Harman-Kardon PB 105 User Manual
Installation & Operating Manual
The Harman PB 105 Pellet Boiler
“Ce manuel est disponible en Français sur demande”
R1
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 ,
R4
3
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
4
Assembly
nt
C
n B
He
W
ere
nt
C
n B
He
W
ere
ombustio
ombustio
ESP Probe
ESP Probe
lue Tunne l Weldme
lue Tunne l Weldme
ater Coil Option Shown H
ater Coil Option Shown H
*Re mo ved w/ Domest ic Ho t
*Re mo ved w/ Domest ic Ho t
Blank Cover*
Blank Cover*
Pressure Relief Valve
Pressure Relief Valve
Aquastat Well
Aquastat Well
Tempera t ure / Pressu re Gauge
Tempera t ure / Pressu re Gauge
Firebox & Ash
Doo r Handle s
Firebox & Ash
QTY (5)
QTY (5)
Doo r Handle s
Thumb Screws (3)
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.
5
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.
6
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
7
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.
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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".
1
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/
1
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 .
1
I. The clearance to service regulator vent outlet
must be a minimum of 6 feet.
1
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”.
1
K. The clearance to a mechanical air supply inlet
must be a minimum of 10 feet.
1
(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.
1
Certain Canadian and or Local codes or regula-
tions may require different clearances.
2
A vent shall not terminate directly above a sidewalk or paved driveway which is located between two
single family dwellings and serves both dwellings.
3
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)
V
= Vent terminal
Fixed
Closed
Openable
A
Openable
= Air supply inlet
Fixed
Closed
Inside
Corner
Detail
= Area where terminal is not permitted
Fig. 2
9
Venting
10
Fig. 3
Venting
Venting
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.
5.
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.
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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.
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