Troubleshooting. Duluth Forge 170154, 170032, 170150

TROUBLESHOOTING

WARNING: If you smell gas:

• Shut off gas supply.

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

WARNING: Only a qualified service technician should service and repair heater. Make sure that power is turned off before proceeding.

Turn off and let cool before servicing.

CAUTION: Never use a wire, needle, or similar object to clean

ODS/pilot. This can damage ODS/ pilot unit.

IMPORTANT: Operating heater where impurities in air exist may create odors. Cleaning supplies, paint, paint remover, cigarette smoke, cements and glues, new carpet or textiles, etc., create fumes. These fumes may mix with combustion air and create odors.

Note: All troubleshooting items are listed in order of operation.

Problem

Using natural gas and pilot will not light.

Possible Cause

Inlet pressure exceeds

9.5" WC.

Pressure Switch

When using natural gas (NG), there is a pressure switch that acts to turn off the gas flow to the pilot if the inlet pressure exceeds

9.5" WC. This is to prevent the operation of the unit on the wrong gas (propane). If your natural gas supply exceeds 9.5" WC the unit will not operate. Either contact your gas supplier to check and adjust the inlet pressure or a qualified service technician can bypass the pressure switch.

Before attempting to bypass the pressure switch, make sure the type of gas being used is correct. Check to make sure the connection fitting is in the correct inlet on the regulator.

Refer to Connecting to Gas Supply , page 14.

Only a qualified installer should bypass the pressure switch. To bypass the pressure switch locate the set screw on the regulator.

Use a small flat bladed screw driver to turn the set screw counterclockwise 2 turns. This will bypass the pressure switch function.

NG

Corrective Action

Bypass pressure switch. See instructions below.

The entire gas delivery piping including connections inside the heater should be leak tested by the qualified installer. After leak testing the qualified installer should light the appliance. Refer to the correct flame pattern as illustrated on page 23. All flame patterns should be safely inside the product. If for any reason they are not, stop use of the appliance and call for repairs.

Pressure

Switch

Set Screw

Figure 35 - Gas Regulator Pressure Switch

28 www.factorybuysdirect.com

200253-01E

TROUBLESHOOTING

Problem

When ignitor button is pressed in, there is no spark at ODS/pilot

When ignitor button is pressed in there is a spark at ODS/pilot but no pilot flame present.

ODS/pilot lights but flame goes out when control knob is released.

Possible Cause

1. Ignitor electrode is positioned wrong. Ignitor electrode is broken.

2. Ignitor electrode is not connected to ignitor cable.

3. Ignitor cable is pinched or wet.

Corrective Action

1. Replace electrode.

2. Replace ignitor cable

4 Broken ignitor cable.

5. Bad piezo ignitor.

6. Low battery.

1. Gas supply is turned off or equipment shutoff valve is closed.

2. Control knob not fully pressed in while pressing ignitor button.

3. Air in gas lines (new installation or recent gas interruption).

4. ODS / pilot is clogged.

5. Incorrect inlet gas pressure or inlet regulator is damaged.

6. Control knob not in PILOT position.

7. Depleted gas supply (propane).

1. Control knob is not fully pressed in.

2. Control knob is not pressed in long enough.

3. Free ignitor cable if pinched by any metal or tubing. Keep ignitor cable dry.

4. Replace ignitor cable.

5. Replace piezo ignitor.

6. Replace battery.

1. Turn on gas supply or open equipment shutoff valve.

2. Fully press in control knob while pressing ignitor button.

3. Continue holding down control knob. Repeat igniting operation until air is removed.

4. Clean ODS/pilot (see Care and Maintenance , page 24) or replace ODS/pilot assembly.

5. Check inlet gas pressure or replace inlet gas regulator.

6. Turn control knob to PILOT position.

7. Contact local propane gas company.

1. Press in control knob fully.

3. Equipment shutoff valve is not fully open.

4. Thermocouple connection is loose at control valve.

5. Pilot flame not touching thermocouple, which allows thermocouple to cool, causing pilot flame to go out. This problem could be caused by one or both of the following:

A) Low gas pressure

B) Dirty or partially clogged

ODS/pilot

6. Thermocouple damaged.

7. Control valve damaged.

2. After ODS/pilot lights, keep control knob pressed in 30 seconds.

3. Fully open equipment shutoff valve.

4. Hand tighten until snug, and then tighten 1/4 turn more.

5. A) Contact local natural or propane gas company

B) Clean ODS/pilot (see

Care and Maintenance , page 24) or replace ODS/ pilot assembly

6. Replace thermocouple.

7. Contact customer service.

200253-01E www.factorybuysdirect.com

29

30

TROUBLESHOOTING

Problem

Burner(s) does not light after ODS/pilot is lit

Delayed ignition of burner(s).

Burner backfiring during combustion

High yellow flame during burner combustion

Gas odor during combustion.

Slight smoke or odor during initial operation

Heater produces a whistling noise when burner is lit..0

Possible Cause

1. Burner orifice is clogged.

Corrective Action

1. Clean burner orifice (see

Care and Maintenance , page 24) or replace burner orifice.

2. Replace burner orifice.

2. Burner orifice diameter is too small.

3. Inlet gas pressure is too low.

1. Manifold pressure is too low.

2. Burner orifice is clogged.

1. Burner orifice is clogged or damaged.

2. Burner is damaged.

3. Gas regulator is damaged.

1. Not enough air.

2. Gas regulator is defective.

3. Inlet gas pressure is too low.

1. Foreign matter between control valve and burner.

2. Gas leak. (See Warning

Statement at top of page 26).

1. Residues from manufacturing process.

1. Turning control knob to high

(5) position when burner is cold.

2. Air in gas line.

3. Air passageways on heater are blocked.

4. Dirty or partially clogged burner orifice.

3. Contact local gas supplier.

1. Contact local gas supplier.

2. Clean burner (see Care and

Maintenance , page 24) or replace burner orifice.

1. Clean burner orifice (see

Care and Maintenance , page 24) or replace burner orifice.

2. Contact dealer or customer service.

3. Replace gas regulator.

1. Check burner for dirt and debris. If found, clean burner

(see Care and Maintenance , page 24).

2. Replace gas regulator.

3. Contact local gas supplier.

1. Take apart gas tubing and remove foreign matter.

2. Locate and correct all leaks

(see Checking Gas Connections , page 16).

1. Problem will stop after a few hours of operation.

1. Turn control knob to low (1) position and let warm up for a minute.

2. Operate burner until air is removed from line. Have gas line checked by local gas supplier.

3 Observe minimum installation clearances (Figure 5, page 9)

4 Clean burner (see Care and

Maintenance , page 24) or replace burner orifice.

www.factorybuysdirect.com

200253-01E