Heat Surge Model X5C Fire Place Insert Service Manual Applies to all units w/30000208 circuit board ©2012 HS M4417A BR16597R-1 HEAT SURGE 8000 FREEDOM AVE, N. CANTON, OH 44720 330-244-8161 WWW.HEATSURGE.
Preface This manual is intended for the servicing of the Heat Surge Model X5C fireplace insert. Only authorized trained technicians should use this manual and perform the service needed. Risk of electrical shock, burn and fire is present when performing service to the insert.
Table of Contents Description Page Removal of front grill and top cover 4 Incoming Power 5 Lamps 6 Flame Tube 8 Blower Assembly 10 Dual Element Heater with Fusible Link 13 Touch Pad Control 17 Temperature Pot and Temperature Sensor 18 Remote Control and Remote Control Sensor 19 Log removal and replacement 20 Electrical Drawing 21 3
Removal of Front Grill and Top Cover To remove the front grill, remove 120vac power from insert, locate the 4 mounting screws, 2 on each side. Remove screws and pull front grill out towards the front. Refer to Figure 1. Front grill assembly 4 mounting screws, 2 on each side Figure 1, removal of front grill To remove the top cover, locate the 9 mounting screws, 2 on each side and 5 in the back of the insert. Remove the screws and pull forward while at the same time lifting out.
Incoming Power The incoming power to the insert is 120vac/60Hz and will draw 15amps when running both heater elements at a total of 1500watts. The incoming power, L1, is protected by a circuit breaker located on the back of the insert. Also the insert is protected by a normally closed tip switch in series with the circuit breaker located inside the top left hand side compartment. To reach this switch the top front grill and the top cover must be removed.
Lamps There are 2 candelabra lamps each with an E-12 (small) socket base rating voltage 120vac, rating power 40watts. These lamps are located inside the bottom of the insert. Unfasten the 2 screws on the 2 sides of the bottom panel, take out the bottom panel. Refer to Figure 5. 2 Fixing Screw Bottom panel Figure 5, bottom panel screw locations Locate the 2 bulbs in the bottom of the unit. Examine the bulbs to determine which bulb requires replacement.
If bulbs refuse to light, check the 2 conductor plug for connection. To examine the plug the front glass must be removed. Locate the 6 mounting screws, 3 on each side, remove all 6 and lift off front glass. Next remove the 3 top screws holding the flame screen; the plug is located on the right hand side. The plug will have a yellow and a white wire on one side and a black and white wire leading to the sockets. Check for good connection. Refer to Figure 7. Front glass mounting screws, quantity 6.
Flame Tube The flame tube assembly consists of the flame tube, flame tube motor and mounting brackets. If there isn’t any rolling frame the following needs performed. To access the flame tube assembly the front glass must be removed and the flame screen pulled forward. Refer to Figure 9. Look for any jams that may cause interference of the rotating tube. Next, inspect for the mounting of the flame tube. Make sure the 2 fasteners are present which hold the flame tube in its place.
If the plug connection is good, check for 110vac between terminals FLAME and AC-N1 on the main control board, refer to Figure 1 and Figure 2 for board and terminal locations, if there isn’t any 110vac present the main control board is defective, replace with a new board. If there is 110vac replace the flame motor. Repair connection and plug in.
Blower Assembly The front grill and top of the insert must be removed to service the blower assembly. Refer to Figure 1 and Figure 2. Lift the top off but leave the touch pad and temperature pot plugged in, be careful not to short circuit against the insert casing. Rest the top on the casing so that the touch keypad points straight up. Insolate the touch keypad from the casing with cardboard. With 120vac cord plugged in, turn the insert on via the touch keypad.
Next the dual heating element has 3 wires associated with it, 2 black and 1 white. The 2 black leads are the 120vac power leads landing on terminals both marked 750W on the main control board. The lower heating element terminal lands on the lower 750W terminal on the main control board and the upper heating element terminal lands on the upper 750W terminal on the main control board. The white common wire is landed on terminal AC-N3 on the main control board, remove all 3 wires from main control board.
Remove the 4 screws, 2 on each side, holding the blower/heater assembly to the insert. Remove the 4 screws and lift blower/heater assembly off of the insert. Next locate the 4 screws, 2 on each side, attaching the dual element heater to the blower. Remove these screws and remove dual element heater from blower. Refer to Figure 15. Screws holding dual element heater to blower. Figure 15 Replace blower and reverse above procedure to assemble.
Dual Element Heater with Fusible Link The front grill and top of the insert must be removed to service the heater assembly. Refer to Figure 1 and Figure 2. Lift the top off but leave the touch pad and temperature pot plugged in, be careful not to short circuit against the insert casing. Rest the top on the casing so that the touch keypad points straight up. Insolate the touch keypad from the casing with cardboard.
If 120vac is not present then replace the main control board. If 120vac is present then the fusible link is defective, replace the dual element/fusible heater. Next select low on the touch keypad, the blower should start running and 10 seconds later the low heat should start; you will hear the contacts clicking of the control relay on the main control board. Select high heat and you will hear the contacts clicking of the control relay on the main control board.
Touch Pad Control With the insert sitting up-right, plug the insert into a known good 120vac source. The insert will beep once. Turn the insert on, the lights will light up and there will be a rolling flame. If the insert doesn’t beep or the flame and lights turn on instantly or not at all, the touch keypad is defective. Check for ribbon cable leads coming unplugged from both ends. Check to make sure there is a good connection at the main control board socket. Refer to Figures 20 and 21.
Temperature Pot and Temperature Sensor With the insert sitting up-right, plug the insert into a known good 120vac source. The insert will beep once. Turn the insert on, the lights will light up and there will be a rolling flame. Turn on the low heat. The blower will turn on and 10 seconds later the low heat will come on. If it doesn’t, make sure the temperature pot is turned to the “HI” setting. If low heat doesn’t come on check to make sure the temperature pot is plugged into the main control board.
Remote Control and Remote Control Sensor The unit comes with a remote control complete with power on/off button, low/high heat selector and up/ down flame setting. Refer to Figure 24. Flame up/down Heat low/high Power on/off Figure 24, remote control description If remote control refuses to work check battery orientation and integrity. Refer to Figure 25. Figure 25, battery location and orientation.
Log removal and replacement The front glass needs to be removed. Locate the 6 screws, 3 on each side, holding the front glass frame in and remove. Refer to Figure 27. Locate 6 screws, 3 on each side Figure 27 Locate the 4 black rubber plugs, 2 on each side of the insert. Remove rubber plugs and remove the 4 screws holding the log set in the insert. Pull the log set straight out towards the front. Reverse above to install new log set. Refer to Figure 28.
Electrical Drawing 21
