Travis Industries Avanti PI Service Manual Download Page 45

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Removal Instructions

3 - 13

93508201

040301

Convection Blower Removal

Make sure the stove has fully cooled (approximately 25 minutes) before conducting service. Unplug the
stove to prevent electrical shock.

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).

Disconnect the wiring from the convection blower following the directions below (orientation of the wires
does not matter when re-connecting).

Disconnect the two wires leading
to the convection blower.

Disconnect the right side of the convection blower following the directions below.

Remove the two nuts holding the
right side of the blower mount.

11/32" Nutdriver

Remove the stud bracket

Summary of Contents for Avanti PI

Page 1: ...et Stove Service Guide AA AA A A A AA AA A A A A A A A AA AA A A AA AA A AAAA AAAA AA AA AA AA AA A A A A A A AA A AA AA AA AA AA AA AA AA AA A AAA AAA AAA This manual addresses the following models Avanti PS Avanti PI Heritage Bay PS Heritage Bay PI ...

Page 2: ...r Inlet Blocked 2 8 Electrical Faulty Exhaust Blower 2 9 Fuse Blown 2 9 Circuit Board Faulty 2 10 Faulty Igniter 2 11 Auger Clearing the Auger 2 12 Auger Motor Defective 2 13 Auger Circuit Faulty 2 14 Pellet Quality 2 15 Noise Noisy Stove 2 16 Convection Blower Faulty Convection Blower 2 17 Convection Blower Circuit Faulty 2 18 Removal Instructions Section 3 Panel Removal Side Panel Opening Stoves...

Page 3: ...cing a component Some procedures may require the heater to be plugged in while diagnosing the problem In these cases use caution to prevent arcing or electrical shocks Before conducting service lay down a drop cloth to prevent flyash and other debris from staining the carpet or other flooring On inserts lay down a piece of cardboard on the hearth to prevent scratches How to Use this Service Guide ...

Page 4: ...or keeping all wires from contacting hot portions of the stove Cleaner paper towels drop cloth cardboard other supplies to clean any flyash entering home Spare Components Circuit Board Auger Motor Exhaust Blower Snap Disks System Hopper Wiring Harness Exhaust Motor Blower Gasket Power Cord Convection Blower Heater Fuses 5 Amp Quick 1 4 x 1 1 4 Circuit Board Fuses 6 Amp 5 mm x 20 mm Burn Pot Door G...

Page 5: ...ll decrease performance before you leave a service call make sure all aspects of the pellet stove are working correctly Just because you fixed a door leak does not mean that you should not check for flyash buildup Test Components Individually Before replacing a component test it against a new component This is especially important for blowers and auger motors Simply plug them in directly to a hotw...

Page 6: ...records 2 Send the form along with the component to Travis Industries Attn PRA Returns 15530 Woodinville Redmond Road Suite 300 Woodinville WA 98072 3 When it is tested defective you will receive full credit 4 Order a new component if needed to replace existing stock NOTE The items must be defective and under warranty to receive credit If the component is tested and found to be workable or if it i...

Page 7: ...AA AA A A A A Pellets ArenÕt Feeding See the flowchart ÒPellets ArenÕt FeedingÓ on page 1 2 Start the stove and check for pellets feeding into the burnpot Yes No Yes No No Yes No Yes No Yes Does ÒMANUALÓ Light Come On Has Household Breaker Blown Has Either Fuse Blown Do Pellets Feed Is the Circuit Board Faulty Make sure the household breaker or fuse is operational Check the Power Outlet Replace th...

Page 8: ...y the hopper of pellets and carefully look at the auger If it moves slightly back and forth during operation the auger is most likely jammed Listen to the auger motor to detect if it is working see Auger Motor Defective for more details The auger circuit is used to disable the auger in cases where the flue becomes hot or the hopper over heats Replace the Circuit Board To check the circuit board re...

Page 9: ... fixing exhaust blowers Air leaks are the most over looked area when troubleshooting pellet stoves Check for blockage where the flue turns upwards and at the cap Make sure the air inlet cap is not blocked and the flex tube is not crushed A poorly burning stove will have a dark sooty flame Often the burnpot will fill up with smoldering pellets Yes No No Yes No Yes Yes No See the section ÒRestrictor...

Page 10: ...e information A A AA AA A AA A A A A A A A A A A A A A A A A HEAT OUTPUT W O L H E D M I G H Pellets ArenÕt Feeding See the flowchart ÒPellets ArenÕt FeedingÓ on page 1 2 No Yes Does the Stove Burn Well Was the fire bright with an occasional pellet jumping out of the firepot before the stove went out Start the stove momentarily and check to see if pellets feed into the burnpot Stove Burns Poorly S...

Page 11: ...tside temperature to verify that 20 000 BTUÕs per hour is adequate Heater location may also be a consideration heaters located in a corner or one side of a room may not distribute heat to other rooms To check draft inspect the pellets inside the burnpot while on Low If un burned pellets jump out of the burnpot you may wish to adjust the restrictor watch for several minutes Yes No Yes No Yes No Thi...

Page 12: ...the Stove Loose components may create noise if allowed to vibrate Locate the source of the noise and tighten it connection See ÒNoisy StoveÓ on page 2 16 more details on fixing noisy stoves Inspect the Auger Motor See ÒNoisy StoveÓ on page 2 16 more details on fixing noisy stoves Dampen the Hearth Inspect Surrround Panels See ÒNoisy StoveÓ on page 2 16 more details on fixing noisy stoves Inspect E...

Page 13: ...osing the door on a piece of paper If the paper slides out easily the door seal is not tight enough The lower airwash gap located next to the burnpot may become plugged with ash Look for ash piling up in the area directly behind the glass on the bottom Clean the Airwash Gap Use a vacuum or brush to dislodge any flyash caught in the airwash gap area AA AA AAA AAA AAA AA AA AAA AAA AA AA AA Try a Di...

Page 14: ...1 8 Flowcharts 1998 Travis Industries Inc 93508201 040301 ...

Page 15: ...t requires cleaning A A A A A A A A A A AA A A AA A A A AA A A A A A A AA AA A A A A A A A Make sure the stove has fully cooled approximately 25 minutes before conducting service Cleaning the Firepot To clean the firepot open the door see page 23 and knock away any debris on the firepot with a screwdriver If severely clogged remove the firepot to gain better access Use a screwdriver or other tool ...

Page 16: ...n the Horizontal Exhaust Duct Once a Year Ð or Every 2 Tons Clean the Exhaust Box and Exhaust Blower Once a Year Ð or Every 2 Tons Make sure the stove has fully cooled approximately 25 minutes before conducting service A shop vacuum with a drywall filter available at most hardware stores will remove flyash well The drywall filter prevents the fine ash particles from entering the air Clean the Fire...

Page 17: ...the vertical exhaust ducts not too hard This should dislodge loose flyash NOTE If the flyash does not dislodge use a bottle brush or other device to scrape the flyash from the ducts Vertical Exhaust Duct Remove the flyash by removing the ash trap doors and sweeping into the ashpan More recent models use the cast iron fireback as the front of the vertical exhaust duct To clean follow the directions...

Page 18: ... vacuum or bottle brush to remove all flyash from the exhaust duct d Clean the Exhaust Box Exhaust Blower a Open the hopper lid and remove the screw hlding the left door in place Swing the left side panel open Remove the six screws holding the exhaust blower motor in place b 11 32 Socket c Pull the motor out be careful not to damage the gasket or wiring Clean the blower blades blower housing and e...

Page 19: ...he vent will produce too much draft for the stove This leads to an inefficient burn and in some cases the flame going out Excessive draft typically happens in tall vertical installations or very short horizontal installations The factory restrictor setting is wide open When to Adjust the Restrictor If un burned pellets are expelled from the firepot often make sure they are un burned not just cylin...

Page 20: ...the door by unlatching it opening it wide open and lifting it straight up off the hinge mounts You may need to swing the door back and forth to loosen the hinge pins 3 Place the door on a flat soft surface with the inside of the door facing upwards do not scratch the gold Find the beginning of the gasket usually near a corner and pull it away from the door assembly Prepare the surface for the new ...

Page 21: ... but loose against the other tighten only the side that is loose Open the door b Swing the side panels open c a Phillips Screwdriver Open the hopper lid and remove the two screws holding the side doors in place Loosen these bolts and slide the hinge adjustment plate back approximately 1 16Ó Then re tighten the bolts e 7 16Ó Socket Door Hinge Adjustment Plate d Loosen these bolts and slide the door...

Page 22: ...the firebox tighten the four nuts on the pressure plate appropriately Trap Door a b c Pull the trap door out Carefully inspect it to make sure it is not warped Clean the trap door and underside of firebox Slide the trap door back in place Air Inlet Blocked In rare cases the air inlet becomes blocked Snow or debris can clog the opening The flexible aluminum duct can be flattened To verify the air i...

Page 23: ...irflow leaving the blower Fuse Blown Make sure the stove has fully cooled approximately 25 minutes before conducting service Unplug the stove to prevent electrical shock There are two fuses on the pellet stove An in line fuse is found at the rear near the power cord A circuit board fuse is found on the back of the circuit board See the section ÒCircuit Board FaultyÓ for details A Small Standard Sc...

Page 24: ...rness from the circuit board On stoves open the right side panel On inserts remove the surround panel trim the top panel and right side panel Attach the wiring harness to the new circuit board and test operation If using a thermostat detach the thermostat wires Wiring Harness Pinch these tabs to remove the wiring harness Check the circuit board fuse If the element inside the fuse is broken replace...

Page 25: ...ce Disconnect the leads and attach to a hot wire Open the door and remove the burnpot Look into the area behind the burnpot Within two to three minutes of hot wiring the igniter you should see it start to glow red If it does not the igniter is faulty A A AA A AA a b c d If the igniter does glow red the igniter is functional Next check the wires leading to the igniter a c Locate the two quick conne...

Page 26: ...sembly you may wish to re start the stove and verify the auger turns Make sure to apply high temperature silicone to the bearing cover see step ÒbÓ above this keeps pellet fines from contacting the upper auger flight Remove the silicone shown here the silicone shown in gray need not be removed NOTE on pellet inserts remove the hopper cover before conducting the following steps Unscrew the six scre...

Page 27: ...ghtly If the auger does not turn over remove the auger motor attach a hotwire and check the output shaft a b c If the auger motor is working correctly the auger may have been incorrectly connected to the auger shaft Use the illustration below to verify the auger motor connection Hopper Auger Flight Inspection Cover Lower Auger Bushing Auger Flight Drive Collar Lock Screw Auger Motor Motor Stop 3 1...

Page 28: ...es the circuit if the vent becomes blocked Follow the directions below to test the flow switch Back of Flow Switch Unplug the stove Disconnect the two wires leading to the flow switch Attach a jumper wire to the two wires removed a b c d Turn the stove on and test operation If the stove still does not work replace the wires and test the hopper snap disk see the directions below If the stove does w...

Page 29: ...rn grate while the stove is burning Poor quality pellets may lead to dirty glass especially if it is black and sooty Poor quality pellets may lead to excessive flyash making the stove require more frequent cleaning Poor quality pellets may lead to the auger jamming frequently A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A AAAA AAAA AAAA AAAA AAA AAA AA Recommendation Bri...

Page 30: ...pen the rattle or replacing the component Use the illustrations to the right to help diagnose stove noises If a blower is creating noise try loosening its connection re aligning the blower gasket and re tightening the connection Any vibration can lead to noise If the auger motor clicks check to see if it is knocking against the motor stop There are two rubber bumpers built into the motor stop desi...

Page 31: ...ction Blower shown here removed With the blower unplugged check the inside of the squirrel cage thoroughly Make sure the squirrel cage turns Debris or pellets can jam the blower If nothing is found replace the blower Unplug the stove Disconnect the two wires leading to the convection blower Attach a a hotwire to the convection blower a b c d e Check for air blowing out of the heat exchanger tubes ...

Page 32: ...ts on the convection blower there is enough bare metal on the post to get a good reading Convection Blower Convection Blower shown removed Start the stove and let it reach normal operating temperature 10 to 15 minutes The voltage should read approximately 70 volts on low blower speed approximately 115 volts on high blower speed a b c VOLTS AC Convection Blower Wires Brown White If No Voltage is De...

Page 33: ... conducting service Phillips Screwdriver Open the hopper lid and remove the screw holding the door in place this works for both sides Rear Panel Removal Stoves Only Make sure the stove has fully cooled approximately 25 minutes before conducting service AA AA Loosen the six screws holding the rear panel in place 1 4 Nutdriver Slide the panel up and away from the stove ...

Page 34: ...ck Tape A A A A A 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 Top Panel Removal Lift the top panel upwards off the joggle clips to remove Side Panel Removal Each side panel has two ...

Page 35: ...mately 25 minutes before conducting service Open the hopper lid and remove the grill b Phillips Screwdriver b a AAA AAA A A AA AA AA Door 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 Door Hinge Hinge Adjustment Bracket attached to side of stove ...

Page 36: ... place with eight glass clips Remove the glass clips to access the glass Before replacing the glass make sure the glass gasket is in place forming a seal around the perimeter of the glass Place the center glass first Place the side glass up against the center glass making sure the center piece is centered in the door frame Re attach the glass clips from the center outwards Replace the airwash brac...

Page 37: ...see page 3 1 For inserts remove the surround panels see page 3 2 2 Remove the circuit board following the directions below If using a thermostat detach the thermostat wires at this time Back Side of Circuit Board attached to right side panel Wiring Harness Pinch these tabs to remove the wiring harness Remove the four screws holding the circuit board in place Phillips Screwdriver Detach the wiring ...

Page 38: ...l component inside the stove If the wiring harness does require removal disconnect all of the wiring and replace If only one wire is damaged you may wish to attach a new wire to replace it use the appropriate connectors and replacement wire After installing the wires make sure to lock tie any loose wiring to prevent contact with hot or moving components Convection Blower Wiring Diagram Key to Quic...

Page 39: ...ector Wires for older wiring harnesses Standard Screwdriver Newer wiring harnesses use ring connectors Standard Screwdriver Phillips Screwdriver There are two types of system snap disks Both operate in the same manner If replacing the snap disk the ceramic snap disk should be used if the phenolic type failed Travis will replace free of charge Phenolic older type Ceramic newer type Phillips Screwdr...

Page 40: ... to the bracket Hopper Snap Disk Disconnect the two wires leading to the hopper snap disk Flow Switch 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 Th...

Page 41: ... 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 Remove this screw 5 16 Nutdriver Remove the igniter Disconnect the two wires leading to the igniter ...

Page 42: ...light Inspection Cover Lower Auger Bushing Auger Flight Drive Collar Lock Screw Auger Motor Motor Stop 3 16 Allen Auger Shaft NOTE If the output shaft on the auger motor does not light up with the auger shaft hole you may hotwire the auger motor to turn the shaft until it lines up When re installing make sure the lock screw goes through the auger shaft and contacts the dimple on the output shaft o...

Page 43: ... 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 The auger flight can now be slid out of the auger on inserts you will need to lift the rear edge of the appliance slightly Remove the four bolts holding the lower auger bushing plate in place Mot...

Page 44: ...ound 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 Cut the silicone where the duct attaches to the blower note when replacing the duct use high temperature silicone to seal the duct air tight Remove the exhaust duct b Phillips Screwdriver Exhaust ...

Page 45: ... inserts remove the surround panels and pull the insert out to access the right side see page 3 2 2 Disconnect the wiring from the convection blower following the directions below orientation of the wires does not matter when re connecting Disconnect the two wires leading to the convection blower 2 Disconnect the right side of the convection blower following the directions below Remove the two nut...

Page 46: ...l not to damage wiring 4 When replacing the blower make sure the blower mounts correctly see below Auger Motor Blower Mounting Plate When replacing the blower make sure the slots on the blower mounting plates slide into the groove on the rubber grommets View from Rear of Heater Side View of Blower Mounting AAA Blower Mounting Plate Stud Plate Mounting Bracket attached to base of heater Bushing Rub...

Page 47: ...120Ó Long 99900402 Door Latch Hook 93005011 Door Latch Tool 93005010 Door Roller Plate Assembly 93005012 Exhaust Adapter Vertical 99300137 Exhaust Blower 90 0391 Exhaust Blower Gasket between Blower stove 90 0392 Exhaust Blower Gasket between motor housing 99300135 Fireback Cast Steel Brick Pattern 93005057 Flow Switch 93005060 Flow Switch Tubing 1 4Ó dia High Heat 99300164 Fuse Holder Pellet 9930...

Page 48: ...Board Removal 3 5 Eliminating False Fixes iii Exhaust Blower Faulty 2 9 Exhaust Blower Removal 3 12 Firebox and Exhaust System Cleaning 2 2 Firepot Clogged Clinkers 2 1 Flow Switch Removal 3 8 Fuse Blown in line fuse 2 9 Glass is Dirty Flowchart 1 7 Glass Removal 3 4 Hopper Snap Disk Removal 3 8 How to Use this Service Guide i Igniter Faulty 2 11 Igniter Removal 3 9 Items to Bring on Service Calls...

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