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2015 Electronic Ignition for Hearth Professionals TomTom Parks, COASTROAD North Central Hearth Patio and Barbecue Association
2015
Electronic Ignition
for Hearth Professionals
TomTom Parks, COASTROAD
North Central Hearth Patio and Barbecue Association
Slide 1 Electronic
Ignition
for Hearth
Professionals
NCHPBA
2015
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Slide 2
About me . . .
• In construction for
last 30 years
• Degree in
electronics
engineering
• In hearth business
since 1998
• Install & service
everything we sell
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Slide 3
About me . . .
• VP and GM of Hearth
& Patio shop
• NFI Master Hearth
Professional
• NFI Instructor since
2008
• On committee that
works on HPBEF Gas
Hearth Systems
manual and test
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Slide 4
Hearth Products Controls
One way to categorize hearth
appliances is by the control valves
they use, which fall into three
general categories:
1. Manual (hand-powered)
2. Millivolt (self-powered)
3. Electronic (externally powered)
o v e r v i e w
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Slide 5 Manual Valves
Require the control valve to be
turned on by hand
May or may not use a flame
detection for safety (pilot light
with thermocouple)
o v e r v i e w
May include a thermostatic
function (thermostat bulb) to turn
burner on and off with changing
room temperature.
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Slide 6
Millivolt valves
Self-powered system
Require a continuous pilot
and thermopile
The thermopile supplies enough voltage
(about a 1/2 volt) to energize a coil inside
the valve to open
The millivolt system allows a separate
control device, such as a wall thermostat,
wireless remote control or wall switch to
operate the appliance
o v e r v i e w
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Slide 7 Electronic valves
By definition, electronic valves use an
external power source, DC or AC
May be remote controlled
without a separate control
module (latchtap)
May include flame height
operation (vari-tap or Maxitrol GV34)
Some systems also include electronic
ignition, using an automatic heat source
instead of a standing pilot for burner
ignition.
o v e r v i e w
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Slide 8
Electronic Ignition
There are several types of electronic ignition, categorized by the ignitortype.
1. I.P.I. – intermittent pilot ignition
Spark-to-pilot ignition
H.S.I. – hot surface ignition (glow plug)
H.W.I. – hot wire ignition (like H.S.I.)
2. D.S.I. – direct spark ignition
(Direct ignition might also be HSI or HWI)
o v e r v i e w
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Slide 9
Electronic
Ignition History
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Slide 10
Electronic Ignition Issues
Early systems used furnace
technology – DSI or HSI & AC
Early systems were much higher cost compared to
standing pilot systems - $500+
h i s t o r y
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Slide 11
Electronic Ignition Problems
Early systems not understood by many of the service people
in the hearth industry
Early systems prone to some
heat transfer problems(things melted)
h i s t o r y
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Slide 12
Electronic Ignition Problems
Early systems had peculiarities
(example: polarity sensitive)
Early systems leaned towards hot surface ignition – trouble
prone in the hearth environment
h i s t o r y
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Slide 13
Electronic Ignition Past
Systems only in markets where
law prohibited standing pilots
(decorative category)
Not all manufacturers produced them
Early systems were dependent on 110 VAC
h i s t o r y
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Slide 14
Today’s
Electronic Ignition
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Slide 15
Current Day Electronic Ignition
Most manufacturers are using
some form of electronic ignition
There is a better understanding of
systems among hearth
professionals
Intermittent pilot types are most
prevalent
t o d a y
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Slide 16
Current Day Electronic Ignition
AC with battery back up is
available
Total battery operation is
available
Battery with manual override is
available (thermocouple)
AC with battery backup &
thermopile is available
t o d a y
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Slide 17
The Future of Electronic Ignition
Consumer demand – energy & cost
savings – standing pilot will burn $30+/-
per month when using propane (about
a litre per day)
Energy regulations may requireelectronic ignition in the near future
Convenience – no bending down to
light pilot
t o m o r r o w
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Slide 18 Current Electronic Ignition
Gas Valves Control Center Ignition Volts
Honeywell Honeywell I.P.I 24 AC
VCG Ambient I.P.I 6VDC/batt/TP
Maxitrol Maxitrol I.P.I/Manual 6VDC
Dexen Dexen I.P.I 3VAC/DC batt
American Flame SkyTech I.P.I. 6VDC/batt
SIT SIT I.P.I. 7VDC/6VDC
t o d a y
. . . and more
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Slide 19
Intermittent Pilot Ignition
or Spark-to-Pilot ignition
Also referred to as I.P.I.
A pilot lights first, and then
the burner lights
When the burner goes out,
the pilot goes out (unless on
continuous pilot)
technical
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Slide 20
Intermittent Pilot Ignition
The system goes to retry if the
pilot goes out unexpectedly
This safety feature is made
possible by Flame Rectification
(or other flame sense)
technical
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Slide 21
The Concept
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Slide 22
BurnerPilot Burner
Grounds (3)
valve
Flame Rod
control module
ignitor
I.P.I.
PS
technical
switch -open
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Slide 23
V
1. Ignitor is powered
I.P.I.
technical
switch - closed
PS
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Slide 24 1. Ignitor is poweredMost have a trial period, and
then the system will go to “lock out”
Some older styles had a 3X try rate, and then would go to lock out
To reset the control, turn off & back on or interrupt the power (switch off, thermostat down then up)
technical
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Slide 25
2. Pilot valve is powered & gas goes to pilot
I.P.I.
PS
technical
switch - closed
V
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Slide 26
V
3. Pilot flame is sensed
DCV
I.P.I.
technical
pilot v.
signal switch - closed
PS
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Slide 27
Flame Rectification
Zone 1 Excess fuel (no combustion)
Zone 2 Combustion
area is ionized and electrons flow
Zone 3 Excess Air
Flame is a conductor of electricity
technical
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Slide 28
Pilot Burner Flame Rod
4 X 1• Flame conducts
electricity
• Four+ times the surface area changes the
voltage from AC to DC
Flame Rectification
technical
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Slide 29
to illustrate . . .
technical
to 1
Can you predict the score on this game?
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Slide 30
to illustrate . . .
technical
***
*
*
*
*
* *
*
*
*
Electrons moving from sensor to pilot head (big target)
Electrons moving from pilot head to sensor (small target)
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Slide 31 Sensing the flame
Once the pilot is proved (flame
rectification) the ignitor will cycle
off, the pilot stays burning
If the ignitor doesn’t quit and the
pilot is on, then there is a flame
sensing problem that must be
resolved.
technical
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Slide 32
V
4. Main valve is powered and burner comes on
DCV
I.P.I.
technical
switch - closed
PS
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Slide 33
V
5.Pilot light goes out, burner goes out
DCV
I.P.I.
technical
switch - closed
PS
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Slide 34
V
6. System Goes Into Relight Mode
I.P.I.
technical
switch - closed
PS
Pilot sensing starts over . . .
Can the sensor be faked out?
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Slide 35
V DCVAC
I.P.I.
technical
switch - closed
Shorted Flame Rod to Pilot Hood
PS
Now for D.S.I. . . .
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Slide 36
V
Burner
Grounds (3)
valve
Flame Rod
Control Center
Ignitor
D.S.I.
technical
switch - open
PS
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Slide 37
V
D.S.I.
1.Spark ignition is initiated
technical
switch - closed
PS
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Slide 38
V
D.S.I.
2.Main burner gas is released
technical
switch - closed
PS
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Slide 39
V
D.S.I.
3. Flame is sensed, gas stays on
technical
switch - closed
PS
DCV
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Slide 40
Control Center OperationI P I D S I
Initiate spark Initiate spark
Open Pilot Gas Open Main Gas
Proof of Pilot Proof of Fire
Open Burner Gas Safety Monitor
Safety Monitor
technical
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Slide 41
Visual
Identification
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Slide 42 Power Supplies
6 Volt DC
battery pack
technical
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Slide 43
Power Supplies
Battery Appliance
Cavity Mounted
6 Volt DC
(Maxitrol)
technical
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Slide 44 Power Supplies
Battery Back-up
Cavity Mounted
3 Volt DC
(Dexen)
technical
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Slide 45 Power Supplies
Transformer
110 VAC
to 3 Volt AC
(Dexen)
technical
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Slide 46 Power Supplies
Transformer110 VAC to 24 VAC
Black WiresHigh Voltage Side
Screw Terminals
Low Voltage Side
technical
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Slide 47 Transformer Construction
Coloured WiresLow Voltage Side
Black and White WiresHigh Voltage Side
Transformer110 VAC to 24 VAC
technical
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Slide 48
Electronic Controls
DEXEN I.P.I.
3 Volt AC
technical
AC adaptor
connection
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Slide 49
Electronic Controls
Label on Dexen
control module
technical
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Slide 50
Electronic Controls
American Flame
6 Volt DC
technical
AC adaptor
“I” ignitor
connection
“S” flame sensorconnection
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Slide 51 VCG Control Module
technical
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Slide 52 Sit ProFlame 1 DFC
technical
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Slide 53
SIT Proflame 1 wiring
technical
(digital flame control)
regulator
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Slide 54 SIT ProFlame 2 IFC
(integrated fireplace control)
technical
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Slide 55 SIT ProFlame 2 IFC
technical
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Slide 56
Electronic Controls
Inside of a
Control
Module
technical
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Slide 57 Typical Control Labeling
M(V) Main valve
P(V) Pilot valve
C Common (might be ground)
S Sensor
I or IGN Ignition (spark electrode)
TR Transformer
TH Thermostat
V Valve
L 1 Hot 110v(black) lead
L 2 Neutral 110v (white) lead
G or GND Ground
technical
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Slide 58 I.P.I.
Sense Rod
Spark Electrode35,000 Volts
Pilot Burner
ignitors
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Slide 59 I.P.I. Ground
Shield
sensing
rodNitride
Hot Surface Ignitor
24 VAC6 Second Warm Up
Pilot
Burner
ignitors
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Slide 60 I.P.I. – VCG
ignitorsensing
rod
Pilot
Burner
ignitors
Thermo-pile
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Slide 61 IPI - VCG Pilot Assembly
ignitors
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Slide 62 D.S.I.
Flame RodIgnitor
35,000 Volts
Ground
ignitors
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Slide 63 D.S.I.
Ground
Combination Ignitor/ Flame Rod
35,000 Volts
ignitors
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Slide 64 D.S.I.
Spark Electrode35.0000 Volts
Ground
Flame Rod
ignitors
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Slide 65 DSI wiring diagram
technical
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Slide 66 Honeywell
Out Pressure
Pilot Adjust
WireTerminals
Regulator Cover/Spring
Change
In Pressure On/off Control
valves
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Slide 67 Honeywell
PV
MVCOM Terminal
Labels
valves
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Slide 68 Robertshaw Operator
Head
RegulatorFlip for Gas
Change
On/Off Control
Terminal Detail
P
C
M
Robertshaw I.P.I.
valves
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Slide 69 Robertshaw valve detail
On/OffControl
valves
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Slide 70
Flame heightServo Motor
Regulator ChangeTurn Screw
American Flame
valves
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Slide 71 American
Flameburner
pressure
incoming
pressure
gas rate set
screw
conversionPilot
Terminal
Burner
Terminalpilot adjust
valves
convertible
regulator
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Slide 72 Maxitrol GV60
Pilot Adjustment accessible thru hole in “ON”
8-wire connection
Servo Motor micro-switch
Manual Override
Servo Motor Connections
Flame Adjustment
valves
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Slide 73
Maxitrol GV60
PressureTaps
valves
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Slide 74
Maxitrol GV60Servo Motor
valves
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Slide 75
Maxitrol GV60
technicalEuro pilot assembly
AC adapter
Battery
compartment
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Slide 76
VCG signature command
Servo Motor
valves
“out”pressure
pilot adjust
battery boxcontrol
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Slide 77 valves
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Slide 78 valves
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Slide 79
VCG Wiring Diagram
technical
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Slide 80
“Out”(manifold) pressure
port
“In” pressure
port
High/Low Flame Control
valves
DEXEN
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Slide 81 SIT PF2 IFC valve
technical
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Slide 82 Wiring Harness
wires often labeled
technical
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Slide 83
Troubleshooting
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Slide 84
Operational issues
Won’t light
Won’t stay lit
Special considerations for Intermittent/continuous pilot
Pilot “on demand”
Anti-condensation setting
Cold weather mode
troubleshooting
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Slide 85
Operational issues
troubleshooting
especially when vertically vented
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Slide 86
Operational issues
troubleshooting
In the case of an aggressive vertical vent,
the pilot will light, proof, and the burner
will light, but the oxygen will be
immediately consumed, so the main
burner and pilot will weaken quickly and
the flame sense will be lost at the pilot.
It will retry a few times, but eventually it will
go into lockout and will have to be reset.
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Slide 87
Helpful Tip
troubleshooting
If the customer prefers not to
leave the pilot on continuously,
turning the pilot on 10-15
minutes before lighting the
main burner will prime the vent
system and alleviate some of
the glass condensation issues.
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Slide 88
Gas valve/control damage
High voltage (lightning,
jumper wires)
High Pressure
High water (flooded)
High temperature (no shield)
troubleshooting
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Slide 89
Ignition Control Damage
technical
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Slide 90 technical
Digital multimeter
Need Direct Current volts.
down to millivolts(tc, tp)
Need Alternating Current
volts (house current,
transformers)
Need Ohms (resistance)
Continuity is nice
Rarely need Amps
(current), except for HSI
systems
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Slide 91 troubleshooting
Isn’t technology great?
Snap a photo of a correct setup before you take it apart. You can use it for reference when you put it back together.
Program all of the manufacturers’ technical help numbers into your phone.
Use a tablet to download installation manuals in the field (using your phone “hotspot”).
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Slide 92
VV
GT H
T R
I G NS
Voltage
AC
Proper “IN” Voltage
Proper “OUT” Voltageto valves
Testing Ignition ControlsLED Flashes
Troubleshooting Code
Power supply
troubleshooting
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Slide 93
DEXEN
WireLabels
troubleshooting
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Slide 94 Gas Control Valves
Pilot Gas Terminal
Gas Type Marking
troubleshooting
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Slide 95 DEXEN
Remove to Test Pilot Coil for Continuity
troubleshooting
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Slide 96 Testing Pilot Coil
Continuity
Ohms
troubleshooting
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Slide 97 Gas Control Valves
Main Burner Terminal
troubleshooting
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Slide 98 Troubleshooting Check List
technical
No spark?
Check power (transformer or batteries)
Check connections, esp. grounds
No pilot flame?
Check gas pressure
Check voltage at valve
No burner flame?
Check connections again
Check voltage at valve
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Slide 99
Troubleshooting Check List
No spark Test Correction
110v power Voltage Check breaker/outlet/switch
Transformer Voltage Replace
Spark Location
Visual Fix/Replace wire,
cracked electrode
Bad Control Replace
technical
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Slide 100 Troubleshooting Check List
NO Pilot Gas Test Correction
Wire Harness Continuity Fix/Replace
Ignition Control Voltage Replace
Pilot Coil Continuity Replace Valve
Gas Flow Pressure Turn on gas
Gas Flow Visual (lighter)
clean orifice,
bleed air
Gas Flow All above Replace Valve
technical
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Slide 101
Troubleshooting Check List
Ignitor keeps sparking Test Correction
Flame Rectification Visual Flame Contact
Flame Rod Continuity Replace
Ground connection Continuity Repair
Ignition Control Switch
leads
Replace
Pilot assembly Switch
leads
Clean/replace
troubleshooting
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Slide 102
Troubleshooting Check List
NO Burner Gas Test Correction
Main Valve wire Continuity Fix/Replace
Ignition Control Voltage Replace
Burner Coil Continuity Replace Valve
Gas Flow low “In” P Supply Pres.
Gas Flow No “Out” P Replace Valve
Gas Flow “Out” P Tube/Orifice
troubleshooting
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Slide 103 SummaryElectronic ignition is here to stay
Systems are getting better
Someday that may be all there is
Electronic Ignition is simple, less
maintenance in some ways
Process of elimination finds most trouble quickly
Fewer pilot cleaning issues, TC or TP issues
Embrace it! This is why you’re still in business
You keep up with technology
Customers trust you to know what you’re doing
This new technology helps you to keep your edge
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