Installation & Operating Manual Cleaning & Maintenance Instructions The Harman Accentra Pellet Insert “Ce manuel est disponible en Français sur demande” R11 SAFETY NOTICE Please read this entire manual before you install and use your new room heater. Failure to follow instructions may result in property damage, bodily injury, or even death. FOR USE IN THE U.S. AND CANADA. SUITABLE FOR INSTALLATION IN MOBILE HOMES IF THIS appliance IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT. FOR YOUR SAFETY, FOLLOW INSTALLATION DIRECTIONS. do not use makeshift compromises. CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA. Contact your local authority (such as municipal building department, fire department, fire prevention bureau, etc.) to determine the need for a permit. Cette guide d'utilisation est disponible en francais. Chez votre concessionnaire de Harman. save these instructions. Item# 3-90-00674 Maintenance - Cleaning Glass on View Door 28 The glass used in your stove is manufactured to exact standards to withstand the high heat of the fire, but like all glass, it must be treated with common sense and care. Never abuse the glass by slamming the door shut or striking the glass with a heavy object. If the glass is broken or damaged, do not operate the stove until it has been replaced. Glass - Replacement If the stove’s glass is cracked or broken, you must replace it before operating your stove. Remove pieces carefully. Replace glass only with Harman replacement glass; do not use substitutes. Carefully remove damaged glass, gasket material, and hold down clips (set aside). Install the self adhesive 1/4"” gasket material around the front face of the glass. Set the glass panel and gasket gently onto the door. Install the hold down clips and tighten with bolts. Glass - Cleaning Sometimes it will be necessary to clean accumulated ash from the glass surface; allowing this ash to remain on the glass for long periods can result in “etching” due to the acidity of the ash. Never clean the glass while it is hot, and do not use abrasive substances. Wash the surface with cool water, and rinse thoroughly. You may wish to use a non-abrasive cleaner specifically designed for use on stove glass. In any case, dry thoroughly before relighting your stove. Disposal of ashes: 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. 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 thoroughly cooled. Soot and fly ash: Formation and need for removal. The products of combustion contain small particles of fly ash. The fly ash will collect in the exhaust venting system and will restrict the flow of the flue gases. Pellet fuels have different ash contents depending on what type of wood has been used to make the pellets. We recommend to clean the system after approximately 1 ton of pellets have been burned and judge from that how often the stove should be cleaned, remember if you change pellets it may change how often you have to clean your stove. When burning wood slowly, the potential exists for creosote to form. The venting system should be inspected periodically throughout the heating season to determine if a creosote buildup 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. If a fire occurs, call the fire department, shut down the stove, and evacuate the residence. Before using the appliance, have the venting system thoroughly inspected and replace any damaged components. Replace glass only with high temperature ceramic glass. Glass Gasket Fig. 57 Inspect door gasket during cleaning and inspection Maintenance - Burn Pot 29 Burn Pot Cleaning and Maintenance Whenever adding fuel, take the opportunity to clean the burn pot.(Weekly at minimum) • Scrape the top holed surface and sides of the burn pot down to auger tube.(Fig 58) It is not necessary to completely remove all material from the burn pot. The excess will be pushed out during the next use. Monthly, or after each ton of fuel burned: • Loosen the (2) wing thumb screws on the lower front angle of the burn pot. (Fig. 59) • Lift off the clean-out cover (Fig.59) to open the bottom clean-out chamber. (Fig.60) Fig.58 DANGER Disconnect the power to the unit before removing cover. Fig. 59 Burn pot igniter • Clean ash buildup from inside the chamber while cover is off. Use the scraper to tap on the top front edge of the burn pot. This will help knock pieces of ash, loosened by the scraping process, down through the holes. It also helps knock scale off of the igniter element. Figure 60 The igniter is made to be removable for service by insulated male/female wire connectors. These connections between the hot leads (the wires inside the burn pot) and the cold leads (the wires from the control board) are always pulled to the inside rear of the feeder body. (Not coiled inside the burn pot.) It is very important that these connections are to the inside rear of the feeder body. Also, the extra wire of the igniter wire service loop must be pulled out through the rear of the feeder and tied up so that it will not be damaged by any moving parts. WARNING Use caution when cleaning burn pot clean-out chamber. Do not damage the high temperature igniter wires. Igniter hot lead wires (high temperature) Fig. 60 Viewed from below through the ash pan opening. Note: The hot lead/cold lead connection must always be pulled to the rear of the feeder body before operation. Maintenance - Cleaning 30 Monthly Cleaning- continued: There is a 2" square exhaust tube on each side (lower left and right corners) of the firebox. They can only be seen with the cast heat exchanger covers removed. Fig. 61 Cleaning the Heat Exchanger tubes Using the cleaning brush provided, clean these tubes after every 1 ton of pellets are used. These tubes are an important part of the heat exchanger. Efficiency will be lost if they are not properly maintained. The right side tube is a straight passage to the combustion blower chamber. The Left side tube follows straight back then makes a right turn, across the back, to the combustion chamber. You will need to use the entire length of the cleaning brush handle to properly clean this tube. Fig. 62 Primary Air Inlets Fig. 63 Cleaning the Heat Exchanger The accordion heat exchanger surfaces are the primary source of heat transfer into the room. Therefore, it is very important to keep them clean from flyash and soot buildup. • The heat exchanger surfaces should be cleaned after approximately every 1 ton of pellets are used. • Use the scraper provided to clean all the way into the point. • Note: An old paint brush works well to clean these surfaces. • Note: The unit “must be cold” before using anything other than a wire brush. • There are 2 primary air inlet holes on the rear flange of the burnpot. They should be checked for blockage and cleaned with a vacuum if necessary. Note: The bottom of the flame guide has 2 notches that match the holes. Maintenance - Cleaning 31 Feeder Chamber Feeder rear chamber/ clean out cover ESP 5/16" wing nut Fig. 64 Pellet Metering slide plate Possible pellet fines buildup area. Fig.65 Close Tolerance 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: • Remove the 5/16" wing nut. • Slide the cover off of the threaded stud. • Inspect and clean the inner chamber if necessary. See Fig. 65. • Reinstall the cover making certain it is centered on the feeder body and tighten as tightly as you can by hand. The combustion blower is made to be removed easily for inspection and cleaning. See Fig. 67. The combustion blower is mounted on a precision cut gasketless mounting plate. This plate is held into place with (3) thumb screws. See Fig. 67. To remove the combustion blower: • Turn the thumb screws counterclockwise approximately 5 turns. Rotate the entire assembly counter clockwise until the points of the retaining slots are visible. • Remove the blower assembly with the fan blade by pulling it directly away from the blower housing. • The cord on the motor is long enough to allow the motor to be set down on the black plastic fan cover. This allows for easy access to inspect and clean the area. See Fig. 66. • With the blower assembly out, inspection should be done on the surfaces of the blower assembly and the housing opening where they meet. These surfaces MUST be clean and free from dirt, grit, flyash, soot or nicks in the metal. This gasketless seal relies on an extremely close tolerance. Therefore, anything other than a clean joint may cause exhaust gases and/or flyash to escape. • The assembly can only be reinstalled in one position: with the motor winding in the upward location. See Fig. 67. The mounting plate will not allow for any other position. • Always make sure that the assembly is fully seated and the (3) thumb screws are tightened before operating the unit. Mating Surface Close Tolerance Fig. 66 Fig. 67 Combustion Motor Feed Motor The Control Board/ESP combination is responsible for all high limit safety control. There are 2 high limits, one normal operation high limit and one backup high limit. The control has an automatic diagnostic circuit that continuously monitors the ESP and Room Sensor for faults. If a fault should occur, the control sends a status alert and at the same time the unit goes down to minimum feed/minimum burn as a safety condition. Silicone sponge docking gasket The Hopper Lid Position Switch is found in the rear corner of the hopper opening. If the hopper lid is not fully closed, the switch opens, interrupting the power to the feed motor and the igniter circuits. This prevents possible injury from reaching into the feeder mechanism during operation. Hopper Lid Position Switch The Low Draft Pressure Switch is a differential pressure switch that monitors the negative pressure (Draft) in the firebox. If the draft becomes too low for proper combustion, the switch opens, cutting power to the feed motor and the igniter circuits. This switch is connected into the AC (high voltage) wiring. Accentra Pellet Insert Safety Devices Distribution Blower (under unit) See Fig. 10, Page 9. Backdraft Damper Assembly Always check to see if the damper plate swings freely inward and that the seating edges are not covered with dirt or lint. Low Draft Pressure Switch Accentra Insert Motor & Component Locations Motor & Component Locations 32 Trouble-Shooting STOVE DOES NOT FEED 1. No fuel in hopper. 2. Firebox draft may be too low for sensing switch in feeder circuit to operate. Check for closed doors, loose or missing gasket on doors or hopper lid. 3. Hopper lid must contact the lid position switch. 4. Feed motor will not run until the ESP control senses a certain temperature. Maybe you did not put enough fuel or starting gel in the burn pot before manually lighting the fire. 5. Restriction in the hopper or feeder. Remove all fuel and examine. Clear the obstruction. 6. Feed motor has failed. PARTIALLY BURNED PELLETS 1. Feed rate too high. 2. Poor air to fuel mixture. (Check burn pot cleanout cover and air intake). 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 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 inlet cover 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. Fuel restrictions as noted above. SMOKE SMELL Seal the vent pipe joints and connection to stove with silicone. The exhaust vent is the only part of the system that is under positive pressure. FIRE HAS GONE OUT- Check for status light. 1. No fuel in hopper. 2. Draft is too low, blocked flue. 3. Something is restricting fuel flow. 4. Hopper lid not closed properly. 5. Feed motor or combustion blower has failed. 33 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 stove 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 stove 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 Turn the Temp Dial to number 1 approximately 30 minutes before removing ashes. This will result in a cooler stove and ash pan. 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 probe prevents the stove from being over-fired. Keep the stove free of dust and dirt. Fuel The Accentra is approved for burning any grade of pelletized bio-mass fuel. It is also approved for burning shelled corn in a mixture with wood pellets, up to 50%.(See Page 46) 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. The moisture content of pellets must not exceed 8%, and corn must not exceed 15%. Higher moisture will rob BTU's and may not burn properly. Fuel should not be stored within the stove installation clearances or within the space required for charging and ash removal. See Page 14.