flowcharts 1-6 Stove is Noisy Try pressing down on various points around the base of the heater to see if it decreases noise. Is Noise Coming From Hearth? Yes Dampen the Hearth See ÒNoisy StoveÓ on page 2-16 more details on fixing noisy stoves. No Try pressing down on the surround panels and decorative trim to see if it decreases noise. Are Surround Panels Noisy? Yes Inspect Surrround Panels See ÒNoisy StoveÓ on page 2-16 more details on fixing noisy stoves.
Go to Main Menu Flowcharts 1-7 Glass is Dirty A Is No Burnpot Clean the Burnpot A plugged burnpot will create creosote and excessive flyash, dirtying the glass. See Clean? ÒClinkersÓ on page 2-1 for details on what causes clinkers. Yes The door seal can be checked by closing the door on a piece of Is Door paper. If the paper slides out easily, the door seal is not tight enough. Check for Air Leaks Yes Gasket Air Leaksl decrease the amount of air coming Leaking? through the airwash.
Go to Main Menu 1-8 © 1998 Travis Industries, Inc.
Go to Main Menu Troubleshooting Steps 2-1 Clinkers If the flames are coming only from the sides, or are orange and black, turn the stove off and check for clinkers. Clinkers are hardened clumps that form over the air holes inside the firepot. The most likely causes are: ¥ Poor pellet quality ¥ The door or glass has an air leak ¥ The stove or vent requires cleaning A A AA A A Make sure the stove has fully cooled (approximately 25 minutes) before conducting service.
Go to Main Menu Troubleshooting Steps 2-2 Stove Cleaning Ash buildup is the leading cause of poor performance. Excessive buildup can even lead to stove failure. Regular cleaning is required to keep pellet stoves operating. Whenever service is conducted, consider cleaning the stove in front of the homeowner to display how this process is conducted.
Go to Main Menu Troubleshooting Steps 2-3 Stove Cleaning (continued) Clean the Vertical Exhaust Duct The following models have vertical exhaust ducts welded in place. Heritage Bay PS serial # below 211650 Heritage Bay PI serial # below 410650 Avanti PS serial # below 121700 Avanti PI serial # below 320525 To clean, follow the directions below. Vertical Exhaust Duct Use a hammer to tap against the fireback in front of the vertical exhaust ducts (not too hard). This should dislodge loose flyash.
Go to Main Menu Troubleshooting Steps 2-4 Stove Cleaning (continued) Clean the Horizontal Exhaust Duct a Open the hopper lid and remove the two screws holding the side doors in place. Phillips Screwdriver b d Swing the side panels open. Remove the cover plates over the exhaust duct (both sides) 5/16" Nutdriver c Use a vacuum or bottle brush to remove all flyash from the exhaust duct.
Go to Main Menu Troubleshooting Steps 2-5 Blocked Vent Flyash that has been expelled by the exhaust blower will accumulate in the vent sections. Check the locations shown below for flyash buildup, and, if necessary, clean the entire vent system. Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Make sure the cap is free of debris (especially if it has a screen that could become blocked).
Go to Main Menu 2-6 Troubleshooting Steps Air Leaks Air leaks can come from the door or ash pan. Follow the directions below to diagnose and fix any air leaks. Checking the Door Seal Close the door on a dollar bill (or a piece of paper). Then try pulling the bill out. If it comes out easily, the door gasket is not forming a seal. Repeat this process around the perimeter of the door to ensure a complete seal. If the seal is inadequate, check the door gasket.
Go to Main Menu Troubleshooting Steps 2-7 Air Leaks (continued) Door Adjustment The door latch plate and hinge plate are adjustable, allowing the door to be pulled in closer to the stove. These plates have notches that line up with dimples on the side of the stove. To adjust the door, loosen both plates and move them back 1/16". Use the notch and dimple to ensure correct alignment (so the door does not tilt up or down). Recheck the door seal after each adjustment.
Go to Main Menu Troubleshooting Steps 2-8 Air Leaks (continued) Ash Pan Seal The trap door above the ash pan seals air from entering the firebox. Check the items below to ensure the trap door is sealing. b Clean the trap door and underside of firebox. Slide the trap door back in place. Trap Door a Pull the trap door out. Carefully inspect it to make sure it is not warped. c The trap door is pressed against the firebox with this pressure plate.
Go to Main Menu Troubleshooting Steps 2-9 Faulty Exhaust Blower The exhaust blower pulls air through the air inlet, burnpot, and exhaust ducts. If these channels are blocked or restricted, performance will decrease. Therefore, before checking the exhaust blower, make sure the stove is clean. Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock.
Go to Main Menu 2 - 10 Troubleshooting Steps Circuit Board Faulty The circuit board is not serviceable (with the exception of the circuit board fuse Ð see below). Test this component by replacing it and checking operation of the stove. Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. a Access the back of the circuit board. On stoves, open the right side panel.
Go to Main Menu Troubleshooting Steps 2 - 11 Faulty Igniter During the start-up sequence the igniter receives electricity for 10 minutes under normal circumstances. To check the igniter, access the right side of the stove and connect a hot wire to the two igniter leads. Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock.
Go to Main Menu Troubleshooting Steps 2 - 12 Clearing the Auger Several different factors can cause the pellets inside the auger to compress and jam the auger. Pellets, left over the summer, can absorb water, expand, and jam the auger. Pellets piling up inside the burnpot can fill the drop tube and then jam the auger. Foreign objects left in the hopper can jam the auger. To remove the auger flight inspection plate and clear any items jamming the auger, follow the directions below.
Go to Main Menu Troubleshooting Steps 2 - 13 Auger Motor Defective The auger motor can be checked while it is still installed inside the stove. Follow the directions below to check the auger motor. Unplug the stove to prevent electrical shock. in the hotwire and watch to see if the b Plug auger turns. NOTE: watch the auger for a couple minutes to verify that it is turning over repeatedly Ð a jammed auger may turn slightly. a Unplug the stove. Disconnect the auger motor leads.
Go to Main Menu Troubleshooting Steps 2 - 14 Auger Circuit Faulty Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. Hopper Snap Disk The auger circuit consists of the auger motor, flow switch, hopper snap disk, and the wiring between. If the auger motor is not receiving electricity during normal operation, you should check the auger circuit for malfunctions. The first step is to check the wiring.
Go to Main Menu Troubleshooting Steps 2 - 15 Pellet Quality With the surge in popularity of pellet heaters came the tremendous increase in pellet demand. Because pellets are made from wood by-products, pellet manufacturing is dependent upon the supply of these by-products and the quality found therein. Unfortunately, this surge in pellet manufacturing has led to a decline in the quality of the raw materials used to produce the pellets.
Go to Main Menu 2 - 16 Troubleshooting Steps Noisy Stove Normal Operating Sounds Before conducting a service call for a noisy stove, try to quantify the amount of sound coming from the stove. Pellet stoves have several components with moving parts that will create noise. You may wish to go over the normal operating sounds with the customer before conducting a service call. Exhaust Blower The flow of exhaust gases may create a low-pitched hum. This sound will change as the FEED RATE is altered.
Go to Main Menu Troubleshooting Steps 2 - 17 Faulty Convection Blower The convection blower pushes air through the heat exchanger tubes located along the top of the firebox, transferring heat from the firebox to the room. It also performs a necessary cooling function for internal components*. To check the convection blower, follow the steps below. Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. a Unplug the stove.
Go to Main Menu 2 - 18 Troubleshooting Steps Convection Blower Circuit Faulty The convection blower is controlled directly by the circuit board. . Follow the directions below to check the convection blower circuit. Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. a Start the stove and let it reach normal operating temperature (10 to 15 minutes).
Go to Main Menu Removal Instructions 3-1 Side Panel Opening (Stoves Only) Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Open the hopper lid and remove the screw holding the door in place (this works for both sides). Phillips Screwdriver Rear Panel Removal (Stoves Only) Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. 1/4" Nutdriver Loosen the six screws holding the rear panel in place.
Go to Main Menu 3-2 Removal Instructions Surround Panel Removal (Inserts Only) Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. A A A A A A A A A Top Panel Trim Removal Pull the bottom of the trim outwards slightly to peel it away from the double-back tape holding it in place. Replace the double-back tape after installing the trim this keeps the trim from rattling or flaring at the bottom.
Go to Main Menu Removal Instructions 3-3 Door Removal Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Phillips Screwdriver Door a Open the hopper lid and remove the grill. b A A b Door Hinge AAA AAA Hinge Adjustment Bracket (attached to side of stove). © 1998 Travis Industries, Inc. AA AA AA 93508201 Open the door. Grasp the door with both hands. Swing the door back and forth while lifting up. The door should lift off the hinges.
Go to Main Menu Removal Instructions 3-4 Glass Removal Remove the door and place it face down on a soft surface. To disassemble the door, follow the directions below. · Remove the door from the stove (see page 3-3) and place it face down on a soft surface. · Peel the door gasket away from the door, noting how it is positioned. Remove the upper and lower airwash brackets (see the illustration below).
Go to Main Menu Removal Instructions 3-5 Circuit Board Removal Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. 1 For stoves, open the right side panel (see page 3-1). For inserts, remove the surround panels (see page 3-2). 2 Remove the circuit board following the directions below. a Detach the wiring harness (and thermostat wires, if used) from the circuit board.
Go to Main Menu Removal Instructions 3-6 Wiring Harness Removal Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. Make sure no wires contact the exhaust box or other high-temperature surface. Furthermore, make sure no wires come near the auger lock screw or convection blower intake (the wires may become snagged in these areas).
Go to Main Menu Removal Instructions 3-7 System Snap Disk Removal Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. 1 For stoves, open the left side panel (see page 3-1). For inserts, remove the surround panels and pull the insert out to access the left side (see page 3-2). 2 The system snap disk is located on the exhaust duct, just in front of the exhaust blower.
Go to Main Menu 3-8 Removal Instructions Hopper Snap Disk Removal Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. 1 For stoves, open the right side panel (see page 3-1). For inserts, remove the surround panels and pull the insert out to access the right side (see page 3-2). 2 The hopper snap disk is located on the hopper, near the top. 3 Remove the snap disk following the directions below.
Go to Main Menu Removal Instructions 3-9 Igniter Removal Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. 1 For stoves, open the right side panel (see page 3-1). For inserts, remove the surround panels and pull the insert out to access the right side (see page 3-2). 2 Remove the convection blower (see page 3-10) 3 Remove the igniter following the directions below.
Go to Main Menu Removal Instructions 3 - 10 Auger Motor Removal Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. 1 For stoves, remove the rear panel (see page 3-1). For inserts, remove the surround panels and pull the insert out to access the rear (see page 3-2). 2 Disconnect the two wires leading to the auger motor. Unscrew the lock screw (see the illustration below).
Go to Main Menu Removal Instructions 3 - 11 Auger Flight Removal Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. 1 For stoves, remove the rear panel (see page 3-1). For inserts, remove the surround panels and pull the insert out to access the rear (see page 3-2). 2 Remove the auger motor following the directions on the previous page. 3 Remove the lower auger bushing plate following the directions below.
Go to Main Menu 3 - 12 Removal Instructions Exhaust Blower Removal Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. 1 For stoves, open the left side panel (see page 3-1). For inserts, remove the surround panels and pull the insert out to access the left side (see page 3-2). 2 Remove the exhaust blower following the directions below. a Remove the four screws holding the exhaust duct to the exhaust blower.
Go to Main Menu Removal Instructions 3 - 13 Convection Blower Removal Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the stove to prevent electrical shock. 1 For stoves, open the right side panel (see page 3-1). For inserts, remove the surround panels and pull the insert out to access the right side (see page 3-2).
Go to Main Menu 3 - 14 3 Removal Instructions Remove the blower following the directions below. Thread the blower out of the heater. You will need to rotate the blower slightly. 4 NOTE: Be careful not to damage wiring. When replacing the blower, make sure the blower mounts correctly (see below).
Go to Main Menu Parts List Air Control Restrictor Ash Door, Stove & Insert Ash Dump Seal Plate, Spring Loaded Ashpan, Pellet Freestanding Stove Ashtrap Clean-Out Doors Auger Assembly Auger Bushing, Lower Auger Bushing, Upper Auger Flight Auger Motor, Brush, Bottle Brush Style Brush, Broom Style Burn Pot Circuit Board Convection Blower Convection Blower Knob, for Rheostat Convection Blower Mounting Grommets, Rubber with Spacers Convection Blower Mounting Plate Convection Snap Disk, 120 Degree - 2 Prong Door
Go to Main Menu Index Air Inlet Blocked...................................... 2 - 8 Glass is Dirty Flowchart ........................... 1 - 7 Air Leaks ............................................... 2 - 6 Glass Removal........................................3 - 4 Ash Pan Seal (Checking) .......................... 2 - 8 Hopper Snap Disk Removal .......................3 - 8 Ash Removal (FireboxÉ Cleaning) .............. 2 - 2 How to Use this Service Guide........................
