Owner’s Manual - Wood Burning Systems Document Library · exterior surface finishes may occur....

3-90-07205R27_08/15www.harmanstove.com

Owner’s ManualMODEL:

PB105 Pellet Boiler

Please read this entire manual before installation and use of this pellet fuel-burning room heater. Failure to follow these instructions could result in property damage, bodily injury or even death.

• Donotstoreorusegasolineorotherflammablevaporsandliquidsinthevicinityofthisoranyotherappliance.

• Donotoverfire-Ifanyexternalpartstartstoglow,youareoverfiring.Reducefeedrate.Overfiringwillvoidyourwarranty.

• Complywithallminimumclearancestocombustiblesasspecified.Failuretocomplymaycausehousefire.

Hot glass will cause burns.• Donottouchglassuntilitiscooled• NEVERallowchildrentotouchglass• Keepchildrenaway• CAREFULLYSUPERVISEchildreninsameroomas

fireplace.• Alertchildrenandadultstohazardsofhightemperatures. High temperatures may ignite clothing or other

flammable materials.• Keepclothing,furniture,draperiesandotherflammable

materialsaway.

HOT SURFACES!Glassandother surfacesarehotduringoperationANDcooldown.

NOTICE

•Importantoperatingandmaintenanceinstructionsincluded.

•Read,understandandfollowtheseinstructionsforsafeinstallationandoperation.

•Leavethismanualwithpartyresponsibleforuseandoperation.

DO NOT DISCARD THIS MANUAL

WARNING WARNING

Testedandapprovedforwoodpelletsandshelledfieldcorn fuelonly. Burningofanyother typeof fuelvoidsyourwarranty.

Checkbuildingcodespriortoinstallation.

• InstallationMUSTcomplywithlocal,regional,stateandnationalcodesandregulations.

• Contactlocalbuildingorfireofficialsaboutrestrictionsandinstallationinspectionrequirementsinyourarea.

To obtain a French translation of thismanual, pleasecontactyourdealerorvisitwww.harmanstoves.com

Pourobtenirunetraductionfrançaisedecemanuel,s’ilvous plaît contacter votre revendeur ou visitezwww.harmanstoves.com

NOTE

Do NotDiscard

Contactyourlocaldealerwithquestionsoninstallation,operationorservice.

CAUTION!

CAUTION!

2 3-90-07205R27_08/15

Blank Cover (Re-moved w/ Domestic Hot Water Option

Cleaning Rods

1-1/4” FMPT Return

Vent Pipe

Combustion Blower

Combustion Blower Cover

3/4” FMPT Boiler Drain

Access Cover to Secondary Ash Chamber

Ash Door

Viewing Glass

Firebox Door

Access Cover to Hopper / Swing Plate Knob

Control Board Cover

Control Board

Hopper

Hopper Lid Latches

1-1/4” FMPT SupplyTemperature / Pressure Gauge

Aquastat Well

Pressure Relief Valve

Parts Locations

3 3-90-07205R27_08/15

ProductSpecificandImportantSafetyInformation. . . . 4Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9Venting...................................10-13OutsideAirInstallation. . . . . . . . . . . . . . . . . . . . . . . . . 14MainWiringHarness. . . . . . . . . . . . . . . . . . . . . . . . . . 15PlumbingInstallations. . . . . . . . . . . . . . . . . . . . . . .16-20 OverheatSafetyZone. . . . . . . . . . . . . . . . . . . . . . . 21 PowerFailure/HeatDissipationLoop. . . . . . . . . . 21LowWaterCut-OffControlTipConnection(LWCO). . 22DraftTestProcedure. . . . . . . . . . . . . . . . . . . . . . . . . . 23FuelSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 24ESPControl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25OutdoorAirResetOperation. . . . . . . . . . . . . . . . . . . . 26ControlBoardOperation. . . . . . . . . . . . . . . . . . . . . . . 27AutomaticIgnition. . . . . . . . . . . . . . . . . . . . . . . . . .28-29ManualIgnition . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-31Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 BurnpotMaintenance. . . . . . . . . . . . . . . . . . . . . . . 32 BurnpotAirChamber . . . . . . . . . . . . . . . . . . . . . . . 32 AshRemovalandDisposal. . . . . . . . . . . . . . . . . . . 33 FireboxMaintenance . . . . . . . . . . . . . . . . . . . . . . . 34 CombustionBlowerMaintenance. . . . . . . . . . . . . . 35 TubeHeatExchangers. . . . . . . . . . . . . . . . . . . . . . 35 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Table of Contents

= Contains updated information

AtmosphericConversion. . . . . . . . . . . . . . . . . . . . . . . 37OptionalDomesticHotWaterCoil. . . . . . . . . . . . . . . . 38Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39WiringDiagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40PowerFailureBack-UpSupply. . . . . . . . . . . . . . . . . . 41SafetyLabel.................................42QuickReferenceStart-Up. . . . . . . . . . . . BackCover44

4 3-90-07205R27_08/15

Appliance Certification:Model:PelletBurningBoiler-PB105Test Lab:Omni-TestLaboratories,Inc.Report #: 135-S-16-6Type:PelletFueledCentral/SupplementaryForResidentialUseStandard(s):CAN/CSAB366.1-M91,andUL391

Note:Thisapplianceisalsoapprovedforinstallationintoashop.Harman® Central Heating Appliances are built and tested to be complete Home Heating solutions. As with any Central Heat system, a backup heating system may be required in the event of power outages or during appliance service or maintenance.

Pleasereadthisentiremanualbeforeyouinstallanduseyournewboiler.Failuretofollowinstructionsmayresultin

propertydamage,bodilyinjury,orevendeath.SAVETHESEINSTRUCTIONSHearth & Home Technologies352MountainHouseRoad

Halifax,PA17032

WARNING! RISK OF FIRE! Hearth&HomeTechnologiesdisclaimsanyresponsibilityfor,andthewarrantyandagencylistingwillbevoidedbythefollowingactions:DO NOT:• Installoroperateadamagedappliance• Modifytheappliance• InstallotherthanasinstructedbyHearth&HomeTechnologies• Operatetheappliancewithoutfullyassemblingallcomponents• Operatetheappliancewithoutwaterinthesystem• Overfiretheappliance• InstallanycomponentorpartnotapprovedbyHearth&HomeTechnologies

Improperinstallation,adjustment,alteration,service,ormaintenancecancauseinjuryorpropertydamage.Forassistanceoradditionalinformation,consultaqualifiedinstaller,serviceagencyoryourdealer.

Product Specific and Important Safety Information

5 3-90-07205R27_08/15

Warranty

4021-645F02-18-13 Page1of2

Hearth & Home TechnologiesLIMITED LIFETIME WARRANTY

Hearth&HomeTechnologies,onbehalfofitshearthbrands(”HHT”),extendsthefollowingwarrantyforHHTgas,wood,pellet,coalandelectrichearthappliancesthatarepurchasedfromanHHTauthorizeddealer.

WARRANTY COVERAGE:HHTwarrantstotheoriginalowneroftheHHTapplianceatthesiteofinstallation,andtoanytransfereetakingownershipoftheapplianceatthesiteofinstallationwithintwoyearsfollowingthedateoforiginalpurchase,thattheHHTappliancewillbefreefromdefectsinmaterialsandworkmanshipatthetimeofmanufacture.Afterinstallation,ifcoveredcompo-nentsmanufacturedbyHHTarefoundtobedefectiveinmaterialsorworkmanshipduringtheapplicablewarrantyperiod,HHTwill,atitsoption,repairorreplacethecoveredcomponents.HHT,atitsowndiscretion,mayfullydischargeallofitsobligationsundersuchwarrantiesbyreplacingtheproductitselforrefundingtheverifiedpurchasepriceoftheproductitself.Themaximumamountrecoverableunderthiswarrantyislimitedtothepurchasepriceoftheproduct.Thiswarrantyissubjecttoconditions,exclusionsandlimitationsasdescribedbelow.

WARRANTY PERIOD:Warrantycoveragebeginsonthedateoforiginalpurchase.Inthecaseofnewhomeconstruction,warrantycoveragebeginsonthedateoffirstoccupancyofthedwellingorsixmonthsafterthesaleoftheproductbyanindependent,authorizedHHTdealer/distributor,whicheveroccursearlier.Thewarrantyshallcommencenolaterthan24monthsfollowingthedateofproductshipmentfromHHT,regardlessoftheinstallationoroccupancydate.Thewarrantyperiodforpartsandlaborforcoveredcomponentsisproducedinthefollowingtable.Theterm“LimitedLifetime”inthetablebelowisdefinedas:20yearsfromthebeginningdateofwarrantycoverageforgasappliances,and10yearsfromthebeginningdateofwarrantycoverageforwood,pellet,andcoalappliances.Thesetimeperiodsreflecttheminimumexpectedusefullivesofthedesignatedcomponentsundernormaloperatingconditions.

Seeconditions,exclusions,andlimitationsonnextpage.

Parts Labor Gas Wood Pellet EPAWood Coal Electric Venting

X X X X X X X

AllpartsandmaterialexceptascoveredbyConditions,

Exclusions,andLimitationslisted

X X X Igniters,electroniccomponents,and glass

X X X X X Factory-installedblowersX Moldedrefractorypanels

X Firepotsandburnpots

5years 1year X X Castingsandbaffles

7years 3years X X X Manifoldtubes,HHTchimneyandtermination

10years 1year X Burners,logsandrefractory

LimitedLifetime 3years X X X X X Fireboxandheatexchanger

X X X X X X X Allreplacementpartsbeyondwarrantyperiod

WarrantyPeriod HHTManufacturedAppliancesandVenting

1Year

ComponentsCovered

3years

2years

90Days

6 3-90-07205R27_08/15

Warranty

4021-645F02-18-13 Page2of2

WARRANTY CONDITIONS:• ThiswarrantyonlycoversHHTappliancesthatarepurchasedthroughanHHTauthorizeddealerordistributor.Alistof

HHTauthorizeddealersisavailableontheHHTbrandedwebsites.• ThiswarrantyisonlyvalidwhiletheHHTapplianceremainsatthesiteoforiginalinstallation.•ThiswarrantyisonlyvalidinthecountryinwhichtheHHTauthorizeddealerordistributorthatsoldtheappliance

resides.• Contactyourinstallingdealerforwarrantyservice.Iftheinstallingdealerisunabletoprovidenecessaryparts,contact

thenearestHHTauthorizeddealerorsupplier.Additionalservicefeesmayapplyifyouareseekingwarrantyservicefromadealerotherthanthedealerfromwhomyouoriginallypurchasedtheproduct.

• Checkwithyourdealerinadvanceforanycoststoyouwhenarrangingawarrantycall.Travelandshippingchargesforpartsarenotcoveredbythiswarranty.

This warranty is void if:• Theappliancehasbeenover-firedoroperatedinatmospherescontaminatedbychlorine,fluorine,orotherdamaging

chemicals.Over-firingcanbeidentifiedby,butnotlimitedto,warpedplatesortubes,rustcoloredcastiron,bubbling,crackinganddiscolorationofsteelorenamelfinishes.

• Theapplianceissubjectedtoprolongedperiodsofdampnessorcondensation.• Thereisanydamagetotheapplianceorothercomponentsduetowaterorweatherdamagewhichistheresultof,but

notlimitedto,improperchimneyorventinginstallation.

LIMITATIONS OF LIABILITY:• Theowner’sexclusiveremedyandHHT’ssoleobligationunderthiswarranty,underanyotherwarranty,expressor

implied,orincontract,tortorotherwise,shallbelimitedtoreplacement,repair,orrefund,asspecifiedabove.InnoeventwillHHTbeliableforanyincidentalorconsequentialdamagescausedbydefectsintheappliance.Somestatesdonotallowexclusionsorlimitationofincidentalorconsequentialdamages,sotheselimitationsmaynotapplytoyou.Thiswarrantygivesyouspecificrights;youmayalsohaveotherrights,whichvaryfromstatetostate.EXCEPTTOTHEEXTENTPROVIDEDBYLAW,HHTMAKESNOEXPRESSWARRANTIESOTHERTHANTHEWARRANTYSPECIFIEDHEREIN.THEDURATIONOFANYIMPLIEDWARRANTYISLIMITEDTODURATIONOFTHEEXPRESSEDWARRANTYSPECIFIEDABOVE.

WARRANTY EXCLUSIONS:Thiswarrantydoesnotcoverthefollowing:• Changesinsurfacefinishesasaresultofnormaluse.Asaheatingappliance,somechangesincolorofinteriorand

exteriorsurfacefinishesmayoccur.Thisisnotaflawandisnotcoveredunderwarranty.• Damagetoprinted,plated,orenameledsurfacescausedbyfingerprints,accidents,misuse,scratches,melteditems,

orotherexternalsourcesandresiduesleftontheplatedsurfacesfromtheuseofabrasivecleanersorpolishes.• Repairorreplacementofpartsthataresubjecttonormalwearandtearduringthewarrantyperiod.Theseparts

include:paint,wood,pelletandcoalgaskets,firebricks,grates,flameguides,batteriesandthediscolorationofglass.• Minorexpansion,contraction,ormovementofcertainpartscausingnoise.Theseconditionsarenormalandcom-

plaintsrelatedtothisnoisearenotcoveredbythiswarranty.• Damagesresultingfrom:(1)failuretoinstall,operate,ormaintaintheapplianceinaccordancewiththeinstallation

instructions,operatinginstructions,andlistingagentidentificationlabelfurnishedwiththeappliance;(2)failuretoinstalltheapplianceinaccordancewithlocalbuildingcodes;(3)shippingorimproperhandling;(4)improperopera-tion,abuse,misuse,continuedoperationwithdamaged,corrodedorfailedcomponents,accident,orimproperly/incorrectlyperformedrepairs;(5)environmentalconditions,inadequateventilation,negativepressure,ordraftingcausedbytightlysealedconstructions,insufficientmake-upairsupply,orhandlingdevicessuchasexhaustfansorforcedairfurnacesorothersuchcauses;(6)useoffuelsotherthanthosespecifiedintheoperatinginstructions;(7)installationoruseofcomponentsnotsuppliedwiththeapplianceoranyothercomponentsnotexpresslyauthorizedandapprovedbyHHT;(8)modificationoftheappliancenotexpresslyauthorizedandapprovedbyHHTinwriting;and/or(9)interruptionsorfluctuationsofelectricalpowersupplytotheappliance.

• Non-HHTventingcomponents,hearthcomponentsorotheraccessoriesusedinconjunctionwiththeappliance.• Anypartofapre-existingfireplacesysteminwhichaninsertoradecorativegasapplianceisinstalled.• HHT’sobligationunderthiswarrantydoesnotextendtotheappliance’scapabilitytoheatthedesiredspace.Informa-

tionisprovidedtoassisttheconsumerandthedealerinselectingtheproperappliancefortheapplication.Consider-ationmustbegiventoappliancelocationandconfiguration,environmentalconditions,insulationandairtightnessofthestructure.

7 3-90-07205R27_08/15

AssemblyBoiler Kit Materials: (Refer to “Parts Locations” section in this manual)Listofitemscontainedwithintheboilerkitshippedwiththeunit. 1-Controlboardcover 1-Accesscover(HopperSwingPlateKnob) 5-SpringHandles 1-3/4”BoilerDrain 1-3/4”SafetyReliefValve 1-1/2”AquastatWell 1-1/2”DualTemperature/PressureGauge 1-100ft.SensorCable(OutdoorAirSensor) 1-OutdoorAirSensor 1-FlueTunnelWeldment 1-CombustionBlowerAssembly 1-HeatShield(Comb.Blower) 2-UYConnectors 2-Terminals1/4Female 1-#8X1/2”TEK 3-1/4-20X5/8”WingScrew 4-1/4”LockWasher 4-1/4-20Nuts

Installation of the Flue Tunnel Weldment, Combustion Blower and Wiring, ESP and Heat Shield:Step1:Firstinstallthefluetunnelweldmentbyaligningthe(4)studswiththe(4)holesintheashchamberbase.Fastenthe (4) nuts and lockwashers provided, to the studs byremovingtheaccesscoveronthesecondaryashchamber.Step 2:Place the combustionmotor onto the flue tunnelweldmentandtightenthe(3)wingscrewsprovided.Step3:InserttheExhaustSensingProbe(ESP)intothe1/8”holeprovidedonthefluepipestub.Fastenwiththe(1)#8x1/2”TEKscrewalsoprovided.ESPwillbetapedtothesheetmetaljacketforshippingpurposes.Step4:Connecttheflexconduit90°elbow(NotShown)totheheatshieldintheholeprovided.Thenconnectthe(3)wiresfromthecombustionblowerwiththe(3)wiresintheflexconduitbyusingthepush-onconnectorsandmatchingthewirecolorsasfollows:RedtoBlack,WhitetoWhiteandGreentoGreen.Step5:PlaceHeatShieldovercombustionblowerandaligntheswelllatcheswiththeholesinthesheetmetalandtighten.

Heat Shield

NOTE: Refer to Fig’s 22, 23, and 24 located in this manual.

Flue Tunnel Weldment

ESP

Combustion Blower

8 3-90-07205R27_08/15

Refer to the illustration under “Parts Locations” in this manual to identify the components listed below:1.Installthecontrolboardcoveraswellastheaccesscover

locatedonthefeedercover.2. Install the spring handles providedwith the unit on

the ash door, firebox door and the heat exchangercleanoutrodhandles.(Fastenhandlesbyturningthemcounterclockwiseandpushinginwardsimultaneously).

3.Install3/4”MPTboilerdraininthefittingasshown.Note: Use pipe thread sealant or Teflon tape on ALL threads before connections are made.4.Install3/4”MPTpressurereliefvalveasshown.5.Installthe1/2”MPTaquastatwellinfittingasshown,then

placeaquastatinthewellandfastenwithaziptie.Theaquastat sensor is located under the top sheetmetaljacket.

6.Installthe1/2”MPTtemperature/pressuregaugeinfittingasshown.

7.Locateandinstalloutsideairtemperaturesensor.Locationofthissensorshouldbeonthenorthsideofthehomeorbuildingandoutofdirectsunlight.Usethecablesuppliedwiththeboilertoattachthesensortotheterminalslocatedonthehopper.(Placeatthebacksidejustaboveandtotherightofthemainpowerconnectionbox)Thewirescanbeconnectedtothesensorwiththeconnectorssupplied.Wirenutorbuttspliceconnectorscouldalsobeused.Theconnectionsattheboilercanbedonewiththetwo1/4”femalepushonconnectorssupplied.

8. Fasten the conduit to the ash basewith the clampsprovided.

Design:Thefirstthingthatneedstobedoneisdecidingwhereandhowtheboilerwillbeinstalled.Things that need to be taken into consideration are theintendeduseoftheboilerforexample,istheboilergoingtobeusedasyourprimaryheatingsystemorisitgoingtobeusedasasecondaryorbackupheatingsystem.Ifitistobeusedinconjunctionwithanexistingoilorgasboilersystemwillitbepipedinparallelorinseries?TheanswerstotheseandotherquestionscanbedeterminedbytalkingtoyourcertifieddealeroraqualifiedHVACorplumbingcontractor.Thiswillensurethattheboilerisinstalledandpipedtoaccommodateyourneedsandexpectations.Considerationmust be given to the venting aswell aselectricalandclearancerequirements.(Clearancesmustbemaintainedtocombustiblesandalsoforservice)Makesurefansarenotusedinthefuelstoragearea,unlesstheyareinstalledsoasnottocreateanegativepressureintheroomwherethesolidfuelburningapplianceislocated.

Assembly

Floor Protection: The striped area indicates theminimum required floorprotection area if the boiler is going to be placed on acombustiblefloor.Itrequires40”X55”(US)or42”X55”(CAN)ofnoncombustiblefloorprotectionasshown.16”(US)or18”(CAN)ofthefloorprotectionmustbeinfrontofthefireboxdoorasshown.Floorprotectionmustbeaminimumof26gaugesheetmetal.Floorprotectionmustalsobeprovidedunderanyhorizontalrunofventpipeequaltotheoutsidediameteroftheventingplus2”toeachside.Example: 4” type “L” or “PL” vent pipe has an outsidediameterof4-1/2”+2”oneachsideequalsaprotectedfloorareaof8-1/2”wideunderneaththehorizontalrun.

42"

CA

NA

DA

18"

CA

N

16"

USA

40"

USA

55" USA & CAN

MINIMUM NON-COMBUSTIBLE FLOOR PROTECTION AREA

NON-COMBUSTIBLE

FLOOR PROTECTOR

55" USA & CAN

42"

CA

NA

DA

40"

USA

9 3-90-07205R27_08/15

Assembly

INSTALLATION IS TO BE PERFORMED BY A QUALIFIED INSTALLER.

NOTE: All installation clearances and restrictions must be adhered to.

NOTE: Use only 4” diameter type “L” or “PL” venting system. Be sure to inspect and clean exhaust venting system frequently.

24.2

5”

*E 36”

*D20”

*I80”

*C 16.5

”

*A18”

*B6”

TOP VIEW*F

*G 22.5

”

*5 66”

62”

43.5

”

FRONT VIEW

Notes:A.Manufacturerrecommendedminimumclearance.B.MinimumclearancetocombustiblesBUTNOTRECOMMENDED!(SeeNoteC).C.Mfr’srecommendationtoallowforfullopeningoffeederswingplate=16.5”D.Minimumclearancetoallowservicingofcombustionblower=20”E.Minimumclearancetocombustibles=36”F. Pelletventclearancetocombustibles=1”G.Stovetoptoceiling=22.5”H.Minimumceilingheightoralcoveheight=66”I. Maximumalcovedepth=80”

10 3-90-07205R27_08/15

V =Vent Terminal A =Air Supply Inlet =Area where termination is not permitted

Door

Sidewalk

FixedClosed

Openable

Openable FixedClosed

Inside CornerDetail

Porch orOpenable

Deck or Fixed

Requirements for Terminating the VentingWARNING:Ventingterminalsmustnotberecessedintoawallorsiding.NOTE:OnlyPLventpipewallpass-throughsandfirestopsshouldbeusedwhenventingthroughcombustiblematerials.NOTE:Always take into consideration the effect theprevailingwinddirectionorotherwindcurrentswillcausewithflyashand/orsmokewhenplacingthetermination.In addition, the following must be observed:A.Theclearanceabovegrademustbeaminimumof12”.B.Theclearancetoawindowordoorthatmaybeopened

must be aminimumof 48” to the side, 48” below thewindow/door, and 12” above thewindow/door. (With outside air installed, 12” to the side or below)

C.A 12” clearance to a permanently closedwindow isrecommendedtopreventcondensationonthewindow.

D.Theverticalclearancetoaventilatedsoffitlocatedabovetheterminalwithinahorizontaldistanceof2feet(60cm)fromthecenter-lineoftheterminalmustbeaminimumof18”.

E.Theclearancetoanunventilatedsoffitmustbeaminimumof12”.

F. Theclearancetoanoutsidecorneris11”fromcenterofpipe.

G.Theclearancetoaninsidecorneris12”.H.Aventmustnotbeinstalledwithin3feet(90cm)above

agasmeter/regulatorassemblywhenmeasuredfromthehorizontalcenter-lineoftheregulator.

Fig. 2

VentingI. Theclearancetoserviceregulatorventoutletmustbea

minimumof6feet.J. Theclearancetoanon-mechanicalairsupplyinlettothe

buildingorthecombustionairinlettoanyotherappliancemustbeaminimumof48”.

K.Theclearancetoamechanicalairsupplyinletmustbeaminimumof10feet.

L. The clearance above a paved sidewalk or a paveddrivewaylocatedonpublicpropertymustbeaminimumof7feet.

M.Theclearanceunderaveranda,porch,deckorbalconymustbeaminimumof12inches. (B Also applies)

NOTE:The clearance to vegetation and other exteriorcombustiblessuchasmulch is36”asmeasuredfromthecenteroftheoutletorcap.This36”radiuscontinuestogradeoraminimumof7feetbelowtheoutlet.CertainCanadianandorLocalcodesorregulationsmayrequiredifferentclearances.A vent shall not terminate directly above a side-walk orpaveddrivewaywhichislocatedbetweentwosinglefamilydwellingsandservesbothdwellings.Onlypermitted ifveranda,porch,deck,orbalcony is fullyopenonaminimumof2sidesbeneaththefloor.NOTE: Where passage through a wall, or partition of combustible construction is desired, the installation shall conform to CAN/CSA-B365. (if in Canada)

11 3-90-07205R27_08/15

5 Ft

10 Ft

15 Ft

20 Ft

25 Ft

30 Ft

0 Ft

0 Ft5 Ft10 Ft15 Ft18 Ft 5 Ft 10 Ft 15 Ft 18 Ft

5 Ft

0 Ft

7 Ft10

9

8

7

6

5

4

3

5 Ft

0 Ft

10 Ft

12 Ft

Note: The total Lineal Feet decreases as the Altitude increases.Note: The maximum length of the Outside Air Flex also decreases to 20 Feet

Total Lineal Feet combined should not exceed 30 Feet.

Altitude in thousands of feet.

Venting

Fig. 3

Avoiding Smoke and Odors -NegativePressure,Shut-downandElectricalPowerFailure.To reduce the probability of back-drafting or burn back in the pellet boiler during a power failure, it must be able to draft naturallywithoutexhaustbloweroperation.Negativepressureinthehousewillresistthisnaturaldraftifnotaccountedforduringinstallation.Heatrisesinahouse,and leaks out at upper levels. This airmust be replacedwithairfromoutsidethedwelling,whichnormallyflowsintolowerlevels.Ventsandchimneysintobasementsandlowerlevels can become the conduit for return air and reverseundertheseconditions.Hearth & Home Technologies strongly recommends the use of outside air in all pellet boiler installations, especially those on lower level and main floor locations. Per national building codes, considerationmust be givento combustion air supply to all combustion appliances.Failuretosupplyadequatecombustionairforallappliancedemands may lead to back-drafting of those and otherapplianceswithinthehome.

To reduce the probability of reverse drafting during shut-down conditions, Hearth & Home Technologies strongly recommends: •Installingthepelletventwithaminimumverticalrunof5feet.Preferablyterminatingabovetheroofline.• Installingtheoutsideairintakeatleastfourfeetbelowtheventtermination.Toprevent sootdamage toexteriorwalls, and topreventre-entryofsootorashintothehouse:•Maintainspecifiedclearancestowindows,doorsandairinlets,includingairconditioners.•Ventsshouldnotbeplacedbelowventilatedsoffits.Runtheventabovetheroof.•Avoidventingintoalcovelocations.• Vents should not terminate under overhangs, decks orontocoveredporches.• Maintain minimum clearance of 12” from the ventterminationtotheexteriorwall.Extendingthisdistancemayberequiredifvisualaccumulationoccurs.

12 3-90-07205R27_08/15

Theminimumventconfigurationisa90°orTeeonastartercollaranda24”lengthhorizontalthroughanexteriorwall.Acapontheendshoulddirectthefluegassesdownandawayfromthestructure.SeeFig.5.Themaximumhorizontal length is 18 feet.Theminimumtermination height above the exterior grade is 18”. Themaximumtotallengthofanyconfigurationis30feet*.*(Seeventinggraph(Fig.3)inthismanualforexceptions)NOTE: Cleanout Tee’s should always be used on the transitions to horizontal pipe to allow easy access for cleaning.Theventinggraphallowsforone(1)90°orTeefittinginanyconfiguration.Ifmore90’s,T’s,or45’sareneeded,thetotallengthmustbeadjustedtoallowfortheaddedrestriction.Uptofour(4)additional90’s,Tee’s,orequivalent45’scanbeaddedaslongastheoveralllengthisadjustedinaccordancewiththevalueslistedbelow.(SeeRequirements for Terminating the Venting under the ventingsectionofthismanual)

EachVertical----90°orTsubtract2.5feetEachVertical----45° subtract1.5feetEachHorizontal-90°orT subtract5.0feetEachHorizontal-45° subtract2.5feet

Any exterior venting (vent pipe exposed to outside ambient temperatures) should be kept to a minimum, due to potential condensation problems.This isespecially important inhighhumiditycoldweatherclimates,suchasmaritimeareas,lakeshores,andlowrivervalleys.

VentingVentingUse4”pelletventpipeonly.A combustion blower is used to extract the combustiongasesfromthefirebox.ThiscreatesanegativepressureinthefireboxandapositivepressureintheventingsystemasshowninFig.4.Thelongertheventpipeandmoreelbowsusedinthesystem,thegreatertheflowresistance.Becauseofthesefactswerecommendusingasfewelbowsaspossibleand30feetorlessofventpipe.Themaximumhorizontalrunshouldnotexceed18feet.Be sure to use wall and ceiling pass through fittings (which are approved for pellet vent pipe ) when going through combustible materials. Besuretouseastartingcollartoattachtheventingsystemtothestove.The starting collar must be sealed to the stove flue collar with high temp silicone caulking or aluminum tape, and screwed into the stove flue collar at least three (3) places.

12”

36”

-

+

Fig. 4

Vent Pipe4”pelletventpipe(alsoknownas“PL”vent)isconstructedof two layerswithair spacebetween the layers.Thisairspaceactsasaninsulatorandreducestheoutsidesurfacetemperaturetoallowaminimumclearancetocombustiblesas low as 1”. In Canada the minimum clearance tocombustiblesis3”.Thesectionsofpipelocktogethertoformanairtightsealinmostcases;however,insomecasesaperfectsealisnotachieved.Forthisreasonandthefactthattheboileroperateswithapositiveventpressure,we specify that all joints within the structure should also be sealed with silicone.NOTE: Use only 4” diameter approved PELLET venting system. Be sure to inspect and clean exhaust venting system frequently.

This is the minimum venting configuration.

Fig. 5

36”

36”

18”

4” Type “L” or “PL” Vent pipe

13 3-90-07205R27_08/15

Chimneystallerthan20’abovetheconnectionwillrequireadrafttesttodetermineifthedraftistoohigh.Note:Thehighburndraftshouldnotexceed.85IWC.Someformofarestrictorplatemayberequiredatthetopofhighchimneystoreducethedraft.SeeDraft Test Procedure under theinstallationsectionofthismanual.ThisboilermaybeusedandinstalledintoanexistingmasonryorClassAmetalchimney.Certain Canadian and Local Codes may require that the chimney be fully relined.The venting Can Not be installed in a chimney servinganotherappliance.The chimney shouldbe cleanedandor inspectedbeforeinstallationoftheventing.

Creosote - Formation and Need for Removal -Whenwoodisburnedslowly,itproducestarandotherorganicvapors,whichcombinewithexpelledmoisturetoformcreosote.Thecreosotevaporscondenseintherelativelycoolchimneyflueofaslow-burningfire.Asaresult,creosoteresidueaccumulatesonthefluelining.Whenignited,thiscreosotemakesanextremelyhotfire.Thepelletventpipeshouldbeinspectedatleasttwicemonthlyduringtheheatingseasontodetermineifacreosotebuilduphasoccurred.Ifcreosotehasaccumulateditshouldberemovedtoreducetheriskofachimneyfire.Guidanceonminimizingcreosoteformationandtheneedforperiodiccreosoteremoval:Thechimneyshouldbeinspectedduringtheheatingseasontodetermineifacreosotebuild-uphasoccurred.Ifasignificantlayerofcreosotehasaccumulated(3mmormore)itshouldberemovedtoreducetheriskofachimneyfire.

Venting Installation

NOTE: All installation clearances and restrictions must be adhered to.

NOTE: Read and follow all of the vent pipe manufacturers’ instructions on the proper installation and support of the vent pipe. Adhere to all clearances.

DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST VENTING SYSTEM OF THIS UNIT.

DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE.

INSTALL VENT WALL PASS-THROUGHS AT CLEARANCES SPECIFIED BY THE VENT MANUFACTURER

INSTALLATION IS TO BE PERFORMED BY A QUALIFIED INSTALLER.

NOTE: Use only 4” diameter approved pellet venting system. Be sure to inspect and clean exhaust venting system frequently.

Otherexamplesofpossibleinstallationsoftheventing.

36”

18”

Cei

ling

Hei

ght

Min

. 66”

62.23

12.40

20.00

12”

36”

KEEP COMBUSTIBLE MATERIALS SUCH AS GRASS, LEAVES, ETC. AT LEAST 3 FEET AWAY FROM THE POINT DIRECTLY UNDER THE VENT TERMINATION. (BETWEEN THE VENT AND THE GROUND)

WARNING!

KEEP COMBUSTIBLES AWAY FROM FLUE OUTLET.

CAUTION!

12”

36”

14 3-90-07205R27_08/15

Outside AirToinstalloutsideair,use3”galvanizedsteelflexpipe.Fig.6.Thereisabreak-awayholeontherearpanelwhichmustberemovedbeforeconnectingtheflexpipe.SeeFig.7.Whentheapplianceissidewallvented:Theairintakeisbestlocatedonthesameexteriorwallastheexhaustventoutlet,andlocatedloweronthewallthantheventoutlet.When theappliance is roofvented:Theair intake isbestlocatedontheexteriorwalloriented toward theprevailingwinddirectionduringtheheatingseason.Neverterminatetheoutsideairabovetheventpipeoutlet.Themaximum length of this pipe is 20 feet.TerminationCappartnumber1-10-09542shouldbeusedtokeepbirds,rodentsetc.outoftheinletpipe.SeeFig.6.NOTE: The Termination Cap should not be placed in an area where drifting of snow or ice will build up, blocking the intake air supply.TheOutsideAirknockoutislocatedonthefaceoftheFeederCover.It ispre-cutexceptforseveralsmall tabs.ThereisalsoafillerplatescrewedtotheinsidetocoverthetopoftheholeaftertheOutsideAirPipehasbeeninstalled.ThiswillallowforremovaloftheFeederCoverwithoutdisconnectingtheOutsideAirPipe.SeeFig.7.If installingoutsideairtoanolderunitAdapterKit(Part#1-00-06809)mustbeused.OnlymetalIntakeFlexshouldbeusedfortheOutsideAirSupplyconnection.TheOutsideAirIntakePipeisinsidetheFeederCoverandtotherightofthefeedermotor.The3”steelflexpipeismadetoslideovertheoutsideoftheAirIntakePipe. SeeFig.8.Itshouldbeheldintoplacewithsomesilicone,foiltape,orahoseclamp.(Notsupplied)Heat Reclaiming Ventilation System (HRV)WheninstallinginahousewithaHeatReclaimingVentilationSystem(HRV)besure thesystem isbalancedand isnotcreatinganegativepressureinthehouse.

Outside Air Installation

Termination Cap part# 1-10-09542Fig. 6

Fig. 8

Hopper/Feeder Swing Plate Knob

Outside Air Inlet Pipe

Fig. 7

Outside Air Pipe Knockout

Feeder Cover

15 3-90-07205R27_08/15

Main Wiring InstallationToinstallpowertotheboiler,firstremovethecoveronthe4”X4”junctionboxlocatedonthebackoftheunit.Thereareseveralknockoutholesprovidedfortheincomingmainpowerwires.Also,aknockoutholecanbeusedfortheauxiliaryoutputoverheatzone(ifused).Theminimumrecommendedcircuitis6AMP-120VAC-60HZ.Thisboilershouldbetheonlyapplianceonthecircuit.This boiler should never be powered by the use of an extension cord.Therecommendedhighandlowvoltagesare,130VAC60Hzmaximumhighvoltage,and113VAC60Hzminimumlowvoltage.Thefurnacewillcontinuetooperateatvoltagesaslowas105VAC,althoughitcannotbeguaranteedthatautomaticignitionwilloccur.NOTE: If other sources of electrical power are to be used ( such as a generator ) for normal operation or emergency operation, this source should be checked before installation. Many generators and inverters may not supply 120 VAC, 60Hz power stable enough to operate the control board properly. (Control board damage could occur).

16 3-90-07205R27_08/15

Plumbing Installation

NOTE: Coldreturnwatertemperature(Sustainedtemperaturesbelow140°F)willleadtocondensationinthefirebox.Thismoisturecanleadtocreosoteformation.Tohelpminimizemoistureandcreosote,itisstronglyrecommendedthatsomeformoftemperaturebalanceisincorporatedintothereturnwatersystem.

NOTICE: When installing with the atmospheric conversion:Allofthepressurizedsystemcomponentsshownarenotnecessary.Airventsorbleederswillneedtoberemovedfromtheplumbingsystemtopreventairfromenteringthelines.Controldipswitch#6willneedtobeturned“ON”.

3/4”

3/4”

17 3-90-07205R27_08/15

Plumbing InstallationBoilers intended to be connected to an existing boiler or boiler system shall:1. Becapableofbeinginstalledwithoutinterferingwiththenormaldeliveryofheatedwaterfromtheoriginalboilertotheradiation

system.2. Becapableofbeinginstalledtooperateasintendedwithoutaffectingtheoperationoftheelectricalandmechanicalsafety

controlsoftheoriginalboiler.3. Provide,uponcompletionoftheinstallation,forachangeoverfromonefueltotheotherwithoutrequiringthemanualadjustment

ofanycontrolsorcomponentsotherthanthethermostats.4. Becompatiblewiththeoperationofaservicewater-heatingcoilwithintheoriginalboilerwithoutbypassingtheoperationofthe

solid-fuelboiler.5. Haveprovisionforpreventing,oradequatewatercapacitywithintheboilertoprevent,damagetotheboilerfromlossofcirculation

duetoelectricalpowerfailure.6. Becapableofbeinginstalledwithoutchangingthefunctionofthecontrolorrewiringoftheoriginalboiler.Awiringinterconnection

ispermitted.Theelectricalsystemofbothboilersshallbepoweredfromasinglebranchcircuitwithoutexception.(CAN/CSA-B366.1-M91)

7. PertainingtoCAN/CSA-B365-01,Haveaclearlylabelleddevice,locatedateachentrancetotheboilerarea,whichcanbethrowntodiscontinueoperationofthefeedsystem.

NOTICE: When installing with the atmospheric conversion: All of the pressurized system components shown are not necessary. Air vents or bleeders will need to be removed from the plumbing system to prevent air from entering the lines. Control dipswitch #6 will need to be turned “ON”.

18 3-90-07205R27_08/15

NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.

HIGHER TEMPERATURE WATER (IF NEEDED)

NOTE: TYPICALLY, AS LONG AS THE WATER TEMPERATURE NEEDED IS NOT MORE THAN 120 F, THE MIXING VALVE SHOWN ABOVE (EXAMPLE 2) IS NOT NEEDED

EXAMPLES OF TYPICAL DOMESTIC HOT WATER STORAGE PIPING

IN

TO BOILEROUT

FROM BOILER

CIRCULATOR

COLD HOT

DOMESTIC HOT WATER STORAGE HEATER

OUT

IN

TO BOILER

HOT

DOMESTIC HOT WATER STORAGE HEATER

COLD

FROM BOILER

CIRCULATOR

MIXING VALVE

EXAMPLE #1 EXAMPLE #2

MIXING VALVE SET TO DESIRED WATER TEMPERATURE.NORMALLY NOT MORE THAN 120 DEGREES.

TEMPERED HOT WATER FOR SHOWERS AND FAUCETS


COLD WATER SUPPLY

MIXING VALVE SET TO DESIRED WATER TEMPERATURE.NORMALLY NOT MORE THAN 120 DEGREES.

FLOW REGULATOR WILL NEED TO MATCH THE GPM RATING OF THE DOMESTIC COIL. (IF USING A DOMESTIC COIL, 4 GPM IS REQUIRED.)

HOSE BIB TO BACKFLUSH COIL IF NEEDED

AQUASTAT WELL LOCATION

HOSE BIB

SAFETY RELIEF VALVE

FLOW REGULATOR ISOLATION VALVE


EXAMPLE OF TYPICAL TANKLESS DOMESTIC HOT WATER PIPING

OUTLET

OPTIONAL DOMESTIC HOT WATER COIL

INLETMIXING VALVE

HIGH TEMPERATURE WATER (IF NEEDED)

TEMPERED HOT WATER TO SHOWERS AND FAUCETS

19 3-90-07205R27_08/15



AIR VENT (TYPICALLY INSTALLED IN THE HIGHEST ACCESSABLE LOCATION IN THE PIPING)

FROM ADDITIONAL ZONES

SYSTEM RETURN 1-1/4"

FROM BOILER

TO BOILER

SYSTEM SUPPLY 1-1/4"

BRANCH ZONES WILL BE REDUCED TO REQUIRED SIZE (TYPICALLY 3/4") AT THIS POINT

NOTE: IF CIRCULATOR DOES NOT HAVE CHECK VALVE THEN A FLOW CONTOL VALVE WILL ALSO BE NEEDED AND INSTALLED IN THIS LOCATION

SHUT-OFF VALVETO ADDITIONAL ZONES

SHUT-OFF VALVE

CIRCULATORS WITH INTEGRAL CHECK VALVE (SEE NOTE)

UNION

EXAMPLE OF A TYPICAL MULTI-ZONE HEATING SYSTEM WITH INDIVIDUAL ZONE CIRCULATORS

ZON

E 2ZO

NE

1

ZON

E 3

AIR VENT

ZONE 1

ZONE 2

ZONE 3

* PRESSURE RELIEF VALVE

* TEMPERATURE/PRESSURE GAUGE

AIR VENT

TYPICAL BOILER HOT WATER PIPING SHOWING AIR REMOVAL SYSTEM, PROVISIONS FOR THE EXPANSION OF WATER AND THE AUTOMATIC COLD WATER SUPPLY. ALSO SHOWN IS THE AUTOMATIC MIXING VALVE. THIS COULD ALSO BE DONE BY (2) CLOSELY SPACED TEE'S. THE PROPER PIPING FOR THE INTENDED USE WILL BE DETERMINED BY THE INSTALLING CERTIFIED PLUMBER OR HVAC CONTRACTOR.

UNION

SHUT-OFF VALVE

* AQUASTAT WELLUNION


* ITEMS SUPPLIED

** OPTIONAL

PRESSURE REDUCING VALVE (PRV) OR COMBINATION PRV AND RELIEF VALVE

* BOILER DRAIN, 1/2" NPT MALE X 3/4" HOSE MALE (NOT SHOWN)

SENSING BULB

EXPANSION TANK (DIAPHRAGM TYPE)

SHUT-OFF VALVE

PIPE TO WITHIN 6" OF THE FLOOR OR A FLOOR DRAIN


** THERMOMETER

CHECK VALVE (OR BACKFLOW PREVENTER IF REQUIRED)

** THERMOMETER


AIR SCOOP

AUTOMATIC MIXING VALVE

COLD WATER SUPPLY 1/2"


SHUT-OFF VALVE



*BOILERDRAIN,3/4”NPTMALEX3/4”HOSEMALE(NOTSHOWN)

20 3-90-07205R27_08/15


EXAMPLE OF A COMBINATION HIGH/LOW MULTI-ZONE HEATING SYSTEM WITH INDIVIDUAL ZONE CIRCULATORS

NOTE: IF CIRCULATOR DOES NOT HAVE CHECK VALVE THEN A FLOW CONTOL VALVE WILL ALSO BE NEEDED AND INSTALLED IN THIS LOCATION


TO BOILER


FROM BOILER

CIRCULATORS WITH INTEGRAL CHECK VALVE (SEE NOTE)

THERMOSTSTIC MIXING VALVE


MIX

COLDHOT

SHUT-OFF VALVE

SHUT-OFF VALVEUNION

ZONE 1

ZONE 3

ZONE 2

(LOW TEMPERATURE) RADIANT FLOOR HEAT

(LOW TEMPERATURE) RADIANT FLOOR HEAT


(HIGH TEMPERATURE) BASEBOARD HEAT

AIR VENTZON

E 3

ZON

E 2

ZON

E 1




FROM ADDITIONAL ZONES

EXAMPLE OF A TYPICAL MULTI-ZONE HEATING SYSTEM WITH A SINGLE CIRCULATOR AND INDIVIDUAL ZONE VALVES

SHUT-OFF VALVE


SYSTEM RETURN 1-1/4"TO BOILER


FROM BOILER

CIRCULATOR

ZON

E 2ZO

NE

1

TO ADDITIONAL ZONES

UNION

ZONE VALVE

BALANCING VALVE

UNION

ZON

E 3 AIR VENT

ZONE 1

ZONE 2

ZONE 3



21

21

3-90-07205R27_08/15

Over Heat Safety ZoneOverheat Safety Zone (Dump Zone): STRONGLY RECOMMENDED in all installations.WhenthepelletboilerisoperatingatHighburn,andalldemandfromtheheatingsystemstops,thecontrolwillreducethefeedrateandshutdowncompletelyasnecessary.Thismaytakeseveralminutes,andtheremainingheatmaycausethewatertemperaturetocontinuetorise.Ifthetemperaturegetstoohigh,theOVERHEATSAFETYZONElightonthecontrolwillilluminate,andtheDARKBLUEcircuitinthejunctionboxisenergized(seewiringdiagram).Thiscircuitwillflow120Vtooperateacirculatorpumpinstalledtoflowtotheoverheatdumpzoneestablishedintheoriginalinstallationplan.Ifopeningazonevalveisthechosenmethodofdumpingtheexcessheat,avoltagereductionrelaywillmostlikelybeneeded.Ifthewatertemperaturecontinuestorisetotheriskofboilingpoint,thefeedsystemwillstopandtheboilerwillshut-down.Amanualresetwillthenberequiredtooperatetheboiler.Withoutadumpzoneinplace,theexcesstemperaturecouldbuildpressuretothepointofopeningthereliefvalve,orwiththeatmosphericconversionitmayallowthewatertoboilandexitthroughtheover-flowoftheatmospherictank.Bothscenariosmaycreatewaterdamageand/orasliphazard.Theboilingtemperatureofwatervariesatdifferentaltitudesandatmosphericpressures.Therefore,atelevationsabove3000feet,andwhenusingtheatmosphericconversion,circuitboarddipswitch#6mustbeinthe“ON”position.

MINIMUM OF 72" OF 3/4" FINNED BASEBOARD(HIGH TEMPERATURE) BASEBOARD HEAT

SYSTEM RETURN

SHUT-OFF VALVE


120VAC,NORMALLY OPEN,FULL FLOW,SOLENOID VALVE or EQUIVALENT

THE SOLENOID SHOULD BE POWERED BY THE SAME CIRCUIT AS THE BOILER

BASEBOARD MUST BE AT LEAST24" HIGHER THAN BOILER FORPROPER GRAVITY FLOW

UNION

BALANCING VALVE

UNION

PIPE TO WITHIN 6" OF THE FLOOR OR A FLOOR DRAIN

* TEMPERATURE/PRESSURE GAUGE

* AQUASTAT WELL

* PRESSURE RELIEF VALVE

SHUT-OFF VALVE

* ITEMS SUPPLIED

POWER FAILURE SYSTEM SUPPLY 3/4"

SYSTEM SUPPLY

POWER FAILURE SYSTEM RETURN 3/4"

EXAMPLE OF PIPING IN ACCORDANCE WITH (CAN/CSA-B366.1)A POWER FAILURE HEAT DISSIPATION LOOP

Power Failure / Heat Dissipation Loop

22 3-90-07205R27_08/15

Lowwatercut-offcontrolLWCOWiringInstructions

TO BE USED WHERE REQUIRED BY LOCAL CODESRead and follow the instructions provided with the specific LWCO Control selected.TheLWCOControlwillprovideasetofcontactsthatareclosedwhenwaterispresentatthesensor.Itwillopenthefeedmotorcircuitwhenalowwaterconditionexist.Dependingonthemodelselected,amanualresetofthecontrolmayberequiredafteralowwaterconditionhasexisted.• WARNING: To prevent electrical shock or equipment damage, make sure power is turned off to the boiler.• Locatetheblackwirefromthewiringharnessthatconnectstothefeedmotor.Fig.1• Separatetheblackwiresatthe¼”pushonconnectorsforthefeedmotor.Fig.2&Fig.3• Themaleconnectorwillbeonthewiringharnessandthefemaleconnectorwillbeonthefeedmotorwire.Fig.3& Fig.4.

Fig. 1 Fig. 2 Fig. 3

• WiretheLWCOcontrolcontactsinserieswiththefeedmotoronthepelletboiler.Fig.4• Aseparatepowersourcemayberequired for theLWCOcontrol.Readand follow the instructionsprovidedwith the

specificLWCOcontrolselected.• Considerationmustbegiventoall localcodesandregulationsregardingtheproper installationof theLWCOcontrol

deviceandassociatedwiring.Note: Always verify proper operation of control after installation

Fig. 4

LWCO Control Contacts. (Open contact circuit when low water condition exists.)

23 3-90-07205R27_08/15

Draft Test ProcedureAftertheventingiscompleted,thefireboxlowdraftwillneedtobecheckedandpossiblyadjusted.Afterremovingthe3/8”boltfromthedraftholeshowninFig.9,insertthedraftmetertube.Theappliancedoorsandhopperlidmustbelatchedduringthistest.(Itisrecommendedthatthedraftmeterhaveascaleof0to1”WC.)Turnthefeedadjusterto“Test”.thiswillstartthecombustionblowerandallowyou to checkand record theHighDraft______ - IWCdate_______ Themaximumdraftmustnotexceed-.85”W.C.Someformofventrestrictormaybeneeded.(ThereisnocontrolboardadjustmentfortheHighDraft)After the first 60 seconds the “Test” mode lowers thecombustionblowervoltagetotheLowBurnvoltage.Duringthis lowered voltage cycle theLow Burn Draft must be checked andadjustedifnecessary.Therecommendedlowdraftsettingshouldbebetween-.25&-.35IWC.Dependingontheamountofverticalrise,itmaynotbepossibletogetalowdraftreadinginthisrange.Inthiscase,amaximumlowdraftof-.55isacceptable.The adjustment screw is through the small hole to therightoftheIgniterLight.SeeFig.10.AdjustedLowDraftis__________-IWC.Don’tforgettoturnthefeedadjusteroffof“Test”.Do not operate if the high draft exceeds -.85” W.C.Excessive draft readings may be due to restriction in the combustion air supply. Check for obstructions.The ControlTheboilerhastheoptiontohavethecontrolpanelcoveredoruncoveredSeeFig.11.Thereisapairofslotsprovidedforeachposition.Simplymovethecovertothedesiredpositionbyplacingthetabsonthecoverintheproperslots.

Firebox Door

Air Wash Slot

Viewing Window

Draft Bolt Location

Fig. 9

“Test”

Low Draft Adjustment Pot

Fig. 10

Covered Uncovered

Fig. 11

CAUTION!Hot while in operation. Do not touch. Keep children, clothing, furniture, and other combustible material out of the installation clearance area.

WARNING!Do not operate with the hopper lid or fire chamber or ash removal doors open.

Do not store fuel or other combustible material within installation clearance area.

WARNING!

24 3-90-07205R27_08/15

Fuel and Fuel StoragePellet fuel quality can fluctuate from manufacturer tomanufacturer,andevenfrombagtobag.Hearth&HomeTechnologiesrecommendsusingonlyfuelthatiscertifiedbythePelletFuelsInstitute(PFI).

FuelMaterial• Madefromsawdustand/orotherwoodby-products• Sourcematerialtypicallydeterminesashcontent

HigherAshContentMaterial• Hardwoodswithhighmineralcontent• Barkandleavesassourcematerial• “Standard”gradepellets,cornandotherbiomass

LowerAshContentMaterial• Softwood;pine,fir,etc.• Materialswithlowermineralcontent• “Premium”gradepellets

ClinkersMinerals and other non-combustible materials, like sand,willturnintoahardglass-likesubstancewhenheated.Treesfromdifferentareaswillvaryinmineralcontent.Forthis reason, some fuels will produce more clinkers thanothers.

MoistureAlways burn dry fuel. Burning fuel with high moisturecontenttakesenergytodryandtendstocooltheappliancethus,robbingheatfromyourhome.Damppelletfuelcouldturnbackintosawdustwhichdoesnotflowproperlythroughthefeedsystem.Size• Pellets are either 1/4 inch or 5/16 inch (6-8mm) in

diameter• Lengthshouldbenomorethan1-1/2inches(38mm)• Pellet length can vary from lot to lot from the same

manufacturer

Tested and approved for usewithwood pelletsONLY.Burningofanyotherfuelwillvoidyourwarranty.

Hearth&HomeTechnologiesisnotresponsibleforstoveperformanceor extramaintenance requiredasaresultofusingfuelwithhigherashormineralcontent.

NOTICE

Fuel SpecificationsPerformance• Higherashcontentrequiresmorefrequentmaintenance.• “Premium”gradepelletswillproducethehighestheat

output.• Burning pellets longer than 1-1/2 inches (38mm) can

causeinconsistentfeedingand/orignition.

Werecommendthatyoubuyfuelinmulti-tonlotswheneverpossible. However, we do recommend trying differentbrands prior to purchasing multi-ton lots, to ensure yoursatisfaction.

When changing from “Premium” grade pellets to a“Standard”or“Economy”gradefuel,theFEEDADJUSTERwill likely need adjusted to a lower setting. When undermaximumdemand,ensurethereisnounburnedfuelbeingpushedintotheashpan.

Storage• Woodpelletsshouldbeleftintheiroriginalsealedbag

untilreadytouse,topreventmoisture.• Donotstorefuelwithinthespecifiedclearanceareas,

or ina locationthatwill interferewithroutinecleaningandmaintenanceprocedures.

CAUTION!Tested and approved for use with wood pellets ONLY. Burning of any other fuel will void your warranty.

CAUTION!

25 3-90-07205R27_08/15

Power LightIndicates power to the control board.

Status LightWill be lit anytime there is a call for heat.

Combustion Blower LightIndicates Power to combustion blower

Feed Motor LightIndicates Power to the feed motor.

MAX. TEMP. DialThe “MAX. TEMP. Dial” is used to set the desired maximum operating temperature of the boiler.

7 Blinks: Boilerwater over heat safety shut down.Thisrequiresamanualresetbycyclingthemainpoweroffforafewsecondsandre-connect.Mode Selector/MIN. TEMP. Usedtoturntheboileronoroffandsetthedesiredminimumoperatingtemperatureoftheboiler.MAX. TEMP./ MIN. TEMP. Water Temperature SettingsSee“SettingtheBoilerTemperature”.OFF ModeTurning theModeSelector/MIN.TEMP. toOFFwill shutdowntheboiler.

Feed adjusterSets the maximum feed rate

TestCombustion blower, feed motor and safety dump zone are fully energized for the first minute. Afterward, combustion blower remains on low only.

Overheat Safety Zone LightIndicates elevated boiler water temperature. Power flowing to Overheat circuit.

Igniter LightIndicates power to the igniter

Lighting Mode SelectorSwitched between Auto and Manual lighting

Mode Selector/MIN. TEMP. DialUsed to turn the boiler on or off and set the desired minimum operating temperature of the boiler.

Status light error messages:3 Blinks:IndicatesthattheESP(ExhaustSensingProbe)has gone out of range, toomany times.May indicateexcessive ashbuild-up in the exhaust stream. If the unitseemstobeoperatingnormally,performamanualresetbycyclingthemainpoweroffforafewsecondsandre-connect.4 Blinks:Indicatesmiscommunicationwiththeaquastat,orthesensorisnotattachedproperly.Mayrequireamanualreset.5 Blinks:(InAutoLightModeOnly)Indicatesthattheigniterhasfailedtolightthefireafter40Minutes.Toreset-TurntheModeSelector/MIN.TEMP.toOFFandthenbacktothedesiredtemperature.6 Blinks:Indicatesthatthecontrolhascalculatedpoororincompletecombustionoccurringfor25ormoreminutes.Asixblinkstatusmaybesetifthestoveisallowedtorunoutofpellets.Toreset,turnModeSelector/MIN.TEMP.dialto“OFF”thenbackontothedesiredtemperature.Iftheunitwasnotoutofpellets,seeTroubleshootingsectionformoredetails.

Diagnostic PortFor diagnostic purposes only. Requires special DDM monitor supplied to trained technicians exclusively.

ESP Control

26 3-90-07205R27_08/15

Outdoor Air Reset OperationPelletB

oilerO

utdoorAirResetOperation

Whentheoutdoorsensorisinstalled,at20°F.orbelow

OAT

(OutdoorAir

Temperature),theboilerw

illoperateatthetemperaturesetontheMaximum

Temperatureknob.Theboilerw

atertemperaturewilldecreaseby1°forevery

1°intemperatureriseoftheOutsideAir.

Example1

OAT

WaterTem

pDegreeChange

Maxsetat185°

65°

140°

-45°

Minsetat140°

60°

145°

-40°

55°

150°

-35°

50°

155°

-30°

45°

160°

-25°

40°

165°

-20°

35°

170°

-15°

30°

175°

-10°

25°

180°

-5°

20°

185°

0°

15°

185°

0°

10°

185°

0°

5°

185°

0°

0°

185°

Example2

OAT

WaterTem

pDegreeChange

Maxsetat180°

65°

150°

*

Minsetat150°

60°

150°

*

55°

150°

*

50°

150°

-30°

45°

155°

-25°

40°

160°

-20°

35°

165°

-15°

30°

170°

-10°

25°

175°

-5°

20°

180°

0°

15°

180°

0°

10°

180°

0°

5°

180°

0°

0°

180°

0°

*Nochangeinboilertem

peratureafterreachingminimum

setpointtemperature.

27 3-90-07205R27_08/15

Setting the Boiler TemperatureWithout the Outdoor Air Temperature Sensor InstalledTosetthemaximumboilerwatertemperature,simplyturntheMAX.TEMP.dialtothedesiredsetting.ThecontrolandtheboilerwillthenperformtoachieveandmaintainthesettemperatureTheMIN. TEMP. Knob is the boiler water temperatureminimum,orthelowesttemperaturethewaterwillgobeforetheunitre-starts.Turningtheknobfullycounter-clockwiseisthe“OFF”position,whileturningtheknobclockwise,pastthe140°marking,isthe“ON”position..With The Outdoor Air Temp - Sensor InstalledMaximumboilertempsettingisasdescribedabove.TheMIN.TEMP.knobinadditiontobeingthemodesetting(onoroff)nowalsohasthefunctionofsettingtheminimumboilerwater temperature.Thiswouldbe the lowestboilerwater temperature that youwant to have based on thefollowingfactors.1. OutdoorAirTemperature(OAT)2. DomesticHotWaterUsea. HotWaterCoilOptionb. IndirectHotWaterStorage

3. OverallVolumeoftheHeatingSystemThe boiler is designed to withstand lower return water temperatures however, extended return temperatures below 140° F can cause condensation in the secondary ash chamber area and also in the venting system, which could cause damage in these areas.NOTE:If the system is run at the lower temperature settings, conditions of the firebox, boiler tubes, secondary ash chamber and venting should be monitored closely. If conditions show excess condensation, the boiler water minimum temperature will need to be increased until condensation does not occur. You should also consider some form of tempering of the return water system. Discuss this with your plumber.

Control Board Operation

Control Board OperationAquastat Sensor:This sensor is located in theaquastatwellonthetopofthewaterjacket.Thissensoralongwiththeoutdoorairsensoriswhatthecontrolboardusestoregulatethefeedratebasedonthesetwoobservedconditions.(BoilerTemp.&OutdoorAirTemperature)Outdoor Air Temperature Sensor (OAT):Thissensor islocatedoutsidethebuilding(onthenorthsideofthehouseandoutofdirectsunlight).TheOutdoorAirSensorisusedtoperformhotwaterresetbasedonoutdoorairtemperatures.WhentheOATsensorisinstalled,at20°F.orbelow(outsidetemperature),theboilerwilloperateatthetemperaturesetontheMAX.TEMP.knob.Theboilerwatertemperaturewilldecreaseby1°F.forevery1°F.intemperaturerise(above20°)oftheoutdoorair.NOTE: Pellet Boiler Outdoor Air Reset Operation Graph located on the following page.

28 3-90-07205R27_08/15

Starting A Fire Automatically1. MIN. TEMP. Selector to “OFF”. Thisresetsthecontrol

inadditiontoturningitoff.2. Clean Burnpot withscraper,ifnecessary.Thisisusually

aweeklymaintenanceprocedure.Cleaningtheburnpotwiththescraperwithasmallamountofnewfuelinthebottomisnotaproblem.First,scrapetheashesonthefrontoftheburnpotintotheashpan.Thenscrapetheholegridsurfacedownwardintotheburnpot.Whenthestoveisignitedthesescrapingswillbepushedoutbythefeeder.

The illustrationat leftshowsthehopperswingplateopenforeasyaccesstotheburnpot.Theburnpotcanalsobereachedthroughthefireboxdoor.NOTE: To minimize the amount of stress placed on the hopper swing plate hinges, opening of the hopper swing plate should be done with the least amount of fuel in the hopper as possible.3. Fill Hopperwithpellets.Whenfillingthehoppercheck

forexcessivefinesinthebottomofthehopper.Finesaresmallpiecesofbrokenpellets(sawdust).Finesdonotfloweasilyandoftenbuilduponthehopperfunnelbottomangles.Thesefinescanbepushedintothefeederopeningandthenfillthehopperwithpellets.Asthesystemworks,theywillbeburned.

4. If Starting After an Empty Hopper, Turn Feed Adjuster to “TEST” (forone60secondcycle).Thiswillfeedpelletsintotheaugertubeandalsoallowyoutocheckthemotorsforoperation.NOTE: The auger motor will not operate with any of the doors open.

5. Turn Feed Adjuster to #4. Ifthisisyourfirstfireoryouaretryingdifferentpellets,setthefeedadjusterto#4,Thisisanaveragenumberformostpelletsandmayneedtobeadjustedforyourparticularfuel.Afteryouknowafeedratesettingthatworkswellforyourapplication,usethatsetting.

NOTE: You know your feed rate is too high when: The overheat safety feature is energized each time the heating zone demand turns off during a high burn. OR, If unburned or partially burned pellets are found in the ash pan. (This may also be an indication of a burn pot in need of scraping.)6. Flip the Igniter Switch up intothe“AUTO”position.7. Turn the MAX. TEMP. Dial onthecontrolboardtothe

desiredtemperature.Thissettingmustalwaysbeatleast5°F.higherthantheMIN.TEMP.setting.

Automatic Ignition

Scrape burnpot to remove any carbon build-up that may have occured

HOT WHILE IN OPERATION. KEEP CHILDREN, CLOTHING, AND FURNITURE AWAY. CONTACT MAY CAUSE SKIN BURNS.

WARNING!

29 3-90-07205R27_08/15

Automatic Ignition (Cont.)

8. Turn the MIN. TEMP. Dial onthecontrolboardtothedesiredMinimumtemperature.Thiswillstartthelightingprocess if the temperature at the aquastat sensor isapproximately5°F.lessthanthesettemperatureontheMAX.TEMP.dial.

This ismore than just an automatic ignition pellet boiler.Theautomaticsystemwillallowthefiresizetobeadjustedtomatch the heating needs and even put the fire out ifnecessary.Ifheatisneededafterthefireisout,theboilerwillautomaticallyre-igniteandadjustthefiresizetomatchtheheatingneed.9. Fill hopperwithpelletsandremove ashesasrequired.Type of Fuel Usepelletizedwoodonly.Thelowertheashcontentofthepellets the less cleaning thatwill be needed of the heatexchangersurfaces.Thecleanerthesesurfacesarekept,themoreefficienttheboilerwillbe.Store pellets in the manufacturer’s wrapping until needed to prevent pellets from absorbing moisture. Do not store fuel within the appliance installation clearances, or within the space required for fueling, ash removal, and other routine maintenance operations.

FireHazard.Keepcombustiblematerials,gasolineandotherflammablevaporsandliquidsclearofappliance.

WARNING!

• DoNOTstoreflammablematerialsintheappliance’svicinity.

• NEVERUSEGASOLINE,GASOLINE-TYPELANTERNFUEL,KEROSENE,CHARCOAL LIGHTERFLUID,ORSIMILARLIQUIDSTOSTARTOR“FRESHENUP”AFIREINTHISHEATER.KEEPALLSUCHLIQUIDSWELLAWAYFROMTHEHEATERWHILEITISINUSE.

• DONOTBURNGARBAGEORFLAMMABLE FLUIDSSUCHASGASOLINE,NAPHTHAORENGINEOIL.

• DONOTUSECHEMICALSOFFLUIDSTOSTARTTHEFIRE.

• Combustiblematerialsmayignite.

30 3-90-07205R27_08/15

Lighting a Fire ManuallyLightingthefiremanuallywillnotbenecessaryunlesstheignitersystemfails.Follow steps 1 through 5 of the instructions for automatic lighting.1. Flip the Igniter Switch Down intothe“MANUAL-LIGHT”

position.SeeFig.12.

Manual Ignition

2. Open hopper swing plate as shown in Fig. 13

3. Fill burnpot with pellets as shown. See Fig. 14. Only fill level with the front edge. (DO NOT OVERFILL)

4. Have matches or other ignition source ready.5. Turn Mode SelectortodesiredMIN.TEMP.setting.This

willstart thecombustionblowerandallowthe ESPtocontrolthefireinrelationtotheMAX.TEMP.Dialsetting.(TheMAX.TEMP.dialsettingmustalwaysbesetabovetheMIN.TEMP.setting)OncethefireiswellestablishedtheMAX.TEMP. dial can remain on any temperaturesettingdesired.

NOTE: When the Switch is set to Manual ignite position the boiler will function as in auto ignite except the fire will not be allowed to go out. It will only be allowed to go to a minimum burn rate between the times the aquastat is calling for heat. This rate is about 1.1 pound of fuel per hour. If used in the Manual ignite mode, be sure there is an overheat dump zone in place. Note that if the dump zone does not provide sufficient cooling, and the water temperature continues rising, the feed motor will be forced to shut off. Because the unit is in Manual Ignite mode, it will not re-ignite when the water temperature cools below the control settings.

Fig. 14

Fig. 13

Fig. 12

STARTER GEL

Fig. 15

FireHazard.Keepcombustiblematerials,gasolineandotherflammablevaporsandliquidsclearofappliance.

WARNING!

• DoNOTstoreflammablematerialsintheappliance’svicinity.

• NEVERUSEGASOLINE,GASOLINE-TYPE LANTERNFUEL,KEROSENE,CHARCOAL LIGHTERFLUID,ORSIMILARLIQUIDSTOSTARTOR“FRESHENUP”AFIREINTHISHEATER.KEEPALLSUCHLIQUIDSWELLAWAYFROMTHEHEATERWHILEITISINUSE.

• DONOTBURNGARBAGEORFLAMMABLEFLUIDSSUCHASGASOLINE,NAPHTHAORENGINEOIL.

• DONOTUSECHEMICALSOFFLUIDSTOSTARTTHEFIRE.

• Combustiblematerialsmayignite.

31 3-90-07205R27_08/15

Manual Ignition (Cont.)

6. Apply starting gel as shown in Fig. 15

Fig. 16

NOTICE: When burning the boiler in the manual ignition mode, there must be an overheat dump zone incorporated into the plumbing system.

Ifheatingdemandstopsduringmanualoperation,thecontrolwilltaketheunittolowburn.Ifnoheatisusedduringthistime,thewatertemperaturewillcontinuetorise.Whenthetemperaturegetstoohigh,thefeederwillbeturnedoffandthefirewillgoout.Thiswillrequireamanualre-startofthesystem.(SeeESPControlsectionofthismanual“7Blinks”)Solid-fuelburningappliancesneedtobecleanedfrequentlybecausesoot,creosote,andashmayaccumulate. If you suspect a chimney/vent pipe fire do the following:1. Callthefiredepartment.2. Removefuelfromtheburnpotusingtheburnpotscraping

tooltoscrapethepelletsintotheashpan.3. Removetheashpanfromtheunitandtakeoutside.Do

notplaceashpanonacombustiblematerial.4. Turnoffcircuitbreakeratunit.5. Donotusetheunituntilaqualifiedpersonhasinspected

yourapplianceandventing.

CAUTION!Avaporflashcouldoccuriftoomuchtimeisallowedtopassbeforelightingthestartinggel.

CAUTION!Caremustbetakennottogetstartinggelonyourhandsorclothing.Seriousburnscouldoccurduringthelightingprocess.

CAUTION!Nevertrytoapplymorestartinggeltoanalreadyburningfire,orafirewithsmolderingpellets.

7. Light the Starting Gel With A Match.

8. Close the Doors the firewill light and the controlwilladjustthefiretotheproperlevelaccordingtotheMAX.TEMP.dialsetting.

32 3-90-07205R27_08/15

Use the flat endof the scraper provided to scrapedownover theholed surfaceof theburnpotgrate.Fig. 18. It isnotnecessarytocleanoutthescrapingsfromthiscleaningbecause theywill bepushedout thenext time theaugeroperates.Note: Make a special effort to scrape the bottom inside corners of the burnpot where the auger tube enters the burnpot. Carbon deposits can build up over time in this area that may cause a restriction to the flow of pellets into the burnpot.Withthefireoutandburnpotcold,usethesuppliedallenwrenchtoremoveanybuild-upthatmayhaveaccumulatedin theholes of theburn pot grate.Simply push theallenwrenchdownthrougheachholeensuringitisclearofanybuild-uppayingattentionnottodamagetheigniterelementintheprocess.Cleaning the Burnpot Air Chamber: Thisareaonlyneedstobecleanedtwiceaheatingseason,unless excessive buildup is noticed during scheduledcleanings.Thereisacoveronthefrontoftheburnpottogainaccesstotheairchamber.Thecoverisheldintoplacebytwothumbscrews.Loosen the thumbscrewsandremove thecover.Fig.19.Theairchambercanbecleanedofanyashthathasfallenthroughtheholesduringoperationandcleaning.Alsoatthistime,removethefeederassemblycoverandremoveanyfinesthatmayhaveaccumulated.NOTE: ALWAYS REMEMBER TO CLOSE THE CLEANOUT COVER AFTER CLEANING. Feeder Chamber (Fig. 20):This chambermaygetabuildupof fines from the feedermechanismmovement.Thisareashouldbecheckedandcleanedatleastonceayear.To remove the feeder cover:• Loosenthe5/16”wingnut.• Slidethecoveroffofthethreadedstudandliftupward.• Inspectandcleantheinnerchamberifnecessary.Fig.20.• Reinstallthecovermakingcertainit iscenteredonthe

feederbodyandhand-tightenthewingnut.

Burnpot Maintenance

Cleanout CoverFig. 19

Fig. 20

Fines area

Feeder cover

Fig. 17

Scrape burnpot to remove any carbon build-up that may have occured

Scrape the burnpot to remove any carbon deposits which may have formed.

Scraping can be done while the boiler is in operation, accessed through the firebox door opening.

Fig. 18

Burnpot Cleaning: Theburnpotshouldbecleanednolessthanonceaweek.Forbestoperationtheburnpotshouldbecleanedeverytimethehopperisfilledwithpellets.Thefiredoesnothavetobeouttoscrapetheburnpotalthoughit isrecommendedtheboilerbeonminimumburnatthetimeofcleaning.Note: Scraping can be done while in operation if performed through the firebox door opening. Fig. 17

33 3-90-07205R27_08/15

Ash Removal

Disposal of AshesAshesshouldbeplacedinasteelcontainerwithatightfittinglid.Theclosedcontainerofashesshouldbemovedoutdoorsimmediatelyandplacedonanon-combustiblefloororontheground,wellawayfromallcombustiblematerials,pendingfinaldisposal. Ifashesaredisposedofbyburial insoilorotherwiselocallydispersed,theyshouldberetainedintheclosed container until all cinders have thoroughly cooled.Otherwasteshallnotbeplacedinthiscontainer.Soot and Flyash: Formation and Need for RemovalThe products of combustionwill contain small particlesof flyash. The flyashwill collect in the exhaust ventingsystemandrestrict theflowof thefluegases. Incompletecombustion, suchas occurs during startup, shutdown, orincorrectoperationoftheroomheaterwillleadtosomesootformationwhichwillcollectintheexhaustventingsystem.Theexhaustventingsystemshouldbeinspectedatleasttwicemonthlytodetermineifcleaningisnecessary.Payparticularattentiontoscreeningintheventcap.Thescreen,ifpresent,willaccumulatewithashesratherquickly.

Fig. 21

Ash Door Handle

Ash Door

Ash Pan Ash Pan Handle

Ash RemovalItisrecommendedtoremovetheasheswhentheboilerisnotinoperation.Thislessensthechancesofcomingincontactwithhotsurfaces.Ashescanberemovedwhileinoperationbut,extracaremustbetaken.Open Ash DoorLiftthelatchandopenthedoorasshowninfig.21.NOTE: Keep hopper lid, hopper swing plate, firebox door and ash pan door closed during operation and maintain all seals in good condition.Remove Ash PanAlwayswearglovestoremoveashpan.Grabtheashpanbythefingerholdandpullitoutoftheboiler.Lifttheashpanbythefingerholdanduseitforcarryingtheashpan.Close the ash door before disposing the ashes.

WARNING!RISK OF FIRE!• Ash, soot or creosote build-up may cause

overheating or fire.• Routine cleaning of heat exchangers and venting

is required.

34 3-90-07205R27_08/15

Firebox Maintenance

CleaningThiscleaningshouldbedoneaftereachtonofpelletsused.Thefrequencyofthiscleaningwillbedirectlyrelatedtothequalityandtheashcontentofthepelletsbeingused.Keepinmindthatthecleanertheheatexchangersurfaceiskept,thehighertheheattransferefficiencywillbe.

Duetoit’seaseofrestartingitisrecommendedthattheboilerbeOFF and COOLbeforecleaning.

Startbyactuatingthe(3)heatexchangercleanoutrodsbypullingandpushingtheserodsvigorouslyseveraltimes.Thisactionwillremoveanyflyashbuiltupontheheatexchangertubes.Thiscanalsobedoneatanytimeduringtheoperationoftheboilertomaintainhigherefficiencies.Makesurethattheserodsarepushedinwhencleaningiscompleted.

Cleaning Steps1. Openthehopperswingplatetoaccessburnpotandalso

thefirebox.Withawispbrush,wirebrush,stiffbristledpaintbrushorasootvaccum,cleanthefireboxwallsandanyflyash thathasaccumulatedon the ledgesof theburnpot,orburnpotopening.Atthistimeyoucanscrapeandcleantheburnpotandfinescleanoutarea.

2. Openfireboxdoorandvacuumashfromledgesandashdeflector.You canalso clean the fireboxdoor viewingglassusingatypicalglasscleanerandsoftcloth.

3. Opentheashdoorandremovetheashpan.Disposeofanyashthathasaccumulatedintheashpanaswellasanyflyashfromwithintheashpanarea.

4. Remove the (4) thumbscrews on the secondary ashchamber access plate and remove it to access thesecondary ash chamber.Removeall fly ash from thisarea.Thisprocessshouldbedoneasneeded.

5. Inspectallsealinggasketstoensureapropersealandre-installallcomponentsremovedforcleaning.

NOTE: To minimize the amount of stress placed on the hopper swing plate hinges, opening of the hopper swing plate should be done with the least amount of fuel in the hopper as possible.

Heat Exchanger Cleanout Rod Handles

Firebox Door

Heat Exchanger Tube

Secondary Ash Chamber Access Plate

Ash DoorFirebox Wall

Fines Cleanout Cover

CAUTION!Cleanout of the heat exchanger, flue pipe, chimney, and combustion blower fan housing, is especially important at the end of the heating season to minimize corrosion during the summer months, caused by accumulated ash.

35 3-90-07205R27_08/15

Combustion Blower/Heat Exchanger MaintenanceTheboilerMUST be OFF and COOL before you shouldattempttocleanthecombustionblower.Thewire to the combustion blower doesn’t need to bedisconnectedduringthecleaningprocess.Loosenthethree(3)thumbscrewsabout4turnseach.SeeFig.23.Holdthemotorheadwithonehandandtheblowerplatehandlewiththeotherhand.Pulloutwardontheplatehandleuntilthecompleteunitcomesloose.Nowrotatetheplatecounter-clockwiseabout1/8turn.Thiswillallowthecompleteassemblytoberemovedfromtheblowerchamber.Clean theblower fanbladesand theblowerplatesealingoverlap.SeeFig.24.NOTE: Be careful not to bend the fan blades, this will throw the fan blade out of balance or it may rub the inner chamber, which may affect the performance of the boiler. Any horizontal and vertical flue pipe directly above the unit should be cleaned at this timeNOTE: The horizontal flue pipe directly above the boiler is the first place fly ash will settle, due to the slowing of flue gas velocity through horizontal pipe. Cleaning of horizontal venting pipes is very important to the efficiency of this boiler.Clean the flueoutlet throat aswell as the inner chamberofthefluetunnel(thisistheholethatgoesupintothefluepipe).SeeFig.24.NOTE: The exhaust probe sensing tip extends into this same area. CARE MUST BE TAKEN NOT TO DAMAGE THE ESP DURING CLEANING. Bending of the ESP will make it difficult to remove if it should become necessary. See Fig. 23.Cleantheboilerblowerplate,sealingoverlap.SeeFig24.Makesuretherearenoflyashbuildupsthatmayblocktheeasyflowof fluegasses into thecombustionblower inlethole.(Aflashlightmaybenecessary.)Cleaning the Tube Heat Exchangers:Three external cleaning rods allow scraping of the heatexchange tubes with a simple in-and-outmotion. Seepreviouspage.Thiscleaningshouldbedoneatleastonceaweek,howeveritcanbedonemoreoftenasdesired.Thecleanertheheatexchangersare,themoreefficienttheboilerwillbe.Itisbesttoperformduringalowfireperiodorwhenthefireisout.Duringhighfireperiods,thecleaningrodsmaystickduetoheatrelatedexpansion.Combustion Blower Cleaning

Removethecombustionblowerheatshield.Therearetwolatchesthatholdtheshieldinplace(SeeFig.22).Flipthelatchesupandpulltheshieldawayfromtheboiler.Itcannotbefullyremoved,itcanonlybemoveddownoverthewireuntilithangsonthejunctionbox.

Fig. 23

Latch

Heat Shield

Fig. 22

Fig. 24

Sealing Overlap

5” Double Bladed Fan

CAUTION!Inspect flue pipes, flue pipe joints and flue pipe seals regularly to ensure that smoke and flue gases are not entering the home.

ESP

Combustion Blower Motor

Thumb Screws (3) Total

36 3-90-07205R27_08/15

FEEDER DOES NOT FEED1. Nopelletsinhopper.2. Fireboxdraftmaybetoolowforlowdraftpressureswitch

infeedercircuittooperate.Check for improperly closed doors,looseormissinggasketondoorsorhopperlid,orafaultypressureswitch.

3. Feedmotorwill not run until theESP senses 170°F.Maybe youdid not put enoughpellets in theburn potbeforelightingthefiremanually.

4. Somethingisrestrictingflowinthehopperorcausingtheslideplatetostick.

5. Feedmotorhasfailed.PARTIALLY BURNED PELLETS1. Feedratetoohigh.2. Drafttoolow.(Checkburnpotclean-outslideanddoor

gasket).3. Burn pot or heat exchanger tubesmay need to be

cleaned.4. Combinationofalltheabove.5. #6statusblink:A6blinkcontrolboardstatusindicationis

causedbypoororincompletecombustion.TheAutomaticIgnitioncircuitboardhastheabilitytotrackthecombustionthrough feed settings andESP temperatures.Whenthe control board has calculated poor or incompletecombustion,itwillshutdowntheunitasasafetyfeature.(Poor or incomplete combustion is a contributor ofcreosotewhichmaycauseachimneyfire)

A 6 blink status may be caused by several things:1. Blockedorpartiallyblockedflue.2. Blockedorpartiallyblockedinletair.

a.Backdraft damper on the inlet pipemaybe stuckclosed.

b.Ifoutsideairisinstalled,theTerminationCapmaybeblocked.

3. Theairchamberundertheburnpotmaybefilledwithfinesandsmallbitsofash.

4. Theholesintheburnpotmaybegettingfilledwithashorcarbonbuildup.

5. Combustionblowerfanbladesmayneedcleaned.6. Thereisnofuelinthehopper.SMOKE SMELLSealtheventpipejointsandconnectiontostovewithsilicone.FIRE HAS GONE OUT1. Nopelletsinhopper.2. Draftsettingistoolow.3. Somethingisrestrictingfuelflow.4. Feedmotororcombustionblowerhasfailed.5. Powerfailureorblownfuse.

TroubleshootingSMOKE IS VISIBLE COMING OUT OF VENT1. Air-fuelratioistoorich.

a. Feedratetoohigh.b. Drafttoolowcausedbyagasketleak.

LOW HEAT OUTPUT1. Feedratetoolow2. Drafttoolowbecauseofgasketleak.3. Poorqualityordamppellets4. Combinationof1and2.

Helpful HintsCleaning Burn PotWheneveryourboiler isnotburning, take theopportunitytoscrapetheburnpottoremovecarbonbuildup.Avacuumcleanerishandytoremovetheresidue.Be sure the boiler is cold if you use a vacuum.Carbonbuildupcanbescrapedloosewiththefireburningusingthespecialtoolprovidedwithyourstove.Scrapethefloorandsidesoftheburnpot.Thecarbonwillbepushedoutbytheincomingfuel.Alwayswearglovestodothis.Removing AshesAshescanbe removedwhile inoperation,butextracaremustbetakenandalwaysweargloves.MaximumFeedAdjuster settingsarenot needed inmostcases.Operatinginthenormalrange(#4)isrecommendedwhenmaximum heat output is not required. The ESPpreventsthestovefrombeingover-fired.Keeptheboilerfreeofdustanddirt.

FuelPelletfuelsareputinto3categoriesintermsofashcontent.Premiumat1%orless,Standardat3%orlessandallothersat3%ormore.Thisunitiscapableofburningall3categoriesofpelletsduetoapatentedfeederandburnpotsystem.It should be noted, however, that higher ash contentwillrequiremorefrequentashremoval,scrapingoftheburnpot,andmayprovidelessBTU’sperpound.Normally,standardandhighashpelletscostlessthanpremiumpelletsandcanbecosteffectivewhenburnedinthisboiler.Themoisturecontentmustnotexceed8%.HighermoisturewillrobBTU’sandmaynotburnproperly.

Summer Operation for Domestic Hot WaterWhentheboilerisusedsolelyfordomestichotwater(e.g.inthesummerorshoulderseasons),extendedperiodsoflowburnmaycausefasterthannormalaccumulationofash&creosoteintheburnpot,fireboxandventingsystem.Cleaningtheburnpotdailyandinspectingthefirebox&ventingsystemweeklyisrecommendedduringthistypeofusage.Theseperiodsmaybeincreasedbasedonthelevelofaccumulationseenduringdaily&weeklycleanings.

37 3-90-07205R27_08/15

Atmospheric ConversionAtmosphericConversion: Item# 1-00-232200, provides automatic fill, and converts the heating systemplumbing frompressurizedtoazeropressuresystem.Allowsforinstallationintomoreplaceswherecodesandstandardsrestrictpressurizedsystems.Notethatwhenusingtheatmosphericconversion,airbleedersandcheckvalvesmayactuallyallowairintothelines.AnotherreasonitisimportanttohavealicensedPlumberinvolvedineachphaseofyourinstallation.

When using the atmospheric conversion, the circuit board dipswitch #6must be in the “ON” position. This will lowerthe overheat temperature parameters to prevent boiling of thewater. Since altitude affects the boiling point, it is alsorecommendedtoset#6to“ON”atelevationsabove3000ft.

38 3-90-07205R27_08/15

Optional Domestic Hot Water CoilThere isadomestichotwatercoil available for yourPB105.Thecoil installs in thesideof theboiler,andallowsyourdomesticwatertobeheatedbytheheatingsystemwater.Installthecoilnow,byremovingtheroundplateandreplacingitwiththecoilandit’sroundplate.Besuretotightentheboltsevenly,toensureagoodseal.

Remove the (6) - 7/16”-14 bolts & Domestic Hot Water Coil Plate.

39 3-90-07205R27_08/15

Specifications16

.87”

24.25”

7.12”

55.7

5”

47.5

”

26”

23.5

”

33.3

7”

11.5

”

17.5”

43.5”

62”

49.75”

17.5”

4.25

” O.D

.4.

12” I

.D.

BTU

Inpu

t Ran

ge=

0, a

nd 9

350

to 1

13,9

00*

0BTU

ifsystemissatisfied.

Min.B

urn=1.1poundperhour

Max.B

urn=13.4poundsperhour

*8500BTU

perpoundfigures

Elec

tric

al

120

VAC

60

Hz

Com

bustionblow

er

1.4AMP

Augermotor

.7AMP

Igniterelement

3.6AMP

Controlboard

.05AMP

Approximateoperatingwattage.2KWH

40 3-90-07205R27_08/15

Wiring Diagram

GREEN/YELLOW

DARK BLUE

PELLET BOILER WIRING DIAGRAM

4" S

QU

ARE

JU

NC

TIO

N B

OX

BLACK

GREEN/YELLOW

WHITE

RED

RED

WH

ITE

GRE

EN

3/8"FLEX CONDUIT

BROWNW

HIT

E

WH

ITE

WHITE

RED

DARK BLUE

AUX. OUTPUT (OVERHEAT ZONE)

120 VAC 60 HZMAIN POWER(SUPPLIEDBY OTHERS)

WHITEGREEN

BLACK

RED

WHITE

BROWN

3/8"FLEX CONDUIT

EXHAUST PROBE (ESP)

2

1

OUTDOOR AIR EXTENSION

4

3

6

5

10

9

11

8

PART NO. 3-90-72194A

7

WHITE

EMPTY

EMPTY

RED

BLACK

YELLOW

DK BLUE

EMPTY

GREEN/YELLOW WIREIS GROUND BONDED TO STOVE BODY

CONTROLBOARD

TCP

34

1

98

11

10

ESP

TWISTED WIRE

BROWN

PLUGGED

WHITE

WH

ITE

11 P

IN P

LUG

6 AMP GLASS FUSE

AQUA TEMP SENSOR

COMBUSTION MOTOR

PVC CORD MOTOR LEAD

IGNITER ELEMENT

120 VAC450 WATTIGNITER PUMP

MOTOR WIRE MALE/FEMALE CONNECTION

FEEDER MOTOR

LOW PRESSURE SWITCH N.O. CONTACTS

YELLOW

SKY BLUE

BLA

CK

SKY

BLU

E

BLA

CK

WH

ITE

YEL

LOW

120 VOLTS A.C. 60 HZ.

1.7 AMPS ( normal operation )

5.3 AMPS ( ignition mode )635 WATTS-

200 WATTS-

“105 Series” PELLET BOILER

WHI

TE

GREENRelay enclosure box - GRAINGER # 1EGH7

REDRED W

HITE

GREEN

DPDT RELAY flange mtd. - GRAINGER #2XCO2

2

4

6

3

1

5

1/2" CONDUIT

8 7

16-3 AWGPVC CORD

These cord tails can be made from an inexpensive 16/3 extension cord. Make sure that the MALE end is long enough to reach the receptacle on the UPS.

CORD CONNECTOR

WHITEBLACK

MALE

CORD CONNECTOR

16-3 AWGPVC CORD

BLACKWHITE

GREEN

FEMALERED

WHITE

GREEN/YELLOW

BLACK

3/8"F

LEX

COND

UIT

to co

mbus

tion m

otor

RED

WHITE

WHI

TE

BROWN

4" SQUARE JUNCTION BOX

GREEN

WHITEGREEN

BLACK

DARK

BLU

E

GREEN

WHITE

WHITE

3/8"FLEX CONDUIT from control board120 VAC power (by installer)

UPS BACKUP FOR COMBUSTION MOTOR

WHITEREDRED

If using a standard UPS, it should be rated at 650 or higher to ensure that the combustion motor operates until the fire is out.(approximately 20 minutes needed)

( UNINTERUPTED POWER SUPPLY / BATTERY BACK-UP )

POWER FROM THE UPS / This plugs into the UPS. When power fails, UPS will supply current to the relay.

POWER TO THE UPS / Plug UPS into here. When current is present, will keep UPS in Ready mode.

Power Failure Backup Supply

41 3-90-07205R27_08/15

Power Failure Backup Supply

Minimizing Smoke During Loss of Power Using Battery Back-upHarman® strongly recommends installing battery back-up to minimize entry of smoke into the room in the event of power loss.

Your pellet/biomass burning appliance relies on a combustion blower to remove exhaust. A power failure will cause the combustion blower to stop. This may lead to exhaust seeping into the room. Vertical rise in the venting may provide natural draft. It is, however, no guarantee against leakage.

Below are Harman® approved battery back-up options for your appliance:

Uninterruptible Power Supply (UPS) UPS battery back-ups are available online or at computer and office equipment stores:

• The APC (American Power Conversion) model #BX1500G and the TrippLite OMNIVS1500 are tested and approved. Other brands or models may not be compatible.

When power is lost, a fully charged UPS will power a safe, combustion blower only shut-down. Yourappliance will pulse the blower every few seconds to clear exhaust until the fire is out. NOTE: The UPS provides safe shut-down only. It is not intended for continued operation.

Your appliance will recognize when power is restored. What happens depends on ESP temperature:• In “Automatic” setting, units will respond to the set point and ESP temperature and resume

normal operation.• In “Manual” setting:• If the ESP is cool, the appliance will remain shut down.• If the fire is out and the ESP is still warm, the feeder may restart. Since the fire is out, the ESP

temperature will not rise. The unit will then shut-down, and may flash a six-blink status error. (See ESP error codes)

• If the fire is still burning, it will resume normal operation.

Contact your dealer if you have questions about UPS compatibility with your appliance.CAUTION! Always keep appliance doors and hopper lid closed and latched during operation and during power failures to minimize risk of smoke or burn-back.CAUTION! Use only Harman® approved battery back-up devices. Other products may not operate properly, can create unsafe conditions or damage your appliance.

42 3-90-07205R27_08/15

Harman PB105 Pellet BoilerLabel measures: 7.875" high X 6.5"wide

OMNI-Test Laboratories, Inc.Report #/Rapport #135-S-16-6

Certified for U.S.A. and CanandaCertifié pour les états-Unis et le Canada

BARCODE LABEL

008Serial No.No de série:

Harman PB-105LISTED PELLET FUEL CENTRAL OR SUPPLEMENTARY FURNACES

FOR RESIDENTIAL USE

APPAREIL DE ChAUFFAgE CENTRAL OU SUPPLéMENTAIRE ENREgISTRé DE gRANULéS COMBUSTIBLES POUR USAgE DANS LES RéSIDENCES

Tested June 2006 to CSA-B366.1-M91, and UL 391-95

Install and use only in accordance with the manufacturer’s installation/operting instructions. Refer to authorities having jurisdiction for proper installation. Contact local building or fire officials about restrictions and installation inspection in your area. If there are no applicable local codes, follow ANSI/NFPA 211 and CAN/CSA B365. Special precaustions are required for passing the chimney through a a combustible wall or ceiling.

Inspect and clean exhaust venting system frequently in accordance with the manufacturer’s instructions. Use a 4” diameter type “L” or “PL” venting system.

Testé en June 2006 à CSA-B366.1-M91, and UL 391-95

Installez et utilisez en accord avec les instructions d’installation et d’opération du fabricant. Référez-vous à des professionnels avec autorité dans l’installation. Contactez le bureau de la construction.ou le bureau des incendies au sujet des restrictions et de l’inspection dans votre voisinage.

S’il n’y a pas de codes locaux, suivez alors ANSI/NFPA211 et CAN/CSA B365. Prenez des précautions spéciales lorsque vous faites passer une cheminée à travers un mur ou un plafond combustibles. Inspectez et nettoyez le sustème de ventilation fréquemment en accord avec les instructions du fabricant. Utilisez un système de ventilation de 4” de diamètre de type “L” ou “PL”.

ModelModèle

FuelCombustible

Chimney Connector SizeGrandeur du Tuyau de Cheminée

BTUH/Kw Input PelletRendement des Granulés BTUH/Kw

Electrical RatingClassification électrique

Maximum Overcurrent ProtectionProtection Maximum du Courant

Sidewall to ApplianceBackwall to ApplianceCombustibles to Pellet VentStove Top to CeilingAlcove HeightAlcove DepthCombustibles from Stove Front

Clearances to Combustibles/Espaces Libres aux Combustibles

20” (507 mm)6” (152 mm)3” (76 mm)

23.5” (596 mm)66” (1673 mm)80” (2032 mm)36” (914 mm)

Mur Latéral à l’AppareilMur Arrière à l’AppareilMatériaux Combustibles au Conduit de FuméeHaut du Poêle au PlafondHauteur de l’AlcôveProfondeur de l’AlcôveDes Combustible au Devant du Poêle

(5) Spring Handles / (5) Poignées à Ressort(1) 3/4” Boiler Drain / (1) Robionet de vidange 3/4”(1) 3/4” Safety Relief Valve / (1) Soupape de Sécurité 3/4”(1) 1/2” Aquastat Well / (1) Plomgeur de l’Aquastat 1/2”(1) 1/2” Dual Temperature/Pressure Gauge / (1) Double Indicateur Température/Pression 1/2”

Essential parts and subassemblies provided for field assembly are as follows /Pièces essentielles et sous-assemblée procurées pour l’assemblage sont les suivantes:

(1) 100’ Sensor Cable / (1) Câble de la Sonde 100’(1) Outdoor Air Sensor / (1) Sonde Extérieure(1) Flue Tunnel Weldment / (1) Ensemble Mécano-soudé de sortie des Gaz de Combustible

(1) Combustion Blower Assembly / (1) Ensamble Ventilateur de Combustion(1) Heat Shield (Combustion Blower) / (1) Carter de Protection du Ventilateur de combustion

Date of Manufacture / Date de fabrication2013 2014 2015 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

Made in the U.S.A. / Fait aux états-UnisDo Not Remove or Cover This Label/Ne pas enlever ou recouvrir cet étiquette

Manufactured by/Fabriqué par: hearth & home Technologies, Inc.352 Mountain house Road - halifax, PA 17032

DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE

NE PAS CONNECTER CET APPAREIL à UN TUYAU DE CHEMINéE SERVANT UN AUTRE APPAREIL

WARNING! DO NOT operate with fire chamber or ash removal doors open.DO NOT store fuel or other combustible material within installation clearance area.

CAUTION! Hot while in operation.DO NOT touch. Keep children, clothing, furniture and other combustible material out of the installation clearance area.

Flooring must be a non-combustible material covering the installation clearance area, and 18” in front of, and 8” to either side of the fuel loading doors.

In the event of loss of electrical power:Consult owner’s manual for restarting your furnace after power is restored.

ATTENTION! Ne pas opérer si la porte du combustible ou la porte de la cuvette des cendres sont ouvertes. Ne pas placer le combustible et les matières combustibles à l’intérieur de l’espace désignée pour l’installation.

ATTENTION! Chaud lors de l’opération.NE PAS toucher. Gardez les enfants, les vêtements, les meubles et les matériaux combustibles loin de l’espace désignée pour l’installation.

Le plancher de l’espace désigné pour l’installation doit ê fait de matière non-combustible, de 18” en avant, et de 8” de chaque côté des portes d’entrée du combustible.

Dans le cas d’un manque d’électricité:Consultez le manuel du propriétaire pour remettre la fournaise en marche lorsque l’electricité ést revenue.

DANGER! Risk of Fire or Explosion - Do not burn garbage, gasoline, naphtha, engine oil, or other inappropriate materials.

DANGER! Risque de feu ou d’explosion. Ne pas brûler des ordures, de l’essence, du pétrole, de l’huile moteur ou autres matériaux inappropriés.

U.S. ENVIROMENTAL PROTECTION AgENCYThis model is exempt from EPA certification under 40 CFR 60.531

by definition [Wood heater (A) “air-to-fuel ratio”].

Rev DP.N. 3-90-07206

PB-105 PelletGranulés 4” 113,900 BTUH (33.4 Kw) 120V, 4.45A, 60 Hz 20 AMP

Safety Label

SAMPLE LABEL ONLY

43 3-90-07205R27_08/15

Service Record / Notes

Date Of Service Description Of ServicePerformed By

3-90-07205R27_08/15

Qui

ck R

efer

ence

(Aut

o-Li

ght)

1 T

urn

Mod

e Se

lect

or to

OFF

.

2 U

se h

eat

exch

ange

r cl

eano

ut r

ods

to c

lean

the

hea

t ex

chan

ger

tube

s.**

3 S

crap

e th

e ai

r hol

es in

the

burn

pot.*

*

4 F

ill th

e ho

pper

with

pel

lets

.

5 T

urn

Feed

Adj

uste

r to

“Tes

t”.*

6 C

heck

the

Com

bust

ion

Blo

wer

and

Fee

der M

otor

for o

pera

tion.

*

7 T

urn

Feed

Adj

uste

r bac

k to

the

#4 s

ettin

g.

8 T

urn

the

MA

X. T

EMP.

dia

l to

the

desi

red

tem

pera

ture

.

9 T

urn

MIN

. TEM

P. d

ial t

o th

e de

sire

d se

tting

s.*

10 F

lip th

e ig

nite

r sw

itch

to A

uto.

*

The

boile

r will

igni

te if

the

tem

pera

ture

of t

he b

oile

r wat

er is

less

than

th

e te

mpe

ratu

re s

et o

n M

AX.

TEM

P. d

ial..

*See

the

sect

ion

on O

pera

tion

for i

nfor

mat

ion

abou

t Man

ual L

ight

ing

and

Emer

genc

y Po

wer

.

**Se

e th

e se

ctio

n on

Mai

nten

ance

for

mor

e de

tails

abo

ut c

lean

ing.

Owner’s Manual - Wood Burning Systems Document Library · exterior surface finishes may occur....

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