Harman-Kardon PB 105 User Manual

Installation & Operating Manual

The Harman PB 105 Pellet Boiler

“Ce manuel est disponible en Français sur demande”

SAFETY NOTICE

PLEASE READ THIS ENTIRE MANUAL BEFORE YOU INST ALL AND USE YOUR NEW BOILER. FAILURE T O FOLLOW INSTRUCTIONS MA Y RESUL T IN PROPERTY DAMAGE, BODIL Y INJURY, OR EVEN DEA TH.

FOR USE IN THE U.S. AND CANADA. SUIT ABLE FOR INST ALLA TION IN MOBILE HOMES IF THIS HARMAN PELLET BOILER IS NOT PROPERL Y

FOLLOW INSTALLATION DIRECTIONS. CONT ACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INST ALLA TION INSPECTION

REQUIREMENTS IN YOUR AREA. CONT ACT YOUR LOCAL AUTHORITY (SUCH AS MUNICIP AL BUILDING DEP ARTMENT , FIRE DEP ARTMENT, FIRE

PREVENTION BUREAU, ETC.) TO DETERMINE THE NEED FOR A PERMIT . CETTE GUIDE D'UTILISA TION EST DISPONIBLE EN FRANCAIS. CHEZ VOTRE CONCESSIONNAIRE DE HARMAN STOVE

COMP ANY.

SA VE THESE INSTRUCTIONS

INST ALLED, A HOUSE FIRE MA Y RESUL T . FOR YOUR SAFETY ,

Table of Contents

Assembly 4

Venting 8

Installation 11

Operation 20

Maintenance 2 7 Troubleshooting 31

Feeder Parts 32

Specifications 3 3

Wiring Diagram 3 4

Parts List & Options 3 5

Warranty 36

Testing Label 37

Quick Reference Start-Up Back Cover

Please read this entire manual before you install and use your new

boiler . Failure to follow instructions may result in

property damage, bodily injury , or even death.

SAVE THESE INSTRUCTIONS

Harman S tove Company

352 Mountain House Road

Halifax, P A 17032

Assembly

n B

ere

n B

ere

ombustio

ESP Probe

lue Tunne l Weldme

ater Coil Option Shown H

*Re mo ved w/ Domest ic Ho t

Blank Cover*

Pressure Relief Valve

Aquastat Well

Tempera t ure / Pressu re Gauge

Firebox & Ash

Doo r Handle s

Firebox & Ash

QTY (5)

Doo r Handle s

Thumb Screws (3)

½”MPT Bo iler Drain

(Not Shown)

½”MPT Bo iler Drain

(Not Shown)

Outdoor Air Temperature Sensor Wiring :

Heat Exchan ger

Cleanout Rod Handles

Heat Exchan ger

Cleanout Rod Handles

Access Cover To Secondary Ash Chamber

Remove Cover to access nuts to fasten Flue

Access Cover To Secondary Ash Chamber

Tunnel Weldment to the Ash C hamber.

Remove Cover to access nuts to fasten Flue

Tunnel Weldment to the Ash C hamber.

Assembly

Boiler Kit Materials: (Refer to pages 4 & 5)

List of items contained within the boiler kit shipped with the unit.

1 - Control board cover 1 - Access cover (Hopper Swing Plate Knob) 5 - Spring Handles 1 - 1/2” Boiler Drain 1 - 3/4” Safety Relief Valve 1 - 1/2” Aquastat Well 1 - 1/2” Dual Temperature/Pressure Gauge 1 - 100ft. Sensor Cable (Outdoor Air Sensor) 1 - Outdoor Air Sensor 1 - Flue Tunnel Weldment 1 - Combustion Blower Assembly 1 - Heat Shield (Comb. Blower) 2 - UY Connectors 2 - Terminals 1/4 Female 1 - #8 X 1/2” TEK 3 - 1/4-20 X 5/8” Wing Screw 4 - 1/4” Lock Washer 4 - 1/4-20 Nuts

Installation of the Flue Tunnel Weldment, Combustion Blower and Wiring, ESP and Heat Shield:

Step 1: First install the flue tunnel weldment by aligning the (4) studs up with the (4) holes in the ash chamber base.Fasten the (4) nuts and lock washers provided, to the studs by removing the access cover on the secondary ash chamber. Step 2: Place the combustion motor onto the flue tunnel weldment and tighten the (3) wing screws provided. Step 3: Insert the Exhaust Sensing Probe (ESP) into the 1/8" hole provided on the flue pipe stub. Fasten with the (1) #8x1/2" TEK screw also provided. ESP will be taped to the sheet metal jacket for shipping purposes. Step 4: Connect the flex conduit 90 degree elbow(Not Shown) to the heat shield in the hole provided. Then connect the (3) wires from the combustion blower with the (3) wires in the flex conduit by using the push-on connectors and matching the wire colors as follows: Red to Black, White to White and Green to Green. Step 5: Place Heat Shield over combustion blower and align the swell latches with the holes in the sheet metal and tighten.

Assembly

After assembly of the flue tunnel weldment, combustion blower assembly with wiring and heat shield, the boiler can now be installed.

1. Install the control board cover as well as the access

cover located on the feeder cover.

2. Install the spring handles provided with the unit on the ash door, firebox door and the heat exchanger cleanout rod handles. (Fasten handles by turning them counterclockwise and pushing inward simultaneously).

3. Install 1/2” MPT boiler drain in the fitting as shown.

Note: Use teflon pipe thread sealant or teflon

tape on ALL threads before connections are made.

4. Install 3/4” MPT pressure relief valve as shown.

5. Install the 1/2” MPT aquastat well in fitting as shown, then place aquastat in the well and fasten with a zip tie.

6. Install the 1/2” MPT temperature/pressure gauge in fitting as shown.

7. Locate and install outside air temperature sensor. Location of this sensor should be on the north side of the home or building and out of direct sunlight. Use the cat cable supplied with the boiler to attach sensor to the terminals located on the hopper. (Place at the back side just above and to the right of the main power connection box) The wires can be connected to the sensor with the connectors supplied. Wire nut or butt splice connectors could also be used. The connections at the boiler can be done with the two 1/4” female push on connectors supplied.

8. Fasten conduit to the ash base with the clamps provided.

Floor Protection:

The striped area indicates the minimum required floor protection area if the PB105 is going to be placed on a combustible floor . It requires 30” X 55” of non combustible floor protection as shown below . 6” of the floor protection must be in front of the boiler as shown. Flooring must be a minimum of 26 gauge sheet metal. Floor protection must also be provided under any horizontal run of vent pipe equal to the outside diameter of the venting plus 2” to each side.

MINIMUM NON-COMBUSTIBLE FLOOR PROTECTION AREA

Non-Combustible

Floor Protector

Design:

The first thing that needs to be done is deciding where and how the boiler will be installed.

Things that need to be taken into consideration are the intended use of the boiler for example, is the boiler going to be used as your primary heating system or is it going to be used as a secondary or backup heating system. If it is to be used in conjunction with an existing oil or gas boiler system will it be piped in parallel or in series? The answers to these and other questions can be determined by talking to your certified dealer or a qualified HV AC or plumbing contractor . This will insure that the boiler is installed and piped to accommodate your needs and expectations.

Consideration must be given to the venting as well as electrical and clearance requirements. (Clearances must be maintained to combustibles and also for service)

Example: 4” type “L” or “PL” vent pipe has an outside diameter of 4-1/2” + 2” on each side equals a protected floor area of 8-1/2” wide underneath the horizontal run.

After the boiler is set into place the venting can be done.

Make sure fans are not used in the fuel storage area, unless they are installed so as not to create a negative pressures in the room where the solid fuel burning appliance is located

Assembly

When installing the PB105 in a mobile home several requirements must be followed:

1. The unit must be bolted to the floor .

2. The unit must be connected to outside air .

3. Floor protection and clearances must be followed.

4. Unit must be grounded to the metal frame of the mobile home.

INSTALLATION IS TO BE PERFORMED BY A QUALIFIED INSTALLER.

NOTE: All installation clearances and restrictions must be adhered to.

NOTE:Use only 4” diameter type “L” or “PL” venting system. Be sure to inspect and clean exhaust venting system frequently.

Venting

Requirements for Terminating the V enting

W ARNING: V enting terminals must not be recessed

into a wall or siding.

NOTE: Only PL vent pipe wall pass-throughs and fire stops should be used when venting through combustible materials.

NOTE: Always take into consideration the ef fect the prevailing wind direction or other wind currents will cause with flyash and /or smoke when placing the termination.

In addition, the following must be observed:

A. The clearance above grade must be a minimum of 18".

B. The clearance to a window or door that may be opened must be a minimum of 48" to the side, 48" below the window/door, and 12" above the window/

door.

( with outside air installed, 18” )

C. A 12" clearance to a permanently closed window is recommended to prevent condensation on the window .

D. The vertical clearance to a ventilated soffit located above the terminal within a horizontal distance of 2 feet (60 cm) from the center-line of the terminal must be a minimum of 18".

E. The clearance to an unventilated soffit must be a minimum of 12".

F . The clearance to an outside corner is 1 1" from center of pipe.

G . The clearance to an inside corner is 12".

H. A vent must not be installed within 3 feet (90 cm) above a gas meter/regulator assembly when measured from the horizontal center-line of the regulator .

I. The clearance to service regulator vent outlet must be a minimum of 6 feet.

J. The clearance to a non-mechanical air supply inlet to the building or the combustion air inlet to any other appliance must be a minimum of 48”.

K. The clearance to a mechanical air supply inlet must be a minimum of 10 feet.

(with outside air installed, 6 feet )

L. The clearance above a paved sidewalk or a paved driveway located on public property must be a minimum of 7 feet.

M. The clearance under a veranda, porch, deck

or balcony must be a minimum of 12 inches.

1,2

1,3

NOTE: The clearance to vegetation and other exterior combustibles such as mulch is 36” as measured from the center of the outlet or cap. This 36” radius continues to grade or a minimum of 7 feet below the outlet.

Certain Canadian and or Local codes or regula-

tions may require different clearances.

A vent shall not terminate directly above a sidewalk or paved driveway which is located between two single family dwellings and serves both dwellings.

Only permitted if veranda, porch, deck, or balcony is fully open on a minimum of 2 sides beneath the floor.

NOTE: Where passage through a wall, or partition of combustible construction is desired, the installation shall conform to CAN/CSA-B365. (if in Canada)

= Vent terminal

Fixed

Closed

Openable

= Air supply inlet

Fixed

Closed

Inside

Corner

Detail

= Area where terminal is not permitted

Fig. 2

Venting

Fig. 3

Venting

Use 4” pellet vent pipe to vent your PB105.

A combustion blower is used to extract the combustion gases from the firebox. This creates a negative pressure in the firebox and a positive pressure in the venting system as shown in Fig. 4. The longer the vent pipe and more elbows used in the system, the greater the flow resistance. Because of these facts we recommend using as few elbows as possible and 30 feet or less of vent pipe. The maximum horizontal run should not exceed 18 feet.

Be sure to use wall and ceiling pass through fittings (which are approved for pellet vent pipe ) when going through combustible materials. Be sure to use a starting collar to attach the venting system to the stove. The starting collar must be sealed to the stove flue collar with high temp silicone caulking or aluminum tape, and screwed into the stove flue collar at least three (3) places.

4” T ype “L” or “PL” Vent pipe

Fig. 5

This is the minimum venting configuration.

Fig. 4

Vent Pipe

4” pellet vent pipe (also known as PL vent) is constructed of two layers with air space between the layers. This air space acts as an insulator and reduces the outside surface temperature to allow a minimum clearance to combustibles of 1 inch. In Canada the minimum clearance to combustibles is 3 inches.

The sections of pipe lock together to form an air tight seal in most cases; however, in some cases a perfect seal is not achieved. For this reason and the fact that the PB105 operates with a positive vent pressure, we specify that all

joints within the structure should also be sealed with clear silicone.

NOTE:Use only 4” diameter type “L” or “PL” venting system. Be sure to inspect and clean exhaust venting system frequently.

The minimum vent configuration is a 90o or T ee on a starter collar and a 24” length horizontal through an exterior wall. A cap or other bird screen on the end should direct the flue gasses down and away from the structure. See Fig.

The maximum horizontal length is 18 feet. The minimum termination height above the exterior grade is 18”. The maximum total length of any configuration is 30 feet*.

* ( see venting graph on page 9 for exceptions )

NOTE: Cleanout Tee’s should always be used on the transitions to horizontal pipe to allow easy access for cleaning.

The venting graph allows for (one) 90 deg. or T ee fitting in any configuration.

If more 90’s, T’s, or 45’ s are needed the total length must be adjusted to allow for the added restriction.

Up to four (4) additional 90’s, Tee’s, or equivalent 45’ s can be added as long as the overall length is adjusted in accordance with the values listed below .

( See the venting graph on page 9.)

Each Vertical ---- 90 deg. or T subtract 2.5 feet

Each Vertical ---- 45 deg. subtract 1.5 feet

Each Horizontal - 90 deg. or T subtract 5.0 feet

Each Horizontal - 45 deg. subtract 2.5 feet

Any exterior venting (vent pipe exposed to outside ambiant temperatures) should be kept to a minimum, due to potential condensation problems.

This is especially important in high humidity cold weather climates, such as maritime areas, lake shores, and low river valleys.

Venting Installation

Chimneys taller than 20’ above the connection will re-

quire a draft test to determine if the draft is too high.

Note: The High Burn Draft should not exceed .85 IWC. Some form of a restrictor plate may be required at the top of high chimneys to reduce the draft. See page 19 for the Draft T est procedure.

The PB105 Boiler may be used and installed into an existing masonary or Class A metal chimney .

Certain Canadian and Local Codes may require that the chimney be fully relined.

It Can Not be installed in a chimney serving another

appliance.

The chimney should be cleaned and or inspected before installation.

Creosote - Formation and Need for Removal - When wood is burned slowly, it produces tar and other organic vapors, which combine with expelled moisture to form creosote. The creosote vapors condense in the relatively cool chimney flue of a slow-burning fire. As a result, creosote residue accumulates on the flue lining. When ignited, this creosote makes an extremely hot fire. The pellet vent pipe should be inspected at least twice monthly during the heating season to determine if a creosote buildup has occurred. If creosote has accumulated it should be removed to reduce the risk of a chimney fire.

Guidance on minimizing creosote formation and the need for periodic creosote removal: The chimney should be inspected during the heating season to determine if a creosote build-up has occurred. If a significant layer of creosote has accumulated (3mm or more) it should be removed to reduce the risk of a chimney fire.

Inlet Cover part# 1-10-09542

Outside Air Pipe

Outside Air Pipe Knockout

Knockout

Feeder Cover

Fig. 7

Installation

Outside Air

Outside air is optional, although it may be required by some building codes. The benefit of outside air is higher efficiency and reduced venting restrictions mainly noticed in small and very tight houses.

T o install outside air, use 2 3/4”" I.D.galvinized steel flex pipe, part # 2-00-08544 ( 12’ 6” length) or part # 2-00-08545 ( 25’ length) See Fig. 6. There is a breakaway hole on the rear panel which must be removed before connecting the flex pipe. See Fig. 7. The pipe

Fig. 6

should be run outside and terminate 3 feet or more below or 1 foot or more to the side of the vent pipe outlet. Never terminate the outside air above the vent pipe outlet. The maximum length of this pipe is 20 feet. Inlet cover part number 1-10-09542 should be used to keep birds, rodents etc.out of the inlet pipe. See Fig.6.

NOTE: If outside air is installed, the inlet cover should not be placed in an area where drifting of snow or ice will build up, blocking the intake air supply.

The Outside Air knockout is located on the face of the Feeder Cover. It is pre-cut except for several small tabs. There is also a filler plate screwed to the inside to cover the top of the hole after the Outside Air Pipe has been installed. This will allow for removal of the Feeder Cover without disconnecting the Outside Air Pipe. See Fig. 7.

Only metal Intake Flex should be used for the Outside Air Supply connection.

Only a screened or rodent protected Outside Air Intake cover should be used as an outside weather cover.

The Outside Air Intake Pipe is inside the Feeder Cover and to the right of the feeder motor. The 2 3/4” steel flex pipe is made to slide over the outside of the Air Intake Pipe. See Fig. 8. It should be held into place with some silicone, foil tape, or a hose clamp. (not supplied)

Outside Air Inlet Pipe

Hopper/Feeder Swing

Hopper/Feeder Swing Plate Knob

Plate Knob

Fig. 8

Heat Reclaiming Ventilation System (HRV)

When installing in a house with a Heat Reclaiming Ventilation System (HRV) be sure the system is balanced and is not creating a negative pressure in the house.

NOTE: If the boiler is installed with the outside air system no adjustments to the HRV should be necessary.

Main Wiring Installation

NOTE: If other sources of electrical power are to be used ( such as a generator ) for normal operation or emergency operation, this

T o install power to the boiler first remove the cover on the 4” X 4” junction box located on the back of the unit. There are several knockout holes

provided for the incoming main power wires. Also, a knockout hole can be used for the auxiliary output overheat zone (if used).

The minimum recommended circuit is 6 AMP - 120 VAC - 60 HZ. This boiler should be the only appliance on the circuit. If a 15 AMP circuit breaker

is used at the distribution box, the boiler must be protected with an in-line fuse rated at 6 AMP .

This boiler should never be powered by the use of an extension cord.

The recommended high and low voltages are, 130 V.A.C. 60 Hz maximum high voltage, and 113 V.A.C. 60 Hz minimum low voltage.The furnace will

continue to operate at voltages as low as 105 V.A.C. , although it can not be guaranteed that automatic ignition will occur.

source should be checked before installation. Many generators and inverters may not supply 120V.A.C. 60Hz. power stable enough to operate

the control board properly. (Control board damage could occur).

Installing Duct

Installation

Installing Duct/Air Conditioning

Boilers intended to be connected to an existing boiler or boiler system shall:

1. Be capable of being installed without interfering with the normal delivery of heated water from the original boiler to the radiation system.

2. Be capable of being installed to operate as intended without affecting the operation of the electrical and mechanical safety controls of the original boiler.

3. Provide, upon completion of the installation, for a change over from one fuel to the other without requiring the manual adjustment of any controls or components other than the thermostats.

4. Be compatible with the operation of a service water-heating coil within the original boiler without bypassing the operation of the solid-fuel boiler.

5. Have provision for preventing, or adequate water capacity within the boiler to prevent, damage to the boiler from loss of circulation due to electrical power failure.

6. Be capable of being installed without changing the function of the control or rewiring of the original boiler. A wiring interconnection is permitted. The electrical system of both boilers shall be powered from a single branch circuit without exception. (CAN/CSA-B366.1-M91)

Installation

Draft Bolt Location

Viewing Window

Installation

Air wash Slot

Fig. 9

Draft T est Procedure

After the venting is completed, the firebox low draft will need to be checked and possibly adjusted. After removing the 3/8” bolt from the draft hole shown in Fig. 9, insert the draft meter tube. The hopper lid must be latched during this test. (It is recommended that the draft meter have a scale of 0 to 1” WC.)

Turn the feed adjuster to “T est”. this will start the combustion blower and allow you to check and record the High Draft ______ - IWC date _______ (There is no adjustment for the High Draft)

After the first 60 seconds the “T est” mode lowers the combustion blower voltage to the Low Burn voltage. (The “T est” mode cycles the voltage from high to low every 60 seconds).During this lowered voltage cycle the Low Burn Draft must be checked and adjusted if necessary . The recommended low draft setting should be between -.25 &

-.35 IWC. Depending on the amount of vertical rise, it may not be possible to get a low draft reading in this range. In this case, a maximum low draft of -.55 is acceptable.

The adjustment screw is through the small hole to the right of the Igniter Light. See Fig. 10. Adjusted Low Draft is __________ -IWC.

Don’t forget to turn the feed adjuster back to #4.

Operation

Power Light

Indicates power to the control board.

Status Light

Will be lit anytime ther e is a call for heat.

Overheat Saftey Zone Light

Indicates that the boiler water temperature has reached 205 Degree F.

Combustion Blower Light

Indicates Power to combustion blower

Feed Motor Light Indicates Power to the feed motor.

Igniter Light

Indicates power to the igniter

Feed adjuster

Sets the maximum feed rate

Test

Combustion blower , feed motor and safety dump zone are fully energized for the first minute. Combustion blower alternates from high to low every minute.

Lighting Mode Selector

Switched between Auto and Manual lighting

Mode Selector/Min Temp Dial

Used to turn the boiler on or off and set the desired minimum operating temperautre of the boiler.

Dealer Diagnostic Port

For dealer maintenance only. Requires special DDM monitor supplied to Harman Dealers exclusively.

Max Temp dial

The “Max Temp Dial” is used to set the desired maximum operating temperature of the boiler.

Status light error messages: 1 Blink: Indicates control board self diagnostic failure. This

requires a manual reset by cycling the main power off for a few seconds and re-connect.

3 Blinks: Indicates ESP (Exhaust Sensing Probe) failure. This requires a manual reset by cycling the main power off for a few seconds and re-connect.

5 Blinks: (In Auto Light Mode Only) Indicates that the igniter has failed to light the fire after 40 Minutes. To reset - Turn the Mode Selector/Min. Temp. to OFF and then back to the desired temperature.

6 Blinks : Indicates that the control has calculated poor or incomplete combustion occurring for 25 or more minutes. A six blink status may be set if the stove is allowed to run out of pellets. To reset, turn Mode Selector/Min Temp dial to "OFF" then back on to the desired temperature. If the unit was not out of pellets, see Troubleshooting section, Page 31, for more details.

7 Blink: Boiler water over heat saftey shut down (210 Degree Farenheit) This requires a manual reset by cycling the main power off for a few seconds and re-connect.

Mode Selector/Min. Temp.

Used to turn the boiler on or off and set the desired minimum operating temperautre of the boiler.

Max. Temp./ Min. Temp. Water Temperature Settings

See “Setting the boiler temperature” found on page 21.

OFF Mode

Turning the Mode Selector/Min.T emp. to OFF will shut down the boiler.

Operation

Setting The Boiler Temperature

Without the Outdoor Air T emperature Sensor Installed

simply turn the Max. T emp. water temperature dial to the desired setting. The control and the boiler will then perform to achieve and maintain the set temperature.

mode switch, on or off. T urning the knob fully counterclockwise is the “OFF” position while turning the knob clockwise past the 120 degree position is the “ON” position.

With The Outdoor Air T emp - Sensor Installed

above.

mode setting (on or off) now also has the function of setting the minimum boiler water temperature. This would be the lowest boiler water temperature that you want to have based on the following factors.

NOTE:

Although the full operational scale of the boiler water temperature setting is from 120 to 185 degrees F, in most cases it would not be recommended to maintain a boiler temperature less than 140 degrees F.

T o set the maximum boiler water temperature,

The Min. T emp. Knob simply becomes the boiler

Maximum boiler temp setting is as described

The MIN. TEMP . knob in addition to being the

1.) Outdoor Air T emperature (OA T)

2.) Domestic Hot W ater Use a.) Hot W ater Coil Option b.) Indirect Hot W ater Storage

3.) Overall Volume of the Heating System

Control Board Operation

Aquastat Sensor - This sensor is located in the aquastat well on the top of the water jacket. This sensor along with the outdoor air sensor is what the control board uses to regulate the feed rate based on these two observed conditions. (Boiler T emp. & Outdoor Air T emperature)

Outdoor Air Temp. Sensor (OAT) - This sensor is located outside the building (on the north side of the house and out of direct sunlight). The Outdoor Air Sensor is used to perform hot water reset based on outdoor air temperatures.

When the OA T sensor is installed, at zero degrees F (outside temperature), the boiler will operate at the temperature set on the MAX. TEMP . knob. The boiler water temperature will decrease by 1 degree F . for every 1 degree F . in temperature rise of the outdoor air .

NOTE: Pellet Boiler Outdoor Air Reset Operation Graph located on page 22.

The PB105 is designed to withstand lower return water temperatures however, extended return temperatures below 130 degrees F can cause condensation in the secondary ash chamber area and also in the venting system both of which could cause damage in these areas.

One Exception to this would be summertime operation with a domestic hot water coil option. The boiler water temperature could be maintained at a lower temperature since there would be no load from the heating system and recovery would be quick.

NOTE:

If the system is run at the lower temperature settings, conditions of the firebox, boiler tubes, secondary ash chamber and venting should be monitored closely. If any indications show excess condensation the boiler water temperature will need to be increased until condensation does not occur.

* No change in boiler tem perature after reaching mini mum s etpoint t emp

Degree

Water Temp

Degree

* No change in boiler tem perature after reaching mini mum s etpoint t emp

Degree

Water Temp

5180

0185

5180

65 120

60 125

55 130

50 135

45 140

40 145

35 150

30 155

25 160

20 165

65 120

60 125

55 130

50 135

45 140

40 145

35 150

OAT

Pellet Boil er Outdoor Ai r Reset Operat i on

Example # 1

1 degree for every 1 degree in t em perat ure rise of the OA

Mi n set @ 12 0

Max set @ 185

30 155

15 170

25 160

20 165

15 170

0185

10 175

Water Temp

5175

0180

5175

65 150

60 150

55 150

50 150

45 150

40 150

35 150

30 150

25 155

20 160

65 150

60 150

55 150

50 150

45 150

40 150

35 150

OAT

Example # 2

Mi n set @ 15 0

Max set @ 180

30 150

15 165

25 155

20 160

15 165

0180

10 170

Operation

S tarting A Fire Automatically

1. Turn Mode Selector to "OFF".

This resets the control in addition to turning it off.

2. Clean burnpot with scraper, if necessary .

This is usually a weekly maintenance procedure. Cleaning the burn pot with the scraper with a small amount of new fuel in the bottom is not a problem. First, scrape the ashes on the front of the burn pot into the ash pan. Then scrape the hole grid surface downward into the burn pot. When the stove is ignited these scrapings will be pushed out by the feeder .

Scrape burnpot to remove any carbon bu i ld- up t ha t m ay have occ urr e d

Scraping can be done while in operation if perf orm ed through the firebox door opening

NOTE: To minimize the amount of stress placed on the hopper swing plate hinges, opening of the hopper swing plate should be done when the hopper fuel level is low whenever possible.

3. Fill hopper with pellets.

When filling the hopper check for excessive fines in the bottom of the hopper. Fines are small pieces of broken pellets (sawdust). Fines do not flow easily and often build up on the hopper funnel bottom angles. These fines can be pushed into the feeder opening and then fill the hopper with pellets. As the system works, they will be burned.

Operation

4. If starting after an empty hopper, turn Feed Adjuster to "TEST" (for one 60

second cycle). the auger tube and also allow you to check the motors for operation. NOTE: The auger

motor will not operate with any of the doors open.

5. Turn Feed Adjuster to #4.

If this is your first fire or you are trying

different pellets, set the feed adjuster to #4, This is a conservative number and will probably need to be increased if maximum BTU output is desired. After you know a feed rate setting that works well for your application, use that setting.

This will purge pellets into

6. Flip the Igniter Switch up into the "AUTO" position.

7. Turn the MAX. TEMP. Dial on the control board to the desired temperature. This setting must always be higher then the MIN. TEMP. setting.

WARNING: HOT WHILE IN OPERATION. KEEP CHILDREN, CLOTHING, AND FURNITURE A WAY. CONTACT MA Y CAUSE SKIN BURNS.

Operation

8. T urn the MIN. TEMP. Dial on the control board to the desired Minimum temperature. This will start the

lighting process if the temperature at the aquastat sensor is less than the set temperature on the MAX TEMP. dial. The PB105 is more than just an automatic ignition pellet boiler . The automatic system will allow the fire size to be adjusted to match the heating needs and even put the fire out if necessary . If heat is needed after the fire is out, the PB105 will automatically re-ignite and adjust the fire size to match the heating need.

Fig. 12

7. Open hopper swing plate as shown in Fig. 13 (See “NOTE” on page 23.)

9. Fill hopper with pellets and remove ashes as required.

Type of Fuel

Use pelletized wood only . The lower the ash content of the pellets the less cleaning that will be needed of the heat exchanger surfaces. The cleaner these surfaces are kept, the more efficient the boiler will be.

NOTE: Do not burn garbage, gasoline, naphtha, engine oil, or other inappropriate materials in the PB105.

Stor e pellets in the manufacturer’s wrapping until needed to prevent pellets from absorbing moisture. Do not store fuel within the appliance installation clearances, or within the space required for fueling, ash removal, and other routine maintenance operations.

Lighting A Fire Manually

Lighting the fire manually will not be necessary unless

the igniter in the burnpot fails.

Follow steps 1 through 5 of the instructions for automatic lighting.

6. Flip the Igniter Switch Down into the

"MANUAL-LIGHT" position. See Fig. 12.

Fig. 13

8. Fill burnpot with pellets as shown. See Fig. 14. Only fill level with the front edge. ( ------- DO NOT OVERFILL ------- )

Fig. 14

9. Have matches or other ignition source ready.

10. Apply starting gel as shown in Fig.15

Operation

Fig. 15

NOTE: Stirring the starting gel into the pellets usu-

ally allows the fire to become established quicker.

11. Turn Mode Selector to desired MIN TEMP setting.

This will start the combustion blower and allow the ESP to control the fire in relation to the MAX TEMP Dial setting. (The MAX TEMP dial setting must always be set above the MIN TEMP setting) Once the fire is well established the MAX TEMP dial can remain on any temperature setting desired.

NOTE: When the Switch is set to Manual igniter position the boiler will function as in auto igniter except the fire will not be allowed to go out. It will only be allowed to go to a minimum burn rate between the times the aquastat is calling for heat. This rate is about 1.1 pound of fuel per hour.

CAUTION: A vapor flash could occur if too much

time is allowed to pass before lighting the starting gel.

CAUTION: Care must be taken not to get starting

gel on your hands or clothing. Serious burns could occur during the lighting process.

CAUTION: Never try to apply more starting gel to

an already burning fire, or a fire with smoldering pellets.

"NEVER USE GASOLINE, GASOLINE-TYPE LANTERN FUEL, KEROSENE, CHARCOAL LIGHTER FLUID, OR SIMILAR LIQUIDS TO ST ART OR "FRESHEN UP " A FIRE IN THIS FURNACE. KEEP ALL SUCH LIQUIDS WELL AWAY FROM THE FURNACE WHILE IN USE".

12. Light The Starting Gel With A Match.

13. Close The Doors

The fire will light and the PB105 will adjust the fire to

proper level according to the MAX TEMP dial setting.

Solid-fuel burning appliances need to be cleaned frequently because soot, creosote, and ash may accumulate. If you suspect a chimney/vent pipe fire do the following:

1. Call the fire department.

2. Remove fuel from the burn pot using the burnpot scraping tool to scrape the pellets into the ash pan.

3. Remove the ash pan from the unit and take outside. Do not place ash pan on a combustible material.

4. Turn of f circuit breaker at unit.

5. Do not use the unit until a qualified person has inspected your appliance and venting.

Fig. 16

Burnpot cleaning:

The burnpot should be cleaned no less than once a week. For best operation the burnpot should be cleaned every time the hopper is filled with pellets. The fire does not have to be out to scrape the burnpot although it is recomended the boiler be on minimum burn at the time of cleaning.

Note: Scraping can be done while in operation if performed throug the firebox door opening. See Fig. 17

Use the flat end of the scraper provided to scrape down over the holed surface of the burnpot grate. See Fig. 18. It is not necessary to clean out the scrapings from this cleaning because they will be pushed out the next time the auger operates.

Note: Make a special effort to scrape the bottom inside corners of the burnpot where the auger tube enters the burnpot. Carbon deposits can build up over time in this area that may cause a restriction to the flow of pellets into the burnpot.

Note: An old long shank scr ewdriver with the end sharpened is an ideal aid in the removal of these deposits.

Cleaning the burnpot air chamber:

This area only needs to be cleaned twice a heating season, unless excessive buildup is noticed during scheduled cleanings.

There is a cover on the front of the burnpot to gain access to the air chamber and igniter. The cover is held into place by two thumb screws. Loosen the thumb screws and remove the cover. See Fig. 19. The air chamber can be cleaned of any ash that has fallen through the holes during operation and cleaning. Also at this time, remove the feeder assembly cover and remove any fines that may have accumulated.

NOTE: ALWAYS REMEMBER TO CLOSE THE CLEANOUT COVER AFTER CLEANING.

Feeder Chamber (Fig. 20):

This chamber may get a buildup of fines from the feeder mechanism movement. This area should be checked and cleaned at least once a year.

To remove the feeder cover:

• Lossen the 5/16" wing nut.

• Slide the cover off of the threaded stud and lift upward.

• Inspect and clean the inner chamber if necessary . See Fig. 20.

• Reinstall the cover making certain it is centered on the feeder body and tighten as tightly as you can by hand.

Ash D oo r

Maintenance

Ash Pan

Ash Pan Handle

Ash Door Handle

S ec o ndary Ash C hamber Ac c ess Co ver

Ash Removal

It is recommended to remove the ashes when the boiler is not in operation. This lessens the chances of coming in contact with hot surfaces. Ashes can be removed while in operation but, extra care must be taken.

Open Ash Door

Lift the latch and open the door as shown in fig. 21.

NOTE: Keep hopper lid, hopper swing plate, fir ebox door and ash pan door closed during operation and maintain all seals in good condition.

Remove Ash Pan

Always wear gloves to remove ash pan. Grab the ash pan by the finger hold and pull it out of the boiler. Lift the ash pan by the finger hold and use it for carrying the ash pan.

Close the ash door before disposing the ashes

Fig. 21

Disposal of Ashes

Ashes should be placed in a metal container with a tight fitting lid. The closed container of ashes should be placed on a non-combustible floor or on the ground, well away from all combustible materials, pending final disposal. If ashes are disposed of by burial in soil or otherwise locally dispersed, they should be retained in the closed container until all cinders have thoroughly cooled.

Soot and Flyash: Formation and Need for Removal

The products of combustion will contain small particles of flyash. The flyash will collect in the exhaust venting system and restrict the flow of the flue gases. Incomplete combustion, such as occurs during startup, shutdown, or incorrect operation of the room heater will lead to some soot formation which will collect in the exhaust venting system. The exhaust venting system should be inspected at least twice monthly to determine if cleaning is necessary .

Maintenance

Cleaning

This cleaning should be done after each ton of pellets used. The frequency of this cleaning will be directly related to the quality and the ash content of the pellets being used. Keep in mind that the cleaner the heat exchanger surface is kept, the higher the heat transfer efficiency will be.

Due to it’s ease of restarting it is recommended that the boiler be OFF and COOL before cleaning.

Start by pulling the (3) heat exchanger cleanout rods by pulling and pushing these rods vigorously severl times. It will remove any fly ash built up on the heat exchanger tubes. This can also be done at any time during the operation of the boiler to maintain higher efficiencies. Make sure that these rods are pushed in at all times.

Cleaning Steps

-Open hopper swing plate to access burnpot and also the firebox. W ith a wisp brush, wire brush, stiff bristled paint brush or a soot vac, clean the firebox walls and any fly ash that has accumilated on the ledges of the burnpot, or burnpot opening. At this time you can scrape and clean the burnpot and fines cleanout area. Be careful not to damage the igniter located inside the burnpot.

-Open firebox door and vaccum ash from ledges and ash deflector. You can also clean the firebox door viewing glass using a typical glass cleaner and soft cloth.

Latch (2)

Combustio n

Combustio n Blower Moto

Blower Moto

Thumb Screws (3 Total)

Heat Shiel

ESP Probe

Maintenance

should attempt to clean the combustion blower .

disconnected during the cleaning process.

See Fig. 23. Hold the motor head with one hand and the blower plate handle with the other hand. Pull outward on the plate handle until the complete unit comes loose. Now rotate the plate counter-clockwise about 1/8 turn. This will allow the complete assembly to be removed from the blower chamber.

Fig. 22

sealing overlap. See Fig. 24.

will throw the fan blade out of balance or it may rub the inner chamber, which may affect the performance of the boiler. Any horizontal and vertical flue pipe directly above the unit should be cleaned at this time

boiler is the first place fly ash will settle, due to the slowing of flue gas velocity through horizontal pipe. Cleaning of horizontal venting pipes is very important to the efficiency of this boiler.

Fig. 23

of the flue tunnel (this is the hole that goes up into the flue pipe). See Fig. 24.

same area. CARE MUST BE TAKEN NOT TO DAMAGE THE ESP PROBE DURING CLEANING. Bending of the ESP probe will make it difficult to remove if it should become necessary. See Fig. 24.

The furnace MUST be OFF and COOL before you

The wire to the combustion blower doesn’t need to be

Loosen the three (3) thumb screws about 4 turns each.

Clean the blower fan blades and the blower plate

NOTE: Be carefull not to bend the fan blades, this

NOTE: The horizontal flue pipe directly above the

Clean the flue outlet throat as well as the inner chamber

NOTE: The ESP probe sensing tip extends into this

Sealing Overlap

5” Double

5” Double Bladed Fan

Bladed Fan

Fig. 24

Combustion Blower Cleaning

Remove the combustion blower heat shield.There are two latches that hold the shield in place . See Fig. 22 Flip the latches up and pull the shield away from the furnace. It can not be fully removed, it can only be moved down over the wire until it hangs on the junction box.

Clean the boiler blower plate, sealing overlap. See Fig

24. Make sure there are no fly ash buildups that may block the easy flow of flue gasses into the combustion blower inlet hole. ( A flashlight may be necessary. )

Cleaning the T ube heat Exchangers:

The heat exchanger tubes have external handles that

operate the cleaning mechanisms. See picture on page 29.

This cleaning should be done at least once a week, although it can be done as often as desired. The cleaner the heat exchangers are, the more efficient the boiler will be. This cleaning can be done at any time and in any mode of operation.

CAUTION: Inspect flue pipes, flue pipe joints and flue pipe seals regularly to ensure that smoke and flue gases are not entering the home.

FEEDER DOES NOT FEED

1. No pellets in hopper .

2. Firebox draft may be too low for low draft pressure switch in feeder circuit to operate. Check for closed doors, loose or missing gasket on doors or hopper lid, or a faulty pressure switch.

3. Feed motor will not run until ESP senses 170 deg. F. Maybe you did not put enough pellets in the burn pot before lighting the fire manually .

4. Something is restricting flow in the hopper or causing the slide plate to stick.

5. Feed motor has failed.

PARTIALLY BURNED PELLETS

1. Feed rate too high.

2. Draft too low. (Check burn pot clean-out slide and door gasket).

3. Burn pot or heat exchanger tubes may need to be cleaned.

4. Combination of all the above.

5. #6 status blink: A 6 blink control board status indication is caused by poor or incomplete combustion. The Automatic Ignition circuit board has the ability to track the combustion through feed settings and ESP temperatures. When the control board has calculated poor or incomplete combustion, it will shut down the unit as a safety feature. (Poor or incomplete combustion is a contributer of creosote which may cause a chimney fire) A 6 blink status may be caused by several things:

1. Blocked or partially blocked flue.

2. Blocked or partially blocked inlet air . a. Backdraft damper on the inlet pipe may be

stuck closed.

b. If outside air is installed, the inlet cover may

be blocked.

3. The air chamber under the burnpot may be

filled with fines and small bits of ash.

4. The holes in the burnpot may be getting filled

with ash or carbon buildup.

5. Combustion blower fan blades may need

cleaned.

6. There is no fuel in the hopper .

SMOKE SMELL

Seal the vent pipe joints and connection to stove with silicone.

FIRE HAS GONE OUT

1. No pellets in hopper .

2. Draft setting is too low .

3. Something is restricting fuel flow.

4. Feed motor or combustion blower has failed.

5. Power failure or blown fuse.

SMOKE IS VISIBLE COMING OUT OF VENT

1. Air-fuel ratio is too rich. A. Feed rate too high. B. Draft too low caused by a gasket leak.

LOW HEAT OUTPUT

1. Feed rate too low

2. Draft too low because of gasket leak.

3. Poor quality or damp pellets

4. Combination of 1 and 2.

Cleaning Burn Pot

Whenever your boiler is not burning, take the opportunity to scrape the burn pot to remove carbon buildup. A vacuum cleaner is handy to remove the residue. Be sure the boiler is cold

if you use a vacuum.

Carbon buildup can be scraped loose with the fire burning using the special tool provided with your stove. Scrape the floor and sides of the burn pot. The carbon will be pushed out by the incoming fuel. Always wear gloves to do this.

Removing Ashes

Ashes can be removed while in operation, but extra care must be taken and always wear gloves.

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Feeder Parts

Specifications

Wiring Diagram

Parts List

ITEM NUMBER DESCRIPTION

0-88-00248 RUBBER GROMMET (Hopper Lid - 7' Needed) 0-88-88100 1" WHITE GASKET W/PSA SINGLE PL Y (Access Plate - 2' Needed)

1" WHITE GASKET W/PSA SINGLE PL Y (FDR Swing Plate - 5' Needed)

0-88-88250 1" WHITE GASKET W/PSA DOUBLE PL Y (Firebox Door - 3.5' Needed)

1" WHITE GASKET W/PSA DOUBLE PL Y (Flue - 1.5' Needed) 1-10-00330 IGNITER ASY 1-10-07210 BURN POT WELDMENT 1-10-09330 CIRCUIT BOARD PLA TE W/LABEL 1-10-72129 ASH P AN 1-10-73416 COMBUSTION BLOWER MOUNT 2-00-73362 CONTROL COVER 3-00-08534 FLAME GUIDE 3-00-677154 UL CAM BLOCK 3-10-05060 1/2" PIPE THREAD MALE DRAIN 3-10-77382 SAFETY RELIEF VAL VE 3-10-78422 PRESSURE/TEMP GAUGE 3-10-935111 WELL 3-20-00607 THERMOST A T EXTENSION 3-20-00744 THERMISTER PROBE 3-20-02583 2 PAIR TWISTED CA T 3 CABLE (100 FT .) 3-20-05630 CIRCUIT BOARD 3-20-09302 FEED MOTOR - 6 RPM 3-20-09302B FEED MOTOR BLADE 3-20-3433 PRESSURE SWITCH 3-20-49447 6 A MP FUSE 3-20-502221 COMBUSTION BLOWER BLADE 3-20-72180 AQUA TEMP SENSOR/OUTDOOR AIR TEMP . SENSOR 3-20-72181 OUTDOOR AIR EXTENSION TCP 3-20-72195 WIRING HARNESS 3-21-08639 COMBUSTION BLOWER 3-31-015 CONTROL BOARD SHAFT (3) 3-31-199110 SWELL LA TCH 3-31-3014 CAM BLOCK BEARING 3-31-605 CONTROL BOARD KNOB (3) 3-31-72196 1/2-13 THREAD RED NYLON KNOB 3-40-00086-3 1/2" SPRING HANDLE 3-44-00409 BURN POT GASKET 3-44-375501 3/8' X 1/2" SILICONE GASKET W/PSA (Hopper to Feeder - 1.5' Needed) 3-44-53500 1/2" ROUND GASKET (Ash Door - 5.5' Needed) 3-50-00565 AUGER

3-90-07205 OWNERS MANUAL 4-00-00042 DOOR HANDLE

Warranty

HARMAN GOLD WARRANTY 6 YEAR TRANSFERABLE LIMITED WARRANTY (Residential) 1 YEAR LIMITED W ARRANTY (Commercial)

Harman Stove Company warrants its products to be free from defects in material or workmanship, in normal use and service, for a period of 6 years from the date of sales invoice and for mechanical and electrical failures, in normal use and service, for a period of 3 years from the date of sales invoice.

If defective in material or workmanship, during the warranty period, Harman Stove Company will, at its option, repair or replace the product as described below.

The warranty above constitutes the entire warranty with respect to Harman Stove Company products. HARMAN STOVE COMPANY MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED, INCLUDING “ANY” WARRANTY OF MERCHANT ABILITY, OR W ARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. No employee, agent, dealer , or other person is authorized to give any warranty on behalf of Harman Stove Company . This warranty does not apply if the product has been altered in any way after leaving the factory. Harman Stove Company and its agents assume no liability for “resultant damages of any kind” arising from the use of its products. In addition, the manufacturer and its warranty administrator shall be held free and harmless from liability from damage to property related to the operation, proper or improper, of the equipment.

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF.

THESE WARRANTIES APPLY only if the device is installed and operated as recommended in the user’s manual.

THESE WARRANTIES WILL NOT APPLY if abuse, accident, improper installation, negligence, or use beyond rated capacity causes damage.

HOW TO MAKE A CLAIM - Any claim under this warranty should be made to the dealer from whom this appliance was purchased. Then contact is made with manufacturer, giving the model and serial numbers, the date of purchase, your dealer’s name and address, plus a simple explanation of the nature of the defect. Extra costs such as mileage and overtime are not covered. Nuisance calls are not covered by these warranties.

THIS WARRANTY IS LIMITED TO DEFECTIVE PARTS - REPAIR AND/OR REPLACEMENT AT HARMAN STOVE COMPANY’S OPTION AND EXCLUDES ANY INCIDENTAL AND CONSEQUENTIAL DAMAGES CONNECTED THEREWITH.

WARRANTY EXCLUSIONS: Failure due, but not limited to, fire, lightning, acts of God, power failures and/or surges, rust, corrosion and venting problems are not covered. Damage and/or repairs including but not limited to; remote controls, filters, fuses, knobs, glass, ceramic brick panels, ceramic fiber afterburners, combustion packages, door packing, tile, ceramic log sets, paint, batteries or battery backups and related duct work are not covered. Also excluded from this warranty are consumable or normal wear items including but not limited to; flame guides, grates, coal bars, afterburner hoods, fire brick, gaskets. Additional exclusions for corn stoves are burn pot housing weldment, burn pot grate weldment (pellet or corn), burnpot front plate (pellet or corn), burnpot front plate lock, corn auger extension, ceramic insert, and ceramic insert plate. Additional or unusual utility bills incurred due to any malfunction or defect in equipment and the labor cost of gaining access to or removal of a unit that requires special tools or equipment are not covered. Maintenance needed to keep the stove in “good operating condition” is not covered. This includes, but is not limited to, cleaning, adjustment of customer controls and customer education. Labor, materials, expenses and/or equipment needed to comply with law and/or regulations set forth by any governmental agencies are not covered.

This Warranty provides specific legal rights and the consumer may have other rights that vary from state to state.

In the event of change in ownership, the remaining portion of this warranty may be transferred to the new owner by sending the new owner information and a transfer fee of $25.00 US to the Harman Stove Company.

PLEASE READ THE LITERATURE BY THE MANUF ACTURER FOR THE VARIOUS ACCESSOR Y DEVICES. THE MANUF ACTURER WARRANTS THESE ACCESSOR Y DEVICES, NOT HARMAN STOVE COMP ANY OR THEIR WARRANTY ADMINISTRA T OR. FUR THERMORE, THESE ACCESSOR Y DEVICES MUST BE INSTALLED AND USED ACCORDING TO THE RECOMMENDATIONS OF THE MANUF ACTURER.

REMEDIES - The remedies set forth herein are exclusive and the liability of seller with respect to any contract or sale or anything done in connection therewith, whether in Contract, in tort, under any warranty, or otherwise, shall not, except as herein expressly provided, exceed the price of the equipment or part of which such liability is based.

CLARIFY - The above represents the complete warranty, which is given in connection with stoves, manufactured by Harman Stove Company. No other commitments, verbal or otherwise, shall apply except by a written addendum to this

warranty.

Testing Label

NOTES

Quick Reference ( Auto-Light )

1 Turn Mode Selector to OFF .

2 Use heat exchanger cleanout rods to clean the heat exchanger tubes.**

3 Scrape the air holes in the burnpot.**

4 Fill the hopper with pellets.

5 T urn Feed Adjuster to “T est”.*

6 Check the Combustion Blower and Feeder Motor for operation.*

7 T urn Feed Adjuster back to the #4 setting.

8 T urn the MAX TEMP dial to the desir ed temperature.

9 Turn MIN TEMP dial to the desired settings.*

10 Flip the igniter switch to Auto.*

The boiler will ignite if the temperature of the boiler water is less than the

temperature set on MAX TEMP dial..

*See the section on Operation for information

about Manual Lighting and Emergency Power.

**See the section on Maintenance for more details

about cleaning.

Harman-Kardon PB 105 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual