United States Stove 5660I User Manual

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Installation and Operating Manual

Models 5660(I)

Tested &

Listed By

Safety Notice

Report #:

215 S 32 4 and 215 S 33 4

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

If your heater is not properly installed, a house fire may result. For everyone’s safety, FOLLOW all Installation and Operating Directions. Never use makeshift compromises during the installation of this appliance.

Contact your local building or fire officials about restrictions and installation inspection requirements in your area.

These Pellet Stove Room Heaters have been designed for use in the US and Canada and are suitable for mobile homes.

Save These Instructions

United States Stove Company • 227 Industrial Park Road, South Pittsburg, TN 37380 • Ph #: (800) 750 2723

Part No.: 851901


	TABLE OF CONTENTS
Topic	Page(s)
Introduction	3
Safety Information	4 5
Specifications	6
Dimensions	6 7
Operating Instructions	8 11
Thermostat Installation	12
Clearances to Combustibles	13
Installing Your Room Heater	14 23
Mobile Home Installations	24
Insert Pellet Stove Installation	25 28
Vent Termination Locations	29
Maintenance	30 33
Troubleshooting	34 36
Wiring Diagram	37
Replacement Parts List	38
Warranty	39

Introduction

The entire family of United States Stove Company thanks you for purchasing your new pellet burning room heater. At U.S. Stove, we build all of our products with a hands on approach to detail and quality. Our old world team of Craftsmen take great pride in their superior workmanship to ensure you have years of trouble free use of your pellet heater.

U.S. Stove Pellet Burning Room Heaters have been tested and listed for installation in residential, mobile home and alcove installations. U.S. Stove Pellet Burning Room Heaters are available in free standing pedestal and fireplace insert versions.

U.S. Stove Pellet Burning Room Heaters have been certified to:

ASTM E1509 04, ULC/ORD C1482 M90, ULC S627 00, & ULC S628 00

The performance of your Pellet Stove Room Heater can be affected by the type of pellet fuel you choose to burn in it. It is important to use only pellet fuel that is dry and free from dirt or other impurities. The Pellet Fuel Industry has established standards for wood pellet manufacturers. We recommend that pellet fuel used in all U.S. Stove Pellet Burning Room Heaters meet or exceed the following specifications:


Fines (fine particles):	Maximum through a 1/8" screen
Bulk Density:	Minimum 40 lbs per cubic foot
Size:	Maximum 3/8" Diameter by 1 1/2" length
Ash Content:	1% Maximum (Premium grade)
	3% Maximum (Standard grade)
Moisture Content:	8% Maximum
Heat Content:	Minimum 8,200 btu’s per hour

It is important to note that the ash content of the fuel and frequency of operation will determine the frequency of which you will be required to clean your Pellet Stove. A high ash fuel may result in daily cleaning, while a low ash content fuel may result in less frequent cleaning.

Occasionally impurities in the fuel will cause a hard mass build up in the burn pot of your Pellet Stove. Impurities such as silica can virtually form little glass balls when subjected to the high heat generated in the burn pot. When allowed to collect, a hard bass build up may block air flow through the burn pot, which will significantly affect the performance and efficiency of your Pellet Stove. It is a good idea to check the burn pot for any hard mass buildup or other blockage on a daily basis, and if necessary let the burn pot cool and then clean the burn pot.

U.S. Stove Company realizes that it cannot control the quality of pellet fuel you choose to use in your Pellet heater; U.S. Stove assumes no responsibility for that choice.

CAUTION: BE SURE TO STORE PELLET FUEL A MINIMUM OF 3' (914.5MM) AWAY FROM THE PELLET HEATER. RADIANT HEAT CAN IGNITE THE FUEL.

Please note that the rating label is located on the inside of the hopper lid on freestanding models and on the back side of the ash pan cover for insert models.

SAFETY INFORMATION

Be sure to read the entire owner’s manual prior to installing and operating this Pellet heater. Failure to follow these instructions could result in fire, property damage, bodily injury or even Death.

This stove’s exhaust system works with negative combustion chamber pressure and a slight positive chimney pressure, it is extremely important to ensure that the exhaust system be sealed and airtight. The ash pan and viewing door must be securely fastened in order for the unit to be airtight. This Pellet heater will not operate using natural draft or without a power source for the blowers.

The use of grates or other methods of supporting the fuel is not permitted.

This Pellet heater is designed to burn pellet wood fuel only. Do not use any other type of fuel; doing so will void any warranties stated in this manual.

THE USE OF SOLID WOOD FUEL IS PROHIBTED BY LAW.

This Pellet heater is designed for residential installation according to current national and local building codes. It is also approved as a mobile home heater which is designed for connection to an outside combustion air source. When installing a Pellet Stove in a mobile home, it must be electrically grounded to the steel chassis of the home and bolted to the floor. Make sure that structural integrity of the home is maintained.

Make sure that structural integrity of the home is maintained when passing vent pipes through walls, ceilings and roofs

It is recommended that the exhaust vent be cleaned bi annually or after every two tons of pellets.

Soot or creosote may accumulate when the pellet heater is operated under incorrect conditions such as an extremely rich burn (black tipped lazy orange flames). Do not operate the stove if the flame becomes dark or sooty or if the burn pot overfills with pellets. Turn the stove off and call your dealer.

The grounded electrical cord must be connected to a standard 120 volt, 60 hertz electrical outlet. Ensure that the electrical cord is not trapped under the appliance and that it is clear of any hot surfaces or sharp edges.

The ash pan and viewing door must be locked securely for proper and safe operation.

DO NOT PLACE UNBURNED OR NEW PELLET FUEL IN THE ASH PAN. A fire in the ash pan may occur.

Do not operate your pellet heater if you smell smoke coming from it. Turn it off, monitor it and call your dealer. Repair and servicing of your U.S. Stove Pellet Burning Room Heater may only be done by a qualified technician. Disconnect the power cord before performing any maintenance or repair.

NOTE: Turning the Pellet Stove Room Heater to "off" does not disconnect power from the unit.

The Pellet Stove Room Heater will not operate during a power outage, if a power outage or tripped circuit occurs, check for smoke spillage and open windows or doors to ventilate as necessary.

SAFETY INFORMATION continued

Keep foreign objects out of the hopper.

Contact your local building officials to obtain a permit and information on any installation restrictions or inspection requirements in your area.

Be sure to notify your insurance company of your new U.S. Stove Pellet Burning Room Heater. Allow the Pellet Stove Room Heater to cool before performing any maintenance.

Ashes must be disposed of in a metal container with a tight lid and placed on a noncombustible surface well away from your home.

Check the venting system, at least twice a year, for creosote build up. Keep all door/lid seals and gaskets in good condition.

Adequate ventilation air is required to operate this heater. During operation the heater draws air for combustion which can be assisted by the installation of outside combustion air inlets. However, certain weather conditions such as icing or use of kitchen exhaust fans may impact and reduce the effectiveness of vents. It is important to note that room air starvation well negatively impact the operation of the heater.

If power outages with battery backup or room air starvation occurs during operation of heater, smoke in the house may result. This may trigger smoke detectors if they are installed.

CAUTION:

DO NOT CONNECT TO ANY AIR DISTRIBUTION DUCT OR SYSTEM.

DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE. NEVER USE GASOLINE, GASOLINE TYPE LANTERN FUEL, KEROSENE, CHARCOAL LIGHTER FLUID, OR SIMILAR LIQUIDS TO START OR FRESHEN UP A FIRE IN THE HEATER. KEEP ALL SUCH LIQUIDS WELL AWAY FROM THE HEATER WHILE IT IS IN USE. USING THESE CHEMICALS COULD CAUSE BODILY HARM, HEATER DAMAGE AND WILL VOID THE WARRANTY.

DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS SUCH AS GASOLINE, NAPHTHA OR ENGINE OIL.

HOT WHILE IN OPERATION. KEEP CHILDREN, CLOTHING AND FURNITURE AWAY FROM THE HEATER. CONTACT MAY CAUSE SKIN BURNS. YOUNG CHILDREN SHOULD BE SUPERVISED WHEN THEY ARE IN THE SAME ROOM AS THE STOVE.

DO NOT ATTEMPT TO OPERATE THE VENT TUBE CLEANER WHILE THE PELLET STOVE IS IN OPERATION OR COOLING DOWN; WAIT UNTIL PELLET STOVE HAS COOLED COMPLETELY BEFORE PERFORMING THIS PROCEDURE.

ENSURE THAT PEOPLE ARE AWARE THAT THE VENT TUBE CLEANER KNOB WILL BE VERY HOT DURING PELLET STOVE OPERATION AND CAN BE A BURN HAZARD.

OTHER RADIANT SURFACES OF THE STOVE WILL BE HOT DURING OPERATION AND CAN BE A BURN HAZARD.

	SPECIFICATIONS
Heating Specifications:
Burn Rate:	*43,900 btu’s per hour or 5.1 lbs. of fuel per hour
Hopper Capacity:	55 lbs.

*Dependent upon quality and heating value of pellet fuel.

DIMENSIONS

Figure 1

DIMENSIONS continued

The minimum installation dimensions, of the insert opening, are:

32” (813mm) wide x 22 3/4” (578mm) high x 12 1/4” (311mm) deep.

Figure 2

OPERATING INSTRUCTIONS

Check and Fill the Fuel Hopper with Pellets:

This Pellet Stove is available as a freestanding unit or as a fireplace insert. There is a different method for filling the hopper for each type of heater:

To check and fill the hopper of the freestanding heater, simply lift the hopper door, visually check the hopper and add pellets when needed.

To check and fill the hopper of the insert heater, pull hopper lid forward, visually check the hopper and add pellets when needed.

CAUTION: DO NOT OVERFILL THE PELLET FUEL HOPPER. AS A SAFETY PRECAUTION, AUGER WILL NOT OPERATE AT ANY TIME WHEN FUEL HOPPER DOOR IS OPEN.

Pre start Check up:

Make sure that all parts of the Pellet Stove Room Heater are cool before proceeding. Remove the burn pot and clean out any ash debris. Be sure to re install the burn pot in the correct position (see page 29).

The blowers and automatic fuel supply are controlled from a panel located on the right hand side of the stove.

Note: Your Pellet Stove may omit an odor as oil residue from the manufacturing process burns off and the high temperature paint cures. You can minimize this effect by running a smaller fire for the first few hours of operation. Avoid placing any items on the stove top during this period as the stove’s paint could be permanently damaged.

Lighting Instructions:

ATTENTION: Viewing door must be securely latched to ensure proper stove operation. Push door handle downward until latch is fully engaged; you will feel the latch engage and hear an audible click.

When first operating your Pellet Stove, depress the MODE button until the LED indicator above MANUAL lights up. This will engage MANUAL mode and provide you with full control of the heater’s control board functions and allow you to familiarize yourself with how the heater works. The heat level for T STAT mode can only be set when the control is in the Manual Mode.

Starting Up The Pellet Stove Room Heater:

Whenever Operating the Pellet Stove for First Time, or if The Stove Runs Out Of Pellets, it is Necessary to Prime the Auger with Pellet Fuel. To do this, Press and Hold the AUGER Button for Approximately 3 Seconds until the AUGER LED illuminates. This Procedure will prime the Auger and then Automatically Initiate the Normal Ignition Cycle.

CAUTION: Do not use this procedure for normal startup. To do so would cause excessive fuel build up in the burn pot.

For normal startup with pellets fuel in the auger, press and release the On/Off button. The LED indicator light above the On/Off button will alternately flash green then red to indicate that the start up cycle has begun. The light above the Auger button will flash intermittently to indicate the activation of the auger feeding the pellets into the burn pot. The electric igniter will also be activated at this time. The igniter takes a few minutes to come up to temperature in order to ignite the pellets in the burn pot. It will normally take between 4 minutes and 8 minutes for pellets to ignite.

NOTE: If pellets do not ignite within 12 minutes the heater will shut down, requiring you to turn on the heater and repeat the start up process.

OPERATING INSTRUCTIONS continued

When the pellets have ignited and flame has been established, the start up cycle will end; this procedure takes between 8 and 12 minutes. If the control is set to Manual Mode, it will now default to the heat level setting the last shutdown time. If the control is set to T STAT Mode the heat output will coincide to the commands from the thermostat.

Auger:

As explained in the starting up step, this button is only served to start up the pellet stove in lieu of the on/off button when there are no pellets in the auger.

Circulation Air Flow:

Your Pellet Stove Room Heater features circulation air flow which will change in accordance with the heat setting. Circulation air flow will be at its maximum setting when the heat setting is also at maximum and subsequently will be at its minimum setting when the heat setting is at minimum. If you desire to operate the circulation fan at its maximum setting regardless of heat setting, you may do so by pressing the FAN button.

Auger Trim:

When operating at Heat Level 1, if the flame goes out or the heat output is too high on the minimum heat level setting, use the AUGER TRIM button to make adjustments. See the AUGER TRIM button description on page 11.

Shutting Down Your Pellet Stove Room Heater:

Turn off the heater by pressing the On/Off button. The stove will enter the shutdown cycle and the pellets will stop feeding into the burn pot to allow the fuel in the burn pot to be combusted and consumed. During this period, the exhaust blower and circulation fan will continue to operate until the flames are out and the heater has cooled down. When the heater has cooled down to its pre set level, it will shut down completely.

CAUTION: NEVER TURN OFF THE HEATER BY UNPLUGGING OR DISCONNECTING ITS ELECTRICAL POWER SOURCE. DOING SO WILL CAUSE THE HEATER TO SKIP THE PROPER SHUTDOWN CYCLE, CAUSING THE HEATER TO OVERHEAT AND THE POSSIBLE RELEASE OF SMOKE INTO THE HOUSE.

Control Board Functions:

Figure 3

OPERATING INSTRUCTIONS continued

MODE Button: The MODE button allows you to switch operating mode on your Pellet Stove Room Heater. Depress the MODE button to switch between Manual and T STAT modes. As you depress the MODE button the indicator light above the desired mode will engage. When you engage the Manual mode, you will be able to manually select the heat settings. If you have installed a remote thermostat for your Pellet Stove Room Heater and wish to have the heater controlled by that thermostat, depress the MODE button to engage T STAT mode. The thermostat will control the heat output of the Heater alternating between the lowest heat level and the highest heat level that you have pre selected.

The T STAT mode provides the most even heat output, for better comfort, and to extend the life of the pellet fuel ignition system. Additionally, the constant flame serves as a warning for people and pets to keep away from the heater while it is in operation.

ON/OFF Button: The ON/OFF button is used to turn the heater on and off. Whenever there is power to the heater, the LED indicator light above the ON/OFF button will be solid red. If the heater is cold prior to start up, press and release the ON/OFF button. The LED light above the ON/OFF button will alternately flash red and green to indicate the startup cycle has started. Fuel pellets will start to feed into the burn pot and the pellet fuel ignition system will be activated. Flames in the burn pot will normally appear between 4 8

minutes, and once the flame has been established, the startup cycle will end, this takes between 8 12 minutes. At this point the LED indicator light above the ON/OFF button will glow solid green. The user will now be able to make heat level adjustments.

HEAT LEVEL Button: Depress the HEAT LEVEL button to advance the heat level by one level until you reach the maximum setting; from the maximum level you will decrease one level each time you depress the HEAT LEVEL button. The circulation fan speed will also increase with the heat level setting. Wait until the startup cycle is complete and the ON/OFF LED is solid green to set Heat Level. (The HEAT LEVEL LEDs are also used as codes to indicate a malfunction, please refer to the Safety Features and warning codes section for more information.)

FAN Button: Depressing the FAN button will set the circulation fan speed to high, overriding the automatic fan speed control. The onboard logic will modulate the fan speed in accordance with the heat level setting. It is recommended that you allow the control to automatically set and adjust the speed of the fan to obtain optimum efficiency and minimal fan noise.

AUGER Button: Whenever Operating the Pellet Stove for First Time, or if The Stove Runs Out Of Pellets, it is Necessary to Prime the Auger with Pellet Fuel. To do this, Press and Hold the AUGER Button for Approximately 3 Seconds until the AUGER LED illuminates. This Procedure will prime the Auger and then Automatically Initiate the Normal Ignition Cycle. NOTICE: Do not use this procedure for normal startup. To do so would cause excessive fuel build up in the burn pot.

AUGER TRIM Button: This Button is only enabled when operating at Heat Level 1. Depress the AUGER TRIM Button to change the Auger feed rate on the minimum heat level; to account for the quality of pellet fuel being used. Increasing

OPERATING INSTRUCTIONS continued

the Auger feed rate will help keep the flames from extinguishing on the minimum heat level setting. You can also use the AUGER TRIM button to lower heat output on the minimum heat level setting:

Depress and release the AUGER TRIM button until the heat level 1 and 5 setting lights appear to slightly increase the feed rate on the minimum heat level.

Depress and release the AUGER TRIM button until the heat level 1 and 4 setting lights appear to slightly reduce the pellet feed rate on the minimum heat level setting. Use this setting to reduce the heat level output on low.

Depress and release the AUGER TRIM button until only the heat level 1 setting light is on, this is the factory setting and works for most types of fuel.

Open Door: During normal operation the heater will automatically shut off if the viewing door is opened for more than 30 seconds. This action causes the heater to go into vacuum error mode. To clear this error and restart the heater, close the door, depress the ON/OFF button and then follow directions for restarting heater.

Refilling the Fuel Hopper: For maximum performance do not let the pellet fuel hopper drop below 1/4 full.

Fuel Hopper Lid Safety Switch: When the Fuel Hopper Lid is opened the auger will stop turning to prevent accidental injury.

KEEP PELLET FUEL HOPPER LID CLOSED AT ALL TIMES EXCEPT WHEN REFILLING. DO NOT OVERFILL HOPPER.

Safety Features and warning code:

1.Your heater is equipped with a temperature “high limit” switch, designed to shutdown the auger in case of an over temperature situation. The high limit switch is a thermo snap disc type and must be manually reset in the event of an overheat shutdown. Once the heater has cooled down, you can reactivate the high limit switch by depressing the manual reset button located on the high limit switch.

2.When the High Limit switch opens, which indicates an overheat failure, the HEAT LEVEL LED’s 3 & 4 will flash red.

3.Your heater is equipped with a vacuum switch that automatically shuts down the auger in the event of a exhaust fan malfunction.

4.When a Vacuum Error is sensed, the HEAT LEVEL LED’s 1 & 2 will flash red. Check to ensure the glass door is latched properly.

5.When the Low Limit switch opens, (fire went out) the HEAT LEVEL LED’s 4 & 5 will flash red. First check fuel supply, then check to ensure Auger is not jammed and finally that pellet hopper door is properly closed.

6.When the Pellets in the Burn Pot fail to ignite HEAT LEVEL LED’s 1 & 5 will flash red.

NOTE: In the event that the high limit switch or vacuum switch activates, please contact your dealer to discuss the cause of this activation and to ensure that your heater continues to operate in a safe manner. Either switch tripping can indicate a problem with the operation of your heater.

THERMOSTAT INSTALLATION

Optional thermostats are available for use with your pellet stove. A thermostat can help you maintain a constant room temperature. The thermostat option will require the installation of a millivolt type thermostat.

NOTE: Your thermostat should be installed by an authorized dealer or service person.

Installation of Remote Thermostat:

Disconnect Pellet Stove Room Heater unit from power supply.

Open right side panel to gain access to rear of control panel.

Strip insulation from thermostat wires and connect to the screw terminal on the rear of the control panel (see Figure 4).

If you have installed a remote thermostat for your pellet stove and wish to have the heater controlled by that thermostat, depress the MODE button to engage T STAT mode. The thermostat will control the heat output of the heater alternating between the lowest heat level and the highest heat level that you have pre selected.

Left: GND

Middle: Thermostat

Right: 5V power source

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