1. Stove Camp 2016
GreenSmart 101

2. What is GreenSmart?
Gives the customer the ability to run there gas appliance in IPI or CPI pilot modes.
Most GreenSmart appliances come standard with the Comfort Control feature which offers a turn-down ratio up to 72%.
2 Operating choices for the customer – Basic or GreenSmart Remote Control
Remote System offers multiple modes of operation – Manual, Programmable Thermostat, or “Smart” Thermostat
GreenSmart Remote Control is a full functioning remote system, not only allowing for the customer to turn on the flame, blower, accent lights, comfort control, pilot (GSR2), and thermostat mode, but also the intensity of the flame, blower, and accent lights (GSR2)

3. IPI vs. CPI Pilot Mode IPI=Intermittent Pilot Mode
Pilot only runs when the main burner is turned on.
Advantages-Fuel Saving Cost
Disadvantage-Does not keep venting & firebox warm, causing draft problems in cold climate areas
CPI=Continuous Pilot Mode
Pilot runs even when the main burner is turned off
Advantages-Keeps the venting & firebox warm allowing for proper draft in cold climates. Better overall performance.
Disadvantage-Pilot is running when the main burner isn’t on, adding additional operating cost.
GreenSmart Systems can be easily switched from IPI to CPI mode with the flip of a switch or the push of a button.
Travis recommends running the continuous pilot in cold operating climates.

4. Geography: Component Names & Functions

5. Main Burner Switch (250-02013) Used to turn main burner ON/OFF
Switch has 2 male spades, use one top and one bottom as illustrated
Used only in base systems (GS1 & GS2)
Discarded when unit is upgraded to GS Remote

6. Comfort Control Switch (250‐01569)
Opens and closes the split flow (comfort control)
valve for rear or outside burner functions
Used only in base systems (GS1 & GS2)
Discarded when unit is upgraded to GS Remote

7. IPI/CPI Switch (250‐01578)
Switches between standing pilot and continuous pilot
Used in base systems (GS1 & GS2)
Used in GS1 Remote System
Not used with GSR2 Remote System

8. Gas Control Valve (250‐01422)
Used on all GreenSmart appliances (GS1 & GS2)
Allows for gas to become present at pilot and burner
Pilot adjustment screw
Pressure taps (incoming and outgoing)
Electrical spades for voltage testing (orange, green)
Manual High/Low regulator for pressure adjustments
Note: GSR units come standard with NG stepper motor

9. Split-Flow (Comfort Control) Valve (250-01423)
Used on all GreenSmart appliances (GS1 & GS2) (Except 616 DF, 564 DF, 3615, 4415, 6015)
Allows on/off control of a portion of the burner
In a base system, batteries needed to function

10. Pilot Assembly SIT Pilot Assembly PSE Pilot Assembly
2-way hood ( )
2-way hood ( )
3-way hood ( ) 33DVI & Cypress
3-way hood ( ) DVL, 33DVI, 864HO, & Cypress only
Spark Rod ( ) ignites gas
3-way hood ( ) 616 only
Pilot Sensor ( ) confirms pilot is lit before gas is allowed to flow to the main burner
Pilot Sensor ( )
No replacement part for pilot hood or spark rod.

11. Stepper motor Natural Gas (NG) – (250‐01566)
( used on non split-flow units)
Liquid Propane (LP) – (250‐01463)
Used in GS1 and GS2 remote upgrade kit
Electronically modulates burner up and down
Works in conjunction with remote transmitter
NG stepper motor standard on GSR1 and GSR2 units

12. Digital Fireplace Control Module (DFC) (GS1) (250-03824)
Central Processor (brain) for all GreenSmart 1 appliances
Provides Spark and monitoring of the pilot
Controls operation of the gas valve
Contains audible tone speaker for diagnostics

13. AC Adapter (GSB1) ( )
Converts 120v line voltage to 7v DC power in base GS1 systems
Polarity is critical to proper operation
If wires are reversed pilot will not light
Discarded when unit is upgraded to GS remote system

14. Fan Control Module (GSR1)
With power cord ( )
All fireplaces and Stoves
With Molex connector ( )
DVL and DVS inserts
Provides adjustable power for fan
Switched power for accent lights
Controlled by remote via the receiver
2 replaceable fuses inside
5 amp fuse – lights and fan circuit
6 amp fuse – constant 120v
Used in upgraded GS 1 remote systems

15. Remote Receiver (GSR1) (250-02302)
On/ Off/ Remote Slide Switch
Learn Button for remote synchronization
Holds 4 AA batteries used during a power outage
Receives signal from transmitter
Built-In blower timer: 5 min. on, 12 min. off

16. Integrated Fireplace Control Base(IFC) (250-03825)
Central processor (brain) for all GreenSmart 2 base appliances
Provides the spark and monitoring of the pilot
Controls operation of the gas valve
A/C connects to IFC (eliminates A/C Adaptor)
Fuse Protected (3.15 A)
24 Hour CPI Shut Down/ Relight safety check
Discarded when upgraded to GS2 remote

17. Integrated Fireplace Control Upgraded(IFC) (GSR2) (250-03826)
Central processor (brain) for all GreenSmart appliances
Provides the spark and monitoring of the pilot
Controls operation of the gas valve
A/C connects to IFC (eliminates A/C Adaptor)
Fan, Accent lights, Stepper Motor, and Split Flow Valve connects to IFC
Fuse Protected (3.15 A)
24 Hour CPI Shut Down/ Relight safety check
Used in upgraded GS2 remote units

18. Remote Battery Box (250‐02663) On/Off/Remote switch
Learn button for remote synchronization
Holds 4 AA batteries used during a power outage
Used in upgraded GS2 remote units

19. Remote Transmitter 250-03262 (250‐02711) Accent light and blower
Sends signal to receiver
On/Off button
Thermostat button
Up and Down arrow key
Mode button
Used in upgraded GS2 remote and GSR 2 units
Compatible to work with GS1 remote systems
Accent light and blower
adjustment
IPI/CPI activation
Amber back light

20. GSR 2 Remote Operation
Warning

21. GSR 2 Remote Operation
Remote Setup:
Verify the Switch is on “REMOTE”

22. GSR 2 Remote Operation Remote Setup:
Synchronize the Transmitter to the IFC
Press the PRG (Program) button on the battery box (IFC will beep 3 times).
Press the “ON” button on the transmitter (IFC will beep 3 times).
Clearing the System Memory
To clear the system memory, MAKE SURE GAS IS TURNED OFF TO THE APPLIANCE then press the PRG (Program) button for 10 seconds. The pilot will start to spark repeatedly, signifying all system memory has been cleared. The system will return to its original configuration: a remote will need to be synchronized; and, the system will operate under continuous pilot mode.

25. What did Travis Industries do?
GreenSmart - Lineage
2009 GreenSmart 1 was introduced into all Travis Industries Gas Burning appliances
2012 GreenSmart 2 was introduced as a new improved version of GS1
In June of 2012 it was noticed the performance of GS1 & GS2 wasn’t as good as the past.
It was discovered the manufacture of the GS system reduced the spark amptitude from 158 volts to 145 volts
The lowering of voltage by the vendor creates unforeseen reaction to the system as tested
What did Travis Industries do?

26. GREENSMART - Improvements
PSE Pilot Assembly (mid 2013)
Sheathing the Rectification Rod Wire (mid 2014)
Shepherds Hook Rectification Rod (beginning of 2015)
IFC & DFC Module Power Increased (end of 2014)
IFC & DFC Module Noise Silencing (Fall of 2015)
Minimized the use of Silicone (beginning of 2015)
Remote Control Signal Strength (mid 2015)
Component Testing (beginning of 2015)
IFC & DFC Module FFRT boards introduced (Fall of 2016)

27. PSE Pilot Assembly (mid 2013) w/ Sheathed Shepherds Hook Rectification Rod (2014/ 2015)
Original Pilot Assembly was a SIT assembly, designed for MV systems
PSE Pilot Assembly is designed for IPI systems, robust Pilot Assembly
Grounding the Pilot Assembly is extremely important for IPI systems
All GreenSmart Units can be upgraded to PSE the Pilot Assembly
Sheathing added to the Rectification Rod wire to cut down on external electrical interference
Shepherds Hook Rectification Rod gives Pilot Flame more surface contact, overcomes pilot flame drop out due to active pilots
Note: Pilot Flame for IPI systems must be a continuous flame with no air gaps between the pilot hood and rectification rod in order for the control module to recognize pilot flame, this is known as pilot flame rectification.

28. IFC (GS2) & DFC (GS1) Module Power Increased (end of 2014)
Module Power has been sacrificed through Module Revision Changes throughout the years
This caused for pilot flame failure (loss of pilot flame rectification) due to low amount of power going through the rectification rod to the pilot hood.
Current Module Revisions, power has been increased to 200 milliamps
50 more milliamps than the original best GS modules
Increased power allows for the Module to overcome restrictions in the pilot circuit.
Dirty or Compromised Pilot Hood
Dirty Rectification Rod
Partially broken Rectification Rod wire
Current Module Revision
DFC (GS1) Revision 14
IFC (GSB2) Revision 6
IFC (GSR2) Revision 7
Continued…

29. IFC (GS2) & DFC (GS1) Improved FFRT Module (Fall of 2016)
Historically, IFC boards have a Flame Failure Response Time (FFRT) of 0.8 seconds.
If the pilot left the flame sensor for longer than 0.8 seconds the board made 3 attempts to re-light.
If no ignition was achieved the board would lock-out
“New Boards” have a FFRT of 5 seconds
If the pilot leaves the flame sensor for longer than 5 seconds, the board will not attempt to re-light.
The board will lock-out
New Part #’s
GS1 DFC Module
GSB2 IFC Module
GSR2 IFC Module
Replacement modules are being phased into inventory throughout the summer 2016
New FFRT Modules are being phased into production units throughout the summer of 2016
Module Revision #’s are starting back at “0”

30. Remote Control Signal Strength (mid 2015)
Customers with the New GSR2 Wall Mount Remote Control were having difficulty operating there unit through the Remote Control
Travis’s Electrical Engineer found the Antenna was not putting out the correct amount of power to communicate with the IFC Module
Wall Mount Remote Controls have had the Antenna Power corrected to give full signal strength
Correct Remotes will either:
Have a label with the word “zero” inside the battery cover
OR, Be Revision 1 Wall Mount Remote Controls
Note: Some fronts & faces can limit the communication to the IFC module, if this is the case an external antenna can be added to the IFC module for better reception.

31. Minimized use of Silicone (beginning of 2015)
Silicone Off Gas during burning
Creates a white film inside the appliance
Travis has changed from using Silicone as a sealant to using Mill Pack
Mill Pack has a higher temperature rating and does not off gas when exposed to high temperatures
Travis does not recommend using Silicone for gas appliance installation

32. Component Testing (beginning of 2015)
All GreenSmart Components are tested in house by Travis before being installed.
When Travis finds a problem with electrical components, that component goes through 100% testing/ inspection process until Travis Engineers are satisfied with results.
Example: All Wall Mount Remote Controls were being tested once Travis was aware of the communication problem. Now that the remote controls are performing to set standards, Travis test 10% of all remotes with less than 1% failure.
Travis has on staff Electrical Engineers that are setting the standards for the manufactured electrical components

33. IFC Safety Feature (GS2)
Continuous Pilot Shutdown Safety Check
When Operating GS2 units in the continuous pilot mode (CPI) every 24 hours the IFC will shut the pilot off then relight it to verify the pilot sensor is fully operational.

34. GS1 Basic GreenSmart Flow of Power
Basic Ignition Flow
Turn switch on to complete the circuit
DFC module recognizes we want the unit to turn on
DFC module begins spark ignition at the spark rod
DFC module sends power to the pilot side of the valve (orange wire)
Valve opens to supply fuel to pilot
Pilot lights, pilot flame engulfs tip of flame rectification rod
Flame rectification rod sends signal to DFC module that pilot lighting sequence is complete
DFC module then does the following
Sends signal to burner side of the valve to open and light the burner (green wire)
Stops spark rod from sparking

35. GS1 Basic GreenSmart Flow of Power
Comfort Control Operation
Comfort control switch is turned on
Comfort Control Valve opens as long as batteries in the battery tray are good
If batteries are not good the valve will not open
Comfort Control Valve is independent of the DFC module
Comfort Control operates the flow of gas to the rear burner
When turned on, gas will flow to the rear burner
When turned off, gas will stop flow to the rear burner

36. GS1 Basic GreenSmart Flow of Power
Blower & Light Operation
Blower & Light Operation is independent from the DFC module. They each have individual rheostats that control operation and intensity.
They receive power directly from the incoming power source.

37. GS 1 Wiring Diagram (Base)

38. GS1 Remote System Flow of Power
GS1 Ignition Flow
Use remote control to turn unit on
Receiver receives signal from remote to tell the unit to turn on
Receiver sends a signal to the DFC module
DFC module receives signal from receiver and begins spark ignition at the spark rod
DFC module sends power to the pilot side of the valve (orange wire)
Valve opens to supply fuel to pilot
Pilot lights, pilot flame engulfs tip of flame rectification rod
Flame rectification rod sends signal to DFC module that pilot lighting sequence is complete
DFC module then does the following
Sends signal to burner side of the valve to open and light the burner (green wire)
Stops spark rod from sparking

39. GS1 Remote System Flow of Power
Variable Flame Operation
Use remote control to adjust flame height
Receiver receives signal to adjust flame height
Receiver sends signal to Stepper Motor to adjust gas flow/ flame height to the burner

40. GS1 Remote System Flow of Power
Comfort Control Operation
Use remote control to turn Comfort Control on/off
Receiver receives signal to turn operate Comfort Control
Receiver sends signal to the Comfort Control valve to turn Comfort Control on/off.

41. GS1 Remote System Flow of Power
Blower Operation
Use remote control to turn on or adjust blower speed
Receiver receives signal to turn on blower or adjust blower speed
Receiver sends signal to Fan Control Module to turn on blower or adjust blower speed.
Fan Control Module will turn on or adjust blower accordingly
Note- blower does not use a snap disc when using a GSR1 system. Blower will turn on without time delay when operating manually through the remote control. When in thermostat mode the blower operates on a start up time delay and an off time delay.

42. GS1 Remote System Flow of Power
Light Operation
Use remote control to turn on/off light
Receiver receives signal to turn on/off light
Receiver sends signal to Fan Control Module to turn on/off light
Fan Control Module will turn on/off light

43. GS 1 Wiring Diagram (Remote)

44. GS2 Basic System Flow of Power
Basic Ignition Flow
Turn switch on to complete the circuit
IFC module recognizes we want the unit to turn on
IFC module begins spark ignition at the spark rod
IFC module sends power to the pilot side of the valve (orange wire)
Valve opens to supply fuel to pilot
Pilot lights, pilot flame engulfs tip of flame rectification rod
Flame rectification rod sends signal to IFC module that pilot lighting sequence is complete
IFC module then does the following
Sends signal to burner side of the valve to open and light the burner (green wire)
Stops spark rod from sparking

45. GS2 Basic System Flow of Power
Comfort Control Operation
Comfort control switch is turned on
Comfort Control Valve opens as long as batteries in the battery tray are good
If batteries are not good the valve will not open
Comfort Control Valve is independent of the IFC module
Comfort Control operates the flow of gas to the rear burner
When turned on, gas will flow to the rear burner
When turned off, gas will stop flow to the rear burner

46. GS2 Basic System Flow of Power
Blower & Light Operation
Blower & Light Operation is independent from the IFC module. They each have individual switches/rheostats that control operation and intensity.
They receive power directly from the incoming source.
The system features a 3 amp fuse for the lights and blower system individually.

47. GS 2 Wiring Diagram (Base)

48. GSR2 Remote System Flow of Power
GSR2 Ignition Flow
Use remote control to turn unit on
IFC module receives signal from unit to turn on unit
IFC module begins spark ignition at the spark rod
IFC module sends power to the pilot side of the valve (orange wire)
Valve opens to supply fuel to pilot
Pilot lights, pilot flame engulfs tip of flame rectification rod
Flame rectification rod sends signal to IFC module that pilot lighting is complete
IFC module then does the following
Sends signal to the burner side of the valve to open and light the burner (green wire)
Stops spark rod from sparking

49. GSR2 Remote System Flow of Power
Variable Flame Operation
Use remote control to adjust flame height
IFC module receives signal from remote to adjust flame height
IFC module sends signal to stepper motor to adjust gas flow to burner

50. GSR2 Remote System Flow of Power
Comfort Control Operation
Use remote control to turn Comfort Control on/off
IFC module receives signal from remote to operate comfort control valve
IFC module sends signal to comfort control valve to open/close

51. GSR2 Remote System Flow of Power
Blower & Light Operation
Use remote control to turn on and adjust blower/light
IFC module receives signal from remote to operate the blower/light
IFC module sends signal to the blower/light to turn on/off and adjust intensity
Note- blower does not use a snap disc when using a GSR2 system. Blower will turn on without time delay when operating manually through the remote control. When in thermostat mode the blower operates on a start up time delay and an off time delay.

52. GSR 2 Wiring Diagram (Remote)

53. COMBUSTION OF GAS Combustion Requirements
The three necessary ingredients for combustion are:
Oxygen (air)
Fuel (gas)
Ignition (heat)

54. COMBUSTION OF GAS Controlled combustion Uncontrolled combustion,
Happens when there is a proper air/fuel ratio. The result is complete burning with a steady flame.
Uncontrolled combustion,
Explosion, occurs when there is an improper air/fuel ratio. The result is rapid burning with the creation of excessive pressure buildup.

55. Developing Trouble Shooting Mentality

56. Developing Trouble Shooting Mentality
ASK GOOD QUESTIONS
What did the fire look like when it went out?
How long did it burn before it went out?
How often does this happen?
When making changes make one change at a time.
Do not assume anything.

57. Problem Generating Categories
Operator
Error
Appliance
Inside
Environment
Outside
• Unrealistic
performance
expectations
• Improper
operation of
appliance
• Defective
components
Mis-assembled/
installed
Factory
Field
• Negative
pressure
conditions
placement &
location
• Surrounding
buildings, roof
lines
Weather
factors

58. Gas Pressure What tool do you use to test gas pressure?
What is your incoming gas pressure supposed to be?
NG Appliances
LP Appliances
What is your outgoing gas pressure suppose to be?

59. Gas Pressure - Affects What can be affected by incorrect Gas Pressure
Pilot Flame
Delayed Ignition
Post Ignition
Sooting
Flame Height
Overall Unit Operation
Heat Output
Component Longevity
Unit longevity

60. Gas Pressure-Testing How do you test incoming gas pressure?
How do you test outgoing gas pressure?
How can incorrect gas pressure affect your pilot light?

61. Troubleshooting GreenSmart System
SIT IPI
(intermittent pilot ignition)
System

62. DFC Audible Explanation (GS1)
Audible Beep
One Audible Beep – Low Battery in either Battery Box or Receiver
Two Audible Beeps – Parasitic Pilot Flame
Three Audible Beeps – System Lock Out

63. IFC Light Explanation (GS2)
Yellow Light
Must be on to sync remote
Red Light
One Flash – initial power up and low battery
Two Flashes – parasitic pilot flame
Three Flashes – lock out

64. GREENSMART 1 Troubleshooting

69. GREENSMART 2 Troubleshooting