Ignition and controls Updated August 2017 1
INDEX Ignitions and controls 3. ODS Oxygen depletion system & Electronic Flame supervision 4. ODS VALVES BM733 5. NOVA VALVES 6. SIT Oxypilot adjustment 7. SIT DBC Valves and Millennium controller with remote control (Pyrotech Dxl & Landscape) 8 9. Remote control Guide Teaching the RF code 10. Fan speeds 11. Magiglo burner Guide 12. Ignition adjustment 13. Heat seeker 14. Modular fires Electronic ignition, controls and troubleshooting 15. Landscape ignition, controls and troubleshooting 16 17. Tech rite module conversion (Power & Conventional flue) 18. Paint used on Real Flame 2
ODS Oxygen depletion system. Electronic flame supervision For Type 1 appliances installation into an existing working chimney / fireplace an ODS type burner must be used. ODS use a pilot that when the oxygen level in the room reaches 15% (normally around 20.9%) the flame will go out and shut the appliance off. Normal pilots and Electronic ignition systems do not detect the room oxygen level. Suitable for type 2 appliances only (not for existing fireplaces / chimneys Type 1 installations), uses flame rectification. Principle of an AC voltage being conducted through a flame to an earth (burner or electrode). The flame only allows the voltage to travel 1 way and hence a very low DC voltage is created. Usually around 200Vac output gives 8 to 20 Millivolts DC through the flame. This is then picked up and monitored by the ignition pack. Too high or too low the flame supervision drops out. Sensor must be in the flame. It is not heat based, the sensor rod must be in the flame. Distance from flame to burner / earthing body burner usually 3 4mm Flame cannot lift from burner (flame is acting as a wire) 3
CONTROLS ODS VALVES BM733 Manual ignition pilot system. Inbuilt spark in control knob. Thermocouple to detect pilot flame and enable valve to open. Pilot should not be adjusted When lighting recommend holding the gas open for a short time (depress / rotate knob to just before spark action) to allow gas to get to the pilot. Notes: ODS pilots can be difficult to ignite. Recommend to the customer to hold in and allow the gas to fill the pilot tube for a few seconds prior to sparking. ODS pilots Spark must cross over the flow of gas to earth near the main nozzles on pilot 4
NOVA VALVES Manual ignition pilot system. Separate sparker. Thermocouple to detect pilot flame and hold pilot open. Thermo generator to detect pilot flame and enable gas valve to open. On/off switch terminals (millivolts) to allow auxiliary switch. Thermo generator connects to TPTH (red wire) and TP (white wire). Is a millivolt, so connections must be clean and long wire runs are not possible. To adjust valve cap must be removed, adjust and refit cap to lock or allow adjustment. Only a slight variance between high and low. 5
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SIT DBC VALVES AND MILLENIUM CONTROLLER WITH REMOTE CONTROL Fitted to Pyrotech deluxe, Landscape 240V control with flame supervision. Two versions pilot (electronic ignition) and direct spark. Operational principle is the same. The pilot version ignites the pilot and supervises the flame using pilot flame. NOTE It is the millennium control receiver box that operates the flame modulation and the fan operation. The remote control is the brain of the system and tells the receiver box what to do. The receiver box does not respond back to the remote. If the signal is not received the remote does not know and will believe all is operational. The Sit gas control does not talk to the millennium controls. It only knows if there is a run signal or an off signal. This is why the heater could be off due to a gas failure and the fan is working and the remote is on (flame position showing). 7
TEACHING RF CODE REMOTE CONTROL Millennium remote control must be programmed to talk to the receiver fitted to the heater. This may occur after power outages, replacement of batteries or a new remote is supplied. Ensure power to heater is on. Have remote within 2m of the heater to ensure signal is received. Turn the remote to off mode. Practice P T TUP and getting LC on the screen Turn the mains power off to the appliance Wait 2 minutes This is important for the memory to discharge so a new code will be accepted Turn the mains power on to the appliance. Within 30 seconds Press the following sequence on the remote. (Sequence must be done within approx 2 seconds) <P>, <T>, <T>, <UP> The remote will briefly show LC on the display then change to normal display. Check if remote is talking to appliance turn on the remote to heat, either wait for ignition or turn off remote again and the appliance room air fan will start and run for 3 minutes. The remote control has auto and manual mode. To start fire be sure fire is in manual mode. The temperature sensor is located in the remote control. 8
SEQUENCE OF OPERATION SIT CONTROL Pilot models Remote control calls for heat and sends signal. Signal received by millennium receiver. Millennium receiver sends 240V run signal to Sit gas valve controller. Orange wire. Sit gas control performs internal safety check. Sit gas control checks high limit circuit is not activated (broken circuit). Millennium receiver sends low flame output signal to gas modulation coil on valve. (Valve is still off). Blue & brown wires located at Mod 1, Mod 2. Sit gas control actuates pilot gas and starts ignition of pilot. Ignition may spark for upto 60 seconds. Upon pilot lighting flame sensing occurs and sparking stops. Main valve opens allowing main burner to cross ignite from pilot. Heater will operate on low fire for approximately 3 minutes. After 3mins heater will operate on full fire (millennium remote changes output signal to gas modulation coil) and fan operates. (Fan speed and flame output is subject to room temperature and the thermostat set point temperature Delta T). Remote control sends signal to stop heat. Signal received by millennium receiver and operate signal to Sit gas control is removed. Sit gas control turns off main burner and pilot. Millennium control operates fan on high for 3 minutes to cool appliance then fan turns off. Millennium control receiver waits for next heat request signal. 9
FAN SPEEDS Most heaters use the same fan. Speeds vary between models. Fan is 3 speeds Real flame use only 2 of the 3 speeds. Fan speeds must not be altered. All fans supplied by Real Flame as from Oct 2015 have fan wheels glued and spring clipped to the motor shaft. When fitting fan ensure clips are holding fan correctly and not allowing fan to rock onto the body of the appliance. When replacing fans in landscape 1600 both fans must be replaced. 10
Magiglo Burners ODS pilots can be difficult to ignite. Recommend to the customer to hold in and allow the gas to fill the pilot tube for a few seconds prior to sparking. ODS pilots Spark must cross over the flow of gas to earth near the main nozzles on pilot. New models burners are now being released. These look similar. They have rear entry aeration tubes with a round aeration cap. Backburning (applies to all models except Landscape) Check ventilation to appliance is correct NO AIR = SPILLAGE OF GAS AT AERATION CAP Check no blockage in injector and aeration tube. Check burner is not blocked and clean. Check burner rail gap is correct 2mm. (10cents = 1.8mm / 20 cents =2.3mm) If gap is to small the pressure builds back and spills from aeration cap. If gap is to large the flame speed can travel down the gap and cause burning inside the burner. 11
IGNITION ADJUSTMENTS Electronic ignition The flame sensing rod runs across the burner. The height is approximately 3mm above rear burner rail, 5mm past rear burner rail. The spark rod height is approximately 3 4mm above the front burner rail with end in line with the front burner rail. Note: An incorrect gap (larger ) may cause shorting of the spark cable, if this occurs the sparker/cable should be replaced or fit insulation over wire. (When short occurs a pinhole occurs in the cable insulation) 12
Heatseeker Electronic ignition ensure spark and sense electrodes are clear. Fan must be mounted using rubber grommets under clip. Position fan so does not touch rear wall or angled panel. An out of balance fan may cause excessive vibration which can lead to panel vibration. 13
Modular range Pure Vison / Simplicity / Hybrid / Signature Critical that ventilation to the front of the appliance is provided. (Front panel cutouts must not be blocked. Burner must not sit lower than the marble. Do not smother the burner channel or the front air gap between burner and marble with pebbles. Melted ignition packs are a sign of lack of ventilation. 50% of service calls of wont start is due to pebbles touching the flame / spark rod or insulation blanket touching sensors. Where installed with a frame out in front of unit ensure there is air access from underneath and block the sides of frame out to prevent air travelling up around the outside of heater. Check gas pressures are correct. Check ventilation to appliance (Burner). Must be air gap at front of appliance under marble. The front panel air cutouts (in casing) must not be blocked. Where ventilation is from underneath or side of enclosure ensure the air can travel freely, all gaps must be at least unit length x 25mm in area. Air gap around burner and marble usually around 5 8mm If marble is high, burner may need to be raised. Burner to sit equal height or above the marble. Flue run should be 3.6m min and approved cowl fitted. (can be less subject to spill test) Changes over past year Ignition pack now located into the lower base of the appliance. 1800 & 1500 models now have a 20mm air gap behind the burner to increase air cooling effect. Increased size in air deflectors on larger models to assist in powerflue runs. FAULTS & POSSIBLE CAUSE Modular decorative fire takes a few times to ignite? Check pebbles / blanket are not touching the sensor. Check the sparker is correctly located. Check the burner channel is not blocked and gap is 2mm (not closed up) Check there are no large gaps in the burner channel. Connect manometer and check gas pressure when sparking. Check the spark wire is not shorting. Visually inspect the spark, should be continuous, strong and travelling across the burner channel. Check the spark is not occurring over a rivet / channel joiner. 14
Landscape Conversion from Nat gas to LPG requires a replacement burner and top plate. Fan replacement requires burner removal and lower plate removal. To remove lower plate a wooden chock and lever is required. Minimum and maximum pressures must be checked. Failure to do this may result in damage to the appliance. 1600 model = 2 fans set low/med 1000 model = 1 fan set med/ high can be set to low/med by using a pin tool and moving wires in the connector. LPG models have a small flame that is very blue in colour, when compared to Natural gas version. Excessive flues / bends will cause flame lift when cold startup and possible pilot failure. Burner plates must sit flush and evenly around burner slots to prevent warping. FAULTS & POSSIBLE CAUSE 15
ONSITE WHITE ROGERS VALVE AND TECHRITE MODULE CONVERSION ELECTRONIC IGNITION (FROM DUNGS VALVE AND MODULE) Version: 01 25/7/2017 SOP 055 Description: Onsite conversion to an installed unit to ensure power is supplied to new valve and ignition module. Method: 1 Cut elegance tail as shown 4 Y1 from valve to Dungs module. Pull out wire from Dungs module and cut red and black back one inch from block. 2 Cut off Green earth wire on end 5 Cut RFG BRAHMA L Loom black and red back one inch (If white rogers valve already installed in burner, disregard this step. 3 Cut off Green earth loop as shown that connects to loom 16
ONSITE WHITE ROGERS VALVE AND TECHRITE MODULE CONVERSION POWERFLUE (FROM DUNGS VALVE AND MODULE) Version: 01 25/7/2017 SOP 056 Method: 1 Cut elegance tail as shown Description: Onsite conversion to an installed unit to ensure power is supplied to new valve and ignition module. 4 Brown and Blue wire from LHS of unit gets connected to Blue Block, (Brown to Brown, Blue to Blue) 2 Cut off Green earth wire on end 5 Use Blue blocks. BF is Power flue Module to Power flue motor (connect block with Brown and Blue). 3 Cut off Green earth loop as shown that connects to loom PS Pressure Switch is for the Vacuum switch (connect block with Orange and white) 17
Paint Mid 2015 all space heaters and heatseekers changed to Senotherm paint previously was Stovebright (Forest paint) Serial number will usually have an S at the end of the code for Senotherm. Paints are not compatible. Senotherm paint should only be touched up where required in feather coats. A light sand to clean surface and give an etch should be done. Senotherm paint has a thin consistency and any repairs need to be well blended / smoothed. Modular heaters are still painted in Stovebright. Stovebright has a grey tinge, is smoother in finish and once cured very hard to sand. All appliances with Stovebright have been sandblasted prior to painting for correct product adhesion. 18