1080 CF Valve Replacement Instructions

Transcription

1 Overview This kit includes the newer American Flame gas control valve designed specifically for the 1080 CF gas fireplace. If you have a 1080 CF fireplace, and you are uncertain as to whether this kit is required, please contact Travis Industries with your serial number. The serial number can be found by removing the glass frame, and pulling out the aluminum tag chained to the right side of the fireplace (see the illustration below). Travis Industries will keep records of all 1080 CF fireplaces that have been modified to the new valve. By contacting Travis, you will be able to verify if your fireplace has been updated. The following serial number ranges have the older valve: 1080 CF serial number through NOTE: If you wish to verify the valve directly, the American Flame gas control valve has a code stamped on the back (see the photo to the right). If you have a gas control valve with a code starting with 06, you must replace the gas control valve (for example: 0643 ). Gas control valves with a date code of 0730 (or greater) are the newer design, and do not require replacement. Page 1 of 16 Printed 10/24/07 Travis Industries, Inc.

2 Packing List Valve Assembly (includes valve, valve tray, pilot assembly, manifold, and gas connections) Hex Key (used to remove the plugs from the burner manifold) RMA Slip (very important must be completed and shipped back with the old valve for credit and to verify records) UPS Pre-Paid Return Slip (attached to the outside of the box in a shipping envelope) Installation WARNING: Installation must be made by a qualified installer. WARNING: Make sure gas has been shut off to the appliance. Turn off the key-valve (if applicable) or shut off the main gas line to the residence. 1. Remove the glass frame, logs, embers, and firebacks from the fireplace (installation instructions are included at the back of this instruction sheet). Remove the floor and ember tray following the directions below. Page 2 of 16 Printed 10/24/07 Travis Industries, Inc.

3 2. Remove the firebox floor following the directions below. 3. Remove the burner following the directions below. Page 3 of 16 Printed 10/24/07 Travis Industries, Inc.

4 4. Remove the valve assembly following the directions below. 5. Reach behind the valve assembly and turn off the built in shutoff valve. Page 4 of 16 Printed 10/24/07 Travis Industries, Inc.

5 6. Disconnect the flexible gas line from the gas control valve. Make sure to hold the elbow securely while removing the flex line. 7. Bend the heat shield above the gas control valve up 90. This allows access to the top of the valve. 8. Remove the pilot flame control connector from the valve (orange and white wire). HINT: A wiring schematic is included on page 14 of these instructions for reference. Page 5 of 16 Printed 10/24/07 Travis Industries, Inc.

6 9. Remove the burner flame control connector from the valve (green and white wire). 10. Remove the battery box connector from the receiver module (4 wire connector). 11. Remove the two power wires from the receiver module. WARNING: To prevent dislodging the wire from the connector, pull on the connector, not the wire. Page 6 of 16 Printed 10/24/07 Travis Industries, Inc.

7 12. Reach in behind the valve assembly and disconnect the DCMD (red and black) wires leading from the gas control valve to the battery box. WARNING: To prevent dislodging the wire from the connector, pull on the connector, not the wire. 13. At this time the valve assembly (gas control valve, receiver module, etc.) may be removed from the fireplace. Place the valve assembly on a suitable work surface so the necessary components (receiver module with bracket, orifices) may be switched from the old valve assembly to the new valve assembly. 14. Remove the igniter ( I orange) and sensor ( S white) wires from the receiver module. WARNING: To prevent dislodging the wire from the connector, pull on the connector, not the wire. Page 7 of 16 Printed 10/24/07 Travis Industries, Inc.

8 15. Remove the two screws that hold the receiver module plate to the bracket attached to the valve. 16. Remove the bracket attached to the valve. NOTE: a grounding wire is attached to the bracket with one of the screws take care to prevent damage to the wire. Page 8 of 16 Printed 10/24/07 Travis Industries, Inc.

9 Special Instructions for LP (Propane) Fireplaces The replacement valve assembly is configured for natural gas. If you are installing this valve assembly into a fireplace with LP (propane), you will need to do the following items. Switch the Pilot Hood to LP Install Rate Screw (from old valve assembly) and Adjust the Input Shaft Page 9 of 16 Printed 10/24/07 Travis Industries, Inc.

10 17. Attach the receiver module bracket to the new valve assembly using the screws removed in step 16. While attaching the bracket, insert the grounding wire under the screw and secure. 18. Attach the receiver module plate to the new valve assembly. NOTE: Make sure to attach the receiver module in the correct orientation see photo below. Page 10 of 16 Printed 10/24/07 Travis Industries, Inc.

11 19. Re-attach the igniter ( I orange) and sensor ( S white) wires to the new valve assembly. NOTE: see the wiring schematic on page 14 for further details. 20. Re-attach the burner and pilot flame control connectors to the new gas control valve. Both sets of wires and connections on the gas control valve are labeled. 21. Bend the heat shield on the new valve assembly to the horizontal position. Page 11 of 16 Printed 10/24/07 Travis Industries, Inc.

12 22. Place the valve assembly back into the firebox and re-attach the DCMD (red and black) wires. Re-attach the connector from the battery box to the receiver module. Re-attach the power wires to the receiver module. 23. Re-attach the flexible gas line to the gas control valve. Make sure to hold the elbow securely while attaching the flex line. Turn the shutoff valve to the on position. Page 12 of 16 Printed 10/24/07 Travis Industries, Inc.

13 Leak Testing the Appliance Because of the unique configuration of this fireplace, the gas connection can not be leak-tested in a normal manner. Follow the steps below to leak test the fireplace gas connection. We suggest that you have immediate access to an external shutoff valve while conducting the leak test. Disconnect the main burner control wire connection (white in green wires) from the gas control valve WARNING: Failure to disconnect the main burner control wire will allow gas to flow to the main burner orifices while leak testing creating an extreme fire and gas-leakage hazard. With the valve assembly inside the firebox, turn the fireplace on using the remote stand back from the pilot, it will light (it may take some time as the gas line purges air). If unit does not spark, check your connections. Once the pilot has lit, you may now start to leak test the gas control valve and gas line connections. Pay close attention to the flexible gas line (both) sides and the gas connections leading from the valve. Any leaks must be properly fixed prior to completing the installation. Replace the main burner control wire after turning the pilot off. Page 13 of 16 Printed 10/24/07 Travis Industries, Inc.

14 24. Re-install the valve assembly, taking care to prevent pinching any wires or gas lines. 25. Remove the plug from the manifold on new valve assembly (use the included hex key). Remove the orifice from the old valve assembly, apply thread-sealant, and attach to the new valve assembly. Orifice Sizing for 1080 CF: Rear NG # 33 LP # Replace the burner and restore the fireplace to the correct configuration. Page 14 of 16 Printed 10/24/07 Travis Industries, Inc.

15 Re-packing and Shipping the Old Valve Assembly (a) Complete the RMA/ Service form. No credit will be issued if the form does not include: Serial Number; Date of Service; and, Customer Name and Address. If the fireplace is still in dealer inventory, substitute the dealer name for customer name. (b) Place the old valve assembly into the box the new valve assembly was shipped in. Make sure to place the foam along the bottom, sides, and top of the box as shown below. (c) Attach the pre-paid shipping label over the old shipping label and ship via UPS to Travis Industries. NOTE: The shipping label is shipped inside a shipping envelope attached to the outside of the box. Page 15 of 16 Printed 10/24/07 Travis Industries, Inc.

16 Wiring Schematic Page 16 of 16 Printed 10/24/07 Travis Industries, Inc.

17 Log Set Installation Overview Finalizing the Installation (for qualified installers only) 43 Below is a picture detailing log placement for this fireplace. Follow the directions on the following pages to place the logs correctly. Lower Rear Log Upper Rear Log Right Twig Left Twig Front Log Center Ember Travis Industries _000

18 44 Finalizing the Installation (for qualified installers only) Lower Rear Log The lower rear log has two holes that insert over pins on the grate and log bracket. Travis Industries _000

19 Upper Rear Log Finalizing the Installation (for qualified installers only) 45 The upper rear log has two holes that insert over pins on the lower rear log. NOTE: With the upper rear log in place, the logs may tend to tilt backward slightly. Once the twigs are installed, the logs will remain in place. Travis Industries _000

20 46 Finalizing the Installation (for qualified installers only) Center Ember Note how the pointed end faces inwards. Push the ember back so it rests against the air channel (and not over any burner holes). Travis Industries _000

21 Upper Left Log Finalizing the Installation (for qualified installers only) 47 Place the upper left log as shown below. The front log has a hole that fits over the pin on the grate. This flat portion rests on the left side of the grate. This bracket is for the front log. Slide the log back until the back edge of the log rests against the bracket. When in place, the front log should look like this. Travis Industries _000

22 48 Finalizing the Installation (for qualified installers only) Left Twig This notch fits over the grate. The left twig has a hole for the pin on the front log. Note how the left twig fits directly over the grate. Travis Industries _000

23 Finalizing the Installation (for qualified installers only) 49 Right Twig The right twig has a hole for the pin on the rear log. This notch fits over the grate Note how the notch in the right twig fits over the grate. Travis Industries _000

24 50 Finalizing the Installation (for qualified installers only) Ember Placement Place the embers along the firebox floor and burner to help conceal the burner. Make sure none of the embers are directly over the burner holes. See the photo below. Note how the embers do not cover any burner holes. Place the embers around the burner to create a realistic effect. Rock Wool Placement The rock wool must be pulled apart and made into a thin gauze prior to placing over the burner. See the illustration below for details. NOTE: Propane (LP) units use a lighter amount of rock wool than natural gas units. Preparing the Rock Wool: The rock wool comes in one clump. Tear off dime sized clumps and flatten. Then pull on the wool to create gauze-like pieces. The wool glows best when very thin and porous. Place small pieces of rock wool next to the burner holes in visible locations. Place the rock wool sparingly so it does not cover large areas of the burner. WARNING: If the rock wool is too thick or placed so it obstructs the flow of gas, sooting will occur. Travis Industries _000

25 56 Finalizing the Installation (for qualified installers only) Fireback Installation (Rectangular ) WARNING WARNING Turn off gas to the appliance and make sure it has fully cooled prior to conducting service. The firebacks are fragile (especially after being burned) handle with care. NOTE The firebacks are 2-sided. When installing, use the desired pattern. Also make sure the rear brick is correctly positioned. Herringbone Pattern Brick Pattern UP UP 1 Remove the glass frame, logs, and grate. 2 Remove and discard the ember tray and burner tray cover.. Remove this clip on the firebox floor. Loosen the screw and remove the clips located on the firebox ceiling (both sides). a b c Remove and discard the ember tray and the burner tray cover. Remove this clip on the firebox floor. Bend the clip upwards to form a 90 angle. d Figure 38 Travis Industries _000

26 Finalizing the Installation (for qualified installers only) 57 3 Install the firebacks following the directions below. b Place the rear firebacks in place. The lower fireback rests on the tabs on the back wall of the firebox. Hold them in place while installing the side firebacks. Left Floor Fireback Upper Rear Fireback Lower Rear Fireback Place the floor firebacks in place. a Right Floor Fireback Slide the side firebacks into place and replace the clip to secure (both sides). c Side Fireback d Replace these clips. Figure 39 4 Restore the fireplace to the correct configuration. Travis Industries _000