Electrical Troubleshooting Guide · Troubleshooting Flow Chart Page A - D Wiring Diagram Page E Gas...

RING OF FIRE“

Electrical TroubleshootingGuide

Troubleshooting Flow Chart Page A - D

Wiring Diagram Page E

Gas Ignition Control Module Page F

Component Location Identification Page G

AC Voltage Testing Page H

Continuity Testing Page I

Low Level Water Switch Testing Page 1

High Temperature Water Snap Switch Testing

Safety Relay Testing (Early Models Only) Page 3

Master Control Module Testing (Input Side Only) Page 4

Remote Switch Testing Page 5

Master Control Module Testing (Output Side) Page 6

Lighting Testing Page 7

Water Pump Testing Page 8

Purging Air Page 9Gas Control (Pilot Side/Burner Side)

Incoming Voltage Testing Page 10Gas Control Pilot Operator and Burner

Operation Continuity Testing Page 11

Incoming Gas Pressure Testing Page 12

Outgoing Gas Pressure Testing Page 13

Flame Rectification Page 14 -15

RING OF FIRE

ACopyright ' 10/27/04 Travis Industries, Inc.

ROF TROUBLESHOOTING FLOW CHART

Simultaneouslydepress light and

water button.

Hold forapproximately

5 seconds,then release.

Switchpad lights

up

YES

NO

¥ Check for low water (fill if needed)

¥ Check for 110 AC incoming voltage

¥ Check low water switch (see page 1)

¥ Test high water temperature snap disk (see page 2)

¥ Continuity test relay (see page 3)

¥ Check for over heated water snap disk

¥ Disconnect power from master control module and ¥ ¥ ¥ ¥ continuity test transformer - Black and White wires (see page 4)¥ Disconnect Blue wires output side of Master Control and conduct test #4 on page 6)

Continuity - GoodNo Continuity - Replace Module

¥ Disconnect switch pad wires from master control module¥ and conduct Tests 1, 2, 3. (see page 5)

Ropelights come on NO

¥ Check control module output side - (Red & White wires) for 110 v AC (See Test #1 page 6)

¥ Test lighting components (see page 7)

YES

WaterComes

onNO

NEXT PAGE

¥ Check control module output side (Yellow and ¥White wires) (See test #2 on Page 6)

¥ Check water pump (See page 8)


PushFlameButton

Switchpad lights

up

YES

NO ¥ Conduct test # 3 on Test Page #3

Ignitionstarts to

clickNO

¥ Verify AC voltage on output of master control module¥ - Grey wires (See test #3 on Test Page #6)

¥ If all of above check out good - replace the gas ¥ ignition control module

NEXT PAGE

B

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Copyright ' 10/27/04 Travis Industries, Inc.


Pilot flamecomes on

NO

YES

¥ Check gas shut offs- main shut offgas control valve

¥ Check fuel supply (LP)

¥ Check wiring to make sure ignition control module is¥ properly wired (see Wiring Diagram pages E & F)

¥ Check orifice for blockage

¥ Purge air (see Test Page #9 for procedure)

¥ Check that 30 VAC is present at the P & C terminals¥ of the wiring harness that connects to the valve

(see Test Page #10) see pilot side test

¥ NO VOLTAGE - Replace the ignition control module

¥ Continuity check the pilot side of the gas control valve¥ (see Test Page #11)

¥ CONTINUITY - Good¥ NO CONTINUITY - Replace gas control valve

¥ Test incoming gas valve pressure (See Test Page #12)

¥ Check pilot tube for blockage

¥ Replace the gas control valve

Ignition sparkturns off

NO

NEXT PAGE

No Flame Rectification

¥ Check pilot flame for proper contact with spark electrode(see Page #14)

¥ Check all ground connections (valve & ignition control)(see Page #15)

¥ If all of the above are good - replace the ignition control¥ module

C

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Burnercomes

on

NO

YES

¥ Check burner orifice for blockage

¥ Check that 30 VAC is present at the M & C terminals of the wiring harness that connects to the valve

(see Test Page #10)

NO VOLTAGE - Replace the ignition control module

¥ Continuity check the burn side of the gas control valve(see Test Page #11)

¥ CONTINUITY - Good¥ NO CONTINUITY - Replace gas control valve

¥ Test incoming gas valve pressure (see Test Page #12)

¥ Check outgoing pressure (see Test Page #13)

¥ IF NO PRESSURE - Replace gas control valve¥ IF PRESSURE IS PRESENT - Blockage is in burner supply tube, burner orifice or burner

Burner stays onfor desired time

NO

YES

¥ Did you exceed automatic 2 hour shut down?

¥ Wind interruption - ROF will lose flame rectification and automatically relight

¥ Lack of primary air see service bulletin

¥ Condensation effecting electronic ignition control see service bulletin

END

D

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Wir

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Gas V

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Blu

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Flo

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Sw

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Wate

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Sw

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Gro

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hite

Bla

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Red

White

Yello

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Gre

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Red

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Yello

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Rem

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Rin

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ire

Co

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Red

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Ign

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780-7

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24V

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(M

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MG

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Pu

mp

Bla

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RING OF FIRE

Igni

tion

Con

trol

Uni

tR

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tSha

w 7

80-7

15 U

Gas

Val

veR

ober

tSha

w 2

0001

PE

RC


Gas Ignition Control ModuleI.P.I.

F

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TH

PV

OPT Sensor

MVMV PV

TR

Ground

Igniter

Accessory Term.

Grey-Power Wire

Blue-Pilot Valve

Not Used

Common SharedBetween Pilot & Burner

Not Used

Green-Ground

Orange-Igniter

Not Used

Red-Main Valve (Burner)White


Total ComponentsMasterControlModule

WaterConnection

Gas IgnitionControl Module

SafetyRelay

Newer ModelsHave This BuiltInto the Circuitry ofMaster Control Module

Remote SwitchTerminal

Low LevelWater Switch

Electronic GasControl Valve

N. C. HighTemperatureSnap Disk140ß

G

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When Testing ROF Componentsfor AC Voltage

AVCAVC

¥ The ROF contains 110 VAC circuits (caution-shock potential)

¥ The ROF contains low voltage circuits 24-30 volts AC

H

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When Testing ROF Componentsfor Continuity

A. Disconnect all power - No live voltage

B. Isolate the component being tested by disconnecting it from the electrical circuit

Use this scale setting

Do not use audiblebeep scale

I

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RING OF FIRETEST Page #1

TESTING ROF COMPONENTS

TESTING LOW WATERLEVEL SWITCH - N.O. Switch

No ContinuityHas Continuity - GoodNo Continuity - Replace

Disconnect Wires Disconnect Wires

1Copyright ' 10/27/04 Travis Industries, Inc.


TESTING THE WATERTEMPERATURE SNAP DISK

CHECK

Continuity Test

COLD = ContinuityWARM = No ContinuityCOOLED = Continuity

If the snap disk does not perform as described• in the above box, it is defective and should be• replaced.

Disconnect all wiresto snap disk

N.C. 140ß F Snap Disk

2




2

¥ Reconnect Blue & White¥ (#7 & #8)

¥ Disconnect Brown & Black wires

¥ Turn on 110 VAC (power)

¥ Continuity test switch (#3-#5)

¥ Continuity - Good No Continuity - Defective Replace Relay

1

¥ Disconnect relay wires (#7 & #8) Blue & White

Continuity TestRelay Coil (#7 & #8)

Continuity - Coil Good

No Continuity - Defective ¥Coil-Replace Relay

1 23 45 6

7 8BROWN WIRE

WHITE W

IRE

BLUE WIRE

BLACK WIRE

1 23 45 6

7 8BROWN WIRE

WHITE W

IRE

BLUE WIRE

BLACK WIRE

3


Note: Found on older units.Newer models have thisbuilt into the circuitry ofmaster control module. Ifthis relay is not seen onthe outside of the mastercontrol, skip this page.



Continuity Test

CONTINUITY -Transformer isgood

NO CONTINUITY- Transformer isdefective. Replacethe Master ControlModule

Disconnect the BLACK and WHITE wires from the•incoming power.

Continuity test the incoming side of the step down transformer. (black and white wires)

Master ControlModule

Incoming 110vPower Wires

Testing Master Control Module - Incoming Side

4




NOReplace Remote

Switch

NOReplace Remote

Switch

NOReplace Remote

Switch

TESTING REMOTE SWITCH

LIGHT

WATER

FLAME

RemoteSwitch

GREENYELLOW

REDBROWN

1

2

3

4

Test# Test Circuit Continuity No Continuity

1 2

1 3

1 4

Continuity

Continuity

Flame

Push in LIGHT

button

Push inWATERbutton

Push in FLAME

button

1

2

3

TestPoints

YESGOOD

YESGOOD

YESGOOD

Disconnect Green wire from the terminal block

before testing

Testpoints

5




ACV

TESTING CONTROL MODULE - Output Side

Testing AC voltage output of control module Disconnect each set of wires as you test them With power ON and the light, water and flame buttons pushed ON,

• conduct the following test

Test# Test Circuit Reading Low or No

Voltage

AC Volts

AC Volts

Lighting

Water Pump

1

2

3

TestPoints

110 - 125VAC Replace Module1 2

3 4 110 - 125VAC Replace Module

7 8

AC Volts

Gas ControlUnit

30 VAC Replace Module

RED

BLUE

WHITE

WHITE

YELLOW

BLUE

GREY

GREY

1

2

3

4

Ground

MasterControlModule

Test Points

6


5

6

7

8

Replace Module 30 VAC WaterSafety4

AC Volts

5

6

BLACK

WHITE

INPUTSIDE Output Side



TESTING LIGHTING CONNECTOR

TESTING ROPE LIGHTING

Continuity: Good

No Continuity: Defective - Replace

7


JumperWire

Continuity: Good

No Continuity: Defective - Replace



TESTING WATER PUMP

Continuity: Pump is Good

No Continuity: Defective - Replace Pump

Continuity Test

8




PURGING AIR

¥ To purge air, loosen the inlet gas pressure port.• When gas is present, re-tighten.

Purge AirThrough InletGas PressureTap (3/16 Hex)

ON/OFFGas Cock

IncomingGas Port

9




TESTING THEROBERTSHAW GAS VALVE

Electrical Connections

GroundConnections

Main Burner &Pilot Burner

Operator

Top of Operator

ContinuityTest of Pilot

Operator

ContinuityTest of Burner

Operator

NOTE: DO NOTCONDUCTCONTINUITYTEST USINGTHE AUDIBLETONE SCALE

M C P

11


Note: Disconnectall wires fromgas valve

Pilot or Burner Coil Side Continuity TestContinuity - Component GoodNo Continuity - Component Defective

Replace Valve



TESTING GAS PRESSURE

INCOMING PRESSURE TESTING1. Turn off gas to Ring of Fire2. Remove inward pressure plug (3/16” Hex)3. Screw barbed adapter into pressure port4. Zero out pressure gauge5. Slip hose over barbed connector6. Turn on gas, turn on fountain and flame7. Read pressure8. Turn fountain off, turn gas off9. Disconnect hose10. Remove barbed connector and replace hex plug

Inlet GasPressure Tap(3/16 Hex)

ON/OFF Gas Cock Incoming Gas Port

ROF IncomingGas Pressur e

NG = 7 W.C.

LP = 13 W.C. If incoming gas pressure is incorrect,•check for adequate pipe sizing and/or

•call your gas supplier.

11. Test for gas leak at replaced plug

12




TESTING GAS PRESSURE

OUTGOING PRESSURE TESTING1. Turn off gas to Ring of Fire2. Remove outward pressure plug (3/16” Hex)3. Screw barbed adapter into pressure port4. Zero out pressure gauge5. Slip hose over barbed connector6. Turn on gas, turn on fountain flame7. Read pressure8. Turn fountain off, turn gas off9. Disconnect hose10. Remove barbed connector and replace hex plug

ROF OutgoingGas Pressur e

NG = 3.5 W.C.

LP = 11 W.C.Gas Outlet ToMain Burner

Reversible (NG & LPGas) Regulator Body

Burner Outgoing GasPressure Tap (3/16 Hex)

Pilot Outlet toPilot Burner

•

11. Test for gas leak at replaced plug

13




Flame Rectification

Proper FlameElectrode ContactFlame completelyimmerses electrode tip

Results in good flamerectification keeping the ROF

Improper FlameElectrode ContactFlame lifts up and is too faraway from electrode tip

Results in no flame rectificationshutting down the ROF

Improper FlameElectrode ContactFlame is too small to reachelectrode tip

Results in no flame rectificationshutting down the ROF

14




¥ Make sure the ground on the valve and the ground on the ignition control are sound

GroundConnections

15



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