Earth Klear Sky 400 Owner's Manual

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Klear Sky 400

P.O. Box 310

Mountain Grove, MO 65711

417-746-0043

www.EarthOutdoor.com

LETTER FROM EARTH O

UTDOOR

Thank You for purchasing an Earth Outdoor Wood Furnace!

We know how exciting this moment is. You may have looked forward to having an

outdoor furnace for days, weeks or years. Our staff has worked hard to provide you

with a quality product that you should enjoy for many years. Please take time to read

over t

he information in this manual and follow the recommendations contained in it to

have the joy of operating your furnace for years to come.

installation will

void warranties. Always follow

local

regulations and code requirements. Please

when installing the furnace or systems associated with your furnace.

We take pride in providing a quality product and friendly service.

Thank you for your business!!!

WOOD FURNACES:

Improper use and/or

state laws or regulations along with

seek the help of qualified craftsmen

FURNACE S

PECIFICATIONS



Make sure you read this manual and follow the recommendations contained in it to have the joy

of operating your furnace for years to come.

warranties.

Always follow

requirements. Please

seek the help of qualified craftsmen when installing the furnace or systems

associated with your furn

ace.Do not operate this equipment for other than its intended purpose nor other than in accordance

with the instructions contained in this manual and all other instructions accompanying the furn

Do not modify the furnace in any manner! Any modifica

manufacturer will void warranty.



Failure to treat water properly will void your warranty.

test for the 1st7 years.

 For furnace

covered by this instruction book, it is important to observe

protect yourself from any



Observe all safety stickers on the furnace.



This furnace must be wired

Electric Codes and must have a power ground.



Never use any type of petroleum product, petroleum based product, charcoal starter, lighter fluid,

lantern fuel, kerosene or any other flammab

KEEP ALL SUCH LIQUIDS WELL AWAY FROM FURNACE WHEN IN USE



Keep antifreeze, which is flammable, well away from the furnace. Use only non

in the unit. Test antifreeze and other chemicals annually.

 The

use of treated wood (painted, treated, etc

toxic

gases into the environment and may be corrosive toward th

are

NOT ALLOWED and

 DO NOT BURN AN

Y OF THE FOLLOWING:

NAPTHA, HOUSEHOLD GARBAGE, ANY MATERIALS TREATED WITH PETROLEUM

PRODUCTS (i.e.

PARTICLE BOARD, RAILROAD TIES, & PRESSURE TREATED WOOD)

LEAVES OR YARD WASTE, PAPER PRODUCTS,

ETC), OR

CARDBOARD IN THE FURNACE.

designed to

burn seasoned

the life of the furnace and will void your warranty.

 Open-loading door –

when opening the door, pause momentarily between the first latch and the

safety latch to allow any combustion gases to burn off.



Earth Manufacturing strongly recommends using a spark arrestor with your furnace.

SAFETY PRECAUTIONS

WARNING!

Improper use and/or installation may void

state laws or regulations along with local

regulations and code

tion without express written consent of

Earth Manufacturing pays for

all

possible injury. Among the many considerations, you are advised to:

by a qualified electrician in accordance with local and/o

le accelerant to start your furnace.

) and any other salvaged material that can emit

e components of the appliance

eliminate the rights of the warranty.

TRASH, PLASTICS, GASOLINE, RUBBER,

DIMENSIONAL LUMBER (i.e.

In most areas, this is illegal. The furnace is

, dry cordwood only. Burning non-approved

materials can reduce

ace.

the water

safety precautions to

r National

-toxic antifreeze

PALLETTS,

materials can reduce

 Always latch the doors securely. If the fire box door is open for any extended amount of time

past the normal loading period, it will cause over-firing of the unit and result in the overheating of the unit. This will cause damage to the electrical equipment and will result in causing the unit to boil over. Always remember to keep your hinges oiled.

 Always use proper care when installing, operating and maintaining the furnace.  Always wear protective gloves and glasses and be aware that loose or hanging clothing can

catch fire!

 Be careful when loading wood into the furnace. Surface areas inside the furnace are hot.

Creosote build up in the furnace can ignite suddenly or cause burns if dripped onto the skin.

 Do not modify the furnace. Do not substitute repairs that can be provided by your dealer,

distributor or manufacturing company. Any such action will void your warranty.

 Do not operate under pressure. This is a non-pressurized system. Addition of valves or plugs

to the system that would cause pressure will void your warranty.

 Keep the overflow tube clean and free of debris, bugs, etc. DO NOT close it off! The tube is

meant to steam if necessary and allow for pressure release.

 Failure to heed these warnings or any additional warnings on the furnace may result in an

accident causing personal injury and damage.

 !! CALL LOCAL UTILITIES BEFORE YOU DIG THE TRENCH!!  Disposal of ashes:

ASHES SHOULD BE PLACED IN A METAL CONTAINER WITH A TIGHT-FITTING LID. THE CLOSED CONTAINER OF ASHED SHOULD BE PLACED ON A NON-COMPUSTIBLE FLOOR

OR ON THE GROUND. ALL COMBUSTIBLE MATERIALS SHOULD BE DISPOSED OF BY BURIAL IN SOIL OR OTHERWISE DISPERSED. ASHES SHOULD BE RETAINED IN THE CLOSED CONTAINER UNTIL ALL CINDERS HAVE THOROUGHLY COOLED.

 Installation, to include wiring and plumbing, and operation must follow Federal, Provincial, State

and Local Codes, electrical, plumbing, fire and building codes.

 The Earth furnace is intended to be the primary source of heat. However, a back-up system

should always be in place and ready for use.

 A back-up generator is HIGHLY recommended so that you can have heat during power outages!

The standard pump and fan draw 120 watts together. The furnace can draw 1350 watts or more on start-up. A small 2000 watt generator will power it all and give you extra power for lights.

 The manufacturer is not liable for damages or property in the case of misuse, improper installation

of equipment or for knowing state or local installation codes. Product owner assumes all responsibility for this. This document is a general manual to aid in installation. We cannot

know all applicable codes in your area!

 Improper use or failure to maintain the outdoor furnace unit may cause nuisance conditions.

Persons operating this outdoor furnace are responsible for operation of the unit so as not to cause a public or private nuisance condition. The manufacturer’s distance and stack height recommendations and the requirements in any applicable laws or other requirements may not

always be adequate to prevent nuisance conditions due to terrain or other factors.

 Remember to give the furnace a “Once Over” regularly.

o “Once” a day check the water level o “Once” a week clean the ashes out (or often if needed) o “Once” a month clean the chimney

Specifications for the Klear Sky Model EPA Phase II Qualified

 Manufacturer: Earth Manufacturing, LLC  Model #Klear Sky 400

 Maximum Output Rating: 70,770 BTU’s/HR  16%-24% Load Capacity: 11,323 to 16,985 BTU’s/HR  25%-50% Load Capacity: 17,683 to 35,385 BTU’s/HR  8-Hr. Output Rating: 45,786 BTU’s/HR.

 8-Hr. Average Efficiency: 62% (Higher Heating Value)

67% (Lower Heating Value)

 Annual Efficiency Rating: 47% (Higher Heating Value)

50% (Lower Heating Value)

 Particle Emissions: 2.41 GRAMS/HR

0.29 LBS/Million BTU Output

GETTING TO KNOW YOUR FURNACE

COMMON QUESTIONS

IS IT SAFE?

Having the furnace outside eliminates the possibility of causing a fire in your home. The furnace is a

non-pressurized system which eliminates any chance of explosion associated with pressurized

furnaces. Also the oversize door makes loading easier.

WHAT CAN I SIT THE FURNACE ON?

A 4 to 6 inch concrete pad is recommended, whether preformed or poured.

HOW FAR AWAY CAN IT BE?

Earth Outdoor Wood Furnaces can be set from 30 to 300 feet away from your home. There are a

few things to keep in mind: 1. The ease of access for digging lines to your house from the furnace 2.

How you will get wood to your furnace 3. How far you want to go when needing to fill the furnace with

wood. 4. Check with your insurance company to make sure you are in compliance with your policy.

Normally you should visit your wood furnace twice a day to check the fire and fill with wood. You will

want to have easy access to this location with a truck or tractor to replenish the wood when needed.

HOW MUCH WOOD WILL I USE?

That depends on your home, insulation and the quality of wood you're burning. This might help:

heating a 2,500 sq ft well-insulated home and a 60 gallon water tank with good wood could take

about 5 to 7 cords per cold season (6 months). The cost of a cord of wood these days is about

$120. You can see the savings of owning an Earth Furnace. That is $600 to $840 a year to heat

your home naturally with renewable energy. What did you spend last year?

WHAT DO I DO WHEN I GO AWAY FOR A COUPLE DAYS?

This is a common question. You have several options depending on your situation.

If your wood furnace is hooked up correctly, leave your pump on, your existing indoor furnace will

back heat the wood furnace preventing it from freezing. The cost of your indoor furnace back heating

your outdoor is very minimum cost if everything is very well insulated.

Here are a few more options for you:

You can set up your unit with a bypass to not heat the home and circulate the water

within itself and the burn time will be much longer--4 to 5 days.

If the weather isn't really cold the circulation pump is moving the water quite quickly.

Moving water is hard to freeze.

Maybe a friend or family member could help and feed the unit while you’re away.

You could look into special anti freeze. Keep in mind most anti freeze is terrible to our

environment and costly.

You can let the fire die down and drain the furnace. It only takes about 10-20 minutes to

drain the unit. When you return simply refill the unit and relight the fire.

"If there is a will there is away!"

WHAT IF THE ELECTRICITY GOES OUT?

The Earth Outdoor Wood Furnace uses very little electricity which can be supported by a small

generator. You can run a regular inexpensive extension cord to the unit and unplug the furnace from

the outlet on the back of the furnace and plug into a small generator. Problem solved. However, when

most homes lose electricity they have no way to power the indoor blower for their duct work. Either

way you will need something to back up your existing home as well as the wood furnace. Another

option would be to use an extension cord on a box style fan and place the fan so that it would blow

into the return vent of your duct work. Then close off the vents to rooms you can afford to let go

cold. Otherwise you will need to look into a system that will power your indoor blower. Consult

electrical contractors for most of that type of work.

FURNACE OVERVIEW –

The overflow port is where you will see water

water expands when heated,

when firing it up.

The manual fill valve: A quarter turn valve used to fill the water tank of the furnace.

3. The light s

witch and light are all pre

that can be used in all weather conditions. The light is a 150 watt halogen light for illuminating

the area around the

front of the furnace

4. 25”x25”

door with double latch safety an

Heating tube chamber doors located in the front and rear of the unit. To open, release the

latches and fold down for easy cleaning and maintenance.

Catalyst access chamber door located in the rear of the un

maintain your catalyst.

7. The automatic

variable speed

as in the rear chamber of the unit

control panel and is

thermostat

factory pre-

set temperature.

RONT

standing

when the furnace is full. Note that cold

therefore water will come out of the overflow

-wired at the factory. The

light is a weather guard switch

d heat shield.

it allows for easy access to clean and

forced air fan/damper system is

located on the

on all Klear sky

models. It is activated by the digital

ically controlled by factory settings

to kick on and off at the

from heat expansion

wood door as well

Klear Sky

HOW DOES IT WORK?

The fire chamber is completely immersed in a jacket of water (except for the front of the furnace at

the fill door). When a fire is built it heats the water and a pump takes the hot water to the house.

Inside the house you have some kind of heat transfer appliance; this can be a heat exchanger that

fits into your duct work, baseboard style heaters, or a radiant floor heating system. The water can

then be returned to the furnace for reheating. The hot water from the furnace can also be sent to a

special heat exchanger to heat your domestic hot water or copper coils of some type may have been

installed in your furnace depending on what options you had ordered with your furnace.

INSTALLATION

It is important that you have the furnace installed by a qualified installer. Earth Outdoor Wood

Furnaces will not be held responsible for complications due to improper installation and in some

cases the warranty may be voided due to improper installation and start up.

There can be many variations in proper installation. Here are some general guidelines to follow.

Setting the Furnace

Depending on your application and site conditions, you may choose a pre-poured pad or you may

choose to pour a concrete pad. Pad size will depend on customer preference. The smallest pad

recommended for the Klear Sky 400 should be no smaller than 4 ½ feet by 5 ½ feet. You may

choose to pour a larger one based on your own situation and preference.

Underground Line

When digging the trench, it is best to dig below the frost line. You will normally need two 1” lines for

the supply and return of the furnace water, one 1/2” line for the furnace fill line, and an electrical line

to power the furnace. Some installations may require more lines check with a qualified installer or

ask our customer service department to help.

Setting up the system

It is best if this system is set up in a continuous loop going from one appliance to another. Parallel

systems with tees will rarely work or will be inefficient in their movement of water.

There are a number of options and ideas on the set up of the whole furnace system. Consult some

one with experience to design a system that will work for you.

STARTING UP THE FURNACE

Make sure all the valves on the back of the furnace are closed and that the power is off.

Begin filling the furnace with water. Turn the manual fill valve on the front of the furnace to allow

water to flow into the furnace tank. You can work on other things while it is filling. Once the water

starts to flow out of the over flow, shut off the water with the manual fill valve.

Double check that all the fittings and connections throughout the system have been tightened or

secured. Then open the valve going to the pump and from the furnace. If you have a way to bleed

the air out of the system then open the bleed valve and turn the power on.

(With a normal set up,

the pump coming out of an upper port and returning to a lower port, all you have to do is open the

ball valve on the top side of the pump and then open the drain valve on the lower port. The pump

has enough pressure to push air out of the lines, however, if you get water in the return lines prior to

pumping water from the furnace your line will become air locked and that will require special help

from another water source to fix.)

Once the pump has started pushing water through the lines, check the various connections

throughout the system to verify they are all good and you have no leaks. After the system has been

purged of air, close the bleeder valve and open the ball valve to the furnace on the return port.

Now it is time to start a fire. It is recommended that you check all the lines prior to starting a fire in

case you have a problem that needs to be repaired. It is easier to repair the lines while they are cold

than when you have hot water flowing through them. When first starting up the furnace, build a

manageable fire to get the water up to temperature. We recommend using a 40 lb. bag of natural

charcoal and propane torch to initially start the fire. Wait 15 to 20 minutes for a bed of coals to form,

and slowly add your seasoned cordwood as it burns, loading/stacking the wood towards the front of

the unit, and never stacking it over ¾ high as this would restrict air flow. Cordwood should be

approximately 22 inches in length. Anything longer will hinder air flow. Once the water has gotten to

your desired temperature setting then you can add wood to start normal operations. Water will come

out of the overflow as it expands.

MAINTENANCE

The front wood door has two “U” bolts that are adjustable. If you feel the door is not closing tightly or

may be too tight, loosen the bolts with the door open and tighten or loosen the bolts as necessary.

It is important that the water is checked daily, especially after the first start up. We also require that

you have your water tested to maintain proper ph and necessary chemicals for your water conditions.

At the end of the season it is important to have all necessary chemical in the water if you will be

leaving the furnace full of water over the summer. Earth will pay for the water test for the 1st7 years

of ownership.

You should clean your ashes out at least once a week, and as needed. The ash and coal bed should

be no higher than the bottom of the unit’s door as it will interfere with the blower and airflow. A flat

shovel works well for this job. We recommend using a metal container of some kind to put the ashes

in when removing them. Rake coals to the back of the furnace, remove the ashes, and then rake

coals back towards the front of the unit. At the end of the season, be sure to completely clean the

ash box. Ashes combined with moisture are very corrosive and can eat through metal. Ash or coal

corrosion is NOT covered under warranty.

You may use a chimney cap with the furnace to keep rain out. It is recommended that you at least

cover the chimney during the summer months when the furnace is not in use to keep rain, birds and

other insects from getting in the furnace.

The light, pump, and blower can all be visually inspected and should only need replacing when they

quit working. They should last for several years however conditions are different at every site and

longevity may vary based on your climate and maintenance.

Periodically check that the combustion blower tube, flame baffle, and chimney are not restricted by

debris (creosote, ash, etc.), and that door seal provides air-tight seal when shut to ensure proper use

of air controls.

TROUBLE SHOOTING

SQUEALING PUMP

On initial start up if the pump is not primed with water it may squeal and can burn your pump out.

Make sure the ball valve to the pump is open and the water tank is full.

On occasion the pump may get a piece of debris in the impellers from the installation process. Shut

the ball valves off and remove the pump. Take a clean garden hose and spray water through the

impeller housing to wash out any debris. Then replace the pump and start it back up.

CAN I OPERATE THE FURNACE WITH DOOR OPEN

It is not recommended that you operate the furnace for very long with the door open. This will cause

your furnace to over heat.

WATER IS NOT GETTING HOT

Several things may contribute to this problem.

Check that the fire is getting enough air. Make sure there is not obstruction in the chimney or

in front of the blower hole.

Ashes may be built up too much in the fire chamber. Before you stoke the fire make sure you

take a shovel or some device and rake the coals towards the middle of the furnace. Ash build up

around the edges work to insulate the fire box from the fire and do not let it heat like it was designed

to.

You may be burning too much green wood. It takes a large amount of Btu’s to burn/boil off

the water in a green log. This makes the fire burn cooler than when you use seasoned wood.

Your water lines may not be insulated enough. If you have exposed lines, or lines that run through

uncontrolled environments you may look into insulating them or putting more insulation on them.

Insulation is key to your performance.

Your blower in the house will drop the water temperature as much as 20 degrees. If the

temperature of the furnace water is not above 150, it makes it real hard to recover temperature loss

when the blower is on. Try turning the blower off and work with the fire to recover heat in the water.

LINES NOT GETTING HOT BUT WATER IS HOT

The water is not moving to the house or through the house.

Make sure the return ball valve is open at the furnace and that all valves are open through

the house.

If you have a multi-speed pump try increasing the speed.

It could be that you have an air bubble stuck in the lines somewhere. Turn the pump off and

loosen the bottom flange bolts until water will run out. Shut off the ball valves to the pump and on the

return into the furnace. Take a garden hose from a house faucet to the furnace. Steal a washing

machine hose from inside the house and use it to hook to the furnace drain and the garden hose.

Turn the water on at the house and open the drain. This will allow water from the hose to move the

entire system and purge any air bubbles. It will also cause the water to spray from the bottom flange

of the pump and you get wet if not careful. Allow this to run for approx two minutes (time can be

based on length of run to the house and back). Shut the water off and close the drain. Tighten the

flange and open all valves.

LINES NOT GETTING HOT THROUGHOUT ENTIRE SYSTEM

If you have put a tee into the system then water may not be flowing through one of the appliances.

You may have to re-plumb the system so that there is a continuous loop from the furnace to the

house and back.

The pump may have reached its operating capacity. Try increasing the speed of a multi-speed pump

or getting a bigger pump.

HOT WATER HEATER SIDEARM NOT HEATING

The sidearm could be air locked or not plumbed properly. Find a way to bleed any air out of the

domestic side of the system at the highest point.

Please refer to your Klear Stak Model 150 Series Installation and User Guide

for electrical guidelines and instructions.

Earth Outdoor Wood Furnaces™

WARRANTY INFORMATION

1. “Earth” Furnaces have a 10 year limited warranty.

2. This warranty is on, and covers the furnace only, NOT FANS, THERMOSTATS, PUMP, ETC. OR ANY

PRODUCT OR WORK YOUR INSTALLER DOES OR SUPPLIES.

3. The electrical components like the thermostat, fan, pump, have their manufacturer’s warranty

(usually 1 year).

4. Doors, grates & damper have a one year warranty.

5. We have a 5 year warranty against any leaks which covers parts and labor. If we cannot repair the

leak, we will send you a new furnace! ٭ With the industry’s heaviest fire wall (1/2 inch) we are not

afraid of rust or burn out.

6. Years 5-10 are pro-rated as follows for coverage of parts & labor*: Year 5 – 50%

Year 6 – 45% Year 7 – 40% Year 8 – 35% Year 9 – 30% Year 10 – 25%

7. The cost of a service call is not covered after 5 years. (Service calls for installation related

problems and not problems with the furnace itself will be charged to the owner)

8. The life of your furnace depends upon proper maintenance. You must submit a water sample to

Wood Boiler Solutions, LLC for professional lab analysis. You must follow their recommendations for

chemicals and brands. Earth Outdoor Wood Furnaces will provide the test kit for the 1st7 years. You

may purchase the “water sample analysis kit” from their store at

www.diswebsites.com/woodboilersolutions/store.cfm or call them at 920-382-6498. Failure to do

so will void your warranty.

When the kit arrives, take a sample according to the easy to follow directions, package it up and mail

it back (postage not included). They will forward the test results to Earth Outdoor Wood Furnaces.

9. All furnaces must be treated with “Water Treatment 101” rust inhibitor. This can be purchased

through Earth Outdoor Wood Furnaces.

10. You must Power Ground your furnace. Failure to do so will void your warranty.

11. Warranty is non-transferable.

* We will give you the percentage discount on the repair or off a replacement furnace. Furnace will be repaired or replaced, whichever is less expensive. Shipping not included. No cash or surrender value.

12. This Warranty will be voided by operating this residential wood furnace/hydronic heater in a

manner inconsistent with this owner’s manual.

Earth Outdoor Wood Furnaces™

WARRANTY EXCLUSIONS

1) Burning any material of any kind other than regular non-treated wood.

2) Any modifications or changes to the unit

3) Lack of maintenance including:

i) Failure to clean out ashes, failure to clean the ash pan & fire box after season.

ii) Allowing moisture to remain in the fire box & ash area off-season.

4) Faulty installation or connection.

5) Not testing and treating your water for recommended chemical treatment, & rust inhibitor.

6) Disasters, such as wind storms, fires, etc.

7) Failure to properly power ground furnace.

8) Insufficient and/or excessive draft

9) Consumption that exceeds use limits

10) Transportation and/or packaging costs

11) Warped doors or grates

12) If your furnace has a failure in the sheet steel that is not in conjunction with a weld, it will NOT be

warranted. (i.e. split door frame, water jacket, etc)

13) Damage to the thermostat due to over-heating from intensive and non-approved use (such as

ash door left open, or the fan left off during high fires)

14) Failure of the water pump resulting in an over heating of the furnace

15) Misuse or incorrect use

16) Insufficient or inadequate relation between the nominal power of the equipment and the heat

requirements of the premise

17) Failure to return the warranty sheet information form within 60 days

18) Consequential or incidental damage, such as loss of anti-freeze and/or water treatment

19) Transportation and installation.

20)Deterioration due to non-use of the unit.

21) All and any costs not previously agreed to and accepted by Earth Outdoor Wood Furnaces.

22)Warranty starts on date of delivery, and is contingent upon receipt of full payment, copy and

verification of water sample directives within 60 days of purchase

HELPFUL TIPS AND LINKS VIA EPA

 How to Use a Moisture Meter Video- http://www.youtube.com/watch?v=jM2WGgRcnm0

EPA offers tips on how to properly use a moisture meter to test firewood before using in a wood-

burning stove or fireplace. Wet wood can create excessive smoke which is wasted fuel.

 Split, Stack, Cover and Store Video- http://www.youtube.com/watch?v=yo1--Zrh11s

EPA offers four simple steps to properly dry firewood before using in a wood-burning stove or

fireplace. Wet wood can create excessive smoke which is wasted fuel. Burning dry, seasoned

firewood with a moisture content of 20% or less can save money and help reduce harmful air

pollution.

 Wet Wood is a Waste brochure-

http://www.epa.gov/burnwise/pdfs/wetwoodwastebrochure.pdf

This tri-fold brochure provides colorful illustrations of the four easy steps to dry firewood.

 EPA’s Burnwise Program- http://www.epa.gov/burnwise

ARRANTY

Fill in the following information and mail a

Owner Name: ______________________________

Address: __________________________

________________________

Phone Number: _______________

E-

mail: ___________________________________

Earth Model: ______________________

Serial Number: _______________

Dat

e of Purchase: ____________

Date of Installation: _____________

Installer: ___________________

Purchased from: _______________

Please keep this man

ual with all other important papers. The information in this manual is necessary

for the installation, operation and proper use of this furnace. If you should ever have a problem or

question please refer to this manual or have it available when you call.

Note:

Wood Boiler Solutions will forward the copy of your water analysis to Earth Outdoor Wood

Furnaces.

DOCUMENTATION F

ORM

copy

within 60 days of purchase.

Earth Outdoor Wood Furnaces

P.O. Box 310

Mountain Grove, MO 65711

417-746-0043

_____________

_____________________

_______________________

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Model 150 Series

Catalytic Gasification

Control Systems

for

Installation &

User

Guide

Patents Pending Updated 4 December 2013

ClearStak Model 150

User Guide

Introduction

Thank you for choosing an Earth Outdoor Klear Sky 400, complete with ClearStak. You have joined a growing group of customers that are leading the industry in improved efficiency and clean burning.

Intended Use

Earth Outdoor The Earth Outdoor model 150 is integrated by Earth

Outdoor into your Klear Sky. It is recommended that the installation be at the customer location by a licensed and trained professional.

Catalytic Gasification Control System (CGCS)

The CGCS is a balanced system designed for your Earth Outdoor furnace that manages fire exhaust temperature, water temperature, and

the fuel to air mixture to provide the highest level of efficiency and safety for our customers. The computer that manages this

system is the Intelligent

Biomass Controller (IBC).

Model 150 Intelligent Biomass Controller

(IBC-3.1)

The IBC measures inputs from sensors such as the temperature of the water, the temperature of the catalyst stack, and the oxygen levels of the furnace exhaust. The IBC uses these inputs to manage the two blowers and dampers located on the front door and back panel on your furnace. The IBC manages the activation temperature of the catalyst It

is able to turn off the heater when the catalyst reaches the activation

temperature, or when the furnace is not calling for heat. The IBC also provides diagnostics to assist the professional during installation and troubleshooting. The IBC is intended to be mounted on the exterior surface of the Earth Outdoor furnace on the back of the furnace near the electrical service.

The Catalyst and Catalyst Pre-heater

The catalyst pre-heater is used to activate the catalyst to a temperature of approximately 510°F. The IBC uses a thermocouple in the PCD to ensure that the catalyst has been preheated to the activation temperature before the blower on the front door of your Earth Outdoor furnace is powered. The catalyst should reach activation in one to five minutes or less during each heating cycle.

The catalyst is a stainless steel ribbon coated in precious metals that causes a chemical reaction. When smoke and oxygen pass through a heated catalyst the smoke ignites, reducing the amount of particulates and harmful gasses released into the atmosphere. This second burn of the smoke reduces your furnace emissions while producing temperatures in the range of 1000F to 1400F. This heat is captured in the Emission Energy Transfer Chamber and transferred to the furnace water, which provides a high level of efficiency in the burning of woody biomass.

Table of Contents

INTRODUCT ION) 2!

INTENDED)USE) 2!

CATALYTIC!GASIFICATION!CONTROL!SYSTEM!(CGCS)! 2! MODEL!150!INTELLIGENT!BIOMASS!CONTROLLER! 2! THE!CATALYST!AND!CATALYST!PRE<HEATER! 3!

POLLUTION)CONTROL)DEVICE)INSTALLATION) 8!

PCD)ASSEMBLY) 8! PCD)MOUNTING)LOCATION) 9! PCD)MOUNTING)REQUIREM ENTS) 9! PCD)P

ROTECTIVE)EARTHING

) 9! PCD)WIRING)REQUIREMENTS) 10! PCD)EXTERNAL)WIRING)REQUIREMENTS)FOR)SWITCHES)AND)BREAKERS10! PCD)VENTILATION)REQUIREMENTS) 10! PCD)V

OLTAGE)AND)CURRENT)MEASUREMENT

) 10!

MODEL)150)INTELLIGENT)BIO@FUEL)CONTROLLER) INSTALLATIO N ) 11!

IBC$3.1)I

NSTALLATION

) 11!

IBC@3.1)ASSEMBLY) 11! IBC@3.1)M

OUNTING)LOCATION

) 11!

IBC@3.1)MOUNTING)REQUIREMENTS) 11! IBC@3.1)P

ROTECTIVE)EARTHING

) 11! IBC@3.1)TO)EXTERNAL)LOW)VOLTAGE)SENSOR)CONNECTIONS) 12! MODEL)150)WIRING)REQUIREMENTS) 12! IBC@3.1)EXTERNAL)WIRING)REQUIREMENTS)FOR)SWITCHES) AND) BREAKERS) 13! IBC@3.1)VENTILATION)REQUIREMENTS) 13! IBC@3.1)VOLTAGE)AND)CURRENT)MEASUREMENT) 13!

DISPLAYS) 14!

LED)DIGITAL)DIS P LA Y ) 14! OPTIONAL)LED)DIGITAL)AN D )ANALOG)DISPLAY) 14! MODEL)150)INTELLIGENT)BIO@FUEL)CONTROLLER) 14!

IBC@3.1)OVERVIEW)AND)TECHNICAL)SPECIFICATION) 16!

IBC@3.1)OVERVIEW) 16! IBC@3.1)COMPONENTS) 17! IBC@3.1) LOW) VOLTAGE) POWER) AND) INPUT) CIRCU IT ) SECTION) 17! IBC@3.1)M

ICROCONTROLLER) AND)COMMUNICATION)CIRCUIT)DETAIL

) 18! IBC)A

NALOG)INPUT)AND)SIGNAL)CONDITIONING)CIRCUIT)SECTION

)18! HIGH)VOLTAGE)POWER)AND)OUTPUT)CIRCUIT)SECTION) 18! FIRMWARE) 18!

PCD)AND)IBC)MAINTENANCE) 19!

REVENTATIVE

) 19! VISUAL)INSPECTION) 20! TESTS) 20! IBC@3.1)LOW)POST@CATALYST)OXYGEN)L EV EL)F EA TURE) 22!

INTEGRATED )SAFETY)FEATURES) 22!

LED)I

NDICATOR)ERROR)CADENCES

) 23!

TECHNICIAN)TROUBLESHOOTING) 27!

LOCKOUT/STANDBY) 27! TRIPPED)FUSE) 27! NO)P

OWER)TO)THE)BOARD

) 27!

CATALYST)BACK)PRESSURE) 28!

BALANCED)SYSTEM)PERFORMANCE) 28!

WARNING)STATEM ENT)AND)WARNING )SYMBOLS) 28!

EST)BURN)PROCEDURE

) 29!

MANUFACTURER’S) LIMITED) WARRANTY

) 34!

)

Pollution Control Device Insta l l at i on

PCD Assembly

The PCD located inside of the exhaust chamber of this Earth Outdoor unit. Before opening any panel or cover of the PCD, disconnect the power to the furnace. When opening the panel on the back of the furnace, please examine the PCD to make sure all components are present and in working order. Please refer to Figure 1. as the reference image for the assembly of the heater power cable. Figure 2. illustrates the connection of

the thermocouple. Please note that ONLY high temperature wire and ring terminals should be used for wiring in the stack enclosure of the PCD.

Figure 1. Illustrates the connection of the heater to the PCD. The ground wire is terminated inside the aluminum enclosure. The Earth furnace should be grounded

as described in the protective earthing se ction. The black and white wires are each connected to the heater terminal inside the aluminum enclosure.

Figure 2. Illustrates the connection of the thermocouple wire and

plug. The yellow wire is the positive connection and the red wire is the negative connection.

PCD Mounting Location

For the best operating performance, the IBC is mounted close to the firebox of

the Earth Outdoor furnace and before the heat exchanger. This provides the best performance by using the heat from

the firebox to reduce

the need for the catalyst pre-heater

and allows the Earth

Outdoor heat exchanger to remove heat

from the burning

of the exhaust to improve efficiency.

PCD Mounting Requirements

The IBC is available in several sizes that are balanced for each model of Earth Outdoor. Proper installation requires that the catalyst match the mounting

bracket that is inside the furnace drawer. If the IBC inside bracket and catalyst do not exactly match, please contact

the factory

immediately. Replacement of your existing catalyst may

be necessary for proper installation.

PCD Protective Earthing

A Protective Earth, known as an equipment grounding conductor in the US National Electrical Code, avoids an electrical

hazard by keeping the exposed conductive surfaces of the furnace and PCD at earth potential. To avoid possible voltage drop, no current is allowed to flow in this conductor under normal circumstances. Fault currents

will usually trip or blow the fuse or circuit breaker,

protecting

the circuit. A high impedance line-to-ground

fault insufficient

to trip the over current protection may still

trip a residual cur

rent

device or a ground fault circuit interrupter (GFCI) if one is present. Make sure the Earth Outdoor furnace is properly grounded

with an approved

grounding rod. A minimum 120 VAC with

50 or 60 cycles, 20 AMP electrical service is required. Please consult with a local licensed electrician to determine if the current installation meets USNE Code.

10!

PCD Wiring Requirements

Two cables connect the PCD to the IBC. The heater cable is a 14/3 gauge SJO cable, high temperature rated. In colder climates, an arctic UL approved 14/3 SJTW cable may be used. The yellow jacketed thermocouple cable is a 22 gauge shielded wire that is designed for low voltage. It is the required cable that is provided with the PCD.

PCD External Wiring Requirements for Switches and Breakers

The catalyst pre-heater is on for approximately one to five minutes in each call for heat (CFH) cycle of the furnace. This heater needs 120 VAC to work properly and will draw approximately 8 to 14 Amps of current. The Earth Outdoor furnace can have several pumps, fans and an exterior light. Please ensure that in the event of all devices being turned on at the same time, the surge and additional load of the heater will not trip or heat the circuit or switch to an unsafe level. Please consult an electrician and consult your Earth Outdoor manual if you do not know how to calculate total and safe draw.

PCD Ventilation Requirements

The PCD is designed for outdoor use. Heat generated in the exhaust stream from the combustion of particulates and

gasses needs ambient air to cool and should not be enclosed. Please ensure that the area around the PCD is clear and

provides an environment for safe operation. Please consult a certified chim ney professional. Organizations such as the National Fireplace Institute, NFI, provide a directory of trained technicians.

PCD Voltage and Current Measurement

Proper voltage and current are very important to the

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correct operation of the PCD. Please have an electrician check to

ensure the heater has 120 VAC and the ability to

safely draw

up to

20 Amps of current.

Model 150 Intelligent Bio-Fuel Controller Installation

IBC-3.1

Installation

IBC-3.1 Assembly

When viewing the IBC-3.1 please examine the labeled enclosure to make sure all parts are present and in working order.

IBC-3.1 Mounting Location

The IBC must be mounted in an area where the panel and LEDs are visible to the user to detect proper operation of the Model 150. The power cord is usually the limiting factor

in determining the proximity of the IBC. Please

ensure that

proper strain reliefs are used to ensure a safe

installation.

IBC-3.1 Mounting Requirements

The IBC-3.1 SHOULD NOT be mounted under a drip edge, roof line, water level indicator or any other area where it will

be subject to any water damage, such as excessive moisture and icing. A protective cover can be obtained from your Earth Outdoor dealer if excessive moisture or icing is a concern.

The IBC-3.1 SHOULD NOT be mounted in an area where heat

from the sun or furnace will dam age the enclosure.

IBC-3.1 Protective Earthing

12!

A Protective Earth, known as an equipment-grounding conductor in the US National Electrical Code, avoids an electrical

hazard by keeping the exposed conductive surfaces of the Earth Outdoor furnace and the IBC-3.1 at earth potential.

To avoid a

possible voltage drop, no current is allowed to

flow in this

conductor under normal circumstances. Fault

currents will

usually trip or blow the fuse or circuit breaker protecting the circuit. A high impedance line-to-ground fault insufficient to

trip the over current protection may still trip a residual current device or a ground fault circuit interrupter (GFCI) if present. Make sure the furnace is properly grounded withan approved grounding rod. A 15 AMP GFCI may trip the breaker with as low as 6-8 Amps of power draw. If a GFCI is required, a 20 AMP GFCI is recommended. Please consult with a local licensed electrician to determine if the current installation meets USNE Code. Failure to do so will void your warranty. We highly recommend taking a picture of the wiring to the IBC-3.1 and keeping it on file for future reference, should the need arise.

IBC-3.1 to External Low Voltage Sensor Connections

Two sensors are located outside the PCD. A 30k ohm thermistor is mounted in a thermal well that is set into the furnace water jacket. This sensor facilitates management of the water temperature.

An oxygen sensor is mounted into the exhaust steam of the furnace to insure the proper fuel air mixture for the best combustion. Two different types of industrial sensors are used depending on your model and year of manufacturing.

MODEL 150 Wiring Requirements

The Model 150 is wired at the factory. The Model 150

13!

implements a common neutral and a common ground. Before powering the Model 150, use a test plug or multimeter to ensure that the existing wiring of the plugs inside the Earth Outdoor furnace is correct. A continuity tester should also be used to

ensure that no wires are

reversed between the power source and the furnace.

IBC-3.1 External Wiri ng Requirements for Switches and Breakers

The catalyst pre-heater is on for approximately one to five minutes in each call for heat (CFH) cycle of the Earth Outdoor furnace. The heater needs 120 VAC to work properly and will draw

approximately 8.3 Amps of current for a standard heater and 14 Amps for a extended heater. Often an Earth Outdoor furnace will have several pumps, fans and an external light. Please ensure that in the event of all devices being turned on at the same time, the surge and additional load of the heater will

not trip, heat the circuit, or switch to an unsafe level. Please co nsult an electrician if you do not know how to calculate total and safe draw. Make sure that all electrical cab les

between the Earth Outdoor furnace and the

breaker box are rated to

handle the power needed to run all components of the furnace. Undersized or under rated cable will decrease the amount of clean power available to the furnace.

IBC-3.1 Ventilation Requirements

The IBC enclosure should not be mounted in an area where exposure to sun or the furnace itself will cause the inside of the controller enclosure to exceed 120°F.

IBC-3.1 Voltage and Current Measurement

Proper voltage and current are very important to the correct

operation of the IBC. Please have an electrician

check to

insure the furnace is providing 120 VAC to the IBC

14!

and that the outlet has the ability to safely source 20 Amps of current.

Displays

ClearStak offers a variety of displays to show the user and/or installer important information of their furnace during operation. The Klear Sky utilizes an LED Digital Display

LED Digital Display

The LED Digital Display should be mounted in an area where the panel and LEDs are visible to the user. It is hooked up using a power cord.

This display shows LEDs that indicate errors, call for heat, lockout/stand by state, catalyst temperature, and damper/fan state.

Optional LED Digital and Analog Display

This display contains a red push button to reset furnace when out of wood. The button will stay lit for standby or blink for an alarm/alert. It also shows through LED analog the water temperature, or air temperature, and stack temperature.

ClearStak Model 150 Operation

Model 150 Intelligent Bio-fuel Controller

This section describes the function of the IBC for the Earth furnace. As of the date of

this document the current electronic software revision is Version 3.1 November 14, 2012 and the current firmware revision is 3.1.0 (2012).

Variable Frequency Drive (VFD) Address Programming Instructions

15!

The VFDs are preprogrammed at the factory. When a VFD is replaced please see the following programming instructions for the combustion fan only.

1. Power-up the VFD without the serial cable attached.

2. Press the ‘M’ button one time. The number displayed

on the right side of the VFD display will start flashing.

3. Press the UP or DOWN key until the number 10 is

flashing on the left of the VFD display.

4. If ‘L2’ is not displayed on the right side of the VFD

display then continue and do steps 5 through 7 otherwise, if ‘L2’ is displayed, skip steps 5 through 7.

5. Press the ‘M’ key one time and the right side of the

VFD display will start flashing.

6. Press the UP or DOWN key until ‘L2’ is displayed

(flashing) on the right side of the VFD displa y.

7. Press the ‘M’ key one time. The left side of the VFD

display will start flashing.

8. Press the UP key until the number 44 is displayed

(flashing) on the left side of the VFD display.

9. If the number 2 (for the combustion fan) or number 1

(for the catalyst fan) is not displayed on the right side of the VFD display then continue and do steps 10 through 12 otherwise, if the correct number is already displayed then skip steps 10 through 12.

10. Press the ‘M’ key one time. The right side of the VFD

display will start flashing.

11. Press the UP or DOWN key until the number 2 (for

the combustion fan) or number 1 (for the catalyst fan) is displayed (flashing) on the right side of the VFD display.

12. Press the ‘M’ key two times. Either ‘RD’ or ‘Ih’ will be

displayed on the left side of the VFD display. You are now done after adjusting the VFD address. Skip step

16!

13. Press the ‘M’ key three times. Either ‘RD’ or ‘Ih’ will be

displayed on the left side of the VFD display. You are now done after not adjusting the VFD address.

Variable Frequency Drive Operation

Please ensure that electronics connected to a frequency drive are running in the proper direction. This should be verified before use.

Please ensure that only three phase electronics (motors and blowers) are attached to the VFD. The blower should run counterclockwise.

IBC-3.1 Overview and Technical Specification

Your product has been inspected at our New England factory and by an Earth Outdoor trained installation professional in Missouri, to be free from defect and have passed diagnostics prior

to shipment.

IBC-3.1 Overview

The IBC is a single circuit board that is housed in an outdoor rated enclosure. Field wiring to the IBC controller assembly is facilitated by quick disconnects, which are located along the edges of the IBC’s circuit board.

The IBC assembly receives 120 VAC nominal input voltage electrical power. Through firmware operating on a RISC microcontroller visible emissions and gasses are reduced by controlling the blowers and motors of the Earth Outdoor Klear Sky as well as the activation and operation management of a catalytic combustor, all

based on the state of inputs from various sensors in coo peration with proprietary patent pending operational algorithms

that

have been developed by ClearStak, LLC. The IBC manages the temperature of the water in the Earth

17!

Outdoor furnace. The IBC assembly receives continuous electrical power (interrupted only by a high limit safety thermostat) and, through the use of a mounted thermistor type temperature sensor, the controller assembly monitors the furnace water temperature. When the water temperature falls

to less than or equal to the setting of the IBC assembly’s low limit control, the furnace is fired. When the water temperature rises to greater than or equal to the setting of the IBC’s high limit control, the furnace is idled.

IBC-3.1 Components

The IBC hardware consists of four functional circuit sections. These functional circuit sections are the following: The Low Voltage Power and I/O Circuit Section, The Micro controller and Communication Circuit Section, The Analog Input and Signal Conditioning Circuit Section, The High Voltage Power, and Output

Circuit Section.

IBC-3.1 Low Voltage Power and Input Circuit Section

Low voltage power for the IBC assembly is provided by an off-line, dual output, positive voltage regulated switching power supply.

IBC-3.1 5VDC

The +5 VDC is used to power the Micro co ntroller and Communication circuit section and the Analog Input and Signal

Conditioning circuit section.

IBC-3.1 12 VDC

The +12 VDC is used to power the Low Voltage I/O circuitry in

the Low Voltage Power and I/O circuit section, and for

driving

the relay coils in the High Voltage Power and

Output circuit

section.

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IBC-3.1 Microcontroller and Communication Circuit Detail

The Microcontroller and Communication Circuit Section features a Microchip Technology microcontroller, RS-232 serial

communications circuitry along with a proprietary communications port, a microcontroller programming port, an operating mode selection jumper, a multi-pin expansion port, and

several LED indicators.

ClearStak factory programmed firmware that resides in the micro controller’s non-volatile memory provides the functional capability for the IBC assembly.

IBC Analog Input and Signal Conditioning Circuit Section

The Analog Input and Signal Conditioning Circuit Section consists of the amplifiers that amplify the signals from the three analog temperature sensors and the oxygen sensor. Also incorporated into this circuit section is the high limit water temperature control potentiometer and the low limit water temperature control potentiometer.

High Voltage Power and Output Circuit Section

The high voltage power and output circuitry accepts 120 VAC input power and distributes it to the various consumers of this input power. This circuit section consists of the power I/O terminal block, four load con trol relays and the low voltage driver circuits for the relays as well as LED indicators that illuminate when their respective load control relay coils are energized.

Firmware

This is done by your manufacturer. Do not swap this controller to another furnace to ensure that the settings are

19!

correct. The firmware is written in a State Machine format wherein

the inputs from the various sensors are read and processed. Based on the data from these sensors as well as the currently active State Machine state and also based on elapsed

time, the various machine states are activated and

deactivated.

PLEASE NOTE:

The Model 150 Catalytic Control System (CCS) is performing properly when only moisture is visible from the stack.

PCD and IBC Maintenance

The person(s) operating the hydronic heater is/are responsible for operation and warranty will be voided if preventative procedures are inconsistent with the ClearStak or Earth Outdoor Klear Sky manual.

Preventative

Catalyst

The catalyst (in the clean-burn catalyst housing) should be inspected at the beginning of the burning season, and at the end to ensure that it is working properly. During the burning season, the catalyst should be inspected monthly, or every 2 cords of wood burned. This is done by visual inspection. If the catalyst appears to contain fly ash, it should be cleaned out. This is usually caused when the furnace ash levels have risen higher than bottom of the door.

CAUTION: DO NOT REMOVE THE CATALYST IF IT IS HOT. Let it cool completely first. Removing the catalyst

while hot will ruin the seal around the catalyst and may cause the individual removing it to be burned.

20!

If you have any questions on proper operation please consult

your dealer. If it is working fine you do not need

to perform

any maintenance. If needed, the catalyst may

be cleaned

with compressed air (which does not contain oil)

at no more than 65 pounds per square inch

(PSI) pressure. A shop vacuum blower is the best solution for cleaning the catalyst. A solution of deionized water can be used to gently clean the catalyst annually.

Please ensure during any cleaning

procedure that you do not remove any of the coating on the surface of the catalyst. High pressure and scrubbing of the catalyst will disable the catalyst. Catalyst replacement is expensive. Please consult your installer if you have any issues

with the

operation of the PCD. Proper operation of

your Klear Sky should require minimal maintenance. If you are having any issues with a clean catalyst please call Earth Outdoor and speak with a Service Representative immediately.

Stack

To prevent water from entering your Earth Outdoor furnace when the furnace is not in use, cover the top of the stack with a cap or

five gallon bucket. When the heating season begins, be sure to remove the cover from the stack before using your Earth Outdoor furnace.

Visual Inspection

Perform a visual inspection of the PCD, IBC, and external cables monthly. Replace, if necessary, any components that appear to be worn or damaged with parts supplied

by the

manufacturer or agent. Please report any damage to

your

installer or Earth Outdoor service representative.

Tests

Polarity Test

21!

Check outlets to insure proper wire polarity. A simple plug-in connector can be obtained to insure that the cable between the furnace and the breaker box are wired properly. A reversed line and neutral wire will cause a controller relay failure and will permanently damage the IBC.

Ground Test

Check the ground connection for any voltage between the ground rod and the furnace. The NEC and UL require a ground rod to be at least 8 feet in length. Two pieced rods are the easiest to install. The ground rod at the furnace should be a copper-bonded, galvanized, or stainless steel rod. The low voltage sensors an d the GFI are very sensitive to poorly grounded or stray voltage conditions. The IBC terminal block uses a common ground. Power entering the IBC through a ground can permanently damage the controller. Failure to insure a proper

ground connection will

void your warranty.

Thermocouple Visual Test

The most common error in the installation of the IBC is the reversal of the yellow (positive) and red (negative) wires

in the thermocouple plug. Red as the negative wire is the low voltage standard for thermocouples and is opposite the automotive wiring convention. A reversal of these two wires

will cause the sensor output of the temperature to be negative. This will cause the pre-heater to remain on and unable to reach activation temperature. This con dition will lead to

an excessive lockout condition.

Thermistor Test

Using an ohm meter, check the amount of resistance from the thermistor at the IBC terminal block. The thermistor has a reference resistance of 30,000 ohms at 77°F (25°C).

Check periodically to make sure the thermistor is installed correctly in thermowell. Failure to do so could result in

22!

furnace to overheat.

Oxygen Sensor Test

Check millivolts from the oxygen (O2) sensor to insure proper

operation. The O2 sensor puts out a milli-volt

signal that will

indicate the amount of oxygen available

post com bu stion. The value for O

is close to zero at ambient atmosphere levels of between 17% and 19%. As the O

levels approach 0%, as a compared to the ambient

air outside the O

sensor, values will approach 1000 MV.

IBC-3.1 Low Post-Catalyst Oxygen Level Feature

In the event that the post-catalyst oxygen is too low, the effectiveness of the catalyst is compromised and smoke may result. To handle this condition, the IBC-3.1 will attempt a patent pending oxygen recovery cycle as defined by ClearStak. The IBC-3.1 oxygen recovery cycle functions as follows: If the Earth Outdoor furnace is operating under a call for heat (CFH) and the IBC is factory configured to perform an oxygen recover cycle and the oxygen level falls below a factory programmed level, then the furnace will engage a variable speed frequency drive (VFD) to power the back blower adding the needed amount of oxygen. In the unlikely event that the blower cannot provide the needed

oxygen the front blower will be slowed down to allow complete combustion. Whenever the post-catalyst oxygen level is equal to or below the factory programmed low

oxygen level, the Low Oxygen LED will be illuminated.

Integrated Safety Featu res

There are certain safety features that are integrated into the IBC assembly’s hardware and firmware.

Upon power-up, the electromechanical reset switch is checked to be sure that it is not stuck in the actuated position.

23!

If this switch is noted to be in the actuated position upon power-up, the controller will not start furnace operation and an LE D error flash cadence is set to indicate the problem.

Further, during a reset operation the electromechanical reset

switch must not only be actuated for one second or

longer

but the switch must be released before the IBC

assembly will reset. The temperature sensor inputs are hardware biased

towards

over-range or under-range conditions as appropriate. In

the event of a disconnected sensor, the

firmware can detect that

the sensor is missing or shorted by testing for sensor under-range and over-range conditions, as is appropriate for a given sensor.

The IBC assembly will detect that the water temperature sensor is missing and will sh ut down the furnace, and an LE D error flash cadence will be

set to indicate the problem.

The potentiometers on the IBC assembly that are used to

set the water temperature high limit and water temperature low limit are monitored for reversed settings. If the water temperature high limit is set to a lower temperature than the water temperature low limit temperature setting, the IBC assembly will detect this reversed setting condition and

the furnace will be shut down resulting in a LED error flash cadence to indicate the problem.

LED Indicator Error Cadences

In order to communicate diagnostic information to the user

of the Earth Outdoor Furnace, the LED indicators that

are visible on

the front panel of the IBC controller assembly will flash as required in order to indicate various operational alerts and

alarms. The error cadences and their

meanings are as follows:

Water Jacket Temperature below 150°F

Call for heat amber LED will pulse

24!

This is expected under annual system start up. If this occurs during normal operation then make sure the furnace is working properly and contact your Earth Factory Service Representative.

Standby LED on continuously:

The purpose of the Standby mode is to prevent extended heating of the catalyst and running of the damper and blower when the furnace is low on fuel.

Try the following operations to isolate the problem:

• Remove ash from the furnace then add fuel

• Insure that the fire is burning well

• Turn off the power and check dampers and blowers

for

obstructions. Remove or clean out obstructions

and recycle the power to the IBC-3.1.

• Turn the power switch behind the back cover of the furnace on and off to re set. If this condition

persists then

check to make sure the

Thermocouple cable is not wired

backward.

Alarm/Alert LED flashes 2 times and then Alarm/Alert LED off

for 1 second

This condition indicates that the inside of the IBC-3.1 is greater than 140°F

• Check for overheated enclosure.

• Make sure the IBC-3.1 is not mounted to the

furnace on

a heated surface.

• Make sure

the IBC-3.1 is not in direct sun light

during

temperatures in excess of 100 °F

• Cycle the Power to Recover.

Post Cat. Therm ocouple Sensor Under-range: Alarm/Alert LED flashes 3 times and then Alarm/Alert LED off for 1 second

25!

This alarm indicates that the thermocouple under range. Try the following operations to isolate the problem: Manually inspect yellow cable for breaks or shorted

connections. Disconnect the Thermocouple plug at the stack and

restart.

Disconnect the yellow cable from the IBC and restart. If the Over-range error below occurs then the board is working properly.

Cycle the Power to Recover.

Post Cat. Thermocouple Sensor Over-range: Alarm/Alert LED flashes 4 times and then Alarm/Alert LED off for 1 second

This alert indicates that the thermocouple is not connected at the plug or at

the controller board.

• Check to see if Thermocouple is connected.

• Manually inspect yellow cable for breaks or shorted

connections.

• Check for ~5.0V across the terminal block.

• Cycle the Power to Recover.

Alarm/Alert LED flashes 5 times and then Alarm/Alert LED off for 1 second

This alarm indicates that the water jacket temperature is very low.

• Check to make sure the water jacket is not frozen.

• Check for disconnected sensor wire.

• Cycle the Power

to Recover.

Alarm/Alert LED flashes 6 times and then Alarm/Alert LED

off for 1 second and Lockout LED on

continuously

This alarm indicates that the water temperature is over-

26!

range.

• Check to see if boiler has overheated.

• Power board off and check for Water jacket sensor

resistance.

• Check for defective sensor (500 Omhs with power off).

• Check for defective sensor (0.0V at terminal block with

power on).

•

Press the Reset Switch for One Second to Recover.

Blue LED is solid due to low oxygen.

Blue LED is extinguished

Alarm/Alert LED flashes 9 times and then Alarm/Alert LED off for 1 second

This alert indicates an error with the computer processor.

• Check for power interference before replacing the IBC board.

• Cycle the Power to Recover.

• Replace controller board if continues.

Alarm/Alert LED on and Lockout LED off 0.5 seconds Alarm/Alert LED off and Lockout LED on

0.5 seconds

This alarm indicates an error with the temperature control potentiometer.

• Replace board if the problem persists.

•

Cycle the Power to Recover.

Stuck Reset Switch (P.O.S.T.)

Alarm/Alert and Lockout LED on 1.02 seconds Alarm/Alert and Lockout LED off 0.2 seconds

27!

• Replace board if the problem persists.

• Cycle the Power to Recover.

• The flashing Alert/Alarm LED indications that

appear with a continuously illuminated Lockout LED can be recovered from

by cycling the power to

the IBC-3.1.

• If the Lockout LED is illuminated without the Alert/Error LED, this typically indicates that the furnace is out

of wood or the fire went out.

• .P.O.S.T means Power-On Self-Test.

Technician Troubleshooting

Lockout/Standby

Lockout/Standby can occur for the following reasons: out of wood, low Stack temperature for an extended period, and thermocouple wired backwards.

Tripped Fuse

• Check wiring and cables to insure that there are no short circuits.

• Check wiring and cables for cuts in the plastic coating.

• Check power to insure 120VAC.

• Check load on the circuit.

•

Isolate issue before replacing the IBC-3.1 board.

No Power to the Board

• Check wires from the IBC-3.1 board to the power supply and replace if necessary and check the fuse on the power supply and replace.

28!

Catalyst Back Pressure

• Check catalyst for clogging from objects such as birds, leaves and bees.

• Check to see if the heater is performing properly.

• Check for excess air causing fly ash problems.

• Check exhaust pipe dimension to insure proper

sizing

of pipe.

Balanced System Performance

Every effort has been made to ensure that your heating furnace has a balanced system performance. This includes: thermal efficiency, combustion efficiency, and fuel capacity. It is important to make sure that you do not make changes to the system without consulting the manufacturer of the heating furnace. Changes to the blower can significantly impact combustion efficiency and changes to the pump can impact thermal efficiency. Changes to the fuel capacity and delivery can impact both combustion and thermal efficiency.

Warning Statement and Warning Symbols

The PCD is very hot during normal operations. DO NOT TOUCH the outside of the PCD or

the area above the PCD.

The Pollution Control Device needs to be clean for proper operation. DO NOT RUN the furnace if the catalyst is OBSTRUCTED. Please check regularly to insure that the catalyst

is free of obstructions. During initial startup after

a period

of dormancy, check the catalyst for obstructions

such as birds, leaves and bees nests. The ClearStak Model 150 uses 120 V for the operation of

the PCD and the Intelligent Bio-Fuel Controller (IBC). DO

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NOT TOUCH THE INSIDE OF THE PCD OR IBC-3.1 ENCLOSURE, HIGH VOLTAGE.

CAUTION! Electrical shock can result from removal of the

enclosure covers. Refer servicing to qualified service personnel.

The circuits inside the PCD assembly and

the Intelligent BioFuel Controller (IBC-3.1) panel have been precisely adjusted for optimal performance and com pliance. Unauthorized

modification of or tampering with the IBC will void the warranty, and may cause improper operation.

Fill the furnace with water before installing and wiring the IBC-3.1 and the PCD. Water that spills from inlets and outlets during installation or maintenance will damage electronic components. Damage to electronics from

moisture is

NOT covered under warranty.

The wires shipped with the IBC and optional PCD are sized for the motors and sensors and for proper operation. DO NOT exchange these wires for ones not sold with the unit or it may affect performance of your furnace and it will void your warranty.

Best Burn Procedure

As the new owner of an Earth Outdoor Klear Sky, you are responsible to comply with applicable laws or other requirements, such as state laws, regulations, or local ordinances.

The owner, or person(s) operating the furnace is/are responsible for operation in a manner that does not create a public or private nuisance condition.

It must be noted that the manufacturer’s installation distance and stack height recommendations and the requirements in any applicable laws or other requirements may not be adequate to prevent nuisance conditions due to the terrain of the land and/or factors.

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CAUTION: Keep small children away from heater.

System Check

Prior to every cold start we would like you to do the following:

1. Test the power coming into the unit to ensure you have 120/220V (What ever voltage required).

2. Check all wiring to ensure that they are in good shape and nothing has been unplugged or damaged.

3. Check the water level, if a hydronic unit, to make sure there is water in it.

4. Make sure all air holes (combustion blower tube

flue baffle, stack) are unclogged and free from debris.

5. Check the pump to make sure it is working properly

and water is flowing through all of the pipes.

6. Power the controller to ensure the power light

(while LED) has turned on

7. Make sure the frequency drives screen change

from inhibit (ih) to ready (rd).

8. Check the probes to make sure the thermistors are

properly located in the thermowells and the thermocouples are located into the furnace.

9. Inspect the furnace and make sure everything is

set according to Earth Outdoor manual.

10. Make sure the door seal provides air-tight seal

when shut.

If you notice any problems or anything unusual please contact your dealer or distributor at any step.

Loading of Fuel

Follow manufacturer’s instructions written to achieve the

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most efficient burn. It is recommended that the firebox is never filled more than

50% to allow room for oxygen. It is recommended that larger logs are placed in the middle

of the firebox and smaller pieces are placed on the sides and the top to reduce bridging. Bridging occurs when the inside of a pile of fuel burns out faster than the surrounded outer fuel. When this pile collapses it will need a higher level of oxygen to recover and can result in higher emissions than in a controlled environment.

Cold-Startup Procedure

For a cold-start, ClearStak recommends that customers fill the furnace with about two pounds of charcoal per square foot of the firebox and light it using a propane torch with a long handle, such as those used in burning weeds to get the fire started in the most efficient, time saving manner. Once charcoal is lit and then add wood slowly until the firebox is about 50% full.

Burn Practices

Warnings

DO NOT cover air supply or exhaust holes. Any debris should not restrict air inlet or combustion blower tubes, stack, and flue baffle at any time during the burn. If problems continue contact an Earth Outdoor Wood Furnace distributor or Earth Outdoor.

Always make sure the door provides an air-tight seal when shut. If door is not air-tight contact an Earth Outdoor Wood Furnace distributer or Earth Outdoor.

Fuel

Use dry wood. Wood that is wet or damp may cause an excessive amount of smoke.

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For more efficient burning, use seasoned firewood. Seasoned firewood is wood that has been cut and stored properly and has aged for at least six months.

Use only the type of fuel recommended by the manufacturer.

DO NOT BURN the following: trash, treated wood, plastics, gasoline, petroleum treated products, rubber, naphtha, cardboard, house hold garbage, any paper products, and leaves. Burning the above mentioned may release toxic air pollutants.

Ash

Clean ash out at least once a week, or as needed. Read furnace manufacturer’s manual for more instructions on proper ash removal.

Location of Furnace

Consider the direction of the prevailing wind when choosing to set up your furnace. Be sure to check with your state’s regulations for more information on proper location of furnace as well as stack height.

Helpful Links Provided by the EPA

How to use a Moisture Meter Video: http://www.youtube.com/watch?v=jM2WGgRcnm0 EPA offers tips on how to properly use a moisture meter to

test firewood before using in a wood-burning stove or fireplace. Wet wood can create excessive smoke which is wasted fuel.

Split, Stack, Cover and Store Video: http://www.youtube.com/watch?v=yo1--Zrh11s EPA offers four simple steps to properly dry firewood

before using in a wood-burning stove or fireplace. Wet wood can create excessive smoke, which is wasted fuel.

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Burning, dry, seasoned firewood with a moisture content of 20% or less can save money and help reduce harmful air pollution.

Wet Wood is a Waste Brochure: http://www.epa.gov/burnwise/pdfs/wetwoodwastebrochure.

pdf This tri-fold brochure provides colorful illustrations of the

four easy steps to dry firewood. For more information please check out Best Burn Practices

on the EPA’s website: http://www.epa.gov/burnwise/bestburn.html

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MANUFACTU RER ’S LIMITED WARRANTY

This Limited Warranty applies to ClearStak products sold by Earth Outdoor or

its authorized distributors. The term “ClearStak products” does not include Earth Outdoor products or Earth Outdoor furnace parts. All nonClearStak

products or non-ClearStak peripherals external

to the ClearStak product, such

as furnace parts, are not covered by the ClearStak warranty. These items may be covered by Earth Outdoor manufacturer and/or supplier warranty.

ClearStak guarantees that the ClearStak-brand products that are purchased

from ClearStak are free from defects in materials or workmanship under normal use during the Limited Warranty Period. The Limited Warranty Period is one calendar year. The Limited Warranty Period starts on the date of purchase from Earth Outdoor or an authorized Earth Outdoor distributor. The dated sales or delivery receipt, showing the date of purchase, is proof of the purchase date. The consumer may be required to provide proof of purchase as a condition of receiving warranty service. The consumer is entitled to warranty service according to the terms and conditions of this Limited Warranty if a repair to

the ClearStak-brand product is

required within the Limited Warranty Period.

During the Limited Warranty Period, ClearStak will, at its discretion, repair or replace any defective component. All component parts removed under the Limited Warranty become the property of ClearStak. In the unlikely event that the ClearStak-brand product has recurring failures, ClearStak, at its sole discretion, may elect to provide the consumer with (1) a replacement unit of ClearStak’s

35!

choosing that is the same or equivalent to the ClearStakbrand product in performance or (2) to provide a refund of the purchase price instead of a replacement. This is the exclusive remedy for a defective product.

It is mandatory that the unit product number and serial number are made available when requesting warranty service. Failure to do so may result in the service request being deemed out of warranty by ClearStak or ClearStak’s authorized Earth Outdoor distributors, and therefore chargeable to the consumer.

Unless otherwise stated, and to the extent permitted by local law, new ClearStak-brand products may be manufactured using new materials or new and used materials equivalent to new in performance and reliability. ClearStak may repair or replace ClearStak-brand products with (1) new or previously used products or parts equivalent to new in performance and reliability, or (2) with equivalent products to an original product that has been discontinued. Re- placement parts are warranted to be free from defects in material or workmanship for ninety (90) days or, for the remainder of the Limited Warranty Period of the ClearStak-brand product, whichever is longer.

Exclusions

ClearStak does not guarantee that the operation of a ClearStak product will

be entirely perfect in every situation. ClearStak is not responsible for damage that occurs as a result of the consumer’s failure to follow the instructions intended for the ClearStak product. User should follow furnace manufacturer instructions for proper burning practices. ClearStak PCDs are not intended for the burning of dimensional lumber, such as pallets. ClearStak PCDs are also not intended for improper burning practices involving the burning of trash or garbage. ClearStak PCDs are intended for wood only. ClearStak warranty does not

36!

include problems that arise due to improper burn practices, such as burning garbage.

Please refer to the ClearStak Model 150 Series Installation and User Guide. The most updated version of the ClearStak Model 150 Series Installation and User Guide can always be found online by scanning the QR code given on the label of the ClearStak IBC. Any departure from the

instructions in

the Installation and User Guide will

void the warranty.

This Limited Warranty does not apply to any product: From which the serial number has been removed,

damages or rendered defective, either (1) as a result of accident, misuse, abuse, contamination, improper or inadequate maintenance or calibration of

other external causes; (2) by operation outside the usage parameters stated in the user documentation;

Comprised of parts or supplies not supplied by ClearStak; Operated on a site which was not properly prepared or

maintained; Which has been modified or serviced by anyone other tha

n: (1) ClearStak; (2) a ClearStak authorized service provider; and/or (3) the consumer following the ClearStak Mo del 150 Series Installation and

User

Limitation of Liability

If the ClearStak product fails to work as warranted above, ClearStak’s maximum liability under the Limited Warranty is expressly limited to the lesser of

the price paid for the product or the cost of repair or replacement of any components that malfunction in conditions of normal.

Failure to comply with Furnace Manufacturer’s Manual

ClearStak’s warranty will be voided if operation of the residential wood furnace/hydronic heater is in a manner inconsistent with the wood furnace/hydronic heater

37!

manufacturer.

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ClearStak,!LLC!

90!Route!171! P.O.!Bo x!875! Woodstock,!CT!06281! www.clearstak.com!

www.facebook.com/ClearStakLLC!

Earth Klear Sky 400 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual