Manual revision August 2015 p/n

Transcription

1 Manual revision August 2015 p/n

2 Mendota Proflame Training Table of Contents PROFLAME I Proflame I Wiring/part information Page 4 Proflame I Digital Fireplace Burner Control box wiring Page 5 Proflame I Light & Pilot continues to Sparks (FCM Fuses) Page 6 Proflame I IPI switch issues OR lockout mode Page 7 Proflame I Rear burner & fan issues Page 8 Proflame I Rear flames or Grounding issues Page 9 Proflame I unit does respond to remote or spark Page 10 Proflame I How to reset lockout mode (Proflame I only) Page 11 Proflame I & Proflame II switch locations Page 12 Proflame II table of contents Page 13 2

3 Mendota Proflame Training Table of Contents PROFLAME II Proflame II Wiring and parts numbers page 13 Proflame II Plug locations & wiring part numbers page 14 Proflame II Wiring Schematic page 15 Proflame II How to check revision code page 16 Proflame II How to Sync remote to fireplace/insert page 17 Proflame II Fireplace/insert doesn t work page 18 Proflame II Burner problems page 19 Proflame II Fan problems page 20 Proflame II Light problems page 21 Proflame II Reset Lockout and clear error codes page 22 Proflame II Putting remote in IPI or CPI page 23 Proflame II Dimming light with remote page 24 Mendota technical information page 25 thru 61 3

4 NG regulator LP/Propane Regulator Remote PF Refer to page 27 for correct p/n for each model Battery Cover PF receiver # way hood #2 For complete valve assembly see parts manual #3 *New 2way or 3 way* Flame Rect. Rod only triangle or 2 way hoods ONLY Door Removal Tool HA Fans Bulb Lens Lens Retainer Bracket HA Round light gasket Dimmer #1 FCM, powered up by 120 VAC, sends out 6.5 to 7 VDC on 3 com wire to receiver. #2 Receiver is brain box / switching box and sends 6 VDC to Digital Valve control box #3 Digital Valve box controls ignition and flame rectification along with VDC to pilot & burner coils on valve 4

5 Flame Rod plugs in here Ground to chassis from bd. Must Be ground 3 from board. Spark Rod plugs in here Pins Valve resistance, 362 Ohm + or 68 degrees Pin 1 RED, (DXV Non LX units only, battery back up wire) (manual flame regulation) Pin 2 RED, (DC supply voltage 6VDC, (LX Units from receiver & Non LX from transformer) Pin 3 BLACK, (DC Ground) Pin 4 GREEN, (TH, label only) Pin 5 BLUE, (IPI, CPI wire) Pin 6 WHITE, (THTP, label only) Pin 7 ORANGE (wire to open pilot coil, 6VDC to open, ¼ to 1 volt to hold open) Pin 8 Green (wire to open burner coil, 6VDC to open, ¼ to 1 volt to hold open) Pin 9 Green/Yellow (Ground wire to valve) Pin 2 to Pin 3, At least 6 VDC (anything less than 6 VDC may be bad/faulty FCM or low/week batteries) Using a Jumper from Pin 4 to Pin 6 should attempt to spark & light pilot & then burner 5

6 1. Light does not work a. Is light turned on via remote?(finger pointing at button PF1 only) b. Is dimmer in the OFF position? Turn dimmer on, Pro Flame I only i. Make sure dimmer is turned up, not at lowest setting c. Check to see if bulb was installed or not burned out G9 25 watt bulb d. Check for loose or miss plugged spade at connections e. Check voltages at light dimmer switch 120 VAC f. Is the dimmer bad? (disconnect and ohm dimmer with volt meter) g. Check voltages at FCM 120 VAC, & verify plugged into correct outlet (AUX OUT) h. Check voltage at AUX plug in on FCM i. Possible bad dimmer ii. Possible bad bulb ii. Possible bad Fan Control Module (FCM) Fuses in the FCM Fuse F1=6A 250 volt 6.3x32mm (Fast) Fuse F3=5A 250 volt 5x20mm (Fast) 2. Pilot keeps sparking all the time, with pilot lit or with pilot not lit a. Is the gas turned on to the unit? b. Blocked pilot orifice or pilot tube? Insect? Inswool/rock wool? Air/gas port on pilot blocked? c. Is the flame from the pilot wrapping around the rectification rod? d. Is Flame rectification rod dirty (use 3m pad to clean / sand rectification rod and pilot hood) e. Check for broken ceramics that might short out flame rod (Can you wiggle flame rod?) f. Check for loose connection on Flame rectification rod at digital fireplace burner control module g. Check orange wire on valve for DC power. Does pilot coil open by using the battery test? h. Make sure pilot assembly is grounded or that valve is grounded (green/yellow wire) 6

7 3. Standing Pilot Switch doesn t work a. Unit in lockout mode? See page 11 b. Check the standing pilot switch and verify it s plugged in correct. i. Unhook switch, jumper past switch with a jumper wire ii. Jumper Pin 5 & 6 on Digital Fireplace box, Blue & White wire c. What is DC voltage on pin 2 & 3 of Digital Valve Control box (see page 5) d. 3Com wire connector, take DC voltage measurement on outside 2 wires (grey & red wire) i. Possible bad IPI / CPI Switch. ii. Possible bad Fan Control Module. iii. Possible bad wiring harness (see current parts manual for p/n) 4. Fireplace or Insert will not light burners. Has light and blower control only. a. Is the unit in lockout mode? See page 11 to clear lockout mode b. Is remote in a thermostatic mode (ON or SMART)? i. if in thermostatic mode, is set temperature set lower than room temp? c. Is the receiver in the OFF position? d. Is the 14 pin plug in the back of the receiver plugged in tight? (Pro Flame I only) e. What is DC voltage on pin 2 & 3 of Digital Valve Control box (see page 5) f. What is the DC voltage going to Green Coil & Orange coil on valve? g. Is the Orange pilot wire hooked to the valve? What is DC voltage of orange wire? h. Do the coils click by doing a battery test on coil tabs? i. Is there a blockage from an insect or inswool (was pilot off over the summer?) j. When you lose AC voltage, you ll lose fireplace, UNLESS batteries are installed. k. Has DFC connector been removed from unit (pertains to older PF 1 model units only) If DFC connector has NOT been removed 1. Shut off all AC power and remove batteries before cutting out DFC connector. 2. Cut 1 wire at a time, cutting out DFC connector 3. Strip & wire nut red wires together, and strip & wire nut black wires together. 3. Turn back on AC power, if this does not work, check power on wires for 6 volts DC 4. If still no power, check your FCM for AC power and check your wire connections. Remember, batteries are only used when AC power to fireplace is not present 7

8 5. Rear Burner Won t work (won t turn on or won t turn off) a. Is burner on via remote? b. Was pilot was shut off over the summer? Possible insect blocking gas to burner. c. Check to verify 14 pin connector is plugged into back of receiver correctly d. Check to make sure rear solenoid is plugged in (pink & blue wire) e. Check voltage on connectors (DC voltage 6 VDC pink & blue wires) f. Possible bad Rear Solenoid Valve g. Possible bad receiver. Ensure step c was checked before replacing receiver. h. Does the pilot still spark? If so see page 6 (step 2) 6. Fans won t work a. Are the fans on via the remote? b. Is remote in Thermostat mode? See bottom of page c. Check A/C voltage at FCM & check power switch d. Is fan plugged in the FAN outlet on FCM? e. Unplug fans, plug cord into an extension cord, do they work? f. Check all connections to fan. g. **DXV DT3 units will have a snap disk & rheostat. Jumper or heat up snap disk. FV units do not have snap or rheostat disk! i. Possible bad Fan Control Module ii. Possible bad blower p/n right** left ** *blowers are reversed in FV41 & FV41Arched & FV44 & FV33 & ML47 & ML39 *DXV units DXV DT3 units only use a snap disk p/n & Rheostat p/n Note, in OFF THERMOSTAT mode, do blowers work? Note, blowers won t turn on until unit has been on 5 minutes in Smart or On thermostat mode. Blowers will shut off 12 minutes after unit has reached set temp in Smart or On thermostat mode. In Off Thermostat mode you should have blower control right away & blowers will shut off with remote 8

9 7. NO flame/btu adjustment (flame height) a. Check gas pressure. IN & OUT taps with regulator on high front burner on. Verify pressures are changing from high to low with manometer. b. Make sure Regulator/stepper motor is connected (motorized) c. Verify an insect isn t restricting gas to burners (pull burners and inspect) d. Check to make sure you have correct orifices in front and rear burner **LP/Propane units may not see the flame height change compared to NG NG & LP/Propane units will change water columns when regulating BTU output. e. Possible bad receiver (rare) but if not regulator, could be receiver. Thought, if you have receiver, swap out first since it s easier to change! If the unit still does not work, swap back receiver and change reg/stepper motor **1st Verify using manometer. If water columns don t change **2 nd Replace regulator (again rare but could be receiver) 8. Ground Issue, Unit sparks intermittently and beeps a. Check for loose ground wire (yellow/green wire) b. Verify Digital fireplace control box, ground wire is grounded b. Fireplace will beep and then spark and may not light pilot if ground is not connected. Ground wire needs to be grounded 3 from box 9

10 9. Fireplace or Insert does not spark, & fireplace/insert has no blowers or light a. Make sure remote is not in thermostat mode (Smart or On) b. Make sure FCM switch is ON ( - = ON, O = OFF) c. Check FCM for AC power and check 120v Outlet for AC power (3 rd outlet) d. Check fuse panel for tripped breaker that powers insert/fireplace e. Run extension cord to unit to see if you can plug in FCM You should have CPI pilot along with light and blower control in lockout mode, provided remote is in OFF thermostat mode Refer to page 40 if you do not know how to operate remote f. Remember there are 2 fuses in FCM Fuse F1=6A 250 volt 6.3 x 32mm (Fast blow fuse) Fuse F3=5A 250 volt 5 x 20mm (Fast blow fuse) g. Has FCM had the heat shield update kit done? FV44 or FV33 the FCM will be on the right outside of firebox Heat Shield kit FV44 & FV33 is HA PF1 units only (Fv44 s/n 3128 and below only FV33 s/n 1193 and below only) FV 41 the FCM will have a metal shield and insulation shield Heat Shield kit FV41 is HA PF1 units only s/n 1277 and below only 10

11 Mendota Proflame Training How to reset lockout mode Proflame I You may be able to clear lockout mode by turning remote on & then OFF *if not, follow the steps below to clear lockout mode. 1. Power off hand held remote (house icon and temp showing if off). 2. Slide receiver slide switch to OFF position. 3. Toggle Standing pilot light switch to OFF, see page 12 for switch locations *doing this will verify the unit is not calling for ignition or heat* 4. Wait 30 seconds after steps 1 thru 3 to reset LOCKOUT mode. 5. Slide receiver to REMOTE position, Power ON remote, then power OFF remote. Lockout mode should now be cleared. You may now proceed to toggle standing pilot switch to up position to light the pilot flame. If the pilot does not attempt to light after this, you ll want to check voltages and connections at *NOTE, Digital in valve lockout control mode box. you will still have blower and light control in OFF thermostat mode Proflame error codes they are as follows (diagnostic light not provided) 1 Red flash = Low Battery (used to power unit during AC voltage loss) 2 Red flashes = Parasitic flame failure, internal test to board failure. 3 Red flashes = Lockout mode 11

12 FV41 & FV46 switch locations PF1 units CPI/IPI switch PF2 units Master Stop Switch *Note, location of the switch in PF1 & PF2 units are the same. The function of the switch in PF2 though is a Master stop switch. In PF2 CPI is control by the remote, please see page 22 SYNC SWITCH FV41 & FV46 SWITCH SHOWING ON PF1 units switch is used for standing Pilot (on pilot should be lit, CPI mode. When down, IPI pilot only will only be lit when unit is calling for burners) PF2 units switch is a stop switch only. The ON position allows unit to work, the OFF position prevents burners from working but allows standing pilot, CPI mode to work. 12

13 Proflame 2 Proflame Wiring 2 Wiring Diagram Diagram For complete valve assembly see parts manual *New 2way or 3 way* Flame Rect. Rod only triangle or 2 way hood ONLY 2 way hood Refer to page 29 for correct p/n for each model Master Stop switch Door Removal Tool HA PF II control bd Battery backup Pack Battery Backup wire harness Bulb Lens Lens Retainer Bracket HA Round light gasket

14 Additional black ground wire to chassis of unit is tied into ground (ties into green ground wire) X1 AC power to board Wire harness p/n Bussmann S506 Mendota Grainger p/n = 2ABY8 Radio Shack p/n = X10 & X11 Power to fan and light Wire harness p/n X3 Flame rod Flame Rect. Rod p/n X2 Spark Rod p/n X4 Master Switch harness only p/n X6 regulator X7 rear solenoid Rear solenoid extension cable p/n X5 Battery power, coils, valve ground Wire harness p/n X0A LED code flashing X8 Sync button relocated to front of unit Wire harness p/n

15 Proflame 2 Wiring Schematic Spark Rectification Master Stop Switch X2 X3 X4 X5 X6 X X8 X10 X11 Error Code LED Flashing 15

16 Proflame 2 Control Board Back of PF2 control board p/n (Revision Code in parenthesis) *When installing a Mendota* Always remove the logs from foam packaging & set them up at the time of start up along with train home owner in proper use of fireplace and remote operation Light 2. Spark 3. Master 4. Rear 5. Fan 6. Pilot 7. Burner

17 How to sync remote to fireplace or insert PF2 1. Install batteries into remote, make sure AC power is turned on to unit 2. Press sync button on unit, you should hear module chime, see page Press the ON/Off button on remote, you should hear chime Once sync button is pressed you have 7 seconds to sync remote to unit Master switch position does not matter when trying to sync remote you must have master switch in ON position to operate the burners if the control module was replaced, you have to re-sync remote to unit Master stop switch does NOT kill CPI pilot Master switch, shown in OFF position On/Off button Thermostat button Mode Button Up down Battery backup socket PF2 Units Can be relocated to surround if desired Sync button FV33i & FV44i switch locations on insert 17

18 Mendota Proflame Training 1. Fireplace or insert does not work a. Check for all 3 (Thermostat mode via remote? Master Stop switch? Lockout mode?) b. Does the remote communicate with fireplace? You should have light and blower in OFF thermostat mode, even when in the lockout mode. If not, you will need to re sync remote to fireplace. See page 17 c. Verify the Master Switch is in the ON position. See page 12 i. Make a jumper to bypass switch connector X4 see page 14 ii. This will bypass switch and wiring. Master switch will kill IPI pilot it does not kill CPI pilot d. Verify that connector X5 is plugged into control bd. See page 14 e. Check for AC power on connector X1, also check for any error code flashing f. Check external fuse on control board, please shut off AC power before pulling fuse to check, 3.15 amp fuse also see page 14 next to X1 connector for fuse part number h. Does board have error code flashing? See codes below. 1 Red flash = Low Battery (used to power unit during AC voltage loss) 2 Red flash = Parasitic flame failure, internal test to board failure. See ** below 3 Red flashes = Lockout more (see page 22 to clear lockout mode / error code) Valve resistance is 362 Ohm + or 68 degrees **Parasitic flame failure could be board or valve Always check screws on green connectors make sure they are tight on PF2 control bd Master stop switch does NOT kill CPI pilot 18

19 Mendota Proflame Training Burner Problems 2. Pilot lights & continues to spark OR pilot keeps sparking all the time and doesn t lit. a. Is the gas turned on to the fireplace? b. Possible Spider mite? Or blockage in air/gas port? Or Inswool/rock wool in pilot? c. Is pilot flame hitting the rectification rod/flame rod? Blocked pilot orifice or pilot tube? d. Does the flame rod have a deposit built up on it? Clean with 3M sand pad e. Does the pilot flame rod have cracked or broken ceramics? f. Pinched, melted, broken, or not plugged in flame rod wire to control bd. g. Does remote control light and blower in off thermostat mode? i. If no, re-sync remote to control board, see page 17. h. Is remote in thermostatic mode (SMART or ON), put in OFF mode, does it work? i. Is Master switch in ON position? Do you have blower and light control? i. Unplug X4 and verify connections are tight & not lose, plug back in X4. ii. Make a jumper and jumper across X4 (this will bypass switch, then test) j. Is green wire plugged onto valve/burner coil correctly? Voltage on green wire? k. Do you hear the valve click by doing the battery test? l. Verify connector X5 is plugged into control bd. (unit would still spark) m. Does valve open with battery? Pilot must be lit (if no, then replace valve) **If the sync button on fireplace/insert is pressed and remote is not powered on within 7 seconds to sync communications, then pilot will attempt to light. 19

20 Mendota Proflame Training 3. Blower will not work on fireplace or insert. a. Make sure blowers are turned on via remote not off. i. Put remote in OFF THERMOSTAT mode, do blowers work? ii. Note, blowers won t turn on until unit has been on 5 minutes in Smart or On thermostat mode. iii. Blowers will not shut off until 12 minutes after unit has reached set temp in Smart or On thermostat mode. iv. In Off Thermostat mode you will have blower control right away & blowers will shut off with remote b. Make sure you have AC power to control board and check external fuse c. Verify connector X10 on Control board is plugged in correctly & screws are tight. d. Check connector X10 for AC power i. If no power to blowers, remote is synced, and blowers are toggled on via remote, and external fuse checks ok, replace control board ii. If power at X1 and fuse checks ok, and blowers are not on, X10 shows 120 VAC, and is plugged in correctly, replace blowers or check all wiring for blowers. iii. **please verify all steps above were checked before replacing both blowers. Always check screws on green connectors and make sure are tight on PF2 control bd *blowers are reversed in FV41 & FV41Arched & FV44 & FV33 & ML47 & ML39* 20

21 Mendota Proflame Training Light does not work 1. Check to see if light is on via remote. 2. Check to see if bulb was installed or burned out G9 25 watt bulb (ohm bulb using volt meter) 3. Check all connections going to light socket (see above picture) 4. Check to see if connector X11 has AC power with light toggled on via remote a. If no power at connector X11 and light is on via remote and blower works, replace control board b. Also, check screws on green connector are tight, along with all wiring going to light socket. Always check screws on green connectors and make sure are tight on PF2 control bd ** Do not touch bulb with bare hands, the oil from your hands will be heated up via the heat from the fireplace and shorten the life of the light bulb 21

22 Mendota Proflame Training How to reset Lockout on Proflame II & clear error code You may be able to clear lockout mode by turning remote on & then OFF *if not, follow the steps below to clear lockout mode. 1. Press On/Off button on remote transmitter to turn OFF remote transmitter. 2. If you have a snowflake present on the display, press the MODE button on remote transmitter and then toggle to IPI mode. page Shut AC power off the control board (breaker or unplug board) 4. Toggle master switch to OFF see page 12 * Doing this will verify the unit is not calling for ignition* 5. Wait 30 seconds after you perform the steps 1 5 above to reset LOCKOUT mode. 6. Turn on AC power & Power on remote, and then power remote back off. 7. Toggle Master switch back up (on position) and turn unit on via remote or toggle switch back to CPI using remote to light the pilot flame. If the pilot does not attempt to light after this, you ll want check connection on X5 and connector X4 *In lockout mode you will still have CPI pilot, Along with blower control and light control in the Off thermostat mode. Master stop switch does NOT kill CPI pilot 22

23 How to put PF 2 Remote into CPI or IPI Mendota Please note, snowflake under the room temp means that the unit is in CPI mode and pilot should be lit. If there is no snowflake under house temp, then unit is in IPI mode and pilot should not be lit. IPI mode. Once set to the desired settings, press On/Off button to activate the fireplace. 23

24 New Proflame 2 Remote adjustments Mendota Picture on left is showing light in step 5, step 6 will show HI on remote 24

25 Mendota Proflame Training Following pages are miscellaneous information for Mendota Battery back up locations PF I and PF II page 26 FV fireplace wall box locations page 27 Converting new Pilot assembly page 28 Mendota s three pilot assemblies page 29 FV 44i and FV 41 pilot shield installation page 30 FV46 Pilot Shield installation page 31 FV33i and DXV35 Pilot shield installation page 32 Modern unit pilot installation page 33 Light bulb install instructions & Lens clip install instructions page 34&35 FV 44i & FV33i Primary air settings/adjustments page 36 FV 33i Secondary air settings/adjustments page 37 Exhaust damper settings FV & DXV units page Proflame IPI / CPI & Master stop switch install instructions page 40 Proflame Remote functions & modes page 41 How to determine mantel depth above Mendota units page42 Proflame starting s/n of PF2 units page 43 Proflame programming features PF1 & PF2 units page 44 Mendota AFUE & P4 Efficiency Ratings page 45 FV 41 & FV46 Guide Removal Chart page 46&467 Electronic Ignition Pilot air to gas mixture port locations page 48 SIT Tech bulletin on using silicone Page 49 SIT Tech bulletin on PF remote Page 50 Suggested tools & Three 30 second checks Page 51 Mendota Dealer website page 52 Mendota dealer repair kits page 53&54 Understanding PF1 vs. PF2 with CPI vs. IPI page 55 DXV 60 & 45 rear burner instructions page 56 Insert Direct Vent liner kits Page 57&58 Re-Syncing a 874 remote to head unit Page 59 Things to check when odors are present Page 60 How to re-gasket a glass Page 61 Mendota Visible Glass & Frame sizes Page 62 25

26 FV Insert Proflame 2 Battery Backup and Switch Location 26

27 Proflame 1 wall box FV41 & FV46 Proflame 2 battery box FV41 & FV46 INSTALLATION: It is important that you install the supplied harness, outlet box and cover plate on the left side of this appliance. The DC Power Inlet harness is 6 feet long, allowing installation of the single gang box up to 5 feet to the left of this appliance. Install the single gang box at a maximum height of 18 to the center of the box or match the mounting height of this single gang box with the height of other AC outlets that are installed in the same room as this appliance. WARNING: DO NOT STAPLE the 6 DC Power Inlet Harness to the wall studs. 27

28 28 NAT should be stamped into metal for Natural Gas Or LP with a RED dot and hole should be stamped into metal for LP/Propane Gas

29 Mendota ZC Fireplace and Insert Models DXV35DT3&4 LX, DXV45DT3&4 LX, ML47, FV41, FV46, FV33i, FV44i units produced after August 1, 2011 utilize a quick-conversion design that incorporates a pushpull tab to convert between NG and LPG configurations. Some existing stock of Fireplaces and Inserts may contain the original Round Hood SIT pilot assembly. NOTE: The new Quick-Conversion design pilot assemblies are backwards compatible and can replace the Round Hood Design Pilots. It is important to make certain that you select the proper Pilot Flame Hood design when replacing the pilot assembly. Two designs exist: 2-way Hood and 3-way Hood. Make certain you use the proper Hood Configuration for your specific model along with converting to proper gas type. ML47 & ML39 DT4 units &FV41 Arch & FV34 M = Modern Please note FV46 uses a 2 way pilot hood with pilot assembly 29

30 All Mendota units had pilot shields installed as of July 2013 Please note, if the FV41 or FV44i has the round pilot hood p/n assembly you will have to change to a to install a new pilot shield 30

31 Mendota Proflame Training p/n HA All Mendota units had pilot shields installed as of July

32 Mendota Proflame Training Pilot Shield DXV 35 DT3 & FV33i p/n HA All Mendota units had pilot shields installed as of July

33 Mendota Proflame Training All Mendota units had pilot shields installed as of July 2013 Pictured is a FV Modern pilot shield. To install, just lay shield over pilot assembly or you can use two self tappers to tap into air box to hold shield in place HA Pilot Shield Enamel Black HA Pilot Shield Enamel Silver HA Pilot Shield Enamel Copper All Modern hoods should come with panoramic liner. 33

34 Round replacement gasket for accent light p/n #

35 35

36 90 deg mark is referenced as flat, closing the air opening down as far as possible FV33i is approved for 70 venting FV44i is approved for 50 venting FV33i 4 x3 Vent adaptor HA FV44i 4 x3 vent adaptor HA FV44 & FV33 4 x 3 Gasket

37 SECONDARY AIR INTAKE DAMPER The SECONDARY AIR INTAKE DAMPER is located in the convection air cavity on top of the firebox. It is accessible through the ½ slot that is located directly above the glass frame s top surface. The SECONDARY AIR INTAKE DAMPER is factory adjusted to full restriction, which is about ½ closed. Adjust this damper to fine tune the Rear Flame Height. Specifically, if the rear flame is licking the top Baffle Brick, open this damper. In most installations, the Primary Air Intake Damper adjustment will suffice. However, if the vent system restricts air flow and the rear flames appear too tall and lick the baffle brick completely, you may choose to open the Secondary Air Intake Damper to reduce the rear flame height. This feature will be of the most use in LPG applications. To adjust, use a 3/8 Open End Wrench to loosen the securing hex nut 2 turns ONLY. Use Glass Latch Tool to Slide Damper Bracket to the right towards CLOSED or to the Left towards OPEN. 37

38 *Please see next page for chart FV41 units & Fv46 Damper Adjustment Use a flash light to look into the convection air cavity and note the Damper Position Indicator. Hook glass latch tool in the hole at the end of the damper rod, release. Use a flashlight to inspect the damper position. The base of the damper adjustment rod has a pointer that indicates the position of the damper. This fireplace is equipped with a vent damper system that can be adjusted using the glass latch tool. Locate damper adjustment rod above the glass frame in convection chamber at the center. Note: if this fireplace s vent is terminated vertically, the damper position may be FULL OPEN or FULL CLOSED. If this fireplace s vent is terminated horizontally, DO NOT CLOSE the vent damper completely. (please see chart on following page) Adjust position of damper by judging the flame characteristics after 30 minutes of burn time. If the flames ghost off burners or if sooting occurs [in LPG units], open the vent damper FULLY and work backwards in increments to determine the correct damper position for that particular installation. You must have the unit running 20 minutes prior to set the damper properly **Always inspect damper position before installing vent pipe 38

39 Also applies to the M50 The table below provides a general guideline for the Exhaust Restrictor Position. Further fine tuning and adjustment may be required, as the performance of each vent system will vary. RESTRICTOR POSITION FULL OPEN 1/4 CLOSED **Note, damper could be at 12 or 6 o clock position from factory **Always inspect damper position before installing vent pipe VENTING CONFIGURATION Minimum Up and Out horizontal terminations, 1:1 vertical to horizontal run ratio, horizontal run is longer than vertical run with a horizontal termination Horizontal Terminations where the vertical run is longer than the horizontal run. 1/2 CLOSED Vertical Terminations with no horizontal runs. Vertical or Horizontal Terminations with vertical runs 3/4 CLOSED exceeding 15 feet. FULL CLOSED NEVER FULLY CLOSE THE EXHAUST RESTRICTOR 39

40 Mendota Proflame Training How to adjust IPI switch PF1 units or Master Stop Switch PF2 units 1. LOOSEN AND REMOVE OUTER NUT. 2. REMOVE SWITCH FROM MOUNTING HOLE. 3. LOOSEN INNER NUT SO 1/8" gap is present between switch body and inner nut. 4. REPLACE WASHER ON SWITCH SHAFT AND INSERT IN MOUNTING PANEL HOLE. 5. SECURE SWITCH TO MOUNTING PANEL USING OUTER NUT and tighten. 40

41 Mendota Proflame Training Looking at the screens, can you tell the difference between a PF I remote & PF II remote? Also see page 42 for serial number break between PF1 and PF2 All Proflame remotes use a frequency of 315 MHZ Power button Thermostat button Off = manual On = thermostatic Smart = Thermostatic, modulates the BTU output A Proflame I remote will have a house icon to the lower right of the room temperature. Where Proflame II remote will just have temperature Up & Down Button Function or Mode Button 1. BTU output, raises or lowers the BTU s of the unit 2. Fan Speed, Controls the speed of fans 3. Light, Turns the light on or off, and in PF II will control the intensity of the light 4. Rear burner, Turns the rear burner on or off 5. In a PF II the 5 th icon is NOT used 41

42 Mendota Proflame Training How to figure combustible mantel height Unit Hearth required Raised, no hearth required Mantel Depth X factor (see below) DXV 60 18" 9" 2.25 DXV 45 14" 6" 1.75 DXV 35 12" 6" 1.75 FV M 50 24" 12" M 27 12" 6" FV 46 18" 6" & 41Arch 18" 6" 2.25 FV 44i 16" 6" 1.5 FV 33i 16" D 40 16" 6" 1.5 D 30 16" 6" 1.5 ML47 Zero 7-7/8 ** 1.5 ML39 Zero 7-7/8 ** 1.5 (** To bottom of unit to bottom guide 7-7/8 & from bottom of unit to glass on ML 47 & ML39 = 8.25 **) For every 1" the unit is raised above the floor, you may reduce the hearth protection by 2 To figure mantle height Use mantel depth factor (see chart above) & multiply by depth of mantel = distance/inches require above fireplace EXAMPLE : DXV 45 customer wants 13" mantel depth 13 x 1.75 = required distance above top opening of fireplace to underside of mantel A combustible trim or mantel leg or that comes down along the side of a unit is a 1:1 measurement. Example, a combustible mantel leg comes down alongside the unit and protrudes out 5. This would mean that the combustible mantel leg would need to be 5 away from the glass frame of the unit. *IF the mantel or mantel leg or trim piece are painted, stained, or cleared. Over time it can discolor, darken, bubble or crack. Always use hi temp paints. 42

43 Mendota Proflame Training Serial Number range of units when PF2 started FV 46 serial number 289 and up PF2 FV 41 serial number 2225 and up Traditional PF2 FV41 Modern 201 and up PF2 FV41 Arched serial number 1 and up PF 2 units DXV 45 DT 3 LX serial number and up PF2 DXV45 DT4 serial # PF 1 only (no remote installed) DXV45 DT4 LX serial # DXV 35 DT3 LX serial # and up PF2 DXV35 DT4 LX serial # and up PF2 FV 44 i 5620 thru 5661 & 6162 & up Traditional PF2 FV44 i 252 and up Modern PF2 FV 33 i serial number 2673 and up Traditional PF2 FV33 i Modern 126 and up PF2 ML 47 Linear serial number 1 and up PF2 units FV34 serial number 1 and up PF2 43

44 Mendota Proflame Training Change remote from F* to C* (temperatures) (PF1 & PF2) Press and hold the Thermostat button and O (bottom button) at the same time and release To put remote in Child Lockout or take out of Child Lockout (PF1 & PF2) Press and hold the ^ (up button) and the O (bottom button) at the same time and release ENABLE / DISABLE Thermostat on a Mendota Proflame II remote only ***This feature is not available on Proflame I remotes Take one battery or all batteries out (this will work just removing one battery) Press and hold down the Thermostat button on the remote Install the 3 rd battery while still holding thermostat button down If you see Set and the thermostat option is now enable If you see Clr the thermostat option is now disabled Repeat the procedure if you did not see the Set or Clr to remove or add the option back to the remote. ENABLE / DISABLE functions on the Mendota Proflame II remote only Take one battery or all batteries out. (this will work just removing one battery) Press and hold both the ON/OFF and the MODE button at the same time Install the 3 rd battery while still holding both buttons (keep holding buttons once 3 rd battery is installed then release the mode button only) The screen will show either Clr or Set with the 1 st mode being your option to disable or enable. 1.Clr will remove the mode by using the up or down arrow while still holding both buttons (icon will disappear once removed, or icon will show up again once added) a.you will use the mode button to move to the next function, please note you should never program out the fan or CPI/IPI mode on the remote. 2.Set will add that mode by using the up or down arrow while still holding both buttons (icon will disappear once removed, or icon will show up again once added) a.you will use the mode button to move to the next function, please note that you should never program out the fan or CPI/IPI mode on the remote. ENABLE / DISABLE functions on the Mendota Proflame I remote only * It is not possible to program out thermostat mode on PF1 remotes Take one battery or all batteries out. (this will work just removing one battery) Press and hold both the ON/OFF and the MODE button at the same time Install the 3 rd battery while still holding both buttons (keep holding both buttons and once 3 rd battery is installed then release the mode button only) The screen will show CFG You can now use the up or down arrow button to program out the function on the remote. Please note that you should never program out the fan feature on the remote 44

45 Mendota Proflame Training ALL AFUE RATINGS CERTIFIED USING U.S. DOE 10 CFR PART 430. ALL P.4 RATINGS CERTIFIED USING CSA.P MODEL AFUE RATING P.4 NG P.4 LPG D % D % DXV % FV34 N/A DXV % N/A N/A DXV % DXV % N/A N/A FV33i 75.9% FV33 M 74.6% FV44i 74.0% FV44 M 77.8% FV % FV41 Arch N/A FV41 M 72.0% FV % M % M % ML-39 LINEAR N/A ML 47 LINEAR 70.0%

46 Mendota Proflame Training FV46 & FV41 removal guide chart DECORATIVE FRONT TYPE INNER GUIDE OUTER GUIDE FULL VIEW/ NO FRONT USE DISCARD DUCHESS OVERLAY (FV 41 only) USE DISCARD WILLOW DOOR KIT HOMESTEAD DOOR KIT GRACE RECTANGLE GRACE ARCHED STELLA TRADITIONS BENTLEY DOORS (front comes with guides) PIONEER WILLOWBROOK DISCARD DISCARD USE USE USE USE DISCARD USE USE USE USE DISCARD DISCARD DISCARD DISCARD DISCARD DISCARD DISCARD You will need to know at the time of install what front is being used to remove the correct guide The guides can be removed either by drilling out rivets, or removing screws. 46

47 Mendota Proflame Training Mendota ML 47 Guide Removal chart DECORATIVE FRONT TYPE INNER GUIDE OUTER GUIDE NO FRONT / SCREEN ONLY USE DISCARD TRADITIONS USE DISCARD WILLOWBROOK USE DISCARD GRACE (see notes below) CAN USE IF *** = Use INNER GUIDE if finishing material is LESS than 2" thick. Grace front over laps inner guide and finish material, brackets only extend 2 CAN USE IF *** USE IF ## Must order^^ MUST USE IF ## = Use OUTER GUIDE if finishing material is MORE than 2" thick. Grace front will be recessed in outer guide. *** NOTE: Grace fronts can use the inner guide and will overlap finish material if finish material is 2" or less in thickness and the material has a uniform surface less than 2 (tile or granite) ## NOTE: Grace fronts must use outer guide if material is thicker than 2" or has a uneven surface (stone or rock) If unsure or you do not know what finish material is to be used, you may want to use the outer guide. ^^ Unit no longer comes with outer guides. If you need the outer guides, you will need to order them, Part number for outer guide kit is HA You will need to know at the time of install what front is being used to remove the correct guide. The guides can be removed either by drilling out rivets, or removing screws. 47

48 Mendota Proflame Training Electronic ignition pilot assemblies showing AIR to GAS mixture port ** ** You can not drill out the air opening on the SIT pilot assembly **Always ensure air to gas port is free of any debris as this will affect pilot flame performance. Suggested any time you do a service or cleaning. The primary air port can be enlarged using a 7/64 drill bit or a #36 drill bit. This will allow more air to gas and assist pilot performance. 48

49 SIT Group Information Bulletin Date: March 2014 Subject: Use of silicone in gas hearth appliances Extensive testing by SIT has shown that the use of silicone in gas hearth appliances and its use on the appliance vent pipe connections can negatively affect the flame sensing circuit of the intermittent pilot ignition system, with the possible result of a nuisance shut off. This affect is due to silicone particulates/vapors coating the flame sensing rod and pilot hood. This coating electrically insulates these components of the pilot assembly which inhibits the ability of the flame sensing circuit. The silicone coating can be transparent, therefore in some cases it cannot be detected by a simple visual inspection. Cleaning of the sensing electrode and pilot hood can help remove silicone deposits and restore the performance of the flame sensing circuit. The cleaning operation should be performed with an abrasive material such as steel wool or a fine metal brush. The surfaces that need to be cleaned are highlighted in blue in figures 1 and 2. After the cleaning operation is completed remove any remaining residue around the pilot. Cleaning the pilot components well will be as effective as replacing the electrode and the hood. Fig. 1 Fig. 2 49

50 SIT Group Information Bulletin Proflame System 24 Hour Safety Shut Off The Proflame Transmitter (Proflame 1 or Proflame 2) sends a refresh message after ~15 seconds from the last user action independently from the current mode. When in T-STAT mode (ON or SMART), the Proflame Transmitter sends a refresh message every ~10 minutes. In the manual mode OFF: If a transmission (user action) has not been detected by the receiver with in 24 hours, the system will shut off. For example, if the user turns on the appliance and leaves the home, after 24 hours the receiver will not have detected any transmissions and the system will be shut off. In the both thermostat modes Smart or ON: The unit will continue to operate unless the receiver continues to receive the same refresh message data for 24 hours. If the same data is transmitted for 24 hrs the unit will shut down. The refresh message data includes the following information: Flame level / BTU output Fan level / speed Aux enable / light Split enable / rear burner Thermostat mode (Off, On, Smart) The only data that can change automatically in Smart thermostat mode without user action is the BTU output that will be 0 (OFF) or level 1 thru 6 (6 being high). For example, if for 24 hours the flame level remains ON at the same level (1..6) the system will be shut-off. Additionally, the Smart thermostat mode will continually adjust the flame down as the room temperature gets closer to the set point. When the set point is achieved the flame will be modulated down to off. 50

51 Mendota Proflame Training Suggested tools to diagnose a Proflame unit 1. Digital Voltmeter (AC voltages & DC voltages & Ohm s) 2. Manometer 3. Standard wrenches and standard deep well sockets 4. Screw drivers 5. Pliers along with a set of needle nose pliers 6. Jumper wire 7. 9 volt battery 8. Door removal tool, Mendota p/n HA Common understanding of electrical, gas pressures, and venting of units The three 30 Second Checks 1. Is the remote in thermostat mode (On or Smart) put in Off mode 2. Is the receiver in OFF (PF1) or Master Stop Switch in off (PF2) 3. Is the unit in lockout mode? See page 11 PF1 See page 22 PF 2 51

52 Mendota Proflame Training Logging onto the dealer website from web page Step #1 Click on Dealer Login in the upper right corner Step #2 Put in your login (usually address) & password If you don t have an account, please click on Register for new account (account # will be needed) Step #3 Click on the Service & Install tab 52

53 Mendota Proflame Training MENDOTA PROFLAME II DEALER REPAIR KIT for FV46, FV41, FV41M, FV44 & FV33, DXV45DT3&4 and DXV35 DT3&4, ML units Part #AA QTY PART# DESCRIPTION PRICE Proflame II control board Proflame II remote control way pilot assembly way pilot assembly Bulb replacement - G9 appliance bulb, 25 watts 3 HA Door removal tool Wiring harness with master off switch Lens 3 HA Lens retainer bracket 2 HA FV 41 and FV44i pilot shield 2 HA FV46 pilot shield 2 HA FV33i and DXV35 DT3 Pilot shield 1 HA FV Modern pilot shield Battery backup harness Battery Backup pack Regular Dealer Cost 25% Dealer Cost See page 4 of Parts Manual 53

54 Mendota Proflame Training FV MENDOTA PROFLAME I DEALER REPAIR KIT for FV41, FV41M, FV44 & FV33, DXV45DT3 and DXV35 DT3 Part #AA QTY PART# DESCRIPTION PRICE Proflame Valve Control Module Fan Control Module (FCM) Hand Held Remote Receiver FV41, FV44, FV33, DXV45DT3 and DXV35DT3 Pilot Assembly - NG/LP complete FV41 Modern Pilot Assembly - NG/LP complete Wire Harness from FCM to Receiver for FV46, FV41, FV44, FV33, Formerly HA Wire Harness Wire Harness from FCM to Receiver for DXV45 DT 3 and DXV35 DT3 Formerly HA Wire Harness HA Wire Harness WITHOUT IPI Switch for Valve Control - Formerly IPI Switch Only Dimmer Control Light FV44 & FV33 Light Kit w/housing, Lens & Bulb Bulb replacement - Xenon, G9, 25 watts Regular Dealer Cost 25% Dealer Cost See page 4 of Parts Manual 54

55 Mendota Proflame Training Proflame 1 All PF1 LX units will have a receiver & remote factory installed. The silver switch (which is usually on the lower left side of the unit, depending upon model) is a IPI/CPI standing pilot switch. IPI meaning Intermittent Pilot Ignition and CPI meaning Continuous Pilot Ignition or standing pilot. *The receiver for the unit, in the OFF position will still allow a CPI pilot to light, but will not allow a IPI pilot and will prevent burners from lighting. ** (if the receiver is in the OFF position, you will still have the light bulb functions & blowers functions, provided the remote is not in a thermostatic mode) Proflame 2 All PF2 units will come standard with remote, and is required to operate the unit. The receiver is now concealed in the unit. The remote will be the only point of ON control for the fireplace. The silver switch (which is usually on the lower left side of the unit, depending upon model) is a master STOP switch, and will kill IPI pilot and burners. *Master stop switch in the OFF position will still allow a CPI pilot light, but will stop an IPI pilot from lighting and will prevent burners from lighting. **(if the master stop switch is in the OFF position, you will still have the light bulb & blowers functions, provided the remote is not in a thermostatic mode, smart or on) When a unit is left in CPI mode continuous pilot ignition it will keep the pilot going provided that wind does not blow out the pilot or AC power has not been lost to the unit. The pilot will remain lit, if batteries are plugged in to the fireplace and AC power is lost. You can keep batteries plugged in at all times provided the end user is making sure that the batteries are changed every few months. The pilot still could be blow out with wind issues. If the unit was just started up, lets just say in IPI mode intermittent pilot ignition or was just put into CPI mode Continuous pilot ignition there can be cold air pushing down the exhaust pipe, not allowing the unit to exhaust properly. If that is the case, the unit cannot exhaust fast enough and burns up all the oxygen in the firebox causing the flames to be really blue and drop out. The unit being in IPI intermittent pilot ignition is very common with homeowners trying to save energy or a homeowners who forgot to turn the unit into CPI mode when the weather turns cold. By keeping the unit in CPI mode this will try and maintain an exhaust path so when the unit is turned on it can exhaust properly and supply the unit with outside air for combustion. There is nothing that is going to prevent wind from taking out a pilot. The unit will attempt to light the pilot 3 times. After the 3rd unsuccessful attempt in a row, the unit will go into lockout mode. Wind, deposits on flame rod (soot & silicon off gassing), gas pressures, improper voltages, flame not hitting the rectification rod will also put the unit into lockout mode. Please refer to page 11 or page 21 for clearing lockout mode. 55

56 Mendota DXV60 & DXV 45 Rear Burner Instructions Mendota has improved the rear burner in the DXV60 & DXV45 units. The part numbers for the burners have not changed; they are still the same part numbers. A bracket has been added to help prevent the rear logs from falling forward, along with holes to assist in lighting the rear burner. Please use the below instructions for the DXV 60 & 45 units. Rear tabs # 1 Front tabs DXV60 rear burner tube P/N HA DXV45 DT rear burner tube HA DXV45 DT3 & DT4 rear burner tube HA Step 1. The burner tube will have tabs both on the front of burner tube. Bend both front tabs all the way over (away from burner, please see front tabs in picture #1 & then bend FRONT burner tabs over in picture #2) # 2 #3 Step 2. Install the two rear logs. Use a flat blade screw driver on both rear tabs on the burner tube. Insert screw driver into tab and bend back (by pushing up and back) this will help the rear log from falling forward (see picture #2) Step 3. Make sure both front tabs are bent over # 4 New holes to assist in lighting rear burner Step 4. Now you can install the coal bed. Please make sure the coal bed rests / lays on the burner air box, not on the front tabs. 56

57 Mendota Direct Vent Inserts AA , 4x3 co-linier direct vent kit (35 ft. kit for 33i & 44i) Please see next page for pictured example AA , 4x4 co-linier direct vent kit (35 ft. kit for D30 & D40) Please see next page for pictured example , 12 ft. x 4 inch exhaust liner insulation wrap (comes with clamps and tape) *optional, does not come with above kits Please note the kit will work with both the AA & the AA Over the course of the last two seasons Mendota Technical services, in cooperation with several dealers/installers have addressed the issue of cold stacking. Labored startup during extreme cold weather, resulting in the unit ghosting, a condition caused by the inability to expel the exhaust gases from the combustion chamber caused by cold air infiltrating and capping the exhaust liner, causing loss of rectification, and dropping out repeatedly until going into lock out. As well as negative house pressures, when the draft pressure inside the home is stronger than the draft pressure inside the unit creating the inability to expel exhaust gases or the tendency to exhaust thru the intake air channels. A scenario that can be caused in an extremely tight home and possibly the combination of powered exhaust fans, attic vents etc. In working thru many hours of these system failures with technicians in the field, Mendota Technical Services has discovered that in most every case these symptoms can be corrected with the use of a complete co-linier vent system, and strongly recommend : 1. Installing both air intake and exhaust liners completely to the termination cap, utilizing a direct vent termination cap with both air intake and exhaust connections, thus creating a Direct Vent system, drawing combustion air and expelling exhaust to the outside of the structure, guaranteeing air quality within the home. 2. Do not insulate the damper area of the existing fireplace. Do insulate the top of the existing flue cavity. Please use un-faced insulation and insulating the top of the existing flue cavity approximately 2 down, This should eliminate cold air infiltration into the flue cavity as well as room space where the existing fireplace is located. Leaving the existing fireplace damper area open will allow residual heated air to infiltrate and warm the existing flue cavity. This will allow the exhaust liner to stay warmer and maintain a stronger draft eliminating the possibility of cold air coming down the exhaust liner and creating negative pressure within the venting system. 3. In the Northern tier, extremely cold climate areas or in extremely tall fireplace applications, insulate the exhaust liner. The pilot light produces a very small amount of BTU output; however, it is what is responsible for maintaining draft between burn cycles. The colder the climate, the quicker the cold air will infiltrate the exhaust liner and the further down the length of the liner it will be able to travel between cycles. Also, the further away termination is from the unit, the more the ability to maintain heat in the exhaust liner decreases. 4. It is imperative that the unit be ran in CPI throughout the burn season. No amount of insulation or any type of venting configuration will make up for the lack of pilot heat maintaining draft between burn cycles. Not only will leaving the unit in standing pilot maintain draft, it will help eliminate the buildup of condensation within the unit and vent system, eliminating corrosion and prolonging the life of components. 57