R
CB1200-I PELLET INSERT
Owner’s Manual
Portland
Oregon USA
Tested and
Listed by
O-T L
Installation and Operation
C
US
OMNI-Test Laboratories, Inc.
Model:
CB1200I-B
NOTICE
DO NOT DISCARD THIS MANUAL
•
Read, understand and
follow these instruc-
tions for safe installa-
tion and operation.
•
Leave this manual with
party responsible for use
and operation.
• Important operating and
maintenance instruc-
tions included.
WARNING
WARNING
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.
HOT SURFACES!
Glass and other surfaces are
hot during operation AND
cool down.
Hot glass will cause burns.
•
•
•
•
Do not touch glass until it is cooled
• Do not store or use gasoline or other flam-
mable vapors and liquids in the vicinity of this
or any other appliance.
NEVER allow children to touch glass
Keep children away
CAREFULLY SUPERVISE children in same room as
• Do not overfire - If any external part starts to
glow, you are overfiring. Reduce feed rate.
Overfiring will void your warranty.
fireplace.
•
Alert children and adults to hazards of high
temperatures.
High temperatures may ignite clothing or other
• Comply with all minimum clearances to com-
bustibles as specified. Failure to comply may
cause house fire.
flammable materials.
•
Keep clothing, furniture, draperies and other flammable
materials away.
CAUTION
CAUTION
Tested and approved for wood pellets and shelled
field corn fuel only. Burning of any other type of fuel
voids your warranty.
Check building codes prior to installation.
•
Installation MUST comply with local, regional, state and national
codes and regulations.
Consult local building, fire officials or authorities having jurisdic-
tion about restrictions, installation inspection, and permits.
•
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September 1, 2008
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CB1200-I Pellet Insert
TABLE OF CONTENTS
Section 1: Listing and Code Approvals
A. Appliance Certifications ......................4
B. Mobile Home Approved ......................4
C. Glass Specifications............................4
D. Electrical Rating..................................4
E. BTU & Efficiency Specifications..........4
Section 8: Operating Instructions
A. Fuel Size & Material............................25
B. General Operation Information...........25
C. Before Your First Fire .........................26
D. Starting Your First Fire........................26
E. Fire Characteristics.............................26
F. Feed Rate Adjustment .......................26
G. Ignition Cycles ....................................26
H. Frequently Asked Questions...............27
Section 2: Getting Started
A. Design, Installation & Location
Considerations....................................5
B. Fire Safety ..........................................5
C. Tools & Supplies Needed...................6
D. Inspect Appliance, Components
and Pre-Check List.............................6
Section 9: Troubleshooting ............................28-30
Section 10: Maintaining & Servicing Appliance
A. Proper Shutdown Procedure...............31
B. Quick Reference Maintanence Chart..31
C. General Maintenance & Cleaning.......31-34
D. High Ash Content Maintenance ..........35
E. Glass Replacement.............................36
F. Igniter Replacement............................37
G. Baffle Removal....................................37
Section 3: Dimensions & Clearances
A. Appliance Dimensions ........................7
B. Clearances to Combustibles
As A Built-In, UL and ULC ..................8
C. Clearances to Combustibles,
Masonry & Zero Clearance.................9
D. Minimum Opening for Factory
Built Fireplace .....................................9
E. Masonry Minimum Opening................10
F. Floor Protection ..................................10
G. Calculating Alternate Floor
Protection Material..............................10
H. Removing Floor of Factory Built
Fireplace .............................................11
Section 12: Reference Material
A. Component Functions.........................38-39
B. Component Locations.........................40
C. Exploded Drawings.............................41-42
D. Service Parts & Accessories...............43-45
E. Warranty Policy...................................46-47
F. Contact Information ............................48
Section 4: Vent Information
A. Chimney & Exhaust Connections........12
B. Venting Termination Requirements....12
C. Equivalent Feet of Pipe.......................13
D. Pipe Selection Chart...........................13
Section 5: Venting Systems
A. Direct Connect with Outside Air..........14
B. Direct Connect without Outside Air.....14
C. Full Reline with Outside Air.................15
Section 6: Mobile Home..................................16
Section 7: Appliance Set-Up
A. Rear Shroud Installation.....................17-18
B. Outside Air Kit.....................................19
C. Adjustable Hopper Option...................19
D. Grille Installation.................................19
E. Adjustable Hearth Support..................20
F. Panel & Trim .......................................21-22
G. Brick Set Installation ...........................23
H. Brick Clip Installation...........................23
I. Log Set Placement..............................24
J. Thermostat Installation........................24
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Listing and Code Approvals
1
A. Appliance Certification
E. BTU & Efficiency Specifications
Emissions Rating:
*BTU Output:
.9 grams/hr
14,000 - 40,000 / hr
MODEL:
1200-I Pellet Insert
LABORATORY: OMNI Test Laboratories, Inc
Heating Capacity:
up to 2,500 sq. ft. depending
on climate zone
REPORT NO.
TYPE:
061-S-13-2
Solid Fuel Room Heater/Pellet Fuel
Burning Type Insert
Hopper Capacity:
Fuel:
60-75 lbs
Wood Pellets or Shelled Corn
STANDARD:
ASTM E1509-95, ULC S628-93, ULC
S610-M87, ULC S628-M93 and ULC/
ORD-C1482-M1990 Room Heater Pellet
Fuel Burning Type and (UM) 84-HUD,
Mobile Home Approved
*BTU output will vary, depending on the brand of fuel you
use in your appliance. Consult your Quadra-Fire dealer
for best results.
B. Mobile Home Approved
NOTE: Hearth & Home Technologies, manufacturer of
this appliance, reserves the right to alter its products,
their specifications and/or price without notice.
This appliance is approved for mobile home installations
when not installed in a sleeping room and when an outside
combustion air inlet is provided. The structural integrity of the
mobile home floor, ceiling, and walls must be maintained.
The appliance must be properly grounded to the frame of
the mobile home and use only listed pellet vent, Class “L” or
“PL” connector pipe. A Quadra-Fire Outside Air Kit must be
installed in a mobile home installation.
C. Glass Specifications
This appliance is equipped with 5mm ceramic glass. Replace
glass only with 5mm ceramic glass. Please contact your
dealer for replacement glass.
NOTE: This installation must conform with local codes. In
the absence of local codes you must comply with the ASTM
E1509-95, ULC S628-93, ULC S610-M87, ULC/ORD-C-
1482-M1990, (UM) 84-HUD.
D. Electrical Rating
115 VAC, 60 Hz, Start 4.1 Amps, Run 1.1 Amps
Page 4
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CB1200-I Pellet Insert
Getting Started
2
A
. Design, Installation & Location
Considerations
B. Fire Safety
Maintain the designated clearances to combustibles. Insu-
lation must not touch the chimney. You must maintain the
designated air space clearance around the chimney. This
space around a chimney is necessary to allow natural heat
removal from the area. Insulation in this space will cause
a heat buildup, which may ignite wood framing. NOTE:
Clearances may only be reduced by means approved
by the regulatory authority having jurisdiction.
1. Appliance Location
Consideration must be given to safety, convenience, traffic
flow, and the fact that the appliance will need a chimney and
chimney connector. It is a good idea to plan your installation
on paper, using exact measurements for clearances and floor
protection, before actually beginning the installation.
If you are not using an existing chimney, place the appliance
in a location to maintain a clear passage for the installation
of any listed and approved pellet venting system. This appli-
ance may be vented vertically or horizontally.
To provide reasonable fire safety, the following should be
given serious consideration:
1. Install at least one smoke detector on each floor of
your home to ensure your safety. They should be
located away from the heating appliance and close
to the sleeping areas. Follow the smoke detector
manufacturer’s placement and installation instructions,
and be sure to maintain regularly.
Maintain specified vent clearance to comubstible require-
ments listed by the pellet manufactures venting instructions
and all clearance to combustivles listed in this manual.
Check with your local building code agency before you begin
your installation. Be sure local building codes do not super-
sede UL specifications and always obtain a building permit
so that insurance protection benefits cannot be unexpectedly
cancelled. If any assistance is required during installation,
please contact your local dealer.
2. A conveniently located Class A fire extinguisher
to contend with small fires resulting from burning
embers.
3. A practiced evacuation plan, consisting of at least 2
escape routes.
We recommend that a qualified building inspector and your
insurance company representative review your plans before
and after installation.
4. A plan to deal with a hopper fire as follows:
In the event of a hopper fire:
2. Thermostat Location
a. Evacuate the house immediately.
b. Notify fire department.
The thermostat’s location will have some effect on the
appliance’s operation. When the thermostat is located close
to the appliance, it may require a slightly higher temperature
setting to keep the rest of the house comfortable. If the
thermostat location is in an adjacent room or on a different
floor level, you will notice higher temperatures near the
appliance.
WARNING
CAUTION
•
•
Do NOT connect this unit to a chimney flue servicing
another appliance.
Fire Risk.
Do NOT connect to any air distribution duct or system.
•
Do not operate appliance before reading
and understanding operating instructions.
Failure to operate appliance properly may
cause a house fire.
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CB1200-I Pellet Insert
D. Inspect Appliance & Components and
Pre-Use Check List
C. Tools And Supplies Needed
Tools and building supplies normally required
for installation, unless installing into an existing
masonry fireplace:
1.
2.
Place the appliance in a location near the
final installation area and follow the proce-
dures below:
Open the appliance and remove all the parts
and articles packed inside the Component
Pack. Inspect all the parts and glass for ship-
ping damage. Contact your dealer if any irregu-
larities are noticed.
Reciprocating Saw
Hammer
Safety Glasses
Framing Square
Phillips Screw driver
Tape Measure
Plumb Line
Electric Drill & Bits (1/4”)
1/4” Self-Tapping Screws
Level
May also need:
Vent Support Straps
Venting Paint
Framing Material
Hi-temp Caulking Material
Gloves
3.
All safety warnings have been read and fol-
lowed.
4.
5.
6.
7.
This Owner’s Manual has been read.
Floor protection requirements have been met.
Venting is properly installed.
The proper clearances from the appliance and
chimney to combustible materials have been
met.
WARNING
Inspect appliance and components for
damage. Damaged parts may impair safe
operation.
•
•
•
Do NOT install damaged components.
Do NOT install incomplete components.
Do NOT install substitute components.
8.
The masonry chimney is inspected by a profes-
sional and is clean, or the factory built metal
chimney is installed according to the manufac-
turer’s instructions and clearances.
Report damaged parts to dealer.
9.
The chimney meets the required minimum
height.
10.
11.
All labels have been removed from the glass
door.
Plated surfaces have been wiped clean, if
applicable.
Thermostat or remote has been installed.
A power outlet is available nearby.
WARNING
Fire Risk.
Hearth & Home Technologies disclaims any
responsibility for, and the warranty will be
voided by, the following actions:
12.
13.
•
•
•
Installation and use of any damaged appliance.
Modification of the appliance.
Installation other than as instructed by Hearth & Home
Technologies.
•
•
•
Installation and/or use of any component part not approved
by Hearth & Home Technologies.
Operating appliance without fully assembling all
components.
Do NOT Overfire.
Or any such action that may cause a fire hazard.
Page 6
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CB1200-I Pellet Insert
Dimensions and Clearances
3
A. Appliance Dimensions
B
40" (1016mm)
29-1/4" (743mm)
22" (559mm)
8-3/4"
(222mm)
13" (330mm)
12" (305mm)
10-3/4"
(273mm)
A
28-1/2" (724mm)
Figure 7.1 - Top View
Figure 7.2 - Front View
Panel
A
B
Standard
Large
30 inches (762mm)
33 inches (838mm)
40 inches (1016mm)
50 inches (1270mm)
12"
(305mm)
13"
(330mm)
10-3/4"
(273mm)
25-1/2"
(648mm)
11"
(279mm)
Figure 7.3 - Side View
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CB1200-I Pellet Insert
B. Clearance To Combustibles, UL and ULC
AS A BUILT-IN
Rear Shroud Kit, Part 811-0680 is Required for Built-In Installation
(see pages 17-18 for installation instructions)
A
C
D
B
B
C
E
0 INCH (0mm) CLEARANCE TO EXPOSED SECTION AND FACE TRIM
Figure 8.1
Inches
Millime-
A
Top of Shroud
Top Vent
Rear Vent
3.0
0
76
0
B
C
Sides of Inside Shroud
Back of Inside Shroud
Top or Rear Vent
Top Vent
Rear Vent
0
2.5
0
0
64
0
D
E
Vent Pipe to Combustible
From Outside Edge of
Panel Set to Combustibles
Top or Rear Vent
3.0
76
0
0
INSTALLED AS A BUILT-IN UNIT
Shown with Rear Vent and Optional Outside Air
Combustible
Mantel
WARNING
Fire Risk.
Shown with Hopper Extended
Comply with all minimum clear-
ances to combustibles as speci-
fied.
12 in
Failure to comply may cause
house fire.
NOTE:
•
Illustrations reflect typical installations
and are FOR DESIGN PURPOSES
ONLY.
6 in
•
•
Illustrations/diagrams are not drawn to
scale.
Rear Shroud
Actual installation may vary due to
individual design preference.
Optional Outside
Air
Figure 8.2
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CB1200-I Pellet Insert
C. Minimum Clearances To Combustibles for
Masonry and Zero Clearance Fireplaces
Inches Millimeters
A
Louvers to combustible
side wall
Insert top to mantel
Top to Face Trim
Hearth Extension - Front
Hearth Extension - Sides
6
153
MANTEL
Face Trim
B
C
D
E
12
3
6
305
76
153
203
B
C
8
A
D
E
Figure 9.1
D. Minimum Opening for Masonry and Zero
Clearance Fireplaces for Built-In Using
Rear Shroud
NOTE: A Quadra-Fire floor protector (Part 811-0730) is
available through your dealer to be used as a floor protector
for the section under the insert body only. Floor protection
to front and sides of insert unit must be supplied in addition
to this part.
Inches
22
15-1/2
25-1/2
22-1/2
29-1/4
Millimeters
558
A
B
Rear Width
Depth
Height - Top Vent
Height - Rear Vent
Front Width
393
647
C*
571
743
D
C
*The size of your floor protector choice must be
added to this dimension. If using Quadra-Fire floor
protector, Part 811-0730, allow 1-1/2” (38mm).
B
A
D
Figure 9.2
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CB1200-I Pellet Insert
E. Masonry Minimum Opening
G. Calculating Alternate Floor Protection Material
Thermal Conductivity: k value
The k value indicates the amount of heat (in BTU’s) that will flow
in 1 hour through 1 square foot of a uniform material 1 inch thick
for each degree (F) of temperature difference from one side of
the material to the other. The LOWER the k factor means less
heat is being conducted through the non-combustible material to
the combustible material beneath it. The k value of a material
must be equal or smaller then the required k value to be accept-
able.
C
B
A
D
(BTU) (inch)
(foot2 (hour) (oF)
Thermal Resistance: R value
The R value is a measure of a material’s resistance to heat
transfer. R value is convenient when more than one materi-
al is used since you can add the R values together, whereas
you can not do this for k value. The HIGHER the R factor
means less heat is being conducted through the non-com-
bustible material to the combustible material beneath it. The
R value of a material must be equal or larger then the re-
quired R value to be acceptable.
Location
Rear Width
Depth
Height - Top Vent
Front Width
Inches
22
13
19-1/2
29-1/4
Millimeters
558
A
B
C
D
330
495
743
Converting k to R:
Divide 1 by k and multiply the results times the thickness in inch-
es of the material.
R = 1/k x inches of thickness
Converting R to k:
F. Floor Protection
Divide the inches of thickness by R.
k = inches of thickness/R
Calculations:
1. Zero Clearance Installations*
It is necessary to install a floor protection of non-combus-
tible material with a R value of 3.0 (1 inch [25mm] minimum
thickness with a “k” value of 0.58) or a 1 inch (25mm) air
space between insert base and hearth.
Example: Floor protection requires k value of 0.84 and 3/4 inch
thick.
Alternative material has a k value of 0.6 and is 3/4 inch thick.
2. Non-Zero Clearance Installations*
Divide 0.6 by .75 = k value of 0.80. This k value is smaller than
0.84 and therefore is acceptable.
A non-combustible floor protector is required with a mini-
mum R value of 3.0 (1 inch [25mm] minimum thickness with
a “k” value of 0.58) extending 6 inches (153mm) in front of
the insert and 8 inches (203mm) to each side of the door
opening.
* See alternate floor protection worksheet.
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H. Removing Metal Floor of Factory-Built
Firebox
Keep sharp edge of
metal floor away from
power cord
•
The firebrick (refractory), glass doors, screen rails,
screen mesh and log grates can be removed from a
factory-built firebox in order to gain minimum insert
opening requirements.
•
•
Any smoke shelves, shields and baffles may be
removed from a factory-built firebox if attached with
mechanical fasteners.
The metal floor of the factory-built firebox may be
removed to facilitate the installation of the insert only
when a 1 inch (25mm) airspace is provided between
the insert and the floor of outer wrap.
Figure 11.3. Place the insert into the fac-
tory-built firebox. Ensure that the power
cord can not be damaged by the sharp metal
edge. You may need to cut out a notch to
accommodate the cord.
•
If the floor is made of thin metal, we recommend using
a Quarda-Fire floor protector, Part 811-0730, which is
available through your dealer.
Starter hole
Mark area of
floor to cut
Figure 11.1. Measure and mark the metal
floor for cutting. With a drill, make a starter
hole in each corner.
Figure 11.2. Using a saws-all, cut out the
floor.
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CB1200-I Pellet Insert
Vent Information
4
B. Venting Termination Requirements
A. Chimney and Exhaust Connection
1. Chimney & Connector: Use 3 or 4 inch (76-102mm)
diameter type "L" or "PL" venting system. It can be vented
vertically or horizontally.
CAUTION
Do not terminate vent in any enclosed or semi-enclosed
area such as a carport, garage, attic, crawl space, under a
sun deck or porch, narrow walkway or closely fenced area,
or any location that can build up a concentration of fumes
such as a stairwell, covered breezeway, etc.
2. Mobile Home: Approved for all Listed pellet vent. Use
Listed double wall flue connector. AQuadra-Fire Outside
Air Kit must be used with manufactured home installa-
tions.
3. Residential: Use 24 gauge single wall flue connector or
Listed double wall flue connector to Class A Listed metal
chimneys, or masonry chimneys meeting national and/or
local codes for solid fuel appliances.
1. Termination must exhaust above air inlet elevation. It is
recommended that at least 60 inches (1524mm) of verti-
cal pipe be installed when appliance is vented directly
through a wall. This will create a natural draft, which
will help prevent the possibility of smoke or odor venting
into the home during a power outage. It will also keep
exhaust from causing a nuisance or hazard by exposing
people or shrubs to high temperatures. The safest and
preferred venting method is to extend the vent vertically
through the roof.
4. INSTALL VENT AT CLEARANCES SPECIFIED BY THE
VENT MANUFACTURER.
5. Secure exhaust venting system to the appliance with at
least 3 screws. Also secure all connector pipe joints with
at least 3 screws through each joint.
2. Distance from doors and opening windows, or gravity or
NOTE: All pipe must be welded seam pipe whenever pos-
sible. Seal pipe joints with high temperature silicone (500°F
[260°C] minimum rated only).
ventilation air inlets into building:
a. Not less than 48 inches (1219mm) below;
b. Not less than 48 inches (1219mm) horizontally
from;
NOTE: If burning shelled field corn, you must use approved
venting specifically designed for corn. Follow the instruc-
tions from the venting manufacturer.
c. Not less than 12 inches (305mm) above.
3. Distance from permanently closed windows:
a. Not less than 12 inches (305mm) below, horizontally
from or above.
4. Distance between bottom of termination and grade
should be 12 inches (305mm) minimum. This is con-
ditional upon plants in the area, and nature of grade
surface. The grade surface must be a non-combustible
material (i.e., rock, dirt). The grade surface must not be
lawn. Distance between bottom of termination and public
walkway should be 84 inches (2134mm) minimum.
WARNING
Fire Risk.
•
Only LISTED venting components may be
used.
•
NO OTHER vent components may be used.
Substitute or damaged vent components may
impair safe operation.
5. Distance to combustible materials must be 24 inches
(610mm) minimum. This includes adjacent buildings,
fences, protruding parts of the structure, roof overhang,
plants and shrubs, etc.
WARNING
Vent surfaces get HOT, can cause burns
if touched. Non-combustible shielding or
guards may be required
6. Termination Cap Location (Home Electrical Service)
•
•
•
•
Side-to-side clearance is to be the same as minimum
clearance to vinyl inside corners.
Clearance of a termination cap below electrical service
shall be the same as minimum clearance to vinyl soffits.
Clearance of a termination cap above electrical service
will be 12 inches (305mm) minimum.
Location of the vent termination must not obstruct or
interfere with access to the electrical service.
Page 12
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WARNING
C. Equivalent Feet of Pipe
The table below can help you calculate the equivalent feet of
pipe which is a method used to determine pellet vent size. See
Figure 13.1.
Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage. Refer
to the owner’s information manual provided with this appli-
ance. For assistance or additional information consult a
qualified installer, service agency or your dealer.
Example of 3 Elbow-Rear Vent Termination Calculation
Pellet Venting
Component
# of
Feet of Multiplied Equivalent
Components
2 ft.
Equivalent Feet
Elbows
Pipe
By
X
Feet
5
o
90 Elbow or Tee
3
15
o
45 Elbow
X
3
Horizontal Pipe
Vertical Pipe
7
2
X
X
1
0.5
7
1
3 ft.
Total Equivalent Feet
23
2 ft.
Note: This is a generic example and is not
intended to represent any specific fuel type.
2 ft.
Figure 13.1
D. Pipe Selection Chart
30
4 in. (102mm) Diameter Pipe Only
The chart will help you in determing proper venting
size according to the equivalent feet of pipe calcuated
above and the altitude above sea level of this installa-
tion. See Figure 13.2.
Example 1
20
Equivalent Pipe
Length In Feet
Locate the calculated equivalent feet of pipe on
the vertical left side of the chart. Move to the right
horizontally on the chart until you reach your altitude
above sea level.
Example 2
10
If you fall below the diagonal line, 3 or 4 inch (76 to
102mm) pipe may be used. If it is anywhere above
the diagonal line, a 4 inch (102mm) diameter pipe is
requried.
3 in. or 4 in. (76mm or 102mm) Diameter Pipe
0
1
2
3
4
5
6
7
8
9
10
ALTITUDE IN THOUSANDS OF FEET
Figure 13.2
The chart reveals that a 90° elbow is 5 times as
restrictive to the flow of exhaust gases under positive
pressure as 1 foot of horizontal pipe, and a foot of
horizontal pipe is twice as restrictive as a foot of
vertical pipe.
Example 1: If the equivalent length of pipe is 23 feet with altitude of
8,000 feet you must use 4 inch (102mm) diameter type “L” or “PL”
vent.
Example 2: If the equivalent length of pipe is 12 feet with altitude of
6,000 feet you may use 3 or 4 inch (76 to 102mm) diameter type “L”
or “PL” vent
WARNING
Fire Risk.
Do NOT pack insulation or other combustibles between firestops.
•
•
ALWAYS maintain specified clearances around venting and firestop systems.
Install firestops as specified.
Failure to keep insulation or other material away from vent pipe may cause fire.
Page 13
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Venting Systems
5
B. Direct Connect Without Outside Air
A. Direct Connect With Outside Air
NOTE: In Canada, only a full reline is
allowed per ULC S-628, ORD ULC C1482.
NOTE; Use metal plate
around exhaust vent pipe
and seal all edges with
non-flammable insulation
such as fiberglass, mineral
wool or ceramic material.
Do not use high tempera-
ture caulking materials to
seal any edge to prevent
future serviceability.
Outside Air
through
Rear Wall
Figure 14.1
NOTE:
Figure 14.2
WARNING
•
Illustrations reflect typical installations and are FOR
DESIGN PURPOSES ONLY.
Fire Risk.
Inspection of Chimney:
• Masonry chimney must be in good condition.
• Meets minimum standard of NFPA 211
•
•
Illustrations/diagrams are not drawn to scale.
Actual installation may vary due to individual design
preference.
• Factory-built chimney must be 6 inch (152mm)
UL103 HT.
CAUTION
Never draw outside combustion air from:
NOTE:
In Canada, where passage through a wall or partition of
combustible construction is desired, the installation shall
conform to CAN/CSA-B365.
•
•
Wall, floor or ceiling cavity
Enclosed space such as an attic or garage
Page 14
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C. Full Reline With Outside Air
NOTE: Check clearances carefully for this
type of installation to ensure adequate room
for outside air venting.
12” (305mm)
min. above
12” (305mm)
min. below
NOTE: In Canada, only a full reline is
allowed per ULC S-628, ORD ULC C1482.
CAUTION
Check building codes prior to installation.
•
Installation MUST comply with local, regional,
state and national codes and regulations.
Consult local building, fire officials or authorities
having jurisdiction about restrictions, installa-
tion inspection, and permits.
•
NOTE; Use metal
plate around
exhaust vent pipe
and seal all edges
with non-flammable
insulation such as
fiberglass, mineral
wool or ceramic.
Outside Air
Termination
at
Do not use high
temperature caulk-
ing materials to seal
any edge to prevent
future serviceability
Chimney Top
Outside Air
through
Rear Wall
Exit through the
Ash Clean-Out of
Masonry Chimney
Figure 15.1
Page 15
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Mobile Home
6
A. Mobile Home Installation
CAUTION
You must use a Quadra-Fire Outside Air Kit for instal-
lation in a mobile home.
Maintain structural integrity of mobile home:
•
Floor, wall, ceiling and/or roof.
Do NOT cut through:
1. An outside air inlet must be provided for the combustion
air and must remain clear of leaves, debris, ice and/or
snow. It must be unrestricted while the appliance is
in use to prevent room air starvation which causes
smoke spillage. Smoke spillage can also set off smoke
alarms.
•
•
Floor joist, wall studs or ceiling trusses.
Any supporting material that would affect the structural
integrity.
2. The combustion air duct system must be made of
metal. It must permit zero clearance to combustible
construction and prevent material from dropping into
the inlet or into the area beneath the dwelling and
contain a rodent screen.
Spark Arrestor Cap
3. The appliance must be secured to the mobile home
structure by bolting it to the floor (using lag bolts). Use
the same holes that secured the appliance to the ship-
ping pallet.
Storm Collar
Roof Flashing
4. The appliance must be grounded with #8 solid copper
grounding wire or equivalent, terminated at each end
with an NEC approved grounding device.
5. Refer to Clearances to Combustibles and floor pro-
tection requirements on pages 8 & 9 for listings to
combustibles and appropriate chimney systems.
Joist Shield/Firestop
Approved Class “L” o
“PL” Pellet Vent
6. Use silicone to create an effective vapor barrier at
the location where the chimney or other component
penetrates to the the exterior of the structure.
7. Follow the chimney manufacturer’s instructions when
installing the vent system for use in a mobile home.
Figure 16.1
8. Installation shall be in accordance with the Manufactur-
ers Home & Safety Standard (HUD) CFR 3280, Part
24.
WARNING
Installation must comply with Manufactured Home and
Safety Standard (HUD), CFR 3280, Part 24.
WARNING
Never install in a sleeping room.
Page 16
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Appliance Set-Up
7
A. Rear Shroud Installation
1. Top Vent Installations
Parts Required:
REAR SHROUD TOP
VENT PART 811-0
0
Part 811-0680, Rear Shroud Kit.
Includes: Six galvanized steel shroud pieces, two cover
plates and fastener package.
Right Corner
Part 811-0650, Rear Shroud Top Vent
Includes: Vent pipe and two 1/4 - 20 x 3/4 inch bolts with
nuts.
Top Vent Opening
Left Corner
Part 811-0660, 3 inch Top Vent Adapter
4 inch Top Vent Adapter
Part 811-0670,
2. Rear vent installations
Parts Required:
Part 811-0680, Rear Shroud Kit.
Part 811-0690, Rear Vent Kit
Includes: Rear Vent Adapter and fastener package.
Figure 17.1
Tools Required:
Electric drill, 1/8 inch drill bit, Phillips screw driver, 3/8 inch
wrench & 7/16 inch wrench, (7/16 inch socket wrench & high
temperature silicone adhesive are also required for rear vent
installations).
Filler Piece
Rear Shroud
Top Vent
Complete the following procedures, based on
your venting installation, prior to installing
the rear shroud kit. (Note: All photos depict top vent
installation).
Figure 17.2
Figure 17.3
Top Vent Installation Preparation
1. Remove the top vent adapter from the vertical exhaust
transition pipe. Figures 17.2 and 17.5.
2. Use 2 screws to attach left corner filler piece of rear
shroud to the insert hopper. Figures 17.1 and 17.2.
Vertical Exhaust
Transition Pipe
3. Use (2) 1/4 - 20 x 3/4 inch bolts with nuts to install rear
shroud top vent to the exhaust transition. See boxed
area in Figure 17.3. (Circled area, top vent adapter,
will be installed later).
Left Corner
Piece
4. Install the left shroud panel corner at 3 points, 2 screws
into back of hopper and 1 down into the filler piece).
Figure 17.4
Top Vent Adapter
Figure 17.5
Figure 17.4
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Rear Vent Installation Preparation:
4. Assemble the right corner and right panel pieces using 4
1. Remove the ENTIRE exhaust blower housing by remov-
ing the 4 nuts using a 7/16 inch socket wrench. Set the
nuts aside for later use.
screws prior to attaching to insert. Figure 18.4.
5. After assembly, attach the right shroud panel/corner piece
assembly to the insert with 3 screws across the bottom and
1 on the side. Figure 18.4.
2. Remove the 4 screws and remove the vertical exhaust
transition pipe exhaust blower housing.
3. Remove any silicone sealant remaining on the blower
housing.
4. Attach the rear vent adapter to the exhaust blower hous-
Knock-Out
Plate
ing with 4 screws. Figure 18.2.
Outside Air
Cover Plate
5. Apply a bead of high temperature silicone adhesive
around the juncture of the blower housing and rear vent
adapter, smoothing it around the joint to ensure that a
good seal is made.
Left Side
Figure 18.3
6. Re-install the exhaust blower housing (now with rear vent
adapter attached) with the 4 nuts previously removed in
Step 1.
Right Corner Piece
7. Use 2 screws to attach left corner filler piece of rear
shroud to the insert hopper. Figures 17.1 & 17.2 on
page 17.
Attach right
corner piece to
side panel first.
Rear Panel
8. Install the left shroud corner with 2 screws into the hopper
Right Side
body and 1 down into filler piece. Figure 18.1.
9. Install cover plate over top vent opening using 4
screws.
Figure 18.4
Attaching Shroud to Hopper Body:
6. Beginning at the right shroud panel drill into hopper body
through the 3 pre-drilled openings and the 2 pre-drilled
openings on the rear shroud panel. Figure 18.5. Continue
around to left shroud corner panel at the 2 pre-drilled
openings. Figure 18.6. Secure with screws to insert.
7. For Top Vent Installation:
Left Corner
Piece
Install 3 inch or 4 inch (76 or 102mm) top vent adapter.
See circled area in Figure 17.3 on page 17. NOTE:
This adapter may be attached to outside venting prior to
latching it on to the top vent pipe.
Figure 18.1
Figure 18.2
rill oles
rill oles
Installing Rear Shroud
Top Vent Applications: Leave knock-out plate in place.
Figure 18.3
Rear Panel
Rear Vent Applications: Clip corners of knock-out plate,
remove and discard, prior to assembling rear shroud kit.
Figure 18.5
1. Install rear panel using 4 screws along bottom and 2 screws
rill oles
into the left shroud corner piece at the top. Figure 18.3.
2. If your installation does not include an outside air kit,
attach cover plate with 4 screws.
3. Attach left shroud panel using seven screws, 3 on top and
bottom and 1 along the side. Figure 18.3.
Figure 18.6
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C. Adjustable Hopper Options
B. Outside Air Kit Instructions
Depending on your installation, the hopper can be vertically
adjusted up to a maximum of 3-1/2 inches (89mm) and will
hold an additional 15 lbs of fuel.
Parts Included in Kit: 1 piece of 2 inch x 3 ft. flex hose,
1 hose clamp and 1 rodent screen.
Tools Needed: Phillips head screw driver; wire cutters;
hole saw or jig saw.
1. Measure distance from floor to air vent opening in appli-
ance and mark location on wall.
To adjust hopper:
1. Using a Phillips head screw drive, remove all the screws
from the top of the hopper securing the top hopper piece
to the bottom hopper piece and insert body.
2. Use saw to cut opening in wall. Cut a 2-1/2 to 3 inches
(64-76mm) opening on inside wall and a 3 to 3-1/2 inch
(76-89mm) opening on outside of house.
2. Adjust upward a maximum of 3-1/2 inches (89mm).
3. Mark location for new holes and drill new holes.
3. Use hose clamp to secure flex pipe to collar assembly.
4. Slide trim ring over flex pipe and run pipe through wall.
4. Secure hopper pieces together using screws removed in
step one.
5. See drawing on page 7, Figure 7.3.
5. Attach hose to outside termination cap with second
hose clamp.
6. Secure termination cap to outside surface.
7. Secure trim ring to interior wall.
D. Optional Grille Installation
1. Remove grille from packaging.
2. Lift top up.
CAUTION
Never draw outside combustion air from:
3. Align the 3 holes in the insert with the holes in the grille.
•
•
Wall, floor or ceiling cavity
Enclosed space such as an attic or garage
4. Use a Phillips screw driver to secure in place. It will be
necessary to go through the hole in the bag support shelf
to gain access to the screw. Figure 19.3.
5. Lower the top into position.
Bag Support Shelf
Outside air
flex pipe
Attach hose clamp to
intake air collar
Figure 19.3
Figure 19.1
ri Rin
le
ose
ose Cla
Collar
Asse
ose Cla
l
er ination
Ca Asse
l
Figure 19.2
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E. Adjustable Hearth Support
EXPLODED VIEW OF SCISSORS
Size: 9”d x 45”w, 2” to 10” Height Adjustment
Included in Kit: (1) trim top, (1) trim front, (2) trim sides,
double-sided tape (already installed)
SCREWS ARE CIRCLED
Tools Needed: Phillips head screw driver, sheet metal
shears, measuring tape, gloves
1. The 10 screws on each set of scissors will already be
DOUBLE-SIDED TAPE
DOUBLE-SIDED TAPE
loose when shipped. Figure 20.1.
Figure 20.1
2. Expand scissors to desired height. Tighten screws to hold
in place using Phillips head screw driver. Figure 20.2.
3. Measure front and side trims to required height to cover
scissors and mark pieces for cutting. Cut excess mate-
rial from top of trim’s edge, not bottom. This edge will
be sharp; wear gloves to prevent injury to your hands.
Figure 20.3.
EXPAND SCISSORS TO DESIRED HEIGH T
4. Using sheet metal shears, cut trim along the marked
edge. The cut edge fits under lip of top trim, so it allows
for some variance in your straight edge.
CUT TOP EDGE OF TRIM,
NOT BOTTOM EDGE
INSTALL FRONT TRIM LAST.
CORNERS OVERLAP SIDE
TRIM PIECES
5. The double-sided tape that holds front and side trims to
scissors has a powerful bonding adhesive. Adjustments
are extremely difficult once trim has adhered to tape. Do
a dry run first without removing paper from tape.
Figure 20.2
6. Place cut edge of trim under top lip and into position on
scissors. Place side pieces on first and then front piece.
The front piece overlaps side pieces.
7. Once you are satisfied with the positioning, remove trim
and set aside.
8. Remove the paper from double-sided tape that is to
accept trim side. Align side and then press hard against
tape to secure side piece. Repeat for other side. Install
front trim piece last.
Decorative tile
may be installed
9. There are 3 holes in the back flange of the top to secure
it to the wall if necessary. Use the appropriate fastener
for the type of wall material, i.e., brick, sheetrock, etc.
Figure 20.3
NOTE: 3/8 inch (9.5mm) thick tile or like material can be
cut to size and fit under lip of top trim edge for a decora-
tive touch. Figure 20.3.
WARNING
Sheet metal trim edges will be sharp.
For safety purposes wear gloves.
Injury can occur.
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F. Panel and Trim Set
Standard Size: 30 inches H x 40 inches W (762mm x 1016mm)
Large Size: 33 inches H x 50 inches W (838mm x 1270mm)
Included in Kit: 2 side panels, 1 top panel, 2 side trim, 1
top trim, 2 corner brackets and fastener package.
Tools Needed Phillips and flat head screw drivers.
1. Unpack and lay out parts face down (flanges up) on a non-
abrasive surface as shown in Figure 21.1. Install (1) 8-32
x 3/8 inch screw into bottom tab of side panel.
Figure 21.3
2. Set the large hole at bottom of side curtain over screw
installed in Figure 21.2.
3. Stand assembly on end and attach and install (1) 8-32 x 3/8
inch screw through tab in side panel and curtain. Figure
21.4. Lay face down as shown in Figure 21.5.
4. Align top panel to side panel setting clearance hole over
screw head in side panel/curtain assembly. Install (2) 8-32
x 3/8 inch screws through holes in side panel into top panel.
Figure 21.6. Complete for both sides.
Corner
Corner
Bracket
Top Trim
Bracket
Top Panel
Right
Trim
Left
Figure 21.4
Trim
Right
Panel
*Right Side
Curtain
Left
*Left Side
Curtain
Panel
Figure 21.1
NOTE: *Right and left side curtains are shipped
with the insert.
Figure 21.5
Figure 21.6
Figure 21.2
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F. Panel and Trim Set (Cont’d)
5. Hold side curtains in open position and lower panel set
over insert setting lower edge of top panel in slot between
hopper lid and panel support as shown in Figure 22.1.
Place existing screw head (installed in Figure 21.2) into
locator hole in floor of insert. Figure 22.2.
6. Lift hopper lid and press down on panel top while installing
(4) 8-32 x 3/8 inch screws into holes in panel support. (If
screws have been factory installed, tighten to secure panel
to panel support.) Return hopper lid to closed position.
7. Install a corner bracket on each side trim piece. Slide
brackets into top trim from each side and secure with
flathead screwdriver. Attach trim assembly to panel set
as follows:
Figure 22.3
a. Ensure that brackets face towards the back.
b. Align trim assembly to panel set sides and slide down
.
View of "L" Bracket
installed
Figure 22.4
Figure 22.1
Panel Locator Hole
Figure 22.5- Completed View
Figure 22.2
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G. Optional Brick Set Installation
WARNING
Risk of Injury.
1. Slide bottom of left rear brick in first; rotate top edge to-
ward rear of appliance and then rotate outer edge toward
rear of appliance, until brick slides into place. Figure 23.1.
Repeat for right rear brick.
Brick may have small wires protruding from
the back of brick.
2. Place left side brick along left side of firebox, making sure
chamfered (beveled) back edge fits snugly next to left rear
brick. Figure 23.2. Repeat with right side brick.
H. Brick Clip Installation
3. Complete brick set, correctly installed. Figure 23.4.
1. After the brick set has been installed, 2 brick clips need to
be installed on the outer edge of baffle to keep the brick
set in place. Remove the baffles from the appliance before
installing the brick clips.
2. Using pliers, bend the brick clip slightly past 90° in the
direction shown in Figure 23.4.
3. Position the brick clip as shown in Figure 23.4 and use pliers
to crimp around the outside edge of the baffle. Figure 23.5
shows the finished shape of the brick clip after being bent
around the outside edge of the baffle.
4. Slide the baffles back into place making sure that the brick
clip holds the brick out toward the wall of the firebox. Push
back on the sides so they keep the rear bricks in place.
Repeat for the opposite side.
Figure 23.1
Approximately
1 inch
Outside edge
of Baffle
Top outside
Brick Clip
corner of Baffle
Figure 23.2
Figure 23.4
Installed Clip
Figure 23.5
Figure 23.3
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I. Optional Log Set Placement Instructions
J. Thermostat Installation
1. A 12 volt AC thermostat is required to operate this pellet
appliance. You may use the included wall mount thermo-
stat or purchase an optional programmable thermostat
or remote control. The included thermostat is equipped
with an adjustable heat anticipator. The current rating is
.05 amps. The anticipator needs to be adjusted to the
lowest setting available.
CAUTION
Logs are FRAGILE. Use extreme care when handling or
cleaning logs.
1. Place the front log in first as shown in Figure 24.1
charred area surrounding firepot.
2. When mounting a thermostat on a wall, be sure to follow
your thermostat installation instructions carefully.
2. Set the left and right logs onto the front log, placing
the holes in the base of the left and right logs over the
locating pins in the front log. See Figure 24.2. Ensure
that the charred ends are facing the firepot.
NOTE: Thermostat must be mounted level for accu-
rate readings. The thermostat should be mounted on
an inside wall and not in direct line with the appliance
convection air. Remove any packaging from inside
the thermostat before using.
NOTE: If the thermostat is located too close to the
appliance, you may need to set the temperature
setting slightly higher to maintain the desired tem-
perature in your home.
3. Open right side plane to access a 4 screw terminal block
located on the bottom right hand side next to the power
cord inlet. The center 2 screws are for the thermostat
wires. The outer 2 are the mounting screws for the ter-
minal block. Figure 24.3.
LOCATING PINS
CAUTION
hock hazard.
Do NOT remove grounding prong from plug.
Plug directly into properly grounded 3 prong
receptacle.
Route cord away from appliance.
Do NOT route cord under or in front of appli-
ance.
Figure 24.1
•
•
Charred Areas in the Bac
Top Log
Right
Top Log, Left
er inal lock
Center Scre s for
er ostat ires
Front Log
Figure 24.2
NOTE:
Po er Outlet
Due to the abrasive nature of a pellet appliance fire, the
logs are not covered under warranty. Any placement vari-
ation other than shown here can cause excessive heat
and shall void the appliance warranty.
Figure 24.3
Page 24
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Operating Instructions
8
B. General Operating Information
1. Thermostat Calls For Heat
A. Fuel Size And Material
1. Wood Pellets
The appliance is like most modern furnaces; when the thermostat
calls for heat, your appliance will automatically light and deliver
heat. When the room is up to temperature and the thermostat
is satisfied, the red call light will shut off and the appliance will
shut down. Figure 25.1.
Fuel pellets are made from sawdust or wood by-products. If the
source material is hardwood, they can have a higher mineral
content, creating more ash. Fuels containing bark will also
have higher ash content. Minerals and other non-combustible
materials such as sand will turn into a hard, glass-like substance
called a clinker when heated to the extreme temperatures
our firepot reaches. This is what forms clinkers in the bottom
of the firepot. Trees from different areas will vary in mineral
content. That is why some fuels produce more clinkers than
others. Pellets are manufactured in either 1/4 inch or 5/16 inch
(6-8mm) diameter and should be no more than 1-1/2 inches
(38mm) in length. Pellet lengths may even vary by lot from the
same manufacturer which is why the feed rate may need to be
adjusted occasionally. If you burn pellets longer than 1-1/2
inches (38mm) you may have an inconsistent fuel feed rate
and/or missed ignitions.
2. Heat Output Controls
This appliance is equipped with a heat output control switch that
has three settings or burn rates; low, medium and high. The
appliance will turn on and off as the thermostat demands. When
the thermostat calls for heat, the appliance will always start up
on High. After burning approximately 4 minutes, the appliance
will then burn at the rate at which it was originally set. If the
appliance is set at one of the lower settings, it will run quieter
but takes longer to heat up an area than if it were set at a higher
burn rate. Regardless of the burn rate, when the area is warm
enough to satisfy the thermostat, the appliance will shut off.
Pellet fuel quality can greatly fluctuate. We recommend using
premium grade fuel with ash content less than 1%. Even in some
fuel labeled “premium” ash content can vary from bag to bag
and possibly exceed 1%. High ash fuel, or lack of maintenance,
can cause the firepot to fill up and thus create a potential for
smoking, sooting and possible hopper fires.
Control
o
Always burn dry fuel. Burning fuel with high moisture content
takes heat from the fuel and tends to cool the appliance,
robbing heat from your home. Damp pellet fuel can clog the
feed system.
eat Out ut S itc
Reset utton
Blue
Blin ing
Light
Red Call Li
t
use
We recommend that you buy fuel in multi-ton lots whenever
possible. Buying large quantities of fuel at once will greatly
reduce the number of times the feed adjustments will need to
be made. However, we do recommend trying various brands
before purchasing multi-ton lots to ensure your satisfaction.
Red / reen
Light
Figure 25.1
ARNING
Fire Risk.
High ash fuels, or lack of maintenance,
can cause the repot to ll with ash
WARNING
and clinker. If the repot lls to the top,
immediately shut down the unit and clean.
Fire Risk.
Keep combustible materials, gasoline and other
flammable vapors and liquids clear of appliance.
Do NOT store flammable materials in the appliance’s
vicinity.
Failure to do so could result in smoking,
sooting and possible hopper res.
•
•
2. Shelled Field Corn
Do NOT use gasoline, lantern fuel, kerosene, charcoal
lighter fluid or similar liquids to start or “freshen up” a fire in
this heater.
Shelled field corn can be an efficient and economical fuel. We
recommend using a 50-50 blend of corn and wood pellets. The
only change in operation; 1) the feed rate may require a slight
adjustment and 2) firepot will require more frequent cleanings.
The BTU output varies slightly compared to pellets, depending
on the quality of the corn used. In cases where it is acceptable
for the appliance to run full time, 100% corn will work after the
fire has been started using wood pellets.
•
•
Keep all such liquids well away from the heater while it is in
use.
Combustible materials may ignite.
Page 25
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CB1200-I Pellet Insert
C. Before Your First Fire
E. Fire Characteristics
1. First, make sure your appliance has been properly
installed and that all safety requirements have been met.
Pay particular attention to the fire protection, venting and
thermostat installation instructions.
A properly adjusted fire with the heat output control switch set
on “HIGH” has a short active flame pattern that extends out
of the firepot approximately 4 to 6 inches (102-105mm). If
the fire has tall flames with black tails and seems somewhat
lazy, the feed rate will need to be reduced. If the fire is not 4
inches to 6 inches (102-105mm) tall, increase the feed rate.
Amedium and low setting will give a shorter flame. The flame
will rise and fall somewhat. This is normal.
2. Double check that the ash pan and firebox are empty!
3. Check the position of the thermocouple, located above
the firepot, and make sure that it protrudes approximately
3/4 inch (19mm) into the firepot.
4. Close the front door.
F. Feed Rate Adjustment Instructions
The feed adjustment control rod is factory set, and should
be adequate for most fuels. The set screw is located at the
bottom of the hopper and set loose at the factory so the fuel
adjustment control rod will slide by only loosening the wing
nut. Do not re-tighten bottom set screw.
CAUTION
Tip of thermocouple must be in contact with the inside
end of the thermocouple cover.
Missed ignitions can occur.
However, if the flame height is too high or too low, you will
need to adjust the feed rate. Wait until the appliance has been
burning for 15 minutes before making your adjustments and
D. Starting Your First Fire
a
llow 15 minutes for feed adjustment to take effect.
1. A thermostat is required for proper operation of this
appliance, except for corn. At this time, fill the hopper
with pellets, set the thermostat to its lowest setting. Plug
the power cord into nearby outlet.
1. Open the hopper lid and locate the fuel adjustment control
rod.
2. Loosen the wing nut on the rod.
2. The exhaust blower will stay on for approximately 10
minutes even though the thermostat is not calling for
heat. This is normal.
3. Adjust the fuel adjustment control rod towards the "+"
symbol to increase the feed rate and flame height or
towards the "-" symbol, to decrease the feed rate and
3. Locate the heat output control switch on the right side
behind the right side panel. Set to the HIGH setting and
then adjust the thermostat to its highest setting. The
red call light will be on which is located on the right side
behind the right side panel. This indicates the thermostat
is calling for heat. See Figure 25.1 on page 25.
G. Ignition Cycles
1. During each ignition cycle, it is normal to see some smoke
in the firebox. The smoke will stop once the fire starts.
2. The convection blower will automatically turn on after your
appliance has reached the set temperature. This blower
transfers heat from your appliance into the room, and will
continue to run after the thermostat has stopped calling
for heat until the appliance has cooled down.
4. The fuel feed system and the igniter should now be on.
5. For your first fire it will be necessary to press the reset
button approximately 2 minutes after start-up and again
at 4 minutes. This will fill the feed system and allow the
appliance to begin dropping pellets. Continue pushing
the reset button until you detect that pellets are being
delivered into the firepot. The appliance will continue to
run as long as the thermostat is calling for heat.
3. Occasionally the appliance may run out of fuel and shut
itself down. When this happens, the red call light will be
on. To restart it, fill the hopper and press the reset button.
When you press the reset button the red call light will go
out. Release the button and the light will come back on.
You should see a fire shortly. If not, follow the instructions
“Starting Your First Fire”.on this page.
6. Once the appliance has ignited, let the it burn for
approximately 15 minutes, then set the thermostat to the
desired room temperature. Adjust the heat output control
switch to the desired setting.
CAUTION
Odors and vapors released during initial operation.
•
•
Curing of high temperature paint.
Open windows for air circulation.
Odors may be irritating to sensitive individuals.
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WARNING
Fire Risk
Do NOT operate appliance:
•
•
•
With appliance door open.
Firepot floor open.
Cleaning slide plates open.
Do NOT store fuel:
•
•
Closer than required clearances to com-
bustibles to appliance
Within space required for loading or ash
removal.
Back side of Firepot
Firepot floor left open
Figure 27.1 - DO NOT LEAVE FIREPOT FLOOR OPEN
H. Frequently Asked Questions
ISSUES
SOLUTIONS
1. Metallic noise.
1. Noise is caused by metal expanding and contracting as
it heats up and cools down, similar to the sound pro-
duced by a furnace or heating duct. This noise does not
affect the operation or longevity of your appliance.
2. Ash buildup on glass.
3. Glass has turned dirty.
2. This is normal. Clean the glass.
3. Excessive build up of ash. The lower burn settings will
produce more ash, the higher burn settings produce
less. The more it burns on low the more frequent clean-
ing of the glass is required.
4. Fire has tall flames with black tails and is lazy.
4. The feed rate needs to be reduced or the firepot needs
cleaning. Heat exchanger or exhaust blower needs
cleaning.
5. Smokey start-up or puffs of smoke from the airwash. 5. Either the firepot is dirty or there is too much fuel at
start-up and not enough air. Close down feed rate 1/4
inch (6mm) at a time until this no longer happens.
6. Large flame at start-up.
6. This is normal. Flame will settle down once the fire is
established.
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With proper installation, operation, and maintenance your appliance will provide years
of trouble-free service. If you do experience a problem, this troubleshooting guide
will assist a qualified service person in the diagnosis of a problem and the corrective
action to be taken. This troubleshooting guide can only be used by a qualified service
technician.
Troubleshooting
9
Possible Cause
No current to outlet.
Corrective Action
Check circuit breaker at service panel.
Replace fuse.
Symptom
Plug in appliance - No
response.
.7 amp fuse defective.
#3 snap disc tripped or defective.
Control box defective.
Reset or replace snap disc.
Replace control box.
Call light on. No fire.
No fuel in firepot.
Out of fuel.
Check hopper. Fill with fuel.
Replace snap disc.
#2 snap disc may be defective.
Vacuum switch not closing, no vacuum.
Check exhaust blower is plugged in and
operating.
Check vacuum switch is plugged in.
Check vacuum hose is in good condition,
clear and connected at both ends.
Check thermocouple is in good condition
and plugged in properly.
Make sure venting system is clean.
Make sure front door is closed.
Replace control box.
Control box defective.
Call light on. No fire.
Partially burned fuel in
firepot.
Firepot clean-out plate not closed.
Check that firepot clean-out plate is fully
closed.
Firepot is dirty (missed ignition).
Clean firepot. Make sure there is no clinker
in the firepot.
Clinkers may have to be broken up with
firepot scraper tool or other means.
Call light on. No fire.
Unburned pellets in
firepot.
Firepot clean-out plate not closed.
Firepot is dirty.
Check that firepot clean-out plate is fully
closed.
Clean firepot. Make sure there is not a
clinker in the firepot. Clinkers may have to
be pushed out of firepot with firepot scraper
tool or other means.
Scrape with solid piece of wire.
Ignition hole blocked.
Igniter not working.
Remove ash pan to see if igniter is glowing
red on start-up.
Check igniter wires for good connection.
Replace igniter using 1/4 inch male /female
spade connectors.
Replace control box.
Control box defective.
Slow or smoky start-up. Firepot clean-out plate not closed.
Firepot is dirty.
Check that firepot clean-out is fully closed.
Clean firepot. Make sure there is not a
clinker in the firepot. Clinkers may have to
pushed out of firepot with firepot scraper
tool or other means.
Reduce feed rate using feed rate adjust-
ment control rod located inside hopper.
Excessive amount of fuel at start-up.
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Corrective Action
Check for ash build up in appliance,
including behind rear panels, firebox, heat
exchanger, exhaust blower and venting.
Troubleshooting (Cont’d)
Symptom
Possible Cause
Slow or smoky start-up Dirty exhaust and/or venting system.
(Cont’d)
Feed system fails to
start.
Out of fuel.
Check hopper, fill with fuel.
#2 snap disc may be defective.
Replace snap disc. Firebox door must be
closed securely.
Vacuum switch not closing. No vacuum.
Check exhaust blower is plugged in and
operating.
Check vacuum switch is plugged in.
Check vacuum hose is in good condition,
clear and connected at both ends.
Check thermocouple is in good condition
and plugged in properly.
Make sure venting system is clean.
NOTE: High winds blowing into the vent-
ing system can pressurize the firebox
causing loss of vacuum.
Feed system jammed or blocked.
Empty hopper of fuel. Use a wet/dry
vacuum cleaner to remove remaining fuel,
from hopper, including feed tube.
Check feed chute for obstructions.
Loosen 2 screws and jiggle feed assembly.
Feed spring not turning with feed motor.
Feed motor defective or not plugged in.
Check that set screw is tight on feed
spring shaft at end of feed motor.
Check connections on feed motor, replace
if defective.
No call light. Appliance Thermostat not set to a high enough tempera-
Adjust thermostat above room tempera-
ture.
does not begin start
sequence.
ture.
Snap Disc #3 tripped.
No power.
Reset snap disc.
Connect to power.
Replace fuse.
Fuse blown.
Connections at thermostat and/or appliance not Check connections at thermostat and
making proper contact.
appliance.
Defective thermostat or thermostat wiring.
Replace thermostat or wiring.
NOTE: To test thermostat and wiring, use
a jumper wire at the thermostat block on
the appliance to by-pass thermostat and
wiring.
Control box defective.
Call light on.
Replace control box.
Turn thermostat off.
If call light does not go out, disconnect
thermostat wires from appliance. If call
light does go out, thermostat or wires are
defective.
Appliance fails to shut
off.
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Troubleshooting (Cont’d)
Symptom
Possible Cause
Corrective Action
Convection blower fails to No call light.
start.
Defective control box.
#1 snap disc defective.
Replace snap disc.
Blower not plugged in.
Check that blower is plugged into wire har-
ness.
Blower is defective.
Replace blower.
Control box is defective.
Blower not plugged in.
Replace control box.
Check that blower is plugged into wire har-
ness.
Exhaust blower fails to
start or does not shut off.
Blower is clogged with ash.
Blower is defective.
Clean exhaust system.
Replace blower.
Replace control box.
Control box is defective.
Large, lazy flame, orange Dirty appliance.
Clean appliance, including firepot, heat
exchangers and venting system. Remove
stainless steel baffle from firebox to clean
ash from on top of baffle. Clean behind rear
brick panels. Change fuel brand to pre-
mium.
color. Black ash on glass. Poor fuel quality, high ash content.
Firepot clean-out plate not completely
closed.
Check that firepot clean-out plate is fully
closed.
Excessive amount of fuel.
Reduce feed rate using feed rate adjustment
control rod located inside hopper.
Nuisance shutdowns.
Low flame.
Increase feed by opening feed rate adjust-
ment control rod located inside hopper.
Sawdust buildup in hopper.
Feed motor is reversing.
Clean hopper, see page 33.
Check for good connections between feed
motor and wire harness.
Defective thermocouple.
Replace thermocouple.
Replace control box.
Defective control box.
Firepot more than 1/2 full
See page 35 for detailed instructions for
“High Ash Fuel Content Maintenance”.
Appliance calls for heat.
Call light illuminates.
Exhaust blower starts.
No feed or igniter.
Thermocouple is defective or not properly
plugged in.
Check connections on thermocouple or
replace if defective.
A flashing yellow light on the control box
indicates a problem with the thermocouple.
Defective control box
Replace control box.
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Maintaining & Servicing Your Appliance
10
C. General Maintenance
1. Types of Fuel
A. Proper Shutdown Procedure
CAUTION
Depending on the type of fuel you are burning will dictate
how often you have to clean your firepot.
hock and Smoke Hazard
If the fuel you are burning has a high dirt or ash content
or you are burning shelled field corn, it may be necessary
to clean the firepot more than once a day.
Turn down thermostat, let appliance completely
cool and exhaust blower must be off. Now you
can unplug appliance before servicing.
Dirty fuel will cause clinkers to form in the firepot. Aclinker
is formed when dirt, ash or a non-burnable substance is
heated to 2000°F (1093°C) and becomes glass-like. See
“D” page 35 in this section for more details on fuels with
high ash content.
• Smoke spillage into room can occur if appliance
is not cool before unplugging.
• Risk of shock if appliance not unplugged before
servicing appliance.
.
Clinker
Figure 31.1 - Clinker
B. Quick Reference Maintenance Chart
Cleaning or Inspection
Ash Pan
Frequency
Every 5 bags of fuel
Daily Weekly Monthly Yearly
OR
X
Ash Removal from Firebox
More frequently depending on OR
the fuel type or ash build-up
X
Beneath Heat Exchanger
Blower, Combustion (Exhaust)
Every 1 ton of fuel
More frequently depending on OR
the fuel type
More frequently depending on OR
the fuel type
Prior to heating season
OR
X
X
X
X
Blower, Convection
Door Latch Inspection
Exhaust Path
OR
More frequently depending on OR
ash build-up
X
X
Firebox - Prepare for Non-Burn Season At end of heating season
OR
OR
OR
OR
Firepot - Burning pellets
Firepot - Burning Corn
Glass
Every 3 bags
Every 1 bag
When clear view of firepot
becomes obscure
X
X
X
Heat Exchanger & Drop Tube
Hopper
Every 1 ton of fuel
Every 1 ton of fuel or when
changing fuel types
OR
OR
X
X
Venting System
More frequently depending on OR
the fuel type
X
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2. Cleaning Firepot with Cleaning Rod & Firepot
Clean-Out Tool
4. Cleaning Ash Pan
•
•
Frequency: Weekly or every 5 bags of fuel
By: Homeowner
•
•
Frequency: Daily or more often as needed
By: Homeowner
Locate the ash pan underneath the firepot and using a
slight pull up and out remove the ash pan. Empty into
a non-combustible container and re-install ash pan.
See Disposal of Ashes.
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off. If you are
just cleaning the firepot, there is no need to unplug the
appliance.
5. Disposal of Ashes
b. Pull firepot cleaning rod OUT and IN a couple of times
to help shake debris loose. If rod is hard to pull, it may
be necessary to use your firepot clean-out tool to chip
away material that has built up on the bottom plate of
the firepot and to push out any clinkers. Larger clinkers
may have to be removed from the top of the firepot.
Corn clinkers can be especially difficult to break up.
•
•
Frequency: As needed
By: Homeowner
Ashes should be placed in a metal container with a
tight-fitting lid. The closed container of ashes should
be placed on a non-combustible floor or on the ground,
well away from all combustible materials, pending final
disposal.
c. The firepot floor plate must be fully closed when
finished. See Figure 27.1 on page 27.
If the ashes are disposed of by burial in soil or otherwise
locally dispersed, they should be retained in the
closed container until all cinders have been thoroughly
cooled.
WARNING
Fire Risk.
WARNING
•
NEVER pull firepot cleaning rods or cleaning
slide plates when appliance is operating. Hot
pellets may fall into ashpan and may start a
fire or have mis-starts due to lack of vacuum.
Heat exchanger cleaning rods may be warm
to the touch. For safety purposes wear
gloves.
3. Ash Removal from Firebox
Do not pull heat exchanger cleaning rods
while appliance is operating.
•
Frequency: Weekly or more frequently depending on
ash build-up.
Push cleaning rods IN when done, DO NOT
leave cleaning rods OUT. Injury can occur.
•
By: Homeowner
a. Allow the appliance to completely cool down. There
must not be any hot ashes in the firebox during
cleaning. Turn the thermostat on and then immediately
off to start the exhaust blower on its cycle time. It will
pull fly ash out the exhaust instead of into the room.
6. Cleaning Heat Exchanger Chambers & Drop Tube
•
•
Frequency: Weekly or every 1 ton of fuel
By: Homeowner
b. Frequent cleaning of the ash in the firebox will help
slow down the build-up of ash in the exhaust blower
and vent system.
The amount of ash buildup in the firepot will be a good
guide to determine how often you should clean the heat
exchangers.
c. Open door. Remove ash with an ash vacuum or whisk
broom and small dust pan.
a. Allow the appliance to completely cool down before
pulling the cleaning rods. Turn the thermostat on and
then immediately off to start the exhaust blower on its
cycle time. It will pull fly ash out the exhaust instead
of into the room.
d. This ash is deposited in the same ash pan as the
firepot debris. The ash pan should be emptied every
time you clean the firebox. Remember to place the ash
and debris into a metal or non-combustible container.
See Disposal of Ashes.
b. To access the cleaning rods lift the hopper lid. Both
black bent handle pull rods are located close to the
face of the appliance to the left and right side.
WARNING
c. To clean, pull the rods straight out until it stops,
approximately 20 inches (508mm). Slide the rods
OUT and IN a couple of times.
Disposal of Ashes
•
•
Ashes should be placed in metal container
with tight fitting lid.
Ashes should be retained in closed container
until all cinders have thoroughly cooled.
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7. Cleaning Beneath Heat Exchanger
10. Door Latch Inspection
•
•
Frequency: Monthly or after burning 1 ton of fuel
By: Homeowner
•
•
Frequency: Prior to heating season
By: Homeowner
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off
.
b. A more thorough cleaning is needed to remove the
excess ash that is left behind from the use of the
cleaning rods for the heat exchanger tubes.
b.To adjust, open the latch and pivot the holding rod out.
Loosen the jam nut on the rod.
c. With a Phillips head screw driver, turn the rod clockwise
to tighten. The latch handle should snap securely in
place when adjusted properly.
c. The ash will be resting on the back of the baffles. This
will require removing the baffles. Please refer to page
37 for instructions on removing the baffles.
d. After adjusting the latch, be sure to tighten the jam nut
on the rod to hold the adjustment.
8. Cleaning Exhaust Path
•
Frequency: Yearly or more frequently depending on
ash build-up.
11. Door Gasket Inspection
•
By: Homeowner
•
•
Frequency: Prior to heating season
By: Homeowner
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off
b. Open the hinged access door on the left of the
insert.
b. To inspect the door rope (gasket), open the door and
see that the door rope extends approximately 1/8 inch
(3mm) to 3/16 inch (9.5mm) from the door rope chan-
nel.
c. Reach in and unlatch the trap door that is connected
to the rear of exhaust blower.
d. Use a small vacuum hose attachment to clean area.
e. Re-latch and close trap door.
c. It should show signs of compaction all the way around
the door where the rope contacts the face of the appli-
ance. Confirm there are no air leaks.
NOTE: There are heavy duty vacuum cleaners specifically
designed for solid fuel appliance cleaning.
12. Cleaning the Hopper
9. Cleaning the Glass
•
•
Frequency: Monthly or after burning 1 ton of fuel
By: Homeowner
•
Frequency: When clear view of the firepot becomes
obscure.
After burning approximately 1 ton of fuel or changing
fuels you will need to clean the hopper to prevent saw-
dust build-up.
•
By: Homeowner
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off.
A combination of sawdust and pellets on the auger
reduces the amount of fuel supply to the firepot. This
can result in nuisance shutdowns and mis-starts.
b. Use a damp paper towel or any nonabrasive glass
cleaner. Wipe off with dry towel.
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off.
CAUTION
b
Empty the hopper of any remaining pellets.
Handle glass assembly with care.
c. Vacuum the hopper and feed tube.
When cleaning glass:
13. Cleaning Exhaust Blower - Requires No Lubrication
•
Avoid striking, scratching or slamming
glass.
•
•
•
Frequency: Yearly or as needed
By: Quality Service Technician/Homeowner
Task:: Contact your local dealer.
•
•
•
•
Do NOT clean glass when it is hot.
Do NOT use abrasive cleaners.
Use a hard water deposit glass cleaner on white film.
Refer to maintenance instructions.
14. Cleaning Convection Blower - Requires No
Lubrication
•
•
•
Frequency: Yearly or as needed
By: Qualified Service Technician
Task: Contact your local dealer.
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15. Soot and Fly Ash: Formation & Need for Removal
in Exhaust Venting System.
•
Frequency: Yearly or more frequently depending on
ash build-up.
By: Qualified Service Technician/Homeowner
•
Be sure the appliance is allowed to cool, has been unplugged
and the exhaust blower is off.
The products of combustion will contain small particles of fly
ash. The fly ash will collect in the exhaust venting system
and restrict the flow of the flue gases.
At start-up if there is incomplete combustion, or if there is a
shutdown or incorrect operation of the appliance it will lead
to some soot formation. This will collect in the exhaust vent-
ing system.
The venting system may need to be cleaned at least once a
year or more often depending upon the quality of your fuel
or if there is a lot of horizontal pipe sections. Ash will build
up more quickly in the horizontal sections.
16. Preparing Firebox for Non-Burn Season
•
•
Frequency: Yearly
By: Homeowner
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off.
b. Remove all ash from the firebox and vacuum thoroughly.
c. Paint all exposed steel, including cast-iron.
•
Use the Touch-Up paint supplied with the appliance;
or,
•
•
Purchase paint from your local dealer.
Must use a high-temperature paint made specifi-
cially for heating appliances.
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D. High Ash Fuel Content Maintenance
•
•
Frequency: When the ash build-up exceeds more
than half way up the firepot.
By: Homeowner
Pellets Back Up
In Feed Tube
Firepot Overfills
Poor quality pellet fuel, or lack of maintenance, can create
conditions that make the firepot fill quickly with ashes and
clinkers.
This condition makes the appliance susceptible to overfill-
ing the firepot with pellets which may result in smoking,
sooting and possible hopper fires. Figure 35.1 shows an
example where the firepot overfills, pellets back up into the
feed tube and ash has accumulated in the firebox.
As
uild
in ire o
Figure 35.1
An inefficient and non-economical method of burning of
fuel caused by poor quality pellet fuel is shown in Figure
35.2.
ncorrect
The correct flame size when good quality, premium pellet
fuel is burned is shown in Figure 35.3.
If the ash buildup exceeds the half way point in the firepot
IMMEDIATE ATTENTION AND CLEANING IS REQUIRED.
ARNING
all La
la e Oran e in Color
ire Risk
i
as fuels or lack of aintenance
Figure 35.2
can cause t e re ot to ll it as
and clinker f t e re ot lls to t e to
i
ediatel s ut do n t e unit and clean
ailure to do so could result in s okin
sootin and ossi le
o
er res
Correct
Correct la e Si e ello
ite in Color
Figure 35.3
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E. Glass Replacement
oor Latc
WARNING
Glass is 5mm thick high temperature heat-
resistant ceramic glass.
o
otto
ra
e
DO NOT REPLACE with any other material.
Center Posts
lass
Alternate material may shatter and cause
injury
Side
ra
• Remove door from appliance and place face down
on a protected surface to avoid scratching the door.
e
• Remove all door rope.
1. Replacing Center Glass
NOTE: DO NOT LET Air Wash Spacers fall down from
top frame when removing and replacing center
glass.
Figure 36.1
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off.
Re ove oor Latc
and t en Side ra
irst
e
b. Using a nut driver remove the (5) bottom nuts and
remove the bottom glass frame. Figure 36.2.
c. Slightly bend up and out of the way the 2 center posts
and slide the glass out the bottom.
oor ra
e
d. Slide new glass in, reposition the 2 center posts and
re-install bottom glass frame.
s o n it no
lass or lass
ra es
e. Re-rope the door.
2. Replacing Side Glass
NOTE: When removing the side glass with the door
latch, you must remove the door latch first
before removing the side frame. Use a pow-
ered Phillips head screw driver to remove the
4 screws.
Re ove nuts fro
otto
ra
e
Figure 36.2
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off.
b. Remove side glass frame.
WARNING
c. Loosen the top and bottom frame and slightly bend
up and out of the way.
Handle glass with care.
•
Inspect the gasket to ensure it is
undamaged.
Do NOT strike, slam or scratch glass.
Do NOT operate appliance with glass
assembly removed.
d. Slide glass out the side and slide new glass in.
•
•
e. Re-install the side glass frame and tighten the top
and bottom frames.
•
Do NOT operate with glass cracked, broken or scratched.
f. Re-install the door latch, if applicable, and re-rope
the door.
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F. Igniter Replacement
G. Baffle Removal
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off.
b. Open glass door.
c. Grasp the bottom of the baffles and pull up to dis-
lodge from hook attachment.
d. Use a standard screw driver to unlatch the covers
beneath the baffles of each side.
e. Re-install in reverse order.
niter racket
niter
u
Scre
Figure 37.1
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off. Remove the
ash pan.
b. The wire leads to the igniter are connected to the wire
harness with 1/4 inch male / female spade connectors.
These wires will pull forward approximately 4 to 5
inches (102mm to 127mm). Disconnect the spade
connections and remove the igniter from the chamber.
Loosen the thumb screw and slide igniter out.
c. Install new igniter into the chamber and tighten the
thumb screw. Re-connect the wires to the 2 leads with
the spade connectors.
d. Push excess wire leads to take-up the 4 to 5 inches
(102mm to 107mm) previously pulled out. This will
keep the wires out of the way of the ash pan. Double
check that the igniter wires are clear of any movement,
i.e. ash pan, firepot cleaning rod, etc.
f. Re-install the ash pan and re-connect the power.
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Reference Materials
When describing the location of a component
part it is always AS YOU FACE THE FRONT
OF THE APPLIANCE.
11
A. Component Function
1. Control Box
ꢀ
a. The control box is located on right side of appliance,
behind the right side panel.
7. Heat Exchangers
The heat exchangers transfer heat from the exhaust system
into convection air. There are 2 clean out rods located under
the heat exchangers.
b. There is a light located inside of the control box. The
internal light will turn green when the appliance has
ο
°
reached a temperature of 200 F (93 C) in the firepot.
and will turn red when it reaches 600 F (315 C).
o
8. Heat Output Switch
°
The heat output switch is located on the right side of firebox,
behind right side panel. The function of the heat output
switch is to regulate the burn rates; low, medium and high
settings.
c. There is also an internal blue light located in the upper
left corner of the control box. When you plug in the
appliance the blue light will automatically start blinking
1 blink every 10 seconds for 60 seconds and then will
stop.
9. Igniter
The igniter is mounted on the base of the firepot. Combustion
air travels over the red hot igniter creating super heated air
that ignites the pellets.
NOTE:
Do NOT open the control box. This will void the
warranty. If you need to plug in or remove the control
box you must first unplug the appliance.
10. Junction Box And Wiring Harness
The junction box is located on the right side of the appliance,
behind the right front access panel. The junction box and
wiring harness are replaced as one component.
2. Convection Blower
The convection blower is mounted at the bottom rear of the
appliance. There are 2 impellers, one on each side of the
motor. The convection blower pushes heated air through the
heat exchange system into the room.
11. Power Supply
The power outlet is located on the right side of the appliance.
Check the wall receptacle for 120 volt, 60 Hz (standard
current). Make sure the outlet is grounded and has the correct
polarity. A good surge protector is recommended. When
operating with a generator you need at least 600 watts of
power, or with an inverter at least 800 watts of power, available
for the appliance during the start cycle.
3. Combustion (Exhaust) Blower
The combustion blower is mounted on the left side of the
appliance behind the left side panel. It is accessible either
when the insert is pulled out onto the hearth or from both
hinged side openings. The blower is designed to pull the
exhaust from the appliance and push it out through the
venting system.
12. Red Call Light
The red call light is on the right side behind the right side
panel. The function of the red call light is to indicate that the
thermostat is calling for heat.
4. Feed System
The feed system is located behind the firebox and can be
removed as an entire assembly. The assembly includes
the feed motor, mounting bracket, bearing and feed spring
(auger). The hollow feed spring (auger) pulls pellets up the
feed tube from the hopper area and drops them down the
feed chute into the firepot.
13. Reset Button
The reset button is located on the right side of firebox
behind right side panel. The function of the reset button is
to momentarily open the thermostat circuit, which restarts
the system.
5. Firepot
14. Thermocouple
The firepot is made of high quality ductile iron and has a
cleaning pull-out rod. The floor of the firepot opens for
cleaning when you pull out the rod. Be sure that the floor
returns to a completely closed position or your appliance
will not operate properly.
The thermocouple is located on top of the firepot inside
the thermocouple cover (ceramic protection tube). The
thermocouple sends a millivolt signal to the control box
indicating the preset temperatures of the green and red lights
have been obtained.
6. Fuse
15. Thermostat
The fuse is located on the right side of the appliance behind
the side panel. The fuse will blow should a short occur and
shut off power to the appliance.
The appliance is designed to run on a 12 volt AC thermostat.
The heat anticipator, if present, should be set on the lowest
setting available.
Page 38
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CB1200-I Pellet Insert
16. Snap Disc #1 (Convection Blower) 125°F
19. Vacuum Switch
Snap disc #1 is located on the right side of the firebox. There
are 2 purple wires connected to it. This snap disc turns the
convection blower on and off as needed. Power is always
present at snap disc #1.
The vacuum switch is located at the rear of the appliance.
This switch turns the feed system on when vacuum is present
in the firebox. The vacuum switch is a safety device to shut
off the feed motor if the exhaust or the heat exchanger
system is dirty or plugged or if the firebox door is open.
17. Snap Disc #2 (Fuel Delivery Interrupt) 200°F
20. Wiring Harness
Snap disc #2 is located on the back side of the feed drop
tube. There is 1 orange wire and 1 black wire connected to
it. This snap disc will turn off the feed system, which will turn
off the appliance if an overfire condition should occur or if the
convection blower should fail to operate. If this occurs the
snap disc with automatically reset itself.
See Figure 39.1 below
18. Snap Disc #3 (Burn Back Protector) 250°F
Snap disc #3 is mounted on the right side of the auger tube
just below feed motor and has a reset button. To access
it remove the right side panel. If the fire tries to burn back
into the feed system or push exhaust up the feed tube, this
snap disc will shut the entire system off. This disc must be
manually reset.
4
1
5
2
6
3
ACCY
JUMPER
T-STAT CONN (YEL)
T-STAT CONN
BURN RATE
SNAP DISC #2 (YEL)
BLUE
SNAP DISC #2 (YEL)
SNAP DISC #3 (GRAY)
PURPLE
ORANGE
GRAY
P.B.
LIGHT
SNAP DISC #1 (PUR)
SNAP DISC #1 (PUR)
POWER IN (BLK)
CONV. BLOWER
BLK
M
AUG.
CAP.
BLACK
AUGER MOTOR (RED/WHT)
M
AUGER MOTOR (BLK)
VA C.
RED
SWITCH
COMB BLOWER (BLU)
BLK
M
NEUTRAL IN (WHT)
NEUTRAL AUGER (WHT)
NEUTRAL CONV (WHT)
NEUTRAL COMB (WHT)
14
15
13
12 11 10
9
8
7
6
5
4
3
2
1
NEUTRAL IGN (HT)
IGNITER (HT)
T/C
Figure 39.1
Page 39
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CB1200-I Pellet Insert
B. Component Locations
Terminal Block
Center 2 Screws for
Thermostat Wires
Control Box
Heat Output
Switch
Reset Button
Blue
Blinking
Light
Red Call Light
Fuse
Red/ Green
Light
Power Outlet
Figure 40.1
Exhaust
Transition
Assembly
Exhaust
Blower
Convection
Blower
Figure 40.2
Page 40
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CB1200-I Pellet Insert
C. Exploded Views
Nbr
1
2
Description
Glass Frame Post
Glass Frame Side
Part Number
not sellable
not sellable
4
3
3
4
Glass Frame Spacer
Glass Frame, Top &
Bottom
not sellable
not sellable
14
2
5
5
Hinge, Female
450-2910
1
11 Door Frame
not sellable
13
12 Glass Assembly, Center 510-5400
13 Glass Assembly, Sides
14 Door Latch Bracket
510-5410
410-4912
11
12
Glass Size Center: 13-7/8” wide x 11” high
Glass Size Sides: 5-1/8” wide x 11” high
Figure 41.1 - Door, Face, Glass, & Latch Assembly
Nbr
7
8
Description
Part Number
36
Thumb Screw
Thermocouple
7000-223/24
812-0210
812-1322
812-3171
36 Thermocouple Cover
39 Thermocouple Holder
40 Firepot Pull Rod (Linkage) 812-4140
8
39
41 Firepot, EZ Clean
42 Igniter Bracket
43 Igniter (Heating Element) SRV7000-462
812-3351
not sellable
41
42
7
40
43
Figure 41.2 - Firepot, Igniter & Thermocouple
Page 41
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CB1200-I Pellet Insert
27
26
28
25
29
32
33
31
30
23
24
22
34
38
37
36
35
40
19
16
39
21
20
18
17
41
42
15
14
43
13
11
12
Figure 42.1
Page 42
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CB1200-I Pellet Insert
D. Service Parts and Accessories
IMPORTANT: This is dated information. The most current information is located on the quadra-fire web site at
SCHEMATIC LIST
Nbr
11
Description
Door Frame, not sellable
Nbr
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Description
Cover, Feed Motor, Top
Feed Motor & Spring Assembly
Heat Exchanger Cleaning Rods
Blower, Convection
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Glass Assembly, Center
Glass Assembly, Side
Door Latch Bracket
Exhaust Adapter Assembly
Exhaust Transition Assembly
Blower, Combustion (Exhaust)
Curtain, Side, Left
Grille, Louver, Top (Black, Gold or Nickel)
Ashpan Door (Panel, Front Access)
Ashpan
Ash Catcher (Ash Lip)
Heat Exchanger Tubes
Power Outlet & Thermostat Block
Curtain, Side, Right
Thermocouple Cover
Gasket, Blower, Exhaust
Mount, Door Hinge
Thermocouple Holder
Latch, Draw (3)
Firepot Pull Rod Assembly
Firepot, EZ Clean
Heat Shield Extension, Top
Junction Box & Wire Harness
Control Box
Igniter Bracket, not sellable
Igniter (Heating Element)
Vacuum Switch
Hopper, Top
SERVICE PARTS
Item #
18
Part Descsription, Alphabetical Order
Part No.
410-7830
Ash Catcher (Ash Lip)
Ash Pan
17
812-4130
410-7900
812-4200
812-4210
812-4900
812-3381
812-4330
16
Ash Pan Door (Panel, Access Front)
Baffle, Left
Baffle, Right
31
34
Blower, Convection
Blower, Combustion (Exhaust)
Component Pack (Includes firepot clean-out tool, touch-up paint, power cord & wiring harness to the
thermostat and manual, owner’s manual, label “Caution Fireplace Altered” warranty card and
“How-To-Operate” DVD)
25
28
35
21
14
Control Box
SRV7000-205
410-7920
812-4310
812-4320
410-4912
410-7910
510-5330
510-5340
812-4421
230-2150
812-3690
Cover, Feed Motor, Top
Curtain, Side, Left
Curtain, Side, Right
Door Latch Bracket
Exhaust Plenum Clean-Out Plate
Exhaust Adapter Assembly
Exhaust Transition Assembly
Feed Motor
32
33
Feed Motor Capacitor Jumper
Feed Motor & Spring Assembly
29
Page 43
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CB1200-I Pellet Insert
Item #
Part Descsription, Alphabetical Order
SKU
SRV7027-024
225-0120
414-0290
226-0090
812-4140
812-3351
812-0380
842-2350
240-0880
240-0940
240-0812
812-4710
510-0530
240-0850
842-5130
510-5400
510-5410
410-8330
410-7860
450-2910
812-4220
410-7730
812-4520
SRV7000-462
SRV7000-155
200-0831
229-0640
229-0631
410-7290
410-7172
410-8200
410-7410
410-7560
7001-045
7001-044
812-1180
230-0470
230-0900
230-1290
812-0210
812-1322
812-3171
7000-223/24
SRV410-7960
SRV7000-447
Feed Spring Only
Firepot Bolt, 1-1/4” long
Firepot Floor (Slide Plate)
Firepot Nut, 1/4-20
40
41
Firepot Pull Rod Assembly (Linkage)
Firepot, EZ Clean
Fuse .7 amp, Junction Box
Gasket (Rope), Door
Gasket, 1200 ft per roll, 3/8”
Gasket, 500 ft per roll, 1/2”
Gasket, Blower, Exhaust
37
Gasket, Exhaust Blower (Round White) between blower & housing
Gasket, Firepot
Gasket, Flue Adapter
Gasket, Tadpole, 10 ft
12
13
Glass Assembly, Center, 13-7/8 in. W x 11 in. H
Glass Assembly, Side, 1 pc, 5-1/8 in. W x 11 in. H
Grille, Bar Bottom
23
5
Heat Sheld Extension, Top
Hinge, Female
Hinge, Hopper Lid
27
Hopper Top
Igniter Wire (5 ft) & 4 Ceramic Nuts
Igniter, (Heating Element), 18 inches
Junction Box & Wire Harness
Knob, Firepot Pull Rod
43
24
22
38
Latch, Draw
Latch, Magnet
Mount, Door Hinge
Mount, Feed Motor
Mount, Hopper Lid Support, Left
Mount, Hopper Lid Support, Right
Mount, hopper Lid Support, Top
Outside Air Collar Assembly
Outside Air Termination Cap
Power Cord
Snap Disc, #1, Convection Blower, 125 degree
Snap Disc, #2, 200 degree
Snap Disc, #3, Manual Reset, 250 degree
Thermocouple
8
36
39
7
Thermocouple Cover
Thermocouple Holder
Thumb Screw, pkg of 24
Top only
26
Vacuum Switch
Page 44
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CB1200-I Pellet Insert
Item No.
Accessories
Part No.
811-0601
Brick Set
Door Assembly, Black
Door Assembly, Gold
Door Assembly, Nickle
Floor Protector
DR-CB12-MBK
DR-CB12-GD
DR-CB12-NL
811-0730
Grille, Louver, Black
Grille, Louver, Gold
Grille, Louver, Nickel
Log Set, 3 pieces
Outside Air Kit
LVGRL-CB12-MBK
LVGRL-CB12-GD
LVGRL-CB12-NL
811-0592
811-0700
Panel & Trim Set, Small, 30” h x 40” w, Gold
Panel & Trim Set, Small, 30” h x 40” w, Nickel
Panel & Trim Set, Large, 33” h x 50” w, Gold
Panel & Trim Set, Large, 33” h x 50” w, Nickel
Rear Shroud Kit
SP-CB12I3040-GD
SP-CB12I3040-NL
SP-CB12I3350-GD
SP-CB12I3350-NL
811-0680
Rear Vent Kit
811-0690
Top Vent Kit, Rear Shroud
811-0650
Top Vent Adapter, 3 inch
811-0660
Top Vent Adapter, 4 inch
811-0670
Thermostat, Mechanical
812-3760
Thermostat, Programmable #9600
Vent Adapter, 3 inch to 4 inch
811-0520
811-0720
Zero Clearance Adjustable Trim Support, 2 inch to 10 inch
841-1000
Appliance
Part No.
CB1200-I Insert, No Door or Grille (order door & grille separately)
CB1200I-B
Page 45
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7014-083E
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CB1200-I Pellet Insert
E. Warranty Policy
Hearth & Home Technologies LIMITED WARRANTY
Hearth & Home Technologies (“HHT”) and its respective brands extends the following warranty for HHT gas, wood,
pellet and electric appliances purchased from an authorized HHT dealer and installed in the United States of America or
Canada. Warranty starts with date of purchase by the original owner (End User) except as noted for replacement parts.
HHT Manufactured Appliances and Venting
EPA
Warranty Period
Parts Labor
Components Covered
Gas
X
Wood
X
Pellet
X
Electric
X
Venting
X
Wood
All Parts and Material Except
as covered by Conditions,
Exclusion, and Limitations
listed
1 Year
X
Igniters, Electronic Compo-
nents, and Glass
Blowers
X
X
X
X
2 years
3 years
X
X
X
Molded Refractory Panels
X
X
Firepots
5 years
3 years
3 years
X
X
Castings & Baffles
Firebox, HHT Chimney, Termi-
nation & Heat Exchanger
7 years
X
X
X
X
10
1 year
1 year
X
years
Burners, Logs & Refractory
Limited
Lifetime
X
X
Firebox & Heat Exchanger
All Replacement Parts
90 Days
X
X
X
See Conditions, Exclusions, and limitations.
CONDITIONS, EXCLUSIONS & LIMITATION OF LIABILITY
9-01-08
ꢀ
This warranty applies to the original owner and is transferable up to two years from date of purchase to the new
homeowner, provided the purchase was made through an authorized dealer or distributor of HHT, and the appliance
remains in its original place of installation.
ꢀ
ꢀ
ꢀ
The maximum amount recoverable under this warranty is limited to the purchase price of the product.
In no event shall HHT be liable for any incidental or consequential damages caused by defects in the product.
Adjustments, regular maintenance, cleaning and temporary repairs, or the failure to duplicate the problem in the home
is not covered under this warranty.
ꢀ
This limited warranty does not extend to or include surface finish on the appliance or terminations, door gasketing,
glass gasketing, glass discoloration, firebrick, pellet logs, kaowool or other ceramic insulating materials. Rust and/or
corrosion on any of the metal surfaces, cast iron components, baffles, firepots, doors, or firebox area are not covered
by this warranty.
ꢀ
Noise resulting from minor expansion, contraction, or movement of certain parts is normal and complaints related to
this noise are not covered by this warranty.
4021-645A 09-01-08
Page 46
7014-083E
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CB1200-I Pellet Insert
Hearth & Home Technologies LIMITED WARRANTY (Cont’d)
ꢀ
HHT’s obligation under this warranty does not extend to damages resulting from: (1) installation, operation or main-
tenance of the appliance not in accordance with the installation instructions; operating instructions and the listing
agent identification label furnished with the appliance; (2) installation which does not comply with local building codes;
(3) shipping, improper handling, improper operation, abuse, misuse, accident or unworkmanlike repairs; (4) environ-
mental conditions, inadequate ventilation or drafting caused by tight sealing construction of the structure or handling
devices such as exhaust fans or forced air furnaces or other such causes; (5) use of fuels other than those specified
in the operating instructions; (6) installation or use of components not supplied with the appliance or any other compo-
nents not expressly authorized and approved by HHT; and/or (7) modification of the appliance not expressly autho-
rized and approved by HHT in writing.
ꢀ
ꢀ
This warranty does not apply to non-HHT venting components, hearth components or other accessories used in con-
junction with the installation of this product.
This warranty is void if the appliance has been over-fired or operated in atmospheres contaminated by chlorine,
fluorine, or other damaging chemicals the appliance is subject to prolonged periods of dampness or condensation, or
there is any damage to the appliance or other components due to water or weather damage which is the result of, but
not limited to, improper chimney or venting installation.
ꢀ
HHT’s liability under this warranty is limited to the replacement and repair of defective components or workmanship
during the applicable period. HHT may fully discharge all of its obligations under such warranties by repairing the
defective component(s) at HHT’s discretion. Shipping costs are not covered under this warranty.
ꢀ
ꢀ
Some states do not allow exclusions or limitation of incidental or consequential damages, so those limitations may not
apply to you. This warranty gives you specific rights; you may also have other rights, which vary from state to state.
EXCEPT TO THE EXTENT PROVIDED BY LAW, HHT MAKES NO EXPRESS WARRANTIES OTHER THAN THE
WARRANTY SPECIFIED HEREIN. THE DURATION OF ANY IMPLIED WARRANTY IS LIMITED TO DURATION OF
THE WARRANTY SPECIFIED ABOVE.
This Limited Warranty is effective on all HHT appliances sold after September 01, 2008 and supersedes any and all war-
ranties currently in existence.
If warranty service is needed, you should contact your installing dealer. If the installing dealer is unable to provide neces-
sary parts or components, contact the nearest authorized HHT dealer or supplier.
4021-645A 09-01-08
Page 47
Septemer 1, 2008
7014-083E
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O T
T
O
T O :
Hearth & Home Technologies
1445 North Highway
Colville, WA 99114
Division of HNI INDUSTRIES
Please contact your Quadra-Fire dealer with any questions or concerns.
For the number of your nearest Quadra-Fire dealer
visit our website at www.quadrafire.com
NOTICE
DO NOT DISCARD THIS MANUAL
•
Read, understand and
follow these instruc-
tions for safe installa-
tion and operation.
•
Leave this manual with
party responsible for use
and operation.
• Important operating and
maintenance instruc-
tions included.
We recommend that you record the following pertinent
information for your CB1200-I PELLET INSERT
Date purchased/installed:
Serial Number:
Location on appliance:
Dealer phone:
Dealership purchased from:
Notes:
This product may be covered by one or more of the following patents: (United States) 4593510, 4686807, 4766876, 4793322,
4811534, 5000162, 5016609, 5076254, 5113843, 5191877, 5218953, 5263471, 5328356, 5341794, 5347983, 5429495, 5452708,
5542407, 5601073, 5613487, 5647340, 5688568, 5762062, 5775408, 5890485, 5931661, 5941237, 5947112, 5996575, 6006743,
6019099, 6048195, 6053165, 6145502, 6170481, 6237588, 6296474, 6374822, 6413079, 6439226, 6484712, 6543698, 6550687,
6601579, 6672860, 6688302B2, 6715724B2, 6729551, 6736133, 6748940, 6748942, 6769426, 6774802, 6796302, 6840261,
6848441, 6863064, 6866205, 6869278, 6875012, 6880275, 6908039, 6919884, D320652, D445174, D462436; (Canada) 1297749,
2195264, 2225408, 2313972; (Australia) 780250, 780403, 1418504 or other U.S. and foreign patents pending.
7014-083E
September 1, 2008
Page 48
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