Travis Industries 36 ELITE-BI Xtrordinair Service Manual Download

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Gas Service Manual

PILOT ADJ

VENT

OFF

December, 1997

Travis Industries

Gas T-Shoot Guide

19203

Summary of Contents for 36 ELITE-BI Xtrordinair

Page 1: ...Gas Service Manual PILOT ADJ VENT TO L P I O N O F F H I L O AA AA AA December 1997 Travis Industries Gas T Shoot Guide 19203 ...

Page 2: ...ple 2 13 Remote Thermostat Faulty 2 14 Blower Circuit Faulty 2 15 Blower Defective 2 16 Gas Control Knob Doesn t Pop Out 2 16 Pilot or Main Burner Does Not Shut Off 2 16 Door Glass Removal 3 Lopi Spirit Spirit DV Spirit Bay 3 1 Avalon 700 700 DV 3 2 Avanti 1995 1996 B Vent DV 3 3 Avanti 1997 B Vent DV 3 4 FPX36 DV 3 5 Lopi Heritage Bay DV and B Vent 3 6 Lopi Heritage Bay Insert 3 7 DVS Insert and ...

Page 3: ...ner turn on On Off switch thermostat or remote control off turn ÒONÓ Gas control knob turned to ÒPILOTÓ turn to ÒONÓ Head Coil Defective pg 2 8 Burner electrical circuit faulty remote thermostat etc pg 2 7 Millivolt production inadequate Thermopile Defective pg 2 6 Does the flame look correct Flame is blue for first 15 minutes This is normal Flame height may be adjusted too low Adjust higher Burne...

Page 4: ...nce questions arise Precautions Warning Turn off all gas to the unit before working on any component on the gas line Warning When the gas is on make sure the remote thermostat or remote on off switch does not turn on Warning Make sure the appliance is unplugged when inspecting the wiring How to use this troubleshooting guide This guide uses a flow chart on the inside of the cover to help direct th...

Page 5: ...ilitate a quick diagnosis and repair of the heater These parts may be used to determine which portion of the appliance is inoperative and can often make the repair quick and effective In addition to the items below gas line equipment should be included if needed Flex Tube or Pipe with Shutoff Valve Spill Switch Snap disk Thermopile Piezo Igniter Burner Pan w Gas Control Valve NG LP Logs Ember Stri...

Page 6: ...hed on small clips on left side Rectangular front glass mounted on firebox Burner orifice attaches to a manifold penetrating the burner assembly which attaches to a flex tube that runs to a fitting attached to the valve Discovery DVS Insert Fireplace 1997 Serial Phase 2 97 DVS 31 000 BTU See Travis Industries DVS Insert or DVS Fireplace Heritage Bay Model Determination Stoves Model Vintage Ser Bur...

Page 7: ...et metal plate with small upright flanges near left right sides at the front to locate the front log Lift off gold door is standard Avanti B Vent 1996 4052 Present Phase 2 96 BVM 40 000 BTU B vent contemporary style bay window unit insert or free standing burner has a raised platform for front log to sit on Has thermo couple for 30 second dropout Natural gas burner standard includes parts to conve...

Page 8: ...ed under burn pan at left side Firebox is 30 1 2 wide at front Natural gas burner 40 000 BTU is standard feature with parts to convert to LP gas included FPX 32 DVS Insert Fireplace Phase 2 97 DVS 31 000 BTU See Travis Industries DVS Insert or DVS Fireplace Travis Industries Model Determination Fireplaces Inserts Model Vintage Ser Burner Description DVS Insert 1996 80000 continuing Phase 2 97 DVS ...

Page 9: ...gniter wire Spark Electrode Too Far From Pilot Hood The spark electrode should be no more than 1 8Ó from the pilot hood You should see the spark travel from the electrode to the pilot hood Pilot Hood No more than 1 8 Spark Electrode Remedy Bend the spark electrode so that it is within 1 8 of the pilot hood The diagonal offset in the electrode allows it to be bent closer to the pilot hood if necess...

Page 10: ...otice that the red button does not create a snap when it is depressed or that the button has no spring resistance The only way to check this component is to replace it and see if it creates a spark Remedy Replace the piezo igniter Gas Line not Purged All air in the gas line must be purged prior to operation Remedy Remove the glass or open the door and depress the gas control knob on pilot while re...

Page 11: ...f it does not you may need to turn the pilot up To adjust the pilot flame remove the cover screw and gasket and turn the needle valve Clockwise lowers the flame while counter clockwise raises it PILOT ADJ TO L P I O N O F F Standard Screwdriver Micro 1 16Ó Standard Screwdriver AA The cover screw and gasket must be replaced to prevent gas from leaking Cover Screw Cover Screw Gasket Needle Valve 3 8...

Page 12: ...table reading is 15 millivolts PILOT ADJ VENT T O L P I O N O F F H I L O To check millivolt production from the thermocouple remove the thermocouple connector and connect the multimeter to the center tab and copper tube min 15 millivolts Thermocouple Connector 3 8 Wrench B Vents Only Copper Tube NOTE Make sure the pilot flame contacts the thermocouple 3 8 for 30 seconds while testing millivolt pr...

Page 13: ... re connecting 1 2 3 Spill Switch Interrupt 3 Replace the spill switch wire nearest the thermocouple connector and measure the millivolt reading on the other terminal of the spill switch interrupt If no millivolts are detected and millivolts were detected in step 2 above the spill switch wires or spill switch snap disk is faulty see steps 4 5 below If millivolts are detected minimum of 15 millivol...

Page 14: ... pilot to achieve 200 millivolts your thermopile may require replacement NOTE If the main burner is turned on the millivolt production will appear to drop because the head coil the valve that operates the main burner will draw electricity NOTE If the heater operates for 1 to 5 minutes then shuts off it may be a defective thermopile Millivolt production is based upon the difference in temperature b...

Page 15: ... Turn off the appliance and carefully inspect the burner electrical circuit wires for damage or loose connections HINT Keep in mind that millivolt circuits are very weak Unlike 110 Volt circuits a slightly loose connection can interrupt the circuit and disable the burner The most frequent cause for faulty on off circuits are connections that are loose or dirty Remove clean and re crimp all connect...

Page 16: ... at the base yellow orange on the top If the flames are too tall or sooty on the ends push up on the lever If the flames are all blue and short pull down the lever Not Enough Air Too Much Air Locate the air shutter adjustment lever behind the gas control valve Move it up or down until the flame is correct Pushing up gives the flame more air making it bluer Pulling it down cuts air down making it m...

Page 17: ... different Logs Placed Incorrectly The ceramic fiber logs must be placed correctly on the burner pan for the heater to burn correctly Too much flame impingement on the logs sooting or no glowing are symptoms of incorrectly placed logs or an incorrectly adjusted air shutter This may lead to excessive sooting increased emissions shortened flames and decreased efficiency Remedy Place the logs correct...

Page 18: ...ng Device LP 11 W C NG 5 5 W C Min Input Pressure PILOT ADJ TO L P I O N O F F Standard Screwdriver Micro 1 16Ó Standard Screwdriver A Cover Screw Cover Screw Gasket Needle Valve Older Models a Remove the cover screw and gasket b Unscrew the needle valve several turns c Place a tube over the needle valve port Newer Models with Gas Inlet Pressure Test Port a Unscrew the gas inlet pressure test port...

Page 19: ...king inside Orifice removed from back side of manifold 1 If the flame height is less than 6 tall in the rear or 2 in front the orifice s may need to be checked for obstructions First check the input pressure to see if that is correct then adjust the air shutter If the flames remain too short remove the orifice s and check for debris inside 2 While the orifices are removed use a flashlight to inspe...

Page 20: ...he appliance to overcome negative pressure install an outside air kit or crack the window Down Drafts Installations in a high wind area may lead to air pushing down the gas vent Homes located next to a lake or on the leeward side of tall trees or a hill are most susceptible This type of problem may be sporadic Remedy Increase the vent height above the downward flow of air or install a draft induci...

Page 21: ...shutting off the main burner Check to see if the pilot flame is being blown off of the thermocouple Thermocouple Remedy Make sure the vent restrictor is in the correct position see the ownerÕs manual for details Make sure vertical terminations utilize the high wind cap part 991 36 DVÕs and Heritage Bays should have a pilot deflector if they do not contact Travis Industries for details If the Herit...

Page 22: ... Weak batteries may adversely affect range 1 Switch the receiver to ÒMANUALÓ and turn the heater on If the heater does not work the malfunction is with the heater or in rare cases with the remote receiver or the wire leading to it Remote Position Off Position Manual Position 2 Switch the receiver to ÒREMOTEÓ Install new batteries in both the receiver and remote and press the ÒMANÓ button on the re...

Page 23: ...o low 1 Check the outlet to make sure it is supplying power 2 With the power cord removed check the wiring using the diagram below as a guide Use a multimeter to check continuity between the wires Check for loose connections or burned wire insulation Replace any damaged component Molex Plug Grounding wire screwed to heater Wires from the power cord Blower Rheostat White Black Black Green Blower Bl...

Page 24: ...e blower Gas Control Knob Doesn t Pop Out when Released If the gas control knob does not pop out when released after starting the pilot the EPU inside the gas control valve is not working correctly PILOT ADJ VENT T O L P I O N O F F H I L O I fthe gas contr olknob does not pop out w hen r el eased the gas contr olval ve M U S T B E R EP LA C ED IM M ED IA T ELY Warning This is a potentially danger...

Page 25: ...iver AAAAA AAAAA AAAAA AAAAA AAAAA AAAAA AAAAA AAAAA b Loosen the nuts on the bottom and left side glass clip Then slide the glass to the right pivot the glass forward and remove it from the heater AAAAAA AAAAAA AAAAAA AAAAAA AAAAAA AAAAAA Follow the directions above in reverse order Make sure the gasket forms an air tight seal around the perimeter of the glass To remove the glass To replace the g...

Page 26: ...eater The door components are shown below 3 8 flat gasketing behind the retaining clips prevents the glass from cracking when being secured Use a 5 16 nutdriver for the retaining clip screws Door Gasket 7 8 rope gasketing is held in place with gasket cement Cross Section Door Frame Glass Retaining Clip Glass Gasket 3 8 dia white rope gasket Make sure there is a small space around the edge of the g...

Page 27: ...ss clip until the glass can be tilted forward and removed Loosen the three glass clips holding the side glass in place Slide the side glass to the rear Do these steps for both sides Remove the glass trim on both sides c DV s Only Replace the glass following the directions to the right AAA A A A A A A A AAA A AA A A A A AA AA Glass Glass Gasket 5 8 self adhesive channel gasket Glass Clip Glass Clip...

Page 28: ... AA AA AA AA AAA AAA AAA A A A AA AA AA AA AA AA AA AA A A A A A A AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAA AAAA AAAA AA AA AA AA AA AA AA AA AA AA AA A A A A A A A A A A A A A A A A A AA AA AA AA AA AA AA AA AA AA AA AA AAA AAA AAAA AAAA AAA AAA AAAA AAA AAA AA AA AA AA AA AA A A A A A A AA AA AA AA AA AA AAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAA AA...

Page 29: ... the bottom glass clip Face of Firebox AA AA AA AA AA AA AA A Glass Clip Glass Gasket Glass Glass Clip Screws 1 2 3 4 5 AAAAAAAAAAAA A A A A A A A A A Front of Fireplace Glass Glass Gasket fits around edge of glass Glass Clip Bracket for securing the faceplate AAAA AAAA AAAA To install the glass Place the bottom glass clip in place and screw the 5 screws that hold it in place a couple of turns use...

Page 30: ... NOTE Do not overtighten the pawl by screwing it in This will permanently damage the latch The illustration below details the door assembly 3 8 Nutdriver Glass Clips Door Gasket Gold Door Glass Clip Nut AA AA AAA AAA AAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAA AAA AAA AAA AAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAA AAA A A A A...

Page 31: ... the gold trim on the ashlip The illustration below details the door assembly AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAA AAA AAA AAA AAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAA AAA A A A A A A A AAA AAA 3 8 Nutdriver Glass Clips Door Gasket Gold Door Glass Clip Nut AA AA AAA AAA AAA To remove the glass peel back the door ...

Page 32: ... they are flush with the end of the stud Pivot the glass forward and remove Tighten the nuts on the bottom glass clip first then the top then the sides Removing the Glass AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA While holding the glass slide the side and top glass clips off c Rep...

Page 33: ...ve Burner Orifice SAME Remove Burner Assembly Remove Pilot Tube Remove Gas Control Valve Remove Burner Orifice Pilot Assembly Remove Burner Assembly Disconnect Thermocouple Thermopile and Pilot Tube Connect New Pilot Asbly SAME SAME Pilot Orifice Remove Burner Pan leave burner asbly in place Disconnect Pilot Assembly Disconnect Pilot Tube Remove Burner Assembly Disconnect Pilot Tube Remove Burner ...

Page 34: ...ons to the right The gas inlet on freestanding stoves protrudes from the rear panel AAAAA AAAAA AAAAA AAAAA AAAA AAAA AAAA AAAA AAAA A A A A A A A A AA A A A A A AA AA Disconnect the gas supply from the gas inlet and turn the pipe counter clockwise with a pipe wrench Stoves The gas inlet on inserts is on the left side either facing to the rear or to the left Inserts DVS Fireplaces Disconnect the f...

Page 35: ... be accessed Control Panel Open the Door on the pedestal 1 4 Nutdriver Access the firebox and remove the burner pan following the directions below Remove the burner pan tilting it forward to allow the gas control valve to clear the front of the heater 7 16Ó Socket a e Disconnect the brown and red wires from the on off switch Disconnect the six nuts used to attach the burner pan Burner Pan Disconne...

Page 36: ...nd burner pan are flush The rear log shelf slides on and off the burner pan assembly Burner Pan Assembly Rear Log Shelf NOTE When installed the log shelf must maintain a parallel 3 8Ó gap to the burner pan Slide the burner pan to the left until the fixed shutter disengages from the orifice Place the burner pan aside Burner Pan Burner Pan Box Fixed shutter Orifice c Remove the two screws holding th...

Page 37: ...ve Slide the burner pan to the left until the fixed shutter disengages from the orifice Place the burner pan aside Fixed shutter Orifice Burner Pan Burner Pan Box Rotate the burner pan upwards Removethe burner box front and rear log shelf Standard Screwdriver Burner Box Front a b c Rear Log Shelf when replacing make sure to slide it all the way back ...

Page 38: ...utter to the left off the orifice be careful not to bend the shutter linkage 1 2 Wrench Slide the adjustable shutter down away from the orifice Remove the spring Use a 1 2Ó open end wrench to unscrew the orifice There is usually a number stamped here to indicate orifice size Make sure to keep any sealant or debris from entering the orifice and blocking gas flow Apply thread sealant to the new orif...

Page 39: ...Control Valve 7 16 Wrench Pilot Assembly Unscrew this compression nut Swivel the pilot tube up to access the pilot orifice a b c The pilot assembly may be removed in its entirety by disconnecting the thermocouple thermopile and pilot tube Or if you wish you can remove an individual component separately AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA A A A AA AA AA AA AAAA AAAA AA...

Page 40: ...e accessed from the bottom IMPORTANT NOTE Make sure the pilot asembly does not rotate while detaching components from the pilot assembly Insert a standard screwdriver between the components or use a vice grip to clamp the assembly in place AA AA AA A A A A AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AAAAAAAA AAAAAAAA AAAA...

Page 41: ...ot orifice Pilot Orifice Compression Nut Compression Sleeve Pilot Tube Port on Pilot Assembly Pilot Tube Make sure the pilot tube inserts into the pilot orifice NG vs LP Orifice 1997 or Later Burners Disconnect the compression nut with a 7 16 open end wrench and move the pilot tube away from the pilot assembly see ÒPilot Assembly RemovalÓ on page 4 8 Make sure the pilot orifice fits over the compr...

Page 42: ...ver Red Thermopile Wire White Thermopile Wire Use a standard screwdriver to remove the two thermopile wires from the gas control valve Thermocouple Removal Remove the burner pan for 1997 or later models see page 4 2 1996 or earlier see page 4 1 Place the burner pan upside down and remove the thermocouple with a 7 16 open end wrench see the illustration on page 4 7 for the location of the thermocou...

Page 43: ...the nut usually this can be done by hand otherwise use an 1 1 16 open end wrench On Off Switch Remove the on off switch following the directions below AA AA AA AA AA AA AA AA Depress the locking tabs on the back of the on off switch Use a screwdriver if necessary to gain enough leverage AA AA AA AA AA AA a c b Carefully thread the on off switch out making sure not to disconnect or damage the wirin...

Page 44: ...1506 Thermocouple 98900748 98900748 98900748 98900748 Thermopile 98900752 98900752 98900752 98900752 Pilot Assembly NG 98900600 98900600 98900600 91001501 95AvantiDV 98900600 91001501 9536 DV Pilot Assembly LP 98900602 98900602 98900602 91001500 95AvantiDV 98900602 91001500 9536 DV PilotTube 91001508 91001508 91001508 98900753A 95AvantiDV 91001508 91001507 9536 DV FrontLog RearLog LeftTwig Right T...

Page 45: ...A A A AA A AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AA AA A A A A A A A A A A A A A A AA AA AA AA AA AA AA AA AA A A A A A A A A A A AA AA A A Rear Panel Disconnect the molex connector leading from the power cord AA AA AA AA 5 16 Nutdriver Molex Connection A A A AA AA A A AA AA A A A A A A Remove the strain relief Disconnect the wires lead...

Page 46: ...the nine screws holding the rear panel in place 5 16 Nutdriver Cover Plate 2 Swing the rear panel to the left and disconnect the molex connector leading from the power cord Remove the Molex Connection 3 Remove the nuts holding the left side panel to the baseplate Remove these nuts left side only 3 8 Wrench 4 Loosen the nuts holding the left side panel to the convection top three turns Loosen these...

Page 47: ...Cover Plate 2 Swing the rear panel to the left and disconnect the molex connector leading from the power cord Remove the Molex Connection 3 Remove the nuts holding the left side panel to the baseplate Remove these nuts left side only 3 8 Wrench 4 Remove the nuts holding the left side panel to the convection top Remove these nuts left side only 3 8 Wrench 5 Remove the left side panel by lifting up ...

Page 48: ...ce Warning Shut off all gas and disconnect the gas line from the heater 1 Remove the insert from the fireplace remove the panels glass and logs first to prevent damage while moving the insert 2 With the left rear of the heater exposed the blower assembly can be accessed Follow the directions on page 5 5 A20 Blower Assembly Removal Disassembly to remove the blower from the heater Sprit Bay Insert B...

Page 49: ...wires leading to the blower NOTE orientation does not matter while reinstalling 2 Remove the four nuts holding the blower in place Slide the blower out Remove the four nuts holding the blower in place 11 32 Nutdriver Slide the blower out to the side 3 When re installing make sure to position the brackets correctly behind the blower assembly AA Stud Plate Rubber Grommet Bushing Mounting Plate on He...

Page 50: ...e the three screws holding the plate in place These nuts hold the blower assembly in place 5 Slide the blower to the left disconnect the electrical connection then slide the blower out Remove the four bolts inside the firebox 7 16Ó Socket 5 16 Nutdriver Remove the three screws holding the convection top to the insert Convection Top Manifold Slide the manifold back NOTE when installing the manifold...

Page 51: ... fireplace see page 3 5 2 Remove the burner pan assembly see page 4 2 1 4 Nutdriver Remove the ten screws holding the plate in place 3 Remove the cover plate at the back of the firebox see the illustration above 4 Remove the heat shield behind the firebox 1 4 Nutdriver Remove the three screws holding the heat shield in place 5 Remove the two nuts and washers on the right side of the blower 6 Remov...

Page 52: ...e two nuts on the left side of the blower Remove the two nuts and washers holding the blower in place 11 32 Wrench Disconnect the two wires leading to the blower 8 Remove the blower from the heater 9 When re installing make sure to position the brackets correctly behind the blower assembly AA Stud Plate Rubber Grommet Bushing Mounting Plate on Heater Washer Nut Blower Plate ...

Page 53: ...e the nuts holding the blower in place Hold the fitting in place with the 3 4 wrench while unscrewing the flex tube with a 7 8Ó wrench 3 4 Wrench 7 8 Wrench Gas Control Valve Fitting Flex Tube 7 16Ó Socket These nuts hold the blower in place 7 16Ó Socket These nuts hold the blower in place 4 Move the blower to the left of the gas control valve and thread it out of the appliance 5 Disconnect the wi...

Page 54: ...he four nuts underneath the blower 2 Slide the blower assembly out You may wish to remove the stud bracket and rubber grommets from the blower assembly to better facilitate removal Remove these nuts 11 32 Nutdriver Blower Assembly Stud Bracket 3 Disconnect the wires from the blower 4 When re installing make sure the grommet slides into make sure the stud bracket is fed through from above with a wa...

Page 55: ...ower cord is disconnected prior to conducting service Warning Shut off gas to the heater you may need to disconnect the gas line depending upon the heater location and the type of gas connection Heritage Bay Only Remove the control panel following the directions to the right Remove the four screws holding the control panel in place Lay the control panel face down so the area behind it may be acces...

Page 56: ...nap disk may be removed from its mounting bracket Disconnect the black white wires from the snap disk orientation does not matter when re connecting Blower Snap Disk Phillips Screwdriver 610046 T O D 60T12 9305 F120 10F Remove the snap disk from its bracket behind the firebox Stoves 1 Remove the rear panel see the instructions under ÒBlower RemovalÓ for the model being serviced pages 5 1 through 5...

Page 57: ...only AvantiB Vent 1996 Avanti DV 1996 700B Vent 1996 700 DV 1996 SpiritB Vent 1996 Spirit DV 1996 Spirit Insert 1996 HeritageInsert 1997 DVSInsert DVSFireplace 36 DV HeritageBayDV HeritageBayB Vent Blower Part 98900755 98900755A 97300102 91000133 Blower Rheostats All Travis products through 1997 use part 98900758 for the blower rheostat Blower Snap Disks All Travis products through 1997 use part 9...

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