Owner’s Manual
MODEL:
PB105 Pellet Boiler
Contact your local dealer with questions
on installation, operation or service.
NOTICE
DO NOT DISCARD THIS MANUAL
Do N
o
Disca t
rd
• Important operating and • Read, understand and • Leave this manual with
these instructions party responsible for use
maintenance instructions follow
for safe installation and and operation.
included.
operation.
WARNING
Please read this entire manual before
installation and use of this pellet fuelburning room heater.
Failure to follow these instructions could
result in property damage, bodily injury
or even death.
WARNING
HOT SURFACES!
Glass and other surfaces are hot
during operation AND cool down.
Hot glass will cause burns.
• Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
• Do not touch glass until it is cooled
• Do not overfire - If any external part starts to glow, you
are overfiring. Reduce feed rate. Overfiring will void
your warranty.
• Keep children away
• Comply with all minimum clearances to combustibles
as specified. Failure to comply may cause house fire.
!
CAUTION
Tested and approved for wood pellets and shelled field
corn fuel only. Burning of any other type of fuel voids
your warranty.
!
CAUTION
Check building codes prior to installation.
• Installation MUST comply with local, regional, state and
national codes and regulations.
• Contact local building or fire officials about restrictions
and installation inspection requirements in your area.
www.harmanstove.com
• NEVER allow children to touch glass
• CAREFULLY SUPERVISE children in same room as
fireplace.
• Alert children and adults to hazards of high temperatures.
High temperatures may ignite clothing or other
flammable materials.
• Keep clothing, furniture, draperies and other flammable
materials away.
NOTE
To obtain a French translation of this manual, please
contact your dealer or visit www.harmanstoves.com
Pour obtenir une traduction française de ce manuel, s’il
vous plaît contacter votre revendeur ou visitez www.
harmanstoves.com
3-90-07205R27_08/15
Parts Locations
1-1/4” FMPT Supply
Hopper Lid
Latches
Temperature / Pressure Gauge
Aquastat Well
Pressure Relief Valve
Blank Cover (Removed w/ Domestic
Hot Water Option
Hopper
Cleaning Rods
Control Board
1-1/4” FMPT Return
Control Board Cover
Vent Pipe
Access Cover to
Hopper / Swing
Plate Knob
Firebox Door
Viewing Glass
Ash Door
Access Cover to Secondary Ash Chamber
Combustion Blower
Combustion Blower Cover
3/4” FMPT Boiler Drain
2
3-90-07205R27_08/15
Table of Contents
Product Specific and Important Safety Information. . . . . 4
Atmospheric Conversion. . . . . . . . . . . . . . . . . . . . . . . . 37
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Optional Domestic Hot Water Coil. . . . . . . . . . . . . . . . . 38
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13
Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Outside Air Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power Failure Back-Up Supply. . . . . . . . . . . . . . . . . . . 41
Main Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Plumbing Installations. . . . . . . . . . . . . . . . . . . . . . . 16-20
Quick Reference Start-Up. . . . . . . . . . . . . Back Cover 44
Overheat Safety Zone. . . . . . . . . . . . . . . . . . . . . . . . 21
Power Failure / Heat Dissipation Loop. . . . . . . . . . . 21
Low Water Cut-Off Control Tip Connection (LWCO). . . 22
 = Contains updated information
Draft Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ESP Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Outdoor Air Reset Operation. . . . . . . . . . . . . . . . . . . . . 26
Control Board Operation. . . . . . . . . . . . . . . . . . . . . . . . 27
Automatic Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29
Manual Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Burnpot Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 32
Burnpot Air Chamber . . . . . . . . . . . . . . . . . . . . . . . . 32
Ash Removal and Disposal. . . . . . . . . . . . . . . . . . . . 33
Firebox Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 34
Combustion Blower Maintenance. . . . . . . . . . . . . . . 35
Tube Heat Exchangers. . . . . . . . . . . . . . . . . . . . . . . 35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3
3-90-07205R27_08/15
Product Specific and Important Safety Information
Appliance Certification:
Model: Pellet Burning Boiler - PB105
Test Lab: Omni-Test Laboratories, Inc.
Report #: 135-S-16-6
Type: Pellet Fueled Central/Supplementary For Residential
Use
Standard(s): CAN/CSA B366.1-M91, and UL 391
Note: This appliance is also approved for installation
into a shop.
Harman Central Heating Appliances are built and
tested to be complete Home Heating solutions. As with
any Central Heat system, a backup heating system may
be required in the event of power outages or during
appliance service or maintenance.
®
Please read this entire manual before you install and use
your new boiler. Failure to follow instructions may result in
property damage, bodily injury, or even death.
SAVE THESE INSTRUCTIONS
Hearth & Home Technologies
352 Mountain House Road
Halifax, PA 17032
WARNING! RISK OF FIRE! Hearth & Home Technologies disclaims any responsibility for, and the warranty and
agency listing will be voided by the following actions:
DO NOT:
• Install or operate a damaged appliance
• Modify the appliance
• Install other than as instructed by Hearth & Home Technologies
• Operate the appliance without fully assembling all components
• Operate the appliance without water in the system
• Overfire the appliance
• Install any component or part not approved by Hearth & Home Technologies
Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. For
assistance or additional information, consult a qualified installer, service agency or your dealer.
4
3-90-07205R27_08/15
Warranty
Hearth & Home Technologies
LIMITED LIFETIME WARRANTY
Hearth&HomeTechnologies,onbehalfofitshearthbrands(”HHT”),extendsthefollowingwarrantyforHHT
gas,wood,pellet,coalandelectrichearthappliancesthatarepurchasedfromanHHTauthorizeddealer.
WARRANTY COVERAGE:
HHTwarrantstotheoriginalowneroftheHHTapplianceatthesiteofinstallation,andtoanytransfereetakingownership
oftheapplianceatthesiteofinstallationwithintwoyearsfollowingthedateoforiginalpurchase,thattheHHTappliance
willbefreefromdefectsinmaterialsandworkmanshipatthetimeofmanufacture.Afterinstallation,ifcoveredcomponentsmanufacturedbyHHTarefoundtobedefectiveinmaterialsorworkmanshipduringtheapplicablewarrantyperiod,
HHTwill,atitsoption,repairorreplacethecoveredcomponents.HHT,atitsowndiscretion,mayfullydischargeallofits
obligationsundersuchwarrantiesbyreplacingtheproductitselforrefundingtheverifiedpurchasepriceoftheproduct
itself.Themaximumamountrecoverableunderthiswarrantyislimitedtothepurchasepriceoftheproduct.Thiswarranty
issubjecttoconditions,exclusionsandlimitationsasdescribedbelow.
WARRANTY PERIOD:
Warrantycoveragebeginsonthedateoforiginalpurchase.Inthecaseofnewhomeconstruction,warrantycoverage
beginsonthedateoffirstoccupancyofthedwellingorsixmonthsafterthesaleoftheproductbyanindependent,
authorizedHHTdealer/distributor,whicheveroccursearlier.Thewarrantyshallcommencenolaterthan24months
followingthedateofproductshipmentfromHHT,regardlessoftheinstallationoroccupancydate.Thewarrantyperiodfor
partsandlaborforcoveredcomponentsisproducedinthefollowingtable.
Theterm“LimitedLifetime”inthetablebelowisdefinedas:20yearsfromthebeginningdateofwarrantycoveragefor
gasappliances,and10yearsfromthebeginningdateofwarrantycoverageforwood,pellet,andcoalappliances.These
timeperiodsreflecttheminimumexpectedusefullivesofthedesignatedcomponentsundernormaloperatingconditions.
WarrantyPeriod
Parts
Labor
1Year
2years
HHTManufacturedAppliancesandVenting
Gas
X
X
Wood
X
X
X
3years
Pellet
EPA
Wood
Coal
X
X
X
X
X
X
X
X
X
ComponentsCovered
Electric Venting
X
X
Allpartsandmaterialexceptas
coveredbyConditions,
Exclusions,andLimitations
listed
Igniters,electroniccomponents,
and glass
Factory-installedblowers
Moldedrefractorypanels
X
Firepotsandburnpots
5years
1year
7years
3years
10
years
1year
X
Limited
3years
Lifetime
X
X
X
X
X
90Days
X
X
X
X
X
X
X
X
Castingsandbaffles
X
X
Manifoldtubes,
HHTchimneyandtermination
Burners,logsandrefractory
Fireboxandheatexchanger
X
X
Allreplacementparts
beyondwarrantyperiod
Seeconditions,exclusions,andlimitationsonnextpage.
4021-645F02-18-13
5
Page1of2
3-90-07205R27_08/15
Warranty
WARRANTY CONDITIONS:
•
ThiswarrantyonlycoversHHTappliancesthatarepurchasedthroughanHHTauthorizeddealerordistributor.Alistof
HHTauthorizeddealersisavailableontheHHTbrandedwebsites.
• ThiswarrantyisonlyvalidwhiletheHHTapplianceremainsatthesiteoforiginalinstallation.
•ThiswarrantyisonlyvalidinthecountryinwhichtheHHTauthorizeddealerordistributorthatsoldtheappliance
resides.
• Contactyourinstallingdealerforwarrantyservice.Iftheinstallingdealerisunabletoprovidenecessaryparts,contact
thenearestHHTauthorizeddealerorsupplier.Additionalservicefeesmayapplyifyouareseekingwarrantyservice
fromadealerotherthanthedealerfromwhomyouoriginallypurchasedtheproduct.
• Checkwithyourdealerinadvanceforanycoststoyouwhenarrangingawarrantycall.Travelandshippingcharges
forpartsarenotcoveredbythiswarranty.
WARRANTY EXCLUSIONS:
Thiswarrantydoesnotcoverthefollowing:
• Changesinsurfacefinishesasaresultofnormaluse.Asaheatingappliance,somechangesincolorofinteriorand
exteriorsurfacefinishesmayoccur.Thisisnotaflawandisnotcoveredunderwarranty.
• Damagetoprinted,plated,orenameledsurfacescausedbyfingerprints,accidents,misuse,scratches,melteditems,
orotherexternalsourcesandresiduesleftontheplatedsurfacesfromtheuseofabrasivecleanersorpolishes.
• Repairorreplacementofpartsthataresubjecttonormalwearandtearduringthewarrantyperiod.Theseparts
include:paint,wood,pelletandcoalgaskets,firebricks,grates,flameguides,batteriesandthediscolorationofglass.
• Minorexpansion,contraction,ormovementofcertainpartscausingnoise.Theseconditionsarenormalandcomplaintsrelatedtothisnoisearenotcoveredbythiswarranty.
• Damagesresultingfrom:(1)failuretoinstall,operate,ormaintaintheapplianceinaccordancewiththeinstallation
instructions,operatinginstructions,andlistingagentidentificationlabelfurnishedwiththeappliance;(2)failureto
installtheapplianceinaccordancewithlocalbuildingcodes;(3)shippingorimproperhandling;(4)improperoperation,abuse,misuse,continuedoperationwithdamaged,corrodedorfailedcomponents,accident,orimproperly/
incorrectlyperformedrepairs;(5)environmentalconditions,inadequateventilation,negativepressure,ordrafting
causedbytightlysealedconstructions,insufficientmake-upairsupply,orhandlingdevicessuchasexhaustfansor
forcedairfurnacesorothersuchcauses;(6)useoffuelsotherthanthosespecifiedintheoperatinginstructions;(7)
installationoruseofcomponentsnotsuppliedwiththeapplianceoranyothercomponentsnotexpresslyauthorized
andapprovedbyHHT;(8)modificationoftheappliancenotexpresslyauthorizedandapprovedbyHHTinwriting;
and/or(9)interruptionsorfluctuationsofelectricalpowersupplytotheappliance.
• Non-HHTventingcomponents,hearthcomponentsorotheraccessoriesusedinconjunctionwiththeappliance.
• Anypartofapre-existingfireplacesysteminwhichaninsertoradecorativegasapplianceisinstalled.
• HHT’sobligationunderthiswarrantydoesnotextendtotheappliance’scapabilitytoheatthedesiredspace.Informationisprovidedtoassisttheconsumerandthedealerinselectingtheproperappliancefortheapplication.Considerationmustbegiventoappliancelocationandconfiguration,environmentalconditions,insulationandairtightnessof
thestructure.
This warranty is void if:
•
•
•
Theappliancehasbeenover-firedoroperatedinatmospherescontaminatedbychlorine,fluorine,orotherdamaging
chemicals.Over-firingcanbeidentifiedby,butnotlimitedto,warpedplatesortubes,rustcoloredcastiron,bubbling,
crackinganddiscolorationofsteelorenamelfinishes.
Theapplianceissubjectedtoprolongedperiodsofdampnessorcondensation.
Thereisanydamagetotheapplianceorothercomponentsduetowaterorweatherdamagewhichistheresultof,but
notlimitedto,improperchimneyorventinginstallation.
LIMITATIONS OF LIABILITY:
•
Theowner’sexclusiveremedyandHHT’ssoleobligationunderthiswarranty,underanyotherwarranty,expressor
implied,orincontract,tortorotherwise,shallbelimitedtoreplacement,repair,orrefund,asspecifiedabove.Inno
eventwillHHTbeliableforanyincidentalorconsequentialdamagescausedbydefectsintheappliance.Somestates
donotallowexclusionsorlimitationofincidentalorconsequentialdamages,sotheselimitationsmaynotapplytoyou.
Thiswarrantygivesyouspecificrights;youmayalsohaveotherrights,whichvaryfromstatetostate.EXCEPTTO
THEEXTENTPROVIDEDBYLAW,HHTMAKESNOEXPRESSWARRANTIESOTHERTHANTHEWARRANTY
SPECIFIEDHEREIN.THEDURATIONOFANYIMPLIEDWARRANTYISLIMITEDTODURATIONOFTHE
EXPRESSEDWARRANTYSPECIFIEDABOVE.
4021-645F02-18-13
6
Page2of2
3-90-07205R27_08/15
Assembly
Boiler Kit Materials: (Refer to “Parts Locations” section
in this manual)
List of items contained within the boiler kit shipped with the
unit.
1 - Control board cover
1 - Access cover (Hopper Swing Plate Knob)
5 - Spring Handles
1 - 3/4” Boiler Drain
1 - 3/4” Safety Relief Valve
1 - 1/2” Aquastat Well
1 - 1/2” Dual Temperature/Pressure Gauge
1 - 100 ft. Sensor Cable (Outdoor Air Sensor)
1 - Outdoor Air Sensor
1 - Flue Tunnel Weldment
1 - Combustion Blower Assembly
1 - Heat Shield (Comb. Blower)
2 - UY Connectors
2 - Terminals 1/4 Female
1 - #8 X 1/2” TEK
3 - 1/4-20 X 5/8” Wing Screw
4 - 1/4” Lock Washer
4 - 1/4-20 Nuts
Installation of the Flue Tunnel Weldment, Combustion
Blower and Wiring, ESP and Heat Shield:
Step 1: First install the flue tunnel weldment by aligning the (4) studs with the (4) holes in the ash chamber base. Fasten
the (4) nuts and lock washers provided, to the studs by
removing the access cover on the secondary ash chamber.
Step 2: Place the combustion motor onto the flue tunnel
weldment and tighten the (3) wing screws provided.
Step 3: Insert the Exhaust Sensing Probe (ESP) into the 1/8”
hole provided on the flue pipe stub. Fasten with the (1) #8 x
1/2” TEK screw also provided. ESP will be taped to the sheet
metal jacket for shipping purposes.
Step 4: Connect the flex conduit 90° elbow(Not Shown) to
the heat shield in the hole provided. Then connect the (3)
wires from the combustion blower with the (3) wires in the
flex conduit by using the push-on connectors and matching
the wire colors as follows: Red to Black, White to White and
Green to Green.
Step 5: Place Heat Shield over combustion blower and align
the swell latches with the holes in the sheet metal and tighten.
Flue Tunnel Weldment
ESP
Combustion Blower
Heat Shield
NOTE: Refer to Fig’s 22, 23, and 24 located in this manual.
7
3-90-07205R27_08/15
Assembly
Refer to the illustration under “Parts Locations” in this
manual to identify the components listed below:
1. Install the control board cover as well as the access cover
located on the feeder cover.
MINIMUM NON-COMBUSTIBLE FLOOR PROTECTION AREA
40" USA
42" CANADA
42" CANADA
FLOOR PROTECTOR
40" USA
NON-COMBUSTIBLE
2. Install the spring handles provided with the unit on
the ash door, firebox door and the heat exchanger
cleanout rod handles. (Fasten handles by turning them
counterclockwise and pushing inward simultaneously).
3. Install 3/4” MPT boiler drain in the fitting as shown.
Note: Use pipe thread sealant or Teflon tape on ALL
threads before connections are made.
4. Install 3/4” MPT pressure relief valve as shown.
55" USA & CAN
5. Install the 1/2” MPT aquastat well in fitting as shown, then
place aquastat in the well and fasten with a zip tie. The
aquastat sensor is located under the top sheet metal
jacket.
8. Fasten the conduit to the ash base with the clamps
provided.
Design:
The first thing that needs to be done is deciding where and
how the boiler will be installed.
Things that need to be taken into consideration are the
intended use of the boiler for example, is the boiler going to be
used as your primary heating system or is it going to be used
as a secondary or backup heating system. If it is to be used
in conjunction with an existing oil or gas boiler system will it
be piped in parallel or in series? The answers to these and
other questions can be determined by talking to your certified
dealer or a qualified HVAC or plumbing contractor. This will
ensure that the boiler is installed and piped to accommodate
your needs and expectations.
16" USA
7. Locate and install outside air temperature sensor. Location
of this sensor should be on the north side of the home or
building and out of direct sunlight. Use the cable supplied
with the boiler to attach the sensor to the terminals located
on the hopper. (Place at the back side just above and to
the right of the main power connection box) The wires can
be connected to the sensor with the connectors supplied.
Wire nut or butt splice connectors could also be used. The
connections at the boiler can be done with the two 1/4”
female push on connectors supplied.
18" CAN
6. Install the 1/2” MPT temperature/pressure gauge in fitting
as shown.
55" USA & CAN
Floor Protection:
The striped area indicates the minimum required floor
protection area if the boiler is going to be placed on a
combustible floor. It requires 40” X 55”(US) or 42” X 55”(CAN)
of non combustible floor protection as shown. 16”(US) or
18”(CAN) of the floor protection must be in front of the firebox
door as shown. Floor protection must be a minimum of 26
gauge sheet metal. Floor protection must also be provided
under any horizontal run of vent pipe equal to the outside
diameter of the venting plus 2” to each side.
Example: 4” type “L” or “PL” vent pipe has an outside
diameter of 4-1/2” + 2” on each side equals a protected floor
area of 8-1/2” wide underneath the horizontal run.
Consideration must be given to the venting as well as
electrical and clearance requirements. (Clearances must be
maintained to combustibles and also for service)
Make sure fans are not used in the fuel storage area, unless
they are installed so as not to create a negative pressure in
the room where the solid fuel burning appliance is located.
8
3-90-07205R27_08/15
Assembly
*C
16.5”
*I
80”
TOP VIEW
*F
*B
6”
*A
18”
24.25”
*5
66”
43.5”
62”
*E
36”
*G
22.5”
FRONT VIEW
*D
20”
Notes:
A. Manufacturer recommended minimum clearance.
B. Minimum clearance to combustibles BUT NOT RECOMMENDED! (See Note C).
C.Mfr’s recommendation to allow for full opening of feeder swing plate = 16.5”
D.Minimum clearance to allow servicing of combustion blower = 20”
E. Minimum clearance to combustibles = 36”
F. Pellet vent clearance to combustibles = 1”
G.Stove top to ceiling = 22.5”
H.Minimum ceiling height or alcove height = 66”
I. Maximum alcove depth = 80”
INSTALLATION IS TO BE PERFORMED BY A
QUALIFIED INSTALLER.
NOTE: All installation clearances and restrictions
must be adhered to.
NOTE: Use only 4” diameter type “L” or “PL” venting
system. Be sure to inspect and clean exhaust venting
system frequently.
9
3-90-07205R27_08/15
Venting
Requirements for Terminating the Venting
WARNING: Venting terminals must not be recessed into a
wall or siding.
I. The clearance to service regulator vent outlet must be a
minimum of 6 feet.
J. The clearance to a non-mechanical air supply inlet to the
building or the combustion air inlet to any other appliance
must be a minimum of 48”.
NOTE: Only PL vent pipe wall pass-throughs and fire stops
should be used when venting through combustible materials.
NOTE: Always take into consideration the effect the
prevailing wind direction or other wind currents will cause
with flyash and /or smoke when placing the termination.
K. The clearance to a mechanical air supply inlet must be a
minimum of 10 feet.
L. The clearance above a paved sidewalk or a paved
driveway located on public property must be a minimum
of 7 feet.
In addition, the following must be observed:
A. The clearance above grade must be a minimum of 12”.
M.The clearance under a veranda, porch, deck or balcony
must be a minimum of 12 inches. (B Also applies)
B. The clearance to a window or door that may be opened
must be a minimum of 48” to the side, 48” below the
window/door, and 12” above the window/door. (With
outside air installed, 12” to the side or below)
C.A 12” clearance to a permanently closed window is recommended to prevent condensation on the window.
D.The vertical clearance to a ventilated soffit located above
the terminal within a horizontal distance of 2 feet (60 cm)
from the center-line of the terminal must be a minimum
of 18”.
NOTE: The clearance to vegetation and other exterior
combustibles such as mulch is 36” as measured from the
center of the outlet or cap. This 36” radius continues to grade
or a minimum of 7 feet below the outlet.
Certain Canadian and or Local codes or regulations may
require different clearances.
A vent shall not terminate directly above a side-walk or
paved driveway which is located between two single  family
dwellings and serves both dwellings.
E. The clearance to an unventilated soffit must be a minimum
of 12”.
Only permitted if veranda, porch, deck, or balcony is fully
open on a minimum of 2 sides beneath the floor.
F. The clearance to an outside corner is 11” from center of
pipe.
NOTE: Where passage through a wall, or partition of
combustible construction is desired, the installation
shall conform to CAN/CSA-B365. (if in Canada)
G.The clearance to an inside corner is 12”.
H.A vent must not be installed within 3 feet (90 cm) above
a gas meter/regulator assembly when measured from the
horizontal center-line of the regulator.
Inside Corner
Detail
Do
or
Fixed
Closed
Openable
Fixed
Closed
Porch or Deck
Openable or Fixed
Openable
Sidewalk
Fig. 2
10
V =Vent Terminal
A =Air Supply Inlet
=Area where termination is not permitted
3-90-07205R27_08/15
Venting
30 Ft
3
Altitude in thousands of feet.
25 Ft
4
5
20 Ft
6
7
15 Ft
8
12 Ft
9
10 Ft
10 Ft
10
5 Ft
5 Ft
0 Ft
18 Ft
15 Ft
10 Ft
5 Ft
5 Ft
0 Ft
Total Lineal Feet combined should not exceed
30 Feet.
0 Ft
Note: The total Lineal Feet decreases as the
Altitude increases.
Note: The maximum length of the Outside Air
Flex also decreases to 20 Feet
0 Ft
7 Ft
5 Ft
10 Ft
15 Ft
18 Ft
Fig. 3
Avoiding Smoke and Odors - Negative Pressure, Shutdown and Electrical Power Failure.
To reduce the probability of back-drafting or burn back
in the pellet boiler during a power failure, it must be
able to draft naturally without exhaust blower operation.
Negative pressure in the house will resist this natural draft if
not accounted for during installation. Heat rises in a house,
and leaks out at upper levels. This air must be replaced
with air from outside the dwelling, which normally flows into
lower levels. Vents and chimneys into basements and lower
levels can become the conduit for return air and reverse
under these conditions.
Hearth & Home Technologies strongly recommends
the use of outside air in all pellet boiler installations,
especially those on lower level and main floor locations.
Per national building codes, consideration must be given
to combustion air supply to all combustion appliances.
Failure to supply adequate combustion air for all appliance
demands may lead to back-drafting of those and other
appliances within the home.
11
To reduce the probability of reverse drafting during
shut-down conditions, Hearth & Home Technologies
strongly recommends:
• Installing the pellet vent with a minimum vertical run of 5
feet. Preferably terminating above the roof line.
• Installing the outside air intake at least four feet below the
vent termination.
To prevent soot damage to exterior walls, and to prevent
re-entry of soot or ash into the house:
• Maintain specified clearances to windows, doors and air
inlets, including air conditioners.
• Vents should not be placed below ventilated soffits. Run
the vent above the roof.
• Avoid venting into alcove locations.
• Vents should not terminate under overhangs, decks or
onto covered porches.
• Maintain minimum clearance of 12” from the vent
termination to the exterior wall. Extending this distance may
be required if visual accumulation occurs.
3-90-07205R27_08/15
Venting
Venting
Use 4” pellet vent pipe only.
This is the minimum venting configuration.
A combustion blower is used to extract the combustion
gases from the firebox. This creates a negative pressure in
the firebox and a positive pressure in the venting system as
shown in Fig. 4. The longer the vent pipe and more elbows
used in the system, the greater the flow resistance. Because
of these facts we recommend using as few elbows as possible
and 30 feet or less of vent pipe. The maximum horizontal run
should not exceed 18 feet.
”
36
Be sure to use wall and ceiling pass through fittings
(which are approved for pellet vent pipe ) when going
through combustible materials. Be sure to use a starting
collar to attach the venting system to the stove. The starting
collar must be sealed to the stove flue collar with high
temp silicone caulking or aluminum tape, and screwed
into the stove flue collar at least three (3) places.
4” Type “L” or
“PL” Vent pipe
Fig. 5
The minimum vent configuration is a 90° or Tee on a starter
collar and a 24” length horizontal through an exterior wall. A
cap on the end should direct the flue gasses down and away
from the structure. See Fig. 5.
12”
”
36
+
Fig. 4
Vent Pipe
4” pellet vent pipe (also known as “PL” vent) is constructed
of two layers with air space between the layers. This air
space acts as an insulator and reduces the outside surface
temperature to allow a minimum clearance to combustibles
as low as 1”. In Canada the minimum clearance to
combustibles is 3”.
The sections of pipe lock together to form an air tight seal
in most cases; however, in some cases a perfect seal is not
achieved. For this reason and the fact that the boiler operates
with a positive vent pressure, we specify that all joints
within the structure should also be sealed with silicone.
NOTE: Use only 4” diameter approved PELLET venting
system. Be sure to inspect and clean exhaust venting
system frequently.
12
The maximum horizontal length is 18 feet. The minimum
termination height above the exterior grade is 18”. The
maximum total length of any configuration is 30 feet*. *(See
venting graph (Fig. 3) in this manual for exceptions)
NOTE: Cleanout Tee’s should always be used on the
transitions to horizontal pipe to allow easy access for
cleaning.
The venting graph allows for one (1) 90° or Tee fitting in any
configuration.
If more 90’s, T’s, or 45’s are needed, the total length must
be adjusted to allow for the added restriction.
Up to four (4) additional 90’s, Tee’s, or equivalent 45’s can be added as long as the overall length is adjusted in accordance
with the values listed below.
(See Requirements for Terminating the Venting under the
venting section of this manual)
Each Vertical ---- 90° or T subtract 2.5 feet
Each Vertical ---- 45°
subtract 1.5 feet
Each Horizontal - 90° or T subtract 5.0 feet
Each Horizontal - 45°
subtract 2.5 feet
Any exterior venting (vent pipe exposed to outside
ambient temperatures) should be kept to a minimum,
due to potential condensation problems.
This is especially important in high humidity cold weather
climates, such as maritime areas, lake shores, and low river
valleys.
3-90-07205R27_08/15
Venting Installation
NOTE: Use only 4” diameter approved pellet venting
system. Be sure to inspect and clean exhaust venting
system frequently.
INSTALLATION IS TO BE PERFORMED BY A QUALIFIED
INSTALLER.
DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST
VENTING SYSTEM OF THIS UNIT.
DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE
SERVING ANOTHER APPLIANCE.
Chimneys taller than 20’ above the connection will require a
draft test to determine if the draft is too high.
INSTALL VENT WALL PASS-THROUGHS AT CLEARANCES
SPECIFIED BY THE VENT MANUFACTURER
Note: The high burn draft should not exceed .85 IWC. Some
form of a restrictor plate may be required at the top of high
chimneys to reduce the draft. See Draft Test Procedure under
the installation section of this manual.
NOTE: All installation clearances and restrictions must
be adhered to.
This boiler may be used and installed into an existing masonry
or Class A metal chimney.
Certain Canadian and Local Codes may require that the
chimney be fully relined.
The venting Can Not be installed in a chimney serving
another appliance.
The chimney should be cleaned and or inspected before
installation of the venting.
”
36
!
WARNING
KEEP COMBUSTIBLE MATERIALS SUCH AS GRASS,
LEAVES, ETC. AT LEAST 3 FEET AWAY FROM THE
POINT DIRECTLY UNDER THE VENT TERMINATION.
(BETWEEN THE VENT AND THE GROUND)
!
CAUTION
KEEP COMBUSTIBLES AWAY FROM FLUE OUTLET.
Ceiling Height
Min. 66”
12”
”
36
18”
NOTE: Read and follow all of the vent pipe manufacturers’
instructions on the proper installation and support of the
vent pipe. Adhere to all clearances.
62.23
12.40
20.00
Other examples of possible installations of the venting.
Creosote - Formation and Need for Removal - When wood is burned slowly, it produces tar and other organic vapors,
which combine with expelled moisture to form creosote. The creosote vapors condense in the relatively cool chimney flue
of a slow-burning fire. As a result, creosote residue accumulates on the flue lining. When ignited, this creosote makes an
extremely hot fire. The pellet vent pipe should be inspected at least twice monthly during the heating season to determine
if a creosote buildup has occurred. If creosote has accumulated it should be removed to reduce the risk of a chimney fire.
Guidance on minimizing creosote formation and the need for periodic creosote removal: The chimney should be inspected
during the heating season to determine if a creosote build-up has occurred. If a significant layer of creosote has accumulated
(3mm or more) it should be removed to reduce the risk of a chimney fire.
13
3-90-07205R27_08/15
Outside Air Installation
Outside Air
To install outside air, use 3” galvanized steel flex pipe. Fig. 6.
There is a break-away hole on the rear panel which must be
removed before connecting the flex pipe. See Fig. 7.
When the appliance is side wall vented: The air intake is best
located on the same exterior wall as the exhaust vent outlet,
and located lower on the wall than the vent outlet.
Fig. 6
Termination Cap part# 1-10-09542
When the appliance is roof vented: The air intake is best
located on the exterior wall oriented toward the prevailing
wind direction during the heating season.
Never terminate the outside air above the vent pipe outlet.
The maximum length of this pipe is 20 feet. Termination
Cap part number 1-10-09542 should be used to keep birds,
rodents etc. out of the inlet pipe. See Fig. 6.
NOTE: The Termination Cap should not be placed in an
area where drifting of snow or ice will build up, blocking the
intake air supply.
The Outside Air knockout is located on the face of the Feeder
Cover. It is pre-cut except for several small tabs. There is
also a filler plate screwed to the inside to cover the top of the
hole after the Outside Air Pipe has been installed. This will
allow for removal of the Feeder Cover without disconnecting
the Outside Air Pipe. See Fig. 7. If installing outside air to
an older unit Adapter Kit (Part #1-00-06809) must be used.
Feeder Cover
Outside Air
Pipe Knockout
Only metal Intake Flex should be used for the Outside Air
Supply connection.
Fig. 7
The Outside Air Intake Pipe is inside the Feeder Cover and
to the right of the feeder motor. The 3” steel flex pipe is made
to slide over the outside of the Air Intake Pipe. See Fig. 8. It
should be held into place with some silicone, foil tape, or a
hose clamp. (Not supplied)
Outside Air Inlet Pipe
Heat Reclaiming Ventilation System (HRV)
When installing in a house with a Heat Reclaiming Ventilation
System (HRV) be sure the system is balanced and is not
creating a negative pressure in the house.
Hopper/
Feeder Swing
Plate Knob
Fig. 8
14
3-90-07205R27_08/15
Main Wiring Installation
To install power to the boiler, first remove the cover on the 4” X 4” junction box located on the back of the unit. There are
several knockout holes provided for the incoming main power wires. Also, a knockout hole can be used for the auxiliary
output overheat zone (if used).
The minimum recommended circuit is 6 AMP - 120 VAC - 60 HZ. This boiler should be the only appliance on the circuit.
This boiler should never be powered by the use of an extension cord.
The recommended high and low voltages are, 130 VAC 60 Hz maximum high voltage, and 113 VAC 60 Hz minimum low
voltage. The furnace will continue to operate at voltages as low as 105 VAC , although it can not be guaranteed that
automatic ignition will occur.
NOTE: If other sources of electrical power are to be used ( such as a generator ) for normal operation or emergency
operation, this source should be checked before installation. Many generators and inverters may not supply 120
VAC, 60Hz power stable enough to operate the control board properly. (Control board damage could occur).
15
3-90-07205R27_08/15
Plumbing Installation
3/4”
NOTE: Cold return water temperature (Sustained temperatures below 140° F) will lead to condensation in the firebox. This moisture can
lead to creosote formation. To help minimize moisture and creosote, it is strongly recommended that some form of temperature balance
is incorporated into the return water system.
NOTICE: When installing with the atmospheric conversion: All of the pressurized system components shown are not necessary. Air
vents or bleeders will need to be removed from the plumbing system to prevent air from entering the lines. Control dipswitch #6 will need
to be turned “ON”.
3/4”
16
3-90-07205R27_08/15
Plumbing Installation
Boilers intended to be connected to an existing boiler or boiler system shall:
1. Be capable of being installed without interfering with the normal delivery of heated water from the original boiler to the radiation
system.
2. Be capable of being installed to operate as intended without affecting the operation of the electrical and mechanical safety
controls of the original boiler.
3. Provide, upon completion of the installation, for a change over from one fuel to the other without requiring the manual adjustment
of any controls or components other than the thermostats.
4. Be compatible with the operation of a service water-heating coil within the original boiler without bypassing the operation of the
solid-fuel boiler.
5. Have provision for preventing, or adequate water capacity within the boiler to prevent, damage to the boiler from loss of circulation
due to electrical power failure.
6. Be capable of being installed without changing the function of the control or rewiring of the original boiler. A wiring interconnection
is permitted. The electrical system of both boilers shall be powered from a single branch circuit without exception. (CAN/CSAB366.1-M91)
7. Pertaining to CAN/CSA- B365-01, Have a clearly labelled device, located at each entrance to the boiler area, which can be
thrown to discontinue operation of the feed system.
NOTICE: When installing with the atmospheric conversion: All of the pressurized system
components shown are not necessary. Air vents or bleeders will need to be removed from the plumbing
system to prevent air from entering the lines. Control dipswitch #6 will need to be turned “ON”.
17
3-90-07205R27_08/15
Plumbing Installation
EXAMPLE OF TYPICAL TANKLESS DOMESTIC HOT WATER PIPING
HIGH TEMPERATURE
WATER (IF NEEDED)
TEMPERED HOT WATER TO
SHOWERS AND FAUCETS
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER
MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.
OPTIONAL DOMESTIC
HOT WATER COIL
INLET
MIXING VALVE
OUTLET
MIXING VALVE SET TO DESIRED WATER TEMPERATURE.
NORMALLY NOT MORE THAN 120 DEGREES.
AQUASTAT WELL LOCATION
HOSE BIB TO
BACKFLUSH COIL
IF NEEDED
SAFETY RELIEF VALVE
ISOLATION VALVE
FLOW REGULATOR
COLD WATER SUPPLY
HOSE BIB
FLOW REGULATOR WILL NEED TO MATCH THE GPM RATING OF THE DOMESTIC COIL. (IF USING A DOMESTIC COIL, 4 GPM IS REQUIRED.)
EXAMPLES OF TYPICAL DOMESTIC HOT WATER STORAGE PIPING
EXAMPLE #2
EXAMPLE #1
HIGHER TEMPERATURE
WATER (IF NEEDED)
FROM BOILER
FROM BOILER
COLD
TEMPERED HOT WATER FOR
SHOWERS AND FAUCETS
HOT
COLD
CIRCULATOR
DOMESTIC HOT
WATER STORAGE
HEATER
HOT
MIXING VALVE SET TO DESIRED WATER TEMPERATURE.
NORMALLY NOT MORE THAN 120 DEGREES.
CIRCULATOR
DOMESTIC HOT
WATER STORAGE
HEATER
IN
TO BOILER
IN
OUT
MIXING VALVE
TO BOILER
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER
MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.
OUT
NOTE: TYPICALLY, AS LONG AS THE WATER
TEMPERATURE NEEDED IS NOT MORE THAN
120 F, THE MIXING VALVE SHOWN ABOVE
(EXAMPLE 2) IS NOT NEEDED
18
3-90-07205R27_08/15
Plumbing Installation
TYPICAL BOILER HOT WATER PIPING SHOWING AIR REMOVAL SYSTEM, PROVISIONS FOR THE EXPANSION OF
WATER AND THE AUTOMATIC COLD WATER SUPPLY. ALSO SHOWN IS THE AUTOMATIC MIXING VALVE. THIS
COULD ALSO BE DONE BY (2) CLOSELY SPACED TEE'S. THE PROPER PIPING FOR THE INTENDED USE WILL BE
DETERMINED BY THE INSTALLING CERTIFIED PLUMBER OR HVAC CONTRACTOR.
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED
INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION
AND LOCATION WITHIN THE PIPING SYSTEM.
** THERMOMETER
AIR VENT
AIR SCOOP
SYSTEM SUPPLY 1-1/4"
SHUT-OFF
VALVE
UNION
SYSTEM SUPPLY 1-1/4"
AUTOMATIC
MIXING VALVE
* TEMPERATURE/PRESSURE
GAUGE
* AQUASTAT
WELL
SHUT-OFF VALVE
* PRESSURE
RELIEF VALVE
COLD WATER
SUPPLY 1/2"
EXPANSION TANK
(DIAPHRAGM TYPE)
PRESSURE REDUCING VALVE (PRV)
OR COMBINATION PRV AND
RELIEF VALVE
PIPE TO WITHIN 6" OF THE
FLOOR OR A FLOOR DRAIN
UNION
CHECK VALVE (OR BACKFLOW
PREVENTER IF REQUIRED)
** THERMOMETER
SENSING BULB
SHUT-OFF VALVE
SYSTEM RETURN 1-1/4"
* ITEMS SUPPLIED
*BOILER DRAIN, 3/4” NPT MALE X
3/4” HOSE MALE (NOT SHOWN)
** OPTIONAL
* BOILER DRAIN, 1/2" NPT MALE X
3/4" HOSE MALE (NOT SHOWN)
NOTE: Cold return water temperature (Sustained temperatures below 140° F) will lead to condensation in the firebox. This moisture can
lead to creosote formation. To help minimize moisture and creosote, it is strongly recommended that some form of temperature balance
is incorporated into the return water system.
NOTICE: When installing with the atmospheric conversion: All of the pressurized system components shown are not necessary. Air
vents or bleeders will need to be removed from the plumbing system to prevent air from entering the lines. Control dipswitch #6 will need
to be turned “ON”.
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED
INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND
LOCATION WITHIN THE PIPING SYSTEM.
ZONE 3
ZONE 2
ZONE 1
EXAMPLE OF A TYPICAL MULTI-ZONE HEATING SYSTEM WITH
INDIVIDUAL ZONE CIRCULATORS
AIR VENT
AIR VENT (TYPICALLY INSTALLED IN THE
HIGHEST ACCESSABLE LOCATION IN THE PIPING)
FROM ADDITIONAL ZONES
SHUT-OFF VALVE
NOTE: IF CIRCULATOR DOES NOT
HAVE CHECK VALVE THEN A FLOW
CONTOL VALVE WILL ALSO BE
NEEDED AND INSTALLED IN THIS
LOCATION
ZONE 1
ZONE 2
CIRCULATORS WITH
INTEGRAL CHECK VALVE
(SEE NOTE)
BRANCH ZONES WILL BE
REDUCED TO REQUIRED SIZE
(TYPICALLY 3/4") AT THIS POINT
FROM BOILER
ZONE 3
TO ADDITIONAL ZONES
SYSTEM SUPPLY 1-1/4"
UNION
SHUT-OFF VALVE
TO BOILER
SYSTEM RETURN 1-1/4"
19
3-90-07205R27_08/15
Plumbing Installation
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED
INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND
LOCATION WITHIN THE PIPING SYSTEM.
AIR VENT
ZONE 3
ZONE 2
ZONE 1
EXAMPLE OF A TYPICAL MULTI-ZONE HEATING SYSTEM WITH A SINGLE
CIRCULATOR AND INDIVIDUAL ZONE VALVES
AIR VENT (TYPICALLY INSTALLED IN THE HIGHEST
ACCESSABLE LOCATION IN THE PIPING)
FROM ADDITIONAL ZONES
BALANCING VALVE
ZONE 1
ZONE VALVE
BRANCH ZONES WILL BE
REDUCED TO REQUIRED
SIZE (TYPICALLY 3/4") AT
THIS POINT
ZONE 2
UNION
ZONE 3
CIRCULATOR
FROM BOILER
TO ADDITIONAL ZONES
SYSTEM SUPPLY 1-1/4"
UNION
SHUT-OFF VALVE
TO BOILER
SYSTEM RETURN 1-1/4"
NOTE: Cold return water temperature (Sustained temperatures below 140° F) will lead to condensation in the firebox. This moisture can
lead to creosote formation. To help minimize moisture and creosote, it is strongly recommended that some form of temperature balance
is incorporated into the return water system.
NOTICE: When installing with the atmospheric conversion: All of the pressurized system components shown are not necessary. Air
vents or bleeders will need to be removed from the plumbing system to prevent air from entering the lines. Control dipswitch #6 will need
to be turned “ON”.
EXAMPLE OF A COMBINATION HIGH/LOW MULTI-ZONE HEATING
SYSTEM WITH INDIVIDUAL ZONE CIRCULATORS
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED
INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND
LOCATION WITHIN THE PIPING SYSTEM.
(HIGH TEMPERATURE) BASEBOARD HEAT
(LOW TEMPERATURE) RADIANT FLOOR HEAT
ZONE 3
ZONE 2
ZONE 1
(LOW TEMPERATURE) RADIANT FLOOR HEAT
AIR VENT
AIR VENT (TYPICALLY INSTALLED IN THE HIGHEST
ACCESSABLE LOCATION IN THE PIPING)
NOTE: IF CIRCULATOR DOES NOT HAVE CHECK
VALVE THEN A FLOW CONTOL VALVE WILL ALSO
BE NEEDED AND INSTALLED IN THIS LOCATION
SHUT-OFF VALVE
CIRCULATORS WITH INTEGRAL
CHECK VALVE (SEE NOTE)
ZONE 3
ZONE 2
BRANCH ZONES WILL BE
REDUCED TO REQUIRED SIZE
(TYPICALLY 3/4") AT THIS POINT
ZONE 1
MIX
FROM BOILER
SYSTEM SUPPLY 1-1/4"
HOT
COLD
UNION
SHUT-OFF VALVE
THERMOSTSTIC
MIXING VALVE
TO BOILER
SYSTEM RETURN 1-1/4"
20
3-90-07205R27_08/15
Over Heat Safety Zone
Overheat Safety Zone (Dump Zone): STRONGLY RECOMMENDED in all installations.
When the pellet boiler is operating at High burn, and all demand from the heating system stops, the control will reduce the
feed rate and shut down completely as necessary. This may take several minutes, and the remaining heat may cause the
water temperature to continue to rise. If the temperature gets too high, the OVERHEAT SAFETY ZONE light on the control
will illuminate, and the DARK BLUE circuit in the junction box is energized(see wiring diagram). This circuit will flow 120V to
operate a circulator pump installed to flow to the overheat dump zone established in the original installation plan. If opening
a zone valve is the chosen method of dumping the excess heat, a voltage reduction relay will most likely be needed. If the
water temperature continues to rise to the risk of boiling point, the feed system will stop and the boiler will shut-down. A
manual reset will then be required to operate the boiler. Without a dump zone in place, the excess temperature could build
pressure to the point of opening the relief valve, or with the atmospheric conversion it may allow the water to boil and exit
through the over-flow of the atmospheric tank. Both scenarios may create water damage and/or a slip hazard.
The boiling temperature of water varies at different altitudes and atmospheric pressures. Therefore, at elevations above 3000
feet, and when using the atmospheric conversion, circuit board dipswitch #6 must be in the “ON” position.
Power Failure / Heat Dissipation Loop
EXAMPLE OF PIPING IN ACCORDANCE
WITH (CAN/CSA-B366.1)
A POWER FAILURE HEAT DISSIPATION LOOP
BALANCING
VALVE
SYSTEM SUPPLY
MINIMUM OF 72" OF 3/4"
FINNED BASEBOARD
BASEBOARD MUST BE AT LEAST
24" HIGHER THAN BOILER FOR
PROPER GRAVITY FLOW
(HIGH TEMPERATURE) BASEBOARD HEAT
POWER FAILURE SYSTEM SUPPLY 3/4"
* TEMPERATURE/PRESSURE GAUGE
UNION
* AQUASTAT WELL
120VAC,NORMALLY OPEN,FULL FLOW,
SOLENOID VALVE or EQUIVALENT
* PRESSURE RELIEF VALVE
THE SOLENOID SHOULD BE
POWERED BY THE SAME
CIRCUIT AS THE BOILER
PIPE TO WITHIN
6" OF THE
FLOOR OR A
FLOOR DRAIN
POWER FAILURE SYSTEM RETURN 3/4"
SHUT-OFF VALVE
UNION
SHUT-OFF VALVE
SYSTEM RETURN
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER
MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.
* ITEMS SUPPLIED
21
21
3-90-07205R27_08/15
Low water cut-off control LWCO Wiring Instructions
TO BE USED WHERE REQUIRED BY LOCAL CODES
Read and follow the instructions provided with the specific LWCO Control selected.
The LWCO Control will provide a set of contacts that are closed when water is present at the sensor. It will open the feed
motor circuit when a low water condition exist.
Depending on the model selected, a manual reset of the control may be required after a low water condition has existed.
• WARNING: To prevent electrical shock or equipment damage, make sure power is turned off to the boiler.
• Locate the black wire from the wiring harness that connects to the feed motor. Fig. 1
• Separate the black wires at the ¼” push on connectors for the feed motor. Fig. 2 & Fig. 3
• The male connector will be on the wiring harness and the female connector will be on the feed motor wire. Fig. 3 &
Fig. 4.
Fig. 1
Fig. 2
Fig. 3
• Wire the LWCO control contacts in series with the feed motor on the pellet boiler. Fig. 4
• A separate power source may be required for the LWCO control. Read and follow the instructions provided with the
specific LWCO control selected.
• Consideration must be given to all local codes and regulations regarding the proper installation of the LWCO control
device and associated wiring.
Note: Always verify proper operation of control after installation
Fig. 4
LWCO Control Contacts. (Open contact circuit
when low water condition exists.)
22
3-90-07205R27_08/15
Draft Test Procedure
Firebox Door
Draft Bolt
Location
Air Wash
Slot
After the venting is completed, the firebox low draft will need
to be checked and possibly adjusted. After removing the 3/8”
bolt from the draft hole shown in Fig. 9, insert the draft meter
tube. The appliance doors and hopper lid must be latched
during this test. (It is recommended that the draft meter have
a scale of 0 to 1” WC.)
Turn the feed adjuster to “Test”. this will start the combustion
blower and allow you to check and record the High Draft ______ - IWC date _______ The maximum draft must
not exceed -.85” W.C. Some form of vent restrictor may be
needed. (There is no control board adjustment for the High
Draft)
Viewing Window
Fig. 9
“Test”
After the first 60 seconds the “Test” mode lowers the
combustion blower voltage to the Low Burn voltage. During
this lowered voltage cycle the Low Burn Draft must be
checked and adjusted if necessary. The recommended low
draft setting should be between -.25 & -.35 IWC. Depending
on the amount of vertical rise, it may not be possible to get a
low draft reading in this range. In this case, a maximum low
draft of -.55 is acceptable.
The adjustment screw is through the small hole to the
right of the Igniter Light. See Fig. 10. Adjusted Low Draft is
__________ -IWC.
Don’t forget to turn the feed adjuster off of “Test”.
Do not operate if the high draft exceeds -.85” W.C.
Excessive draft readings may be due to restriction in the
combustion air supply. Check for obstructions.
Low Draft
Adjustment Pot
Fig. 10
Covered
Uncovered
The Control
The boiler has the option to have the control panel covered
or uncovered See Fig. 11. There is a pair of slots provided for
each position. Simply move the cover to the desired position
by placing the tabs on the cover in the proper slots.
!
CAUTION
!
WARNING
Hot while in operation. Do not touch. Keep children,
clothing, furniture, and other combustible material
out of the installation clearance area.
Do not operate with the hopper lid or fire chamber or
ash removal doors open.
!
Fig. 11
23
WARNING
Do not store fuel or other combustible material within
installation clearance area.
3-90-07205R27_08/15
Fuel Specifications
Fuel and Fuel Storage
Pellet fuel quality can fluctuate from manufacturer to
manufacturer, and even from bag to bag.
Hearth & Home Technologies recommends using only fuel
that is certified by the Pellet Fuels Institute (PFI).
Fuel Material
• Made from sawdust and/or other wood by-products
• Source material typically determines ash content
Higher Ash Content Material
• Hardwoods with high mineral content
• Bark and leaves as source material
• “Standard” grade pellets, corn and other biomass
Lower Ash Content Material
• Softwood; pine, fir, etc.
• Materials with lower mineral content
• “Premium” grade pellets
Clinkers
Minerals and other non-combustible materials, like sand,
will turn into a hard glass-like substance when heated.
Trees from different areas will vary in mineral content. For
this reason, some fuels will produce more clinkers than
others.
Moisture
Always burn dry fuel. Burning fuel with high moisture
content takes energy to dry and tends to cool the appliance
thus, robbing heat from your home. Damp pellet fuel could
turn back into sawdust which does not flow properly through
the feed system.
Size
• Pellets are either 1/4 inch or 5/16 inch (6-8mm) in
diameter
• Length should be no more than 1-1/2 inches (38mm)
• Pellet length can vary from lot to lot from the same
manufacturer
Performance
• Higher ash content requires more frequent maintenance.
• “Premium” grade pellets will produce the highest heat
output.
• Burning pellets longer than 1-1/2 inches (38mm) can
cause inconsistent feeding and/or ignition.
We recommend that you buy fuel in multi-ton lots whenever
possible. However, we do recommend trying different
brands prior to purchasing multi-ton lots, to ensure your
satisfaction.
!
CAUTION
Tested and approved for use with wood pellets ONLY.
Burning of any other fuel will void your warranty.
When changing from “Premium” grade pellets to a
“Standard” or “Economy” grade fuel, the FEED ADJUSTER
will likely need adjusted to a lower setting. When under
maximum demand, ensure there is no unburned fuel being
pushed into the ash pan.
Storage
• Wood pellets should be left in their original sealed bag
until ready to use, to prevent moisture.
• Do not store fuel within the specified clearance areas,
or in a location that will interfere with routine cleaning
and maintenance procedures.
!
CAUTION
Tested and approved for use with wood pellets ONLY.
Burning of any other fuel will void your warranty.
NOTICE
Hearth & Home Technologies is not responsible for
stove performance or extra maintenance required
as a result of using fuel with higher ash or mineral
content.
24
3-90-07205R27_08/15
ESP Control
Power Light
Indicates power to the control
board.
Status Light
Will be lit anytime there is a call
for heat.
Overheat Safety Zone Light
Indicates elevated boiler water
temperature. Power flowing to
Overheat circuit.
Combustion Blower Light
Indicates Power to combustion
blower
Feed adjuster
Sets the maximum feed rate
Test
Combustion blower, feed motor
and safety dump zone are fully
energized for the first minute.
Afterward, combustion blower
remains on low only.
Lighting Mode Selector
Switched between Auto and Manual
lighting
Mode Selector/MIN. TEMP. Dial
Used to turn the boiler on or off and
set the desired minimum operating
temperature of the boiler.
Feed Motor Light
Indicates Power to the feed motor.
Igniter Light
Indicates power to the igniter
MAX. TEMP. Dial
The “MAX. TEMP. Dial” is used to set the desired
maximum operating temperature of the boiler.
Status light error messages:
3 Blinks: Indicates that the ESP (Exhaust Sensing Probe)
has gone out of range, too many times. May indicate
excessive ash build-up in the exhaust stream. If the unit
seems to be operating normally, perform a manual reset by
cycling the main power off for a few seconds and re-connect.
4 Blinks: Indicates miscommunication with the aquastat, or
the sensor is not attached properly. May require a manual
reset.
5 Blinks: (In Auto Light Mode Only)
Indicates that the igniter has failed to light the fire after 40
Minutes. To reset - Turn the Mode Selector/MIN. TEMP. to
OFF and then back to the desired temperature.
Diagnostic Port
For diagnostic purposes only. Requires special DDM
monitor supplied to trained technicians exclusively.
7 Blinks: Boiler water over heat safety shut down. This
requires a manual reset by cycling the main power off for a
few seconds and re-connect.
Mode Selector/MIN. TEMP.
Used to turn the boiler on or off and set the desired minimum
operating temperature of the boiler.
MAX. TEMP./ MIN. TEMP. Water Temperature Settings
See “Setting the Boiler Temperature”.
OFF Mode
Turning the Mode Selector/MIN. TEMP. to OFF will shut
down the boiler.
6 Blinks: Indicates that the control has calculated poor or
incomplete combustion occurring for 25 or more minutes.
A six blink status may be set if the stove is allowed to run
out of pellets. To reset, turn Mode Selector/MIN. TEMP. dial
to “OFF” then back on to the desired temperature. If the unit
was not out of pellets, see Troubleshooting section for more
details.
25
3-90-07205R27_08/15
26
Example 2
Max set at 180°
Min set at 150° OAT
65°
60°
55°
50°
45°
40°
35°
30°
25°
20°
15°
10°
5°
0°
OAT
65°
60°
55°
50°
45°
40°
35°
30°
25°
20°
15°
10°
5°
0°
Water Temp
150°
150°
150°
150°
155°
160°
165°
170°
175°
180°
180°
180°
180°
180°
Water Temp
140°
145°
150°
155°
160°
165°
170°
175°
180°
185°
185°
185°
185°
185°
Degree Change
*
*
*
-30°
-25°
-20°
-15°
-10°
-5°
0°
0°
0°
0°
0°
Degree Change
-45°
-40°
-35°
-30°
-25°
-20°
-15°
-10°
-5°
0°
0°
0°
0°
* No change in boiler temperature after reaching minimum set point temperature.
Example 1
Max set at 185°
Min set at 140° When the outdoor sensor is installed, at 20° F. or below OAT (Outdoor Air
Temperature), the boiler will operate at the temperature set on the Maximum
Temperature knob. The boiler water temperature will decrease by 1° for every
1° in temperature rise of the Outside Air.
Pellet Boiler Outdoor Air Reset Operation
Outdoor Air Reset Operation
3-90-07205R27_08/15
Control Board Operation
Setting the Boiler Temperature
Without the Outdoor Air Temperature Sensor Installed
To set the maximum boiler water temperature, simply turn
the MAX. TEMP. dial to the desired setting. The control and
the boiler will then perform to achieve and maintain the set
temperature
The MIN. TEMP. Knob is the boiler water temperature
minimum, or the lowest temperature the water will go before
the unit re-starts. Turning the knob fully counter-clockwise
is the “OFF” position, while turning the knob clockwise, past
the 140° marking, is the “ON” position..
With The Outdoor Air Temp - Sensor Installed
Maximum boiler temp setting is as described above.
The MIN. TEMP. knob in addition to being the mode setting
(on or off) now also has the function of setting the minimum
boiler water temperature. This would be the lowest boiler
water temperature that you want to have based on the
following factors.
1. Outdoor Air Temperature (OAT)
2. Domestic Hot Water Use
a. Hot Water Coil Option
b. Indirect Hot Water Storage
3. Overall Volume of the Heating System
The boiler is designed to withstand lower return water
temperatures however, extended return temperatures
below 140° F can cause condensation in the secondary ash
chamber area and also in the venting system, which could
cause damage in these areas.
Control Board Operation
Aquastat Sensor: This sensor is located in the aquastat
well on the top of the water jacket. This sensor along with the
outdoor air sensor is what the control board uses to regulate
the feed rate based on these two observed conditions. (Boiler
Temp. & Outdoor Air Temperature)
Outdoor Air Temperature Sensor (OAT): This sensor is
located outside the building (on the north side of the house and out of direct sunlight). The Outdoor Air Sensor is used to
perform hot water reset based on outdoor air temperatures.
NOTE:
If the system is run at the lower temperature settings,
conditions of the firebox, boiler tubes, secondary ash chamber
and venting should be monitored closely. If conditions show
excess condensation, the boiler water minimum temperature
will need to be increased until condensation does not occur.
You should also consider some form of tempering of the
return water system. Discuss this with your plumber.
When the OAT sensor is installed, at 20° F. or below (outside
temperature), the boiler will operate at the temperature set
on the MAX. TEMP. knob. The boiler water temperature will
decrease by 1° F. for every 1° F. in temperature rise (above
20°) of the outdoor air.
NOTE: Pellet Boiler Outdoor Air Reset Operation Graph
located on the following page.
27
3-90-07205R27_08/15
Automatic Ignition
Starting A Fire Automatically
1. MIN. TEMP. Selector to “OFF”. This resets the control
in addition to turning it off.
2. Clean Burnpot with scraper, if necessary. This is usually
a weekly maintenance procedure. Cleaning the burn pot
with the scraper with a small amount of new fuel in the
bottom is not a problem. First, scrape the ashes on the
front of the burn pot into the ash pan. Then scrape the
hole grid surface downward into the burn pot. When the
stove is ignited these scrapings will be pushed out by the
feeder.
The illustration at left shows the hopper swing plate open
for easy access to the burn pot. The burn pot can also be
reached through the firebox door.
NOTE: To minimize the amount of stress placed on the
hopper swing plate hinges, opening of the hopper swing
plate should be done with the least amount of fuel in the
hopper as possible.
3. Fill Hopper with pellets. When filling the hopper check
for excessive fines in the bottom of the hopper. Fines
are small pieces of broken pellets (sawdust). Fines do
not flow easily and often build up on the hopper funnel
bottom angles. These fines can be pushed into the
feeder opening and then fill the hopper with pellets. As
the system works, they will be burned.
Scrape burnpot to remove any carbon
build-up that may have occured
4. If Starting After an Empty Hopper, Turn Feed Adjuster
to “TEST” (for one 60 second cycle). This will feed pellets
into the auger tube and also allow you to check the motors
for operation. NOTE: The auger motor will not operate
with any of the doors open.
5. Turn Feed Adjuster to #4. If this is your first fire or you
are trying different pellets, set the feed adjuster to #4, This
is an average number for most pellets and may need to
be adjusted for your particular fuel. After you know a feed
rate setting that works well for your application, use that
setting.
NOTE: You know your feed rate is too high when: The
overheat safety feature is energized each time the
heating zone demand turns off during a high burn. OR,
If unburned or partially burned pellets are found in the
ash pan. (This may also be an indication of a burn pot
in need of scraping.)
6. Flip the Igniter Switch up into the “AUTO” position.
7. Turn the MAX. TEMP. Dial on the control board to the
desired temperature. This setting must always be at least
5° F. higher than the MIN. TEMP. setting.
!
WARNING
HOT WHILE IN OPERATION. KEEP CHILDREN,
CLOTHING, AND FURNITURE AWAY. CONTACT MAY
CAUSE SKIN BURNS.
28
3-90-07205R27_08/15
Automatic Ignition (Cont.)
!
WARNING
Fire Hazard.
Keep combustible materials, gasoline
and other flammable vapors and liquids
clear of appliance.
• Do NOT store flammable materials in the appliance’s vicinity.
8. Turn the MIN. TEMP. Dial on the control board to the
desired Minimum temperature. This will start the lighting
process if the temperature at the aquastat sensor is
approximately 5° F. less than the set temperature on the
MAX. TEMP. dial.
This is more than just an automatic ignition pellet boiler.
The automatic system will allow the fire size to be adjusted
to match the heating needs and even put the fire out if
necessary. If heat is needed after the fire is out, the boiler
will automatically re-ignite and adjust the fire size to match
the heating need.
• NEVER USE GASOLINE, GASOLINE-TYPE LANTERN
FUEL, KEROSENE, CHARCOAL LIGHTER FLUID, OR
SIMILAR LIQUIDS TO START OR “FRESHEN UP” A FIRE
IN THIS HEATER. KEEP ALL SUCH LIQUIDS WELL AWAY
FROM THE HEATER WHILE IT IS IN USE.
• DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS
SUCH AS GASOLINE, NAPHTHA OR ENGINE OIL.
• DO NOT USE CHEMICALS OF FLUIDS TO START THE
FIRE.
• Combustible materials may ignite.
9. Fill hopper with pellets and remove ashes as required.
Type of Fuel
Use pelletized wood only. The lower the ash content of the
pellets the less cleaning that will be needed of the heat
exchanger surfaces. The cleaner these surfaces are kept,
the more efficient the boiler will be.
Store pellets in the manufacturer’s wrapping until needed
to prevent pellets from absorbing moisture. Do not store
fuel within the appliance installation clearances, or within
the space required for fueling, ash removal, and other
routine maintenance operations.
29
3-90-07205R27_08/15
Manual Ignition
Lighting a Fire Manually
4. Have matches or other ignition source ready.
Lighting the fire manually will not be necessary unless the
igniter system fails.
5. Turn Mode Selector to desired MIN. TEMP. setting. This
will start the combustion blower and allow the ESP to
control the fire in relation to the MAX. TEMP. Dial setting.
(The MAX. TEMP. dial setting must always be set above
the MIN. TEMP. setting) Once the fire is well established
the MAX. TEMP. dial can remain on any temperature
setting desired.
Follow steps 1 through 5 of the instructions for automatic
lighting.
1. Flip the Igniter Switch Down into the “MANUAL-LIGHT”
position. See Fig. 12.
Fig. 12
2. Open hopper swing plate as shown in Fig. 13
NOTE: When the Switch is set to Manual ignite position the
boiler will function as in auto ignite except the fire will not be
allowed to go out. It will only be allowed to go to a minimum
burn rate between the times the aquastat is calling for heat.
This rate is about 1.1 pound of fuel per hour. If used in the
Manual ignite mode, be sure there is an overheat dump zone
in place. Note that if the dump zone does not provide sufficient
cooling, and the water temperature continues rising, the feed
motor will be forced to shut off. Because the unit is in Manual
Ignite mode, it will not re-ignite when the water temperature
cools below the control settings.
RT
GE ER
L
STA
Fig. 13
3. Fill burnpot with pellets as shown. See Fig. 14. Only
fill level with the front edge. (DO NOT OVERFILL)
Fig. 15
!
WARNING
Fire Hazard.
Keep combustible materials, gasoline
and other flammable vapors and liquids
clear of appliance.
• Do NOT store flammable materials in the appliance’s vicinity.
• NEVER USE GASOLINE, GASOLINE-TYPE LANTERN
FUEL, KEROSENE, CHARCOAL LIGHTER FLUID, OR
SIMILAR LIQUIDS TO START OR “FRESHEN UP” A FIRE
IN THIS HEATER. KEEP ALL SUCH LIQUIDS WELL AWAY
FROM THE HEATER WHILE IT IS IN USE.
Fig. 14
• DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS SUCH
AS GASOLINE, NAPHTHA OR ENGINE OIL.
• DO NOT USE CHEMICALS OF FLUIDS TO START THE
FIRE.
• Combustible materials may ignite.
30
3-90-07205R27_08/15
Manual Ignition (Cont.)
!
CAUTION
6. Apply starting gel as shown in Fig. 15
A vapor flash could occur if too much time is allowed to
pass before lighting the starting gel.
!
CAUTION
Care must be taken not to get starting gel on your hands
or clothing. Serious burns could occur during the lighting
process.
!
CAUTION
Never try to apply more starting gel to an already burning
fire, or a fire with smoldering pellets.
7. Light the Starting Gel With A Match.
8.Close the Doors the fire will light and the control will
adjust the fire to the proper level according to the MAX.
TEMP. dial setting.
NOTICE: When burning the boiler in the manual
ignition mode, there must be an overheat dump zone
incorporated into the plumbing system.
If heating demand stops during manual operation, the control
will take the unit to low burn. If no heat is used during this
time, the water temperature will continue to rise. When the
temperature gets too high, the feeder will be turned off and
the fire will go out. This will require a manual re-start of the
system. (See ESP Control section of this manual “7 Blinks”)
Fig. 16
Solid-fuel burning appliances need to be cleaned frequently
because soot, creosote, and ash may accumulate. If you
suspect a chimney/vent pipe fire do the following:
1. Call the fire department.
2. Remove fuel from the burn pot using the burnpot scraping
tool to scrape the pellets into the ash pan.
3. Remove the ash pan from the unit and take outside. Do
not place ash pan on a combustible material.
4. Turn off circuit breaker at unit.
5. Do not use the unit until a qualified person has inspected
your appliance and venting.
31
3-90-07205R27_08/15
Burnpot Maintenance
Use the flat end of the scraper provided to scrape down
over the holed surface of the burnpot grate. Fig. 18. It is
not necessary to clean out the scrapings from this cleaning
because they will be pushed out the next time the auger
operates.
Note: Make a special effort to scrape the bottom inside
corners of the burnpot where the auger tube enters the
burnpot. Carbon deposits can build up over time in this area
that may cause a restriction to the flow of pellets into the
burnpot.
Scrape the burnpotScrape
to remove
carbon
which may have formed.
burnpot any
to remove
any deposits
carbon
build-up that may have occured
Scraping can be done while the boiler is in operation, accessed through the
firebox door opening.
Fig. 17
With the fire out and burn pot cold, use the supplied allen
wrench to remove any build-up that may have accumulated
in the holes of the burn pot grate. Simply push the allen
wrench down through each hole ensuring it is clear of any
build-up paying attention not to damage the igniter element
in the process.
Cleaning the Burnpot Air Chamber:
This area only needs to be cleaned twice a heating season,
unless excessive buildup is noticed during scheduled
cleanings.
There is a cover on the front of the burnpot to gain access to
the air chamber. The cover is held into place by two thumb
screws. Loosen the thumb screws and remove the cover.
Fig. 19. The air chamber can be cleaned of any ash that has
fallen through the holes during operation and cleaning. Also
at this time, remove the feeder assembly cover and remove
any fines that may have accumulated.
NOTE: ALWAYS REMEMBER TO CLOSE THE CLEANOUT
COVER AFTER CLEANING. Feeder Chamber (Fig. 20):
Fig. 18
This chamber may get a buildup of fines from the feeder
mechanism movement. This area should be checked and
cleaned at least once a year.
To remove the feeder cover:
• Loosen the 5/16” wing nut.
• Slide the cover off of the threaded stud and lift upward.
• Inspect and clean the inner chamber if necessary. Fig. 20.
• Reinstall the cover making certain it is centered on the
feeder body and hand-tighten the wing nut.
Fig. 19
Cleanout Cover
Fines area
Burnpot Cleaning:
The burnpot should be cleaned no less than once a week.
For best operation the burnpot should be cleaned every time
the hopper is filled with pellets. The fire does not have to be
out to scrape the burnpot although it is recommended the
boiler be on minimum burn at the time of cleaning.
Note: Scraping can be done while in operation if performed
through the firebox door opening. Fig. 17
32
Fig. 20
Feeder cover
3-90-07205R27_08/15
Ash Removal
Ash Door
Ash Door Handle
Ash Pan
Ash Pan Handle
Fig. 21
!
WARNING
RISK OF FIRE!
•
Ash, soot or creosote build-up may cause
overheating or fire.
•
Routine cleaning of heat exchangers and venting
is required.
Ash Removal
It is recommended to remove the ashes when the boiler is not
in operation. This lessens the chances of coming in contact
with hot surfaces. Ashes can be removed while in operation
but, extra care must be taken.
Open Ash Door
Lift the latch and open the door as shown in fig. 21.
NOTE: Keep hopper lid, hopper swing plate, firebox door
and ash pan door closed during operation and maintain
all seals in good condition.
Disposal of Ashes
Ashes should be placed in a steel container with a tight fitting
lid. The closed container of ashes should be moved outdoors
immediately and placed on a non-combustible floor or on the
ground, well away from all combustible materials, pending
final disposal. If ashes are disposed of by burial in soil or
otherwise locally dispersed, they should be retained in the
closed container until all cinders have thoroughly cooled.
Other waste shall not be placed in this container.
Soot and Flyash: Formation and Need for Removal
The products of combustion will contain small particles
of flyash. The flyash will collect in the exhaust venting
system and restrict the flow of the flue gases. Incomplete
combustion, such as occurs during startup, shutdown, or
incorrect operation of the room heater will lead to some soot
formation which will collect in the exhaust venting system. The
exhaust venting system should be inspected at least twice
monthly to determine if cleaning is necessary. Pay particular
attention to screening in the vent cap. The screen, if present,
will accumulate with ashes rather quickly.
Remove Ash Pan
Always wear gloves to remove ash pan. Grab the ash pan
by the finger hold and pull it out of the boiler. Lift the ash pan
by the finger hold and use it for carrying the ash pan. Close
the ash door before disposing the ashes.
33
3-90-07205R27_08/15
Firebox Maintenance
Heat Exchanger Cleanout Rod Handles
Firebox Door
Heat Exchanger Tube
Secondary Ash
Chamber Access Plate
Fines Cleanout Cover
Firebox Wall
Cleaning
This cleaning should be done after each ton of pellets used.
The frequency of this cleaning will be directly related to the
quality and the ash content of the pellets being used. Keep
in mind that the cleaner the heat exchanger surface is kept,
the higher the heat transfer efficiency will be.
Due to it’s ease of restarting it is recommended that the boiler
be OFF and COOL before cleaning.
Start by actuating the (3) heat exchanger cleanout rods by
pulling and pushing these rods vigorously several times. This
action will remove any fly ash built up on the heat exchanger
tubes. This can also be done at any time during the operation
of the boiler to maintain higher efficiencies. Make sure that
these rods are pushed in when cleaning is completed.
Cleaning Steps
1. Open the hopper swing plate to access burnpot and also
the firebox. With a wisp brush, wire brush, stiff bristled
paint brush or a soot vaccum, clean the firebox walls and
any fly ash that has accumulated on the ledges of the
burnpot, or burnpot opening. At this time you can scrape
and clean the burnpot and fines cleanout area.
34
Ash Door
2. Open firebox door and vacuum ash from ledges and ash
deflector. You can also clean the firebox door viewing
glass using a typical glass cleaner and soft cloth.
3. Open the ash door and remove the ash pan. Dispose of
any ash that has accumulated in the ash pan as well as
any fly ash from within the ash pan area.
4. Remove the (4) thumbscrews on the secondary ash
chamber access plate and remove it to access the
secondary ash chamber. Remove all fly ash from this
area. This process should be done as needed.
5. Inspect all sealing gaskets to ensure a proper seal and
re-install all components removed for cleaning.
!
CAUTION
Cleanout of the heat exchanger, flue pipe, chimney,
and combustion blower fan housing, is especially
important at the end of the heating season to minimize
corrosion during the summer months, caused by
accumulated ash.
NOTE: To minimize the amount of stress placed on the
hopper swing plate hinges, opening of the hopper swing
plate should be done with the least amount of fuel in the
hopper as possible.
3-90-07205R27_08/15
Combustion Blower/Heat Exchanger Maintenance
The boiler MUST be OFF and COOL before you should
attempt to clean the combustion blower.
The wire to the combustion blower doesn’t need to be
disconnected during the cleaning process.
Heat Shield
Latch
Fig. 22
Clean the blower fan blades and the blower plate sealing
overlap. See Fig. 24.
ESP
Combustion
Blower Motor
Thumb Screws (3) Total
Fig. 23
Loosen the three (3) thumb screws about 4 turns each. See
Fig. 23. Hold the motor head with one hand and the blower
plate handle with the other hand. Pull outward on the plate
handle until the complete unit comes loose. Now rotate the
plate counter-clockwise about 1/8 turn. This will allow the
complete assembly to be removed from the blower chamber.
NOTE: Be careful not to bend the fan blades, this will
throw the fan blade out of balance or it may rub the inner
chamber, which may affect the performance of the boiler.
Any horizontal and vertical flue pipe directly above the
unit should be cleaned at this time
NOTE: The horizontal flue pipe directly above the boiler
is the first place fly ash will settle, due to the slowing
of flue gas velocity through horizontal pipe. Cleaning
of horizontal venting pipes is very important to the
efficiency of this boiler.
Clean the flue outlet throat as well as the inner chamber
of the flue tunnel (this is the hole that goes up into the flue
pipe). See Fig. 24.
NOTE: The exhaust probe sensing tip extends into this
same area. CARE MUST BE TAKEN NOT TO DAMAGE
THE ESP DURING CLEANING. Bending of the ESP will
make it difficult to remove if it should become necessary.
See Fig. 23.
Clean the boiler blower plate, sealing overlap. See Fig 24.
Make sure there are no fly ash buildups that may block the
easy flow of flue gasses into the combustion blower inlet
hole. (A flashlight may be necessary.)
Sealing
Overlap
5” Double
Bladed Fan
Fig. 24
Combustion Blower Cleaning
Remove the combustion blower heat shield. There are two
latches that hold the shield in place (See Fig. 22). Flip the
latches up and pull the shield away from the boiler. It can not
be fully removed, it can only be moved down over the wire
until it hangs on the junction box.
35
Cleaning the Tube Heat Exchangers:
Three external cleaning rods allow scraping of the heat
exchange tubes with a simple in-and-out motion. See
previous page.
This cleaning should be done at least once a week, however
it can be done more often as desired. The cleaner the heat
exchangers are, the more efficient the boiler will be. It is best
to perform during a low fire period or when the fire is out.
During high fire periods, the cleaning rods may stick due to
heat related expansion.
!
CAUTION
Inspect flue pipes, flue pipe joints and flue pipe seals
regularly to ensure that smoke and flue gases are not
entering the home.
3-90-07205R27_08/15
Troubleshooting
FEEDER DOES NOT FEED
1. No pellets in hopper.
2. Firebox draft may be too low for low draft pressure switch
in feeder circuit to operate. Check for improperly closed
doors, loose or missing gasket on doors or hopper lid, or
a faulty pressure switch.
3. Feed motor will not run until the ESP senses 170° F.
Maybe you did not put enough pellets in the burn pot
before lighting the fire manually.
4. Something is restricting flow in the hopper or causing the
slide plate to stick.
5. Feed motor has failed.
PARTIALLY BURNED PELLETS
1. Feed rate too high.
2. Draft too low. (Check burn pot clean-out slide and door
gasket).
3. Burn pot or heat exchanger tubes may need to be
cleaned.
4. Combination of all the above.
5. #6 status blink: A 6 blink control board status indication is
caused by poor or incomplete combustion. The Automatic
Ignition circuit board has the ability to track the combustion
through feed settings and ESP temperatures. When
the control board has calculated poor or incomplete
combustion, it will shut down the unit as a safety feature.
(Poor or incomplete combustion is a contributor of
creosote which may cause a chimney fire)
A 6 blink status may be caused by several things:
1. Blocked or partially blocked flue.
2. Blocked or partially blocked inlet air.
a. Backdraft damper on the inlet pipe may be stuck
closed.
b. If outside air is installed, the Termination Cap may
be blocked.
3. The air chamber under the burnpot may be filled with fines
and small bits of ash.
4. The holes in the burnpot may be getting filled with ash or
carbon buildup.
5. Combustion blower fan blades may need cleaned.
6. There is no fuel in the hopper.
SMOKE SMELL
Seal the vent pipe joints and connection to stove with silicone.
FIRE HAS GONE OUT
1. No pellets in hopper.
2. Draft setting is too low.
3. Something is restricting fuel flow.
4. Feed motor or combustion blower has failed.
5. Power failure or blown fuse.
36
SMOKE IS VISIBLE COMING OUT OF VENT
1. Air-fuel ratio is too rich.
a. Feed rate too high.
b. Draft too low caused by a gasket leak.
LOW HEAT OUTPUT
1. Feed rate too low
2. Draft too low because of gasket leak.
3. Poor quality or damp pellets
4. Combination of 1 and 2.
Helpful Hints
Cleaning Burn Pot
Whenever your boiler is not burning, take the opportunity
to scrape the burn pot to remove carbon buildup. A vacuum
cleaner is handy to remove the residue. Be sure the boiler
is cold if you use a vacuum.
Carbon buildup can be scraped loose with the fire burning
using the special tool provided with your stove. Scrape the
floor and sides of the burn pot. The carbon will be pushed out
by the incoming fuel. Always wear gloves to do this.
Removing Ashes
Ashes can be removed while in operation, but extra care
must be taken and always wear gloves.
Maximum Feed Adjuster settings are not needed in most
cases. Operating in the normal range (#4) is recommended
when maximum heat output is not required. The ESP
prevents the stove from being over-fired.
Keep the boiler free of dust and dirt.
Fuel
Pellet fuels are put into 3 categories in terms of ash content.
Premium at 1% or less, Standard at 3% or less and all others
at 3% or more.
This unit is capable of burning all 3 categories of pellets due
to a patented feeder and burn pot system.
It should be noted, however, that higher ash content will
require more frequent ash removal, scraping of the burn pot,
and may provide less BTU’s per pound. Normally, standard
and high ash pellets cost less than premium pellets and can
be cost effective when burned in this boiler.
The moisture content must not exceed 8%. Higher moisture
will rob BTU’s and may not burn properly.
Summer Operation for Domestic Hot Water
When the boiler is used solely for domestic hot water (e.g. in
the summer or shoulder seasons), extended periods of low
burn may cause faster than normal accumulation of ash &
creosote in the burnpot, firebox and venting system. Cleaning
the burnpot daily and inspecting the firebox & venting system
weekly is recommended during this type of usage. These
periods may be increased based on the level of accumulation
seen during daily & weekly cleanings.
3-90-07205R27_08/15
Atmospheric Conversion
Atmospheric Conversion: Item # 1-00-232200, provides automatic fill, and converts the heating system plumbing from
pressurized to a zero pressure system. Allows for installation into more places where codes and standards restrict pressurized
systems. Note that when using the atmospheric conversion, air bleeders and check valves may actually allow air into the
lines. Another reason it is important to have a licensed Plumber involved in each phase of your installation.
When using the atmospheric conversion, the circuit board dipswitch #6 must be in the “ON” position. This will lower
the overheat temperature parameters to prevent boiling of the water. Since altitude affects the boiling point, it is also
recommended to set #6 to “ON” at elevations above 3000 ft.
37
3-90-07205R27_08/15
Optional Domestic Hot Water Coil
There is a domestic hot water coil available for your PB105. The coil installs in the side of the boiler, and allows your
domestic water to be heated by the heating system water. Install the coil now, by removing the round plate and replacing it
with the coil and it’s round plate. Be sure to tighten the bolts evenly, to ensure a good seal.
Remove the (6) - 7/16”-14 bolts &
Domestic Hot Water Coil Plate.
38
3-90-07205R27_08/15
1.4 AMP
Combustion blower
Auger motor
Igniter element Control board 23.5”
33.37”
Approximate operating wattage .2 KWH
.05 AMP
3.6 AMP
.7 AMP
120 VAC 60 Hz
Electrical
* 8500 BTU per pound figures
Max. Burn = 13.4 pounds per hour
Min. Burn = 1.1 pound per hour
0 BTU if system is satisfied.
BTU Input Range= 0, and 9350 to 113,900*
26”
24.25”
17.5”
62”
55.75”
7.12”
4.25” O.D.
4.12” I.D.
17.5”
39
47.5”
11.5”
16.87”
Specifications
3-90-07205R27_08/15
49.75”
43.5”
Wiring Diagram
PELLET BOILER WIRING DIAGRAM
120 VAC 60 HZ
MAIN POWER
(SUPPLIED
BY OTHERS)
BROWN
WHITE
DARK BLUE
RED
GREEN/YELLOW
WHITE
WHITE
WHITE
RED
RED
WHITE
GREEN
RED
1
3
4
3/8"FLEX CONDUIT
GREEN/YELLOW
CONTROL
BOARD
DARK BLUE
8
9
10
TCP
GREEN/YELLOW WIRE
ESP
11
EXHAUST PROBE
(ESP)
IS GROUND BONDED TO
STOVE BODY
TWISTED WIRE
YELLOW
WHITE
6 AMP GLASS FUSE
3/8"FLEX CONDUIT
WHITE
BROWN
AQUA TEMP SENSOR
BLACK
BLACK
4" SQUARE JUNCTION BOX
BLACK
WHITE
GREEN
AUX. OUTPUT (OVERHEAT ZONE)
LOW PRESSURE SWITCH
N.O. CONTACTS
BLACK
FEEDER MOTOR
YELLOW
SKY BLUE
MOTOR WIRE MALE/FEMALE CONNECTION
COMBUSTION MOTOR
TT
WA
450
VAC
120
IGNITER PUMP
120 VOLTS A.C. 60 HZ.
5.3 AMPS ( ignition mode )
635 WATTS200 WATTS1.7 AMPS ( normal operation )
IGNITER ELEMENT
BROWN
1
PLUGGED
2
WHITE
3
WHITE
4
EMPTY
5
EMPTY
6
EMPTY
7
YELLOW
8
DK BLUE
9
RED
10
BLACK
11
WHITE 11 PIN PLUG
SKY BLUE
OUTDOOR AIR EXTENSION
PVC CORD MOTOR LEAD
PART NO. 3-90-72194A
Power Failure Backup Supply
4" SQUARE JUNCTION BOX
“105 Series” PELLET BOILER
UPS BACKUP FOR COMBUSTION MOTOR
BLACK
BROWN
WHITE
WHITE
If using a standard UPS, it should be rated at 650 or higher to
ensure that the combustion motor operates until the fire is out.
(approximately 20 minutes needed)
GREEN
RED
GREE
CORD CONNECTOR
16-3 AWG
PVC CORD
N
BLACK
WHITE
GREEN
BLACK
WHITE
WHITE
RED
GREEN
RE
D
N
EE
GR
Relay enclosure box - GRAINGER # 1EGH7
RE
D
8
7
4
3
6
5
2
1
GREEN
BLACK
DPDT RELAY flange mtd. - GRAINGER #2XCO2
40
FEMALE
POWER TO THE UPS / Plug UPS into here.
When current is present, will keep UPS in Ready
mode.
These cord tails can be made from an inexpensive 16/3
extension cord. Make sure that the MALE end is long
enough to reach the receptacle on the UPS.
WHITE
RED
RED
WHITE
WHITE
1/2" CONDUIT
DARK BLUE
GREEN/YELLOW
WHITE
3/8"FLEX CONDUIT to
combustion motor
WHITE
( UNINTERUPTED POWER SUPPLY / BATTERY BACK-UP )
3/8"FLEX CONDUIT
from control board
120 VAC power (by installer)
WHITE
MALE
16-3 AWG
PVC CORD
POWER FROM THE UPS / This plugs into
the UPS. When power fails, UPS will supply
current to the relay.
CORD CONNECTOR
3-90-07205R27_08/15
Power Failure Backup Supply
Minimizing Smoke During Loss of Power Using Battery Back-up
Harman® strongly recommends installing battery back-up to minimize entry of smoke into the room
in the event of power loss.
Your pellet/biomass burning appliance relies on a combustion blower to remove exhaust. A power failure will
cause the combustion blower to stop. This may lead to exhaust seeping into the room. Vertical rise in the
venting may provide natural draft. It is, however, no guarantee against leakage.
Below are Harman® approved battery back-up options for your appliance:
Uninterruptible Power Supply (UPS) UPS battery back-ups are available online or at computer and office
equipment stores:
• The APC (American Power Conversion) model #BX1500G and the TrippLite OMNIVS1500 are
tested and approved. Other brands or models may not be compatible.
When power is lost, a fully charged UPS will power a safe, combustion blower only shut-down. Your
appliance will pulse the blower every few seconds to clear exhaust until the fire is out. NOTE: The UPS
provides safe shut-down only. It is not intended for continued operation.
Your appliance will recognize when power is restored. What happens depends on ESP temperature:
• In “Automatic” setting, units will respond to the set point and ESP temperature and resume
normal operation.
• In “Manual” setting:
• If the ESP is cool, the appliance will remain shut down.
• If the fire is out and the ESP is still warm, the feeder may restart. Since the fire is out, the ESP
temperature will not rise. The unit will then shut-down, and may flash a six-blink status error. (See
ESP error codes)
• If the fire is still burning, it will resume normal operation.
Contact your dealer if you have questions about UPS compatibility with your appliance.
CAUTION! Always keep appliance doors and hopper lid closed and latched during operation and
during power failures to minimize risk of smoke or burn-back.
CAUTION! Use only Harman® approved battery back-up devices. Other products may not operate
properly, can create unsafe conditions or damage your appliance.
41
3-90-07205R27_08/15
Harman PB105 Pellet Boiler
Label
Label measures: 7.875" highSafety
X 6.5"wide
Harman PB-105
LISTED PELLET FUEL CENTRAL OR SUPPLEMENTARY FURNACES
FOR RESIDENTIAL USE
OMNI-Test Laboratories, Inc.
Report #/Rapport #135-S-16-6
Certified for U.S.A. and Cananda
Certifié pour les états-Unis et le Canada
Serial No.
No de série:
APPAREIL DE ChAUFFAgE CENTRAL OU SUPPLéMENTAIRE ENREgISTRé DE
gRANULéS COMBUSTIBLES POUR USAgE DANS LES RéSIDENCES
008
BARCODE LABEL
Y
L
N
Tested June 2006 to CSA-B366.1-M91, and UL 391-95
Testé en June 2006 à CSA-B366.1-M91, and UL 391-95
Install and use only in accordance with the manufacturer’s installation/operting
instructions. Refer to authorities having jurisdiction for proper installation. Contact
local building or fire officials about restrictions and installation inspection in your area.
If there are no applicable local codes, follow ANSI/NFPA 211 and CAN/CSA B365.
Special precaustions are required for passing the chimney through a a combustible
wall or ceiling.
Installez et utilisez en accord avec les instructions d’installation et d’opération du
fabricant. Référez-vous à des professionnels avec autorité dans l’installation.
Contactez le bureau de la construction.ou le bureau des incendies au sujet des
restrictions et de l’inspection dans votre voisinage.
S’il n’y a pas de codes locaux, suivez alors ANSI/NFPA211 et CAN/CSA B365.
Prenez des précautions spéciales lorsque vous faites passer une cheminée à travers
un mur ou un plafond combustibles. Inspectez et nettoyez le sustème de ventilation
fréquemment en accord avec les instructions du fabricant. Utilisez un système de
ventilation de 4” de diamètre de type “L” ou “PL”.
Inspect and clean exhaust venting system frequently in accordance with the
manufacturer’s instructions. Use a 4” diameter type “L” or “PL” venting system.
Model
Modèle
PB-105
Fuel
Combustible
Pellet
Granulés
Chimney Connector Size
Grandeur du Tuyau de Cheminée
BTUH/Kw Input Pellet
Rendement des Granulés BTUH/Kw
4”
113,900 BTUH (33.4 Kw)
L
E
O
Electrical Rating
Maximum Overcurrent Protection
Classification électrique Protection Maximum du Courant
120V, 4.45A, 60 Hz
Clearances to Combustibles/Espaces Libres aux Combustibles
B
A
Sidewall to Appliance
20” (507 mm)
Mur Latéral à l’Appareil
Backwall to Appliance
6” (152 mm)
Mur Arrière à l’Appareil
Combustibles to Pellet Vent
3” (76 mm)
Matériaux Combustibles au Conduit de Fumée
Stove Top to Ceiling
23.5” (596 mm)
Haut du Poêle au Plafond
Alcove Height
66” (1673 mm)
Hauteur de l’Alcôve
Alcove Depth
80” (2032 mm)
Profondeur de l’Alcôve
Combustibles from Stove Front
36” (914 mm)
Des Combustible au Devant du Poêle
E
L
L
20 AMP
Essential parts and subassemblies provided for field assembly are as follows /
Pièces essentielles et sous-assemblée procurées pour l’assemblage sont les suivantes:
(5) Spring Handles / (5) Poignées à Ressort
P
(1) 3/4” Boiler Drain / (1) Robionet de vidange 3/4”
(1) 100’ Sensor Cable / (1) Câble de la Sonde 100’
(1) Outdoor Air Sensor / (1) Sonde Extérieure
(1) 3/4” Safety Relief Valve / (1) Soupape de Sécurité 3/4”
(1) Flue Tunnel Weldment / (1) Ensemble Mécano-soudé de sortie des Gaz de Combustible
(1) 1/2” Aquastat Well / (1) Plomgeur de l’Aquastat 1/2”
(1) Combustion Blower Assembly / (1) Ensamble Ventilateur de Combustion
M
A
(1) 1/2” Dual Temperature/Pressure Gauge / (1) Double Indicateur Température/Pression 1/2” (1) Heat Shield (Combustion Blower) / (1) Carter de Protection du Ventilateur de combustion
DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING
ANOTHER APPLIANCE
DANGER! Risk of Fire or Explosion - Do not burn garbage, gasoline,
NE PAS CONNECTER CET APPAREIL à UN TUYAU
DE CHEMINéE SERVANT UN AUTRE APPAREIL
DANGER! Risque de feu ou d’explosion. Ne pas brûler des ordures, de
WARNING! DO NOT operate with fire chamber or ash removal doors open.
ATTENTION!
CAUTION! Hot while in operation.
ATTENTION! Chaud lors de l’opération.
naphtha, engine oil, or other inappropriate materials.
S
DO NOT store fuel or other combustible material within
installation clearance area.
DO NOT touch. Keep children, clothing, furniture and other combustible
material out of the installation clearance area.
Flooring must be a non-combustible material covering the installation
clearance area, and 18” in front of, and 8” to either side of the fuel loading
doors.
In the event of loss of electrical power:
Consult owner’s manual for restarting your furnace after power is restored.
U.S. ENVIROMENTAL PROTECTION AgENCY
This model is exempt from EPA certification under 40 CFR 60.531
by definition [Wood heater (A) “air-to-fuel ratio”].
Made in the U.S.A. / Fait aux états-Unis
Do Not Remove or Cover This Label/Ne pas enlever ou recouvrir cet étiquette
l’essence, du pétrole, de l’huile moteur ou autres matériaux
inappropriés.
Ne pas opérer si la porte du combustible ou la porte de la cuvette des
cendres sont ouvertes. Ne pas placer le combustible et les matières
combustibles à l’intérieur de l’espace désignée pour l’installation.
NE PAS toucher. Gardez les enfants, les vêtements, les meubles et les
matériaux combustibles loin de l’espace désignée pour l’installation.
Le plancher de l’espace désigné pour l’installation doit ê fait de matière noncombustible, de 18” en avant, et de 8” de chaque côté des portes d’entrée
du combustible.
Dans le cas d’un manque d’électricité:
Consultez le manuel du propriétaire pour remettre la fournaise en marche
lorsque l’electricité ést revenue.
Manufactured by/Fabriqué par: hearth & home Technologies, Inc.
352 Mountain house Road - halifax, PA 17032
Date of Manufacture / Date de fabrication
2013 2014 2015 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
P.N. 3-90-07206
42
Rev D
3-90-07205R27_08/15
Service Record / Notes
Date Of Service
43
Performed By
Description Of Service
3-90-07205R27_08/15
3-90-07205R27_08/15
**See the section on Maintenance for more
details about cleaning.
*See the section on Operation for information
about Manual Lighting and Emergency Power.
The boiler will ignite if the temperature of the boiler water is less than
the temperature set on MAX. TEMP. dial..
10 Flip the igniter switch to Auto.*
9 Turn MIN. TEMP. dial to the desired settings.*
8 Turn the MAX. TEMP. dial to the desired temperature.
7 Turn Feed Adjuster back to the #4 setting.
6 Check the Combustion Blower and Feeder Motor for operation.*
5 Turn Feed Adjuster to “Test”.*
4 Fill the hopper with pellets.
3 Scrape the air holes in the burnpot.**
2 Use heat exchanger cleanout rods to clean the heat exchanger
tubes.**
1 Turn Mode Selector to OFF.
Quick Reference (Auto-Light)
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