AWS 30VDC Troubleshooting Guide

30 VDC AWS TROUBLESHOOTING GUIDE When installed with a 1420-AOD Remote Control I’VE TRIED EVERYTHING AND IT STILL DOESN’T WORK!

A couple of notes before starting to diagnose: 1)

This guide is ONLY for 30VDC systems

2)

Please ensure that the gas supply is turned OFF for all tests.

Items that you should check before troubleshooting the system: 1)

GEO-30VDC is plugged into a proper functioning outlet.

2)

FG-1420-AOD receiver is plugged into a proper functioning outlet.

3)

Wiring from the power supply to the remote receiver to the valve box (FG-ICB) is correct.

4)

If additional wiring added, 12-gauge wire used within tolerable distances (preferably with Die Electric Greased Wire Nuts).

5)

Remote transmitter is LEARNED to the remove receiver.

6)

Valve installed correctly (not upside down).

7)

Ensure that th pilot assembly fittings, igniter plug, and thermopile plug are secured and locked in place correctly.

If you have completed the list above, then you may have a faulty one of the following: TESTING THE

Remote Receiver 1)

Check transmitter battery by pushing on button. If red light seems faint, replace A23 battery.

2)

Unplug transmitter power supply and remote receiver.

3)

Disconnect the remote receiver out of the loop and directly connect the power supply to the valve box.

Red to Red and Black to Black.

4)

Plug the power supply into outlet and observe.

If the Igniter Starts Glowing: The FG-1420-AOD Receiver may be faulty or wire nuts were not securely tightened.

Reconnect the FG-1420-AOD making sure the wire nuts are tightly secured. Then try the remote to see if the igniter starts glowing.

If Nothing Happens: You may have a faulty Power Supply, Igniter, Thermopile, or Valve Box.

TESTING THE

Power Supply 1)

Unplug Power Supply.

2)

Disconnect the Red wire from Power Supply to the Valve Box.

3)

Set your Multi-Meter to the DC side of meter at a setting above 30VDC.

4)

Connect 1 lead of the Multi-Meter to the Red wire of the Power supply and the other lead to the Red wire of the Valve Box. It should look like this.

Valve Box

5)

Power Supply Multi-Meter

DO NOT ATTEMPT TO IGNITE SYSTEM!

This may cause damage to your multi-meter

Plug in your Power Supply. You should have a reading between 28.5 VDC and 31.5 VDC.

If Your Multi-Meter Reads Between 28.5 VDC and 31.5 VDC The power supply is working as intended.

If Your Multi-Meter Reads Outside 28.5 VDC and 31.5 VDC The Power Supply may be faulty.

Historically speaking there are 3 parts on the AWEIS Historically that might speaking needthere to beare replaced 3 partsover on the time.

AWEIS The Hot that Surface might need to be replaced over time. The Hot Surface Igniter (Glow Plug) which is located in the PilotIgniter Burner(Glow Assembly Plug)used which to be is located the partinthat thewould Pilot Burner fail most Assembly often. With usedthe to be the part that would fail most often. With the introduction of the “Commercial Grade” Pilot Burner introduction Igniterof failures the “Commercial are not as common Grade” Pilot as they Burner used Igniter to be. The failures nextare partnot as common as they used to be. The next part most often to fail (due to high heat in the feature) most wasoften the Controller to fail (duewhich to high is heat located in the inside feature) the AWEIS was theIgnition Controller Control which is located inside the AWEIS Ignition Control Field Serviceable AWEIS Replacement Parts Install Instructions Box. And the part least likely to fail is the Thermal Box.Sensor And the which partisleast located likely in to thefail Pilot is the Burner Thermal Assembly.

Sensor The which new is “Field located in the Pilot Burner Assembly. The new “Field Serviceable” AWEIS makes it possible to there replace Serviceable” all of these parts with makes minimal it possible effort. to replace all 3 of these parts with effort.

Historically speaking are 3 3parts onAWEIS the AWEIS that might need to be replaced over time.

The minimal Hot Surface TESTING THE Igniter (Glow Plug) which is located in the Pilot Burner Assembly used to be the part that would fail most often. With the introduction of the “Commercial Grade” Pilot Burner Igniter failures are not as common as they used to be. The next part most often to fail (due to high heat in the feature) was the Controller which is located inside the AWEIS Ignition Control Box. And the part least likely to fail is the Thermal Sensor which is located in the Pilot BurnerController Assembly. The new “Field Controller 1)it possible Unplug to power supply from Serviceable” AWEIS makes replace all 3 of theseoutlet. parts with minimal effort.

If Your Multi-Meter Reads Between Controller Replacement Field Serviceable AWEIS Replacement Parts Install Instructions

Igniter

2) 3) 4) 5)

At right is a photo of the underside of the Pilot Burner.

Unplug Igniter plugIgniter from side of Valve Box. Hot Surface

1.6 OHMS and 6.5 OHMS

Hotthere Surface Igniter Historically speaking are 3 parts on the AWEIS that might need to be replaced over time. The Hot Surface TheBurner igniter is functioning properly.

Igniter (Glow Plug) which is located in the Pilot Assembly used to be the part that would fail most often. With the introduction of the Set you Multi-Meter to Ohms (No less than 10“Commercial OHMS). Grade” Pilot Burner Igniter failures are not as common as they used to be. The next part Controller Step 1 Step 2 most often to fail (due to high heat in the feature) was the Controller which is located inside the AWEIS Ignition Control Thermal Sensor Thermal Sensor Box. And the part least likely Replacement to fail is the Thermal Sensor which is located in Reads the Pilot Burner Assembly. The new “Field Controller If Your Multi-Meter Outside Using a wrench loosen the Remove Serviceable” AWEIS makes it possible to replace all 3 of thesethe partsbrass with minimal effort.

Stick the two leads from your Multi-Meter into the

protruding from Hot Surface Igniter fitting andand lid of6.5 the OHMS 1.6 OHMS Igniter plug. brass fitting the outlet of the AWEIS as box to expose the The inside igniterofmay be faulty. shown inReplacement the photo at right. the box.

Hot MUST Surface Igniter Hot Surface Igniter Replacement You a reading of 1.6 to 6.5 OHMS. Step have 1 Step 2 Controller

Thermal Sensor Using a wrench loosen the brass fitting protruding from Replacing Hot Surface Igniter the outlet of the the AWEIS as At right is Controller a photo of Replacement the shown in the photo at Surface right. Step Hot Igniter 3 underside of the Pilot Burner. Replacement

Remove the brass fitting and lid of theHot Surface Igniter box to expose the inside of the box.

Step 4 Thermal Sensor

Unplug the wire harness Liftbythe controller Highlighted by a red circle is Highlighted a red circle isup out of from the old controller. the head box asscrew shownthat in the photo the Philips head screw the Philips Stepthat 1 Step 2 Plug the wire harness into at right. secures the Igniter in place. secures the Igniter in place.

Hot Surface Igniter Replacement the new controller.

At right is a loosen photo ofthethe Using a wrench Remove the brass The photo at right shows the TheStep photo right shows box the in the Reassemble 4 at Step 3 underside of the Pilot Burner. brass fitting protruding from fittingand and of the Igniter removed thelid small Igniter removed and the smallshown in reverse order the outlet of the AWEIS as to that expose Unplug Philips the wire harness screw holdsthe headthese screw that holds steps. out of headbox Highlighted by a red circle is Lift the controller up Philips shown in the photo at right. inside of the box. from theit old controller. it in place. in place.

At right is a photoField of theServiceable the Philips head screw that the box as shown in the photo AWEIS Replacement Parts Install Instructions underside of the Pilot Burner. Plug the wire harness into secures the Igniter in place. at right.

Installation of the new Igniter of the new Historically speaking there 3 Installation parts on the AWEIS thatIgniter might need to be replaced over time. The Hot Surface theare new controller.

Highlighted by a red circle is photo at right shows thelocated is the reverseThe ofIgniter the removal is Pilot the reverse of the the removal in the BurnerinAssembly used to be the part that would fail most often. With the Reassemble box the (Glow PhilipsPlug) head which screw isthat Igniter removed and the small reverse introduction ofIgniter the “Commercial Grade” Pilot Igniter in failures are not as common as they used to be. The next part of the old Igniter. oforder theBurner old Igniter. shown secures the in place.

Thermal Sensor Replacement most often fail (due high heat in the feature) was the Controller which is located inside the AWEIS Ignition Control Philips head to screw that toholds these steps.

The photo at right shows the Box. And the4part least likely to fail is the Thermal Sensor which is located in the Burner Assembly. The new “Field Step it in place.

Step 3 Igniter removed andPilot the small with minimal effort.

Using a Philips head screw Using a Philips head screw Serviceable” AWEIS makes it possible to replace all 3 of these parts Philips head screw that holds Unplug the ofwire harness Installation the new Igniter it in place.

Lift thethe controller driver remove screw up out of driver remove the screw On the securing underside of the pilotthe Remove the screw that secures Insert the new igniter and then thereverse old controller. is the of the removal the box as shown securing the Igniter to thein the photo the Igniter to from Installation of the new Igniter Plug the harness into and then remove the burner, the circle highlights the igniter replace the screw into the ofof the oldwire Igniter.

At right is a photo the side at right.

Pilot Burner Assembly as Pilotred Burner Assembly as is the reverse of the removal Thermal Sensor Replacement the new controller.

Controller the Phillips screw that igniter. using a Phillips head of the old assembly Igniter.

PilotatBurner. shown in the photo at right. shownhead inof thethe photo right.

Reassemble box in the secures the igniter. screwdriver. order shown in Using a Philips head screw Highlighted by areverse red rectangle Using a Philips head screw Hot Surface Igniter these steps. driver remove the screw is the Thermal Sensor. driver remove the screw securing the Igniter to the securing the Igniter to the Pilot Burner Assembly asAt right is a photo of the side Pilot Burner Assembly as Thermal Sensor the Thermal Sensor The photo at right shows shown in the photo at right. of the Pilot Burner. shown in the photo at right. Replacing the Thermal Sensor being Highlighted by a redThermal rectangle Sensor Replacement slid out of the Pilot Burner. is the Thermal Sensor.

Hot Surface Igniter Replacement Installation of the new Thermal Sensor is the The photo at rightreverse showsof the steps shown the Thermal Sensor being Using a 7/16” open end here.

At right is a photo of the At right is a photo of the side slid out of the Pilot Burner. wrench loosen the brass nut underside of the Pilot Burner. of the Pilot Burner. that secures the Thermal Installation of the new Sensor to the Pilot Highlighted Burner. by a red circle is Highlighted by a red rectangle the Philips head screw that Thermal Sensor is the Once loose unthread by hand secures the Igniter in place. is the Thermal Sensor. reverse of the steps shown to remove the Thermal The photo at right shows the Using a 7/16” open end here.

Sensor completely.

Igniter removed and the small wrench loosen the brass nut Philips head screw that holds The photo at right shows that secures the Thermal it in place. the Thermal Sensor being Sensor to the Pilot Burner. slid out of the Pilot Burner. new Igniter On the underside the pilot Using a 7/16” open end wrench, Installation of the This image shows the sensor Once loose unthread byofhand is the reverse of the removal burner, the red highlights Installation loosen the bras nut that secures completely removed from the to remove thesquare Thermal of the old Igniter. of the new Thermal Sensor.

Thermal Sensor. Once loose, pilot burner. Insert the new Sensorthe completely.

Thermal the Sensor is the by hand to remove the sensor and screw back into reverse ofunthread the Using a Philips headsteps screwshown sensor completely place.

Using a 7/16” open end driver here.remove the screw wrench loosen the brass nut securing the Igniter to the Pilot Burner Assembly as that secures the Thermal shown in the photo at right.

Sensor to the Pilot Burner.

Once loose unthread by hand to remove the Thermal Sensor completely.

REASON FOR A FAULTY

Valve Box (FG-ICB)

The most common reason is that the 120VAC power was sent directly to the Valve Box. This means that the power supply was bypassed and then damaged the valve.

THIS IS NOT COVERED BY OUR WARRANTY The Power Supply (GOE-30VDC) takes the 120VAC power and converts it to 30VDC to operate the gas valve.

Controller Controller Replacement Replacement Replacing the Controller in the Valve Box Step Step 1 1 Using Using a wrench a wrench loosen loosen thethe brass brass fitting fitting protruding protruding from from thethe outlet outlet of of thethe AWEIS AWEIS as as shown shown in the in the photo photo at right. at right.

Step Step 2 2 Remove Removethethebrass brass fitting fitting and and lid lid of the of Controller Replacement the boxbox to to expose expose thethe Controller Replacement inside inside of the of the box. box.

Step 1 Step 2 Step 1 Step 2 Using a wrench loosen the Remove the brass a wrench loosen Remove the and brass Step 1 Step Step 4 of4 the Step 2 rass fitting Step protruding fitting lid Step 3 3the from fitting protruding from as Using a wrench loosen the fitting and lid of the brass fitting Remove the brass fitting and lid of the he outlet of the AWEIS box totheexpose theharness Unplug the wire wire harness LiftLift the controller controller outout of of protruding from the outlet box utlet of the AWEIS asup of theUnplug AWEIS box to expose the inside of the box. toinside expose the hown inthe the photo atupright. of the box. from from thethe oldold controller. controller. boxbox as shown as shown in the in the photo photo as shown in the photo at right. nthe in the the photo at right. inside of the box.

Plug Plug thethe wire wire harness harness intointo at right. at right. thethe newnew controller. controller.

Reassemble Reassembleboxboxin inthethe reverse reverseorder ordershown shownin in these these steps. steps.

Step 4 Step 3 Step 4 Step 3 Unplug the wire harness ift the controller up out of Unplug the wire harness he controller up out of from the old controller. he box as shown in the photo from the old controller. x as shown in the photo Plug theharness wire harness Thermal Thermal Sensor Sensor Replacement Replacement t right.

Plug the wire into into ht. the new controller. the new controller.

Reassemble Reassemble box inboxthein the in reversereverse order order shown shown in these steps. these steps.

At At right right is aisphoto a photo of the of the sideside f the of the Pilot Pilot Burner.

Burner.

Step 3

Step 4

Highlighted Highlighted by by a red a red rectangle rectangle Lift the controller up out of the box as shown in theThermal photo at right.

Thermal Sensor Replacement s the is the Thermal Thermal Sensor.

Sensor.

Sensor Replacement

tright is a photo of theofside is a photo the side ilotPilot Burner. the Burner.

hted by a by redarectangle ghlighted red rectangle Using aSensor. a7/16” 7/16”open openendend hermal heUsing Thermal Sensor. wrench wrench loosen loosen thethe brass brass nutnut hatthatsecures securesthetheThermal Thermal Sensor Sensor to to thethe Pilot Pilot Burner.

Burner.

Once Once loose loose unthread unthread by by hand hand o toremove removethetheThermal Thermal Sensor Sensor completely. completely.

a 7/16” open open end end ing a 7/16” loosen the brass nut

Unplug the wire harness from the old controller. Plug the wire harness into the new controller. Reassemble box in the reverse order shown in these steps.

TheThe photo photo at at right right shows shows thethe Thermal Thermal Sensor Sensor being being slidslid outout of the of the Pilot Pilot Burner.

Burner.

Installation Installationof ofthethenewnew Thermal ThermalSensor Sensoris isthethe reverse reverse of the of the steps steps shown shown here. here.

The photo at rightatshows The photo right shows the Thermal Sensor Sensor being being the Thermal slid outslid of the outPilot of theBurner.

Pilot Burner.

Installation of theof new Installation the new Thermal Sensor is the is the Thermal Sensor reversereverse of the steps of theshown steps shown here. here.