Hearth and Home Technologies CASTINS-CWL, CASTINS-CSB, 810-03201 PMH, 810-02901 MBK User Manual
CASTILE PELLET INSERT
OMNI-Test Laboratories, Inc.
R
Owner’s Manual
Installation and Operation
Models:
810-02901 (MBK)
810-03201 (PMH)
CASTINS-CSB
CASTINS-CWL
• Important operating and
maintenance instructions included.
WARNING
CAUTION
DO NOT DISCARD THIS MANUAL
•
•
Read, understand and
follow these instructions for safe installation and operation.
Leave this manual
with party responsible for use and
operation.
Tested and
Listed by
C
WARNING
O-T L
Oregon USA
US
Portland
DO NOT
DISCARD
Please read this entire manual
before installation and use of this
pellet fuel-burning room heater.
Failure to follow these instructions
could result in property damage,
bodily injury or even death.
• Do not store or use gasoline or other flam-
mable vapors and liquids in the vicinity of this
or any other appliance.
• Do not overfire - If any external part starts
to glow, you are overfiring. Reduce feed rate.
Overfiring will void your warranty.
• Comply with all minimum clearances to com
bustibles as specified. Failure to comply may
cause house fire.
CAUTION
Tested and approved for wood pellets and shelled
field corn fuel only. Burning of any other type of fuel
voids your warranty.
HOT! DO NOT TOUCH.
SEVERE BURNS MAY RESULT.
CLOTHING IGNITION MAY RESULT.
Glass and other surfaces are hot
during operation and cool down.
• Keep children away.
• CAREFULLY SUPERVISE children in same room as
appliance.
• Alert children and adults to hazards of high
temperatures.
• Do NOT operate with protective barriers open or
removed.
-
• Keep clothing, furniture, draperies and other
combustibles away.
CAUTION
Check building codes prior to installation.
• Installation MUST comply with local, regional, state
and national codes and regulations.
• Consult local building, fire officials or authorities
having jurisdiction about restrictions, installation
inspection, and permits.
www.quadrafire.com
250-7251F
September 1, 2008
Castile Pellet Insert
R
Hearth & Home Technologies welcomes you to our
tradition of excellence! In choosing a Quadra-Fire
appliance, you have our assurance of commitment
to quality, durability, and performance.
This commitment begins with our research of the
market, including ‘Voice of the Customer’ contacts,
ensuring we make products that will satisfy your
needs.
Our Research and Development facility then
employs the world’s most advanced technology
to achieve the optimum operation of our stoves,
inserts and fireplaces. And yet we are old-fashioned when it comes to craftsmanship. Each unit
is meticulously fabricated and are hand-finished for
lasting beauty and enjoyment.
Our pledge to quality is completed as each model
undergoes a quality control inspection. From
design, to fabrication, to shipping: We wish you
and your family many years of enjoyment in the
warmth and comfort of your hearth appliance.
Thank you for choosing Quadra-Fire.
SAMPLE OF CLEARANCE TO COMBUSTIBLES LABEL
LOCATION: On beaded chain behind right access
panel. Panel hinges open.
Tested and
Listed by
C
OMNI-Test Laboratories, Inc.
Report No.
#061-S-42-2
Listed Solid Fuel Room Heater/Pellet Type Insert.
appliance has been tested and listed for use in Manufactured Homes in accordance with OAR
814-23-9000 through 814-23-909.
Tested to: ASTM E-1509-95, ULC S628-93, ULC /ORD-C1482-M1990 Room Heating Pellet Burning Type,
(UM) 84-HUD FOR USE
Route power cord away from unit. Do not route cord under or in front of appliance.
A
C
0 in. Clearance To Exposed Section and Face Trim
SIDE WALL
A
Portland
O-T L
Oregon USA
US
Electrical Rating:
ONLY WITH PELLETIZED WOOD OR SHELLED FIELD CORN FUEL.
MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS
C
B
SAMPLE
MANTEL
B
C
F
E
SAFETY LABEL
Castile Pellet Insert
Input Rating: 30,000 BTU/HR.
115 VAC, 60 Hz, Start 4.1 Amps, Run 1.1 AMPS.
D
B
Masonry or Zero Clearance
A Insert side to combustible
Face Trim
B
C Insert top to face trim 0 in. 0mm
D
D
E Hearth extension from door opening
F
DO NOT REMOVE THIS LABEL
Also suitable for Mobile Home Installation. This
AS A BUILT-IN UNIT
A Top of Hopper Top/Rear Vent
B
Side of Outside Skin
C Back of Hopper Rear Vent 0 in. (0mm)
Top Vent 2.5 in. (64mm)
D
Vent Pipe to Combustible
E
E From Panel Edge 0 in. (0mm)
Insert top to mantel
Insert side face trim
Hearth extension from side of door opening
0 in. 0mm
Manufactured by:
R
1445 Highway North, Colville, WA 99114
www.quadrafire.com
Top/Rear Vent
Rear Vent 3.0 in. (76mm)
0 in. 0mm
12 in. 305mm
6 in. 152mm
6 in. 152mm
0 in. (0mm)
0 in. (0mm)
7014-143
Page 2
Tested and
Listed by
Test Lab &
Rpt Nbr.
SAMPLE OF SERIAL NUMBER & DATE OF MANUFACTURE LABEL
LOCATION: Inside hopper on the top
T E ER T T T C EE C RE C T F R T RE . C T CT C SE S
CT
R S. SEE E TE
res lt in emissions prod cts com stion rom t e opper nder certain conditions. aintain opper seal in
STR CT S.
perate t is nit it el opper lid closed. Fail re to do so ma
ood condition. o not o er ill opper.
TTE T
C RS E R T . E S T C ER. R E ES E F TS ET ES TE E TS E
ES CE S E ST T . E C T CT E T C SER ES R RES E . R
T ETTE ET ES STR CT S.
p re cet appareil a ec le co ercle de la tr mie erm . e d a t de ne pas s i re les instr ctions
pe t r s lter so s certaines conditions en ne com stion des missions des prod its enant de la tr mie. e pas remplir la tr mie trop pleine.
Portland
US
Oregon USA
Report / Rapport
#061-S-42-2
DO NOT REMOVE THIS LABEL
NE PAS ENLEVER L TI UETTE
Made in U.S.A.
Fait A tats-Unis
O-T L
C
OMNI-Test Laboratories, Inc.
00 00 010
AN FEB MAR APR MAY UNE ULY AU SEPT OCT NOV DEC
Mfg Date
R
CASTILE PELLET INSERT
U.S. ENVIRONMENTAL
PROTECTION A ENCY
This model is exempt from EPA certification
under 40 CFR 60.531 by definition [Wood
Heater (A) "Air-to-Fuel Ratio"].
Model
Name
SERIAL NO.
007
/ NUM RO DU S RIE
Serial No.
250-7251F
0-7 F
September 1, 2008
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Castile Pellet Insert
TABLE OF CONTENTS
Section 1: Listing and Code Approvals
A. Appliance Certifications ......................4
B. Mobile Home Approved ......................4
C. Glass Specifications ............................4
D. Electrical Rating ..................................4
E. BTU & Efficiency Specifications ..........4
Section 2: Getting Started
A. Design, Installation & Location
Considerations ....................................5
B. Fire Safety ..........................................5
C. Tools & Supplies Needed ...................6
D. Measuring Standards..........................6
E. Inspect Appliance, Components
and Pre-Check List .............................6
Section 3: Dimensions & Clearances
A. Appliance Dimensions ........................7
B. Clearances to Combustibles
As A Built-In, UL and ULC ..................8
C. Clearances to Combustibles,
Masonry & Zero Clearance .................9
D. Floor Protection ..................................9
E. Minimum Opening for Factory
Built Fireplace .....................................9
F. Removing Floor of Factory Built
Fireplace .............................................10
Section 4: Vent Information
A. Chimney & Exhaust Connections ........11
B. Venting Termination Requirements ....11
C. Equivalent Feet of Pipe....................... 12
D. Pipe Selection Chart ...........................12
Section 5: Venting Systems
A. Direct Connect with Outside Air ..........13
B. Direct Connect without Outside Air .....13
C. Full Reline with Outside Air .................14
Section 8: Operating Instructions
A. Fuel Size & Material ............................22
B. General Operation Information ...........22
C. Before Your First Fire .........................23
D. Starting Your First Fire ........................23
E. Fire Characteristics ............................. 23
F. Feed Rate Adjustment .......................23
G. Ignition Cycles ....................................24
H. Frequently Asked Questions...............24
Section 9: Troubleshooting ............................25-27
Section 10: Maintaining & Servicing Appliance
A. Proper Shutdown Procedures ............. 28
B. Quick Reference Maintenance Chart ..28
C. General Maintenance & Cleaning .......28-32
D. High Ash Content Maintenance ..........32
E. Igniter Replacement ............................33
F. Glass Replacement .............................33
G. Baffle & Brick Removal & Replace ......34-35
Section 11: Reference Material
A. Component Functions.........................36-37
B. Component Locations .........................38
C. Exploded Drawings .............................39-40
D. Service Parts & Accessories ...............41-42
E. Service & Maintenance Log ................43-44
F. Homeowner’s Notes ............................45
F. Warranty Policy ...................................46-47
G. Contact Information .............................48
Section 6: Mobile Home .................................. 15
Section 7: Appliance Set-Up
A. Reverse Top or Rear Flue Adapter.....16
B. Leveling System ................................. 16
C Outside Air Kit .....................................17
D. Zero Clearance Trim Support ............. 17-18
E. Panel Set & Cast Trim Set ..................19
F. Panel & Trim Set, Econo .....................19
G. Log Set Placement ..............................20
H. Thermostat Installation ........................21
September 1, 2008
250-7251F
Page 3
Castile Pellet Insert
Listing and Code Approvals
1
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A. Appliance Certification
MODEL: Castile Pellet Insert
LABORATORY: OMNI Test Laboratories, Inc
REPORT NO. 061-S-42-2
TYPE: Solid Fuel Room Heater/Pellet Fuel
Burning Type Insert
STANDARD: ASTM E1509-95, ULC S628-93 and
ULC/ORD-C1482-M1990 Room
Heater Pellet Fuel Burning Type and
(UM) 84-HUD, Mobile Home Approved
Colorado: Approved 11-15-02
B. Mobile Home Approved
This appliance is approved for mobile home installations
when not installed in a sleeping room and when an outside
combustion air inlet is provided.
The structural integrity of the mobile home floor, ceiling, and
walls must be maintained. The appliance must be properly
grounded to the frame of the mobile home and use only listed
pellet vent, Class “L” or “PL” connector pipe. A Quadra-Fire
Outside Air Kit must be installed in a mobile home installation.
E. BTU & Efficiency Specifications
Particulate Emissions Rating:
*BTU Output: 8,000 - 30,000 / hr
Heating Capacity: up to 1,500 sq. ft. depending
Hopper Capacity: 45 lbs
Fuel: Wood Pellets or Shelled Corn
Shipping Weight: 260 lbs
*BTU output will vary, depending on the brand of fuel you
use in your appliance. Consult your Quadra-Fire dealer
for best results.
NOTE: Hearth & Home Technologies, manufacturer of
this appliance, reserves the right to alter its products,
their specifications and/or price without notice.
.7 grams/hr
on climate zone
C. Glass Specifications
This appliance is equipped with 5mm ceramic glass. Replace
glass only with 5mm ceramic glass. Please contact your
dealer for replacement glass.
NOTE: This installation must conform with local codes.
In the absence of local codes you must comply with the
ASTM E1509-95, ULC S628-93, ULC/ORD-C-1482
and (UM) 84-HUD
D. Electrical Rating
115 VAC, 60 Hz, Start 4.1 Amps, Run 1.1 Amps
Page 4
250-7251F
September 1, 2008
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Castile Pellet Insert
2
A
. Design, Installation & Location
Getting Started
Considerations
1. Appliance Location
Consideration must be given to safety, convenience, traffic
flow, and the fact that the appliance will need a chimney and
chimney connector. It is a good idea to plan your installation
on paper, using exact measurements for clearances and floor
protection, before actually beginning the installation.
If you are not using an existing chimney, place the appliance
in a location to maintain a clear passage for the installation
of any listed and approved pellet venting system. This appliance may be vented vertically or horizontally.
Maintain specified vent clearance to comubstible requirements listed by the pellet manufactures venting instructions
and all clearance to combustivles listed in this manual.
Check with your local building code agency before you begin
your installation. Be sure local building codes do not supersede UL specifications and always obtain a building permit
so that insurance protection benefits cannot be unexpectedly
cancelled. If any assistance is required during installation,
please contact your local dealer.
We recommend that a qualified building inspector and your
insurance company representative review your plans before
and after installation.
2. Thermostat Location
The thermostat’s location will have some effect on the
appliance’s operation. When the thermostat is located close
to the appliance, it may require a slightly higher temperature
setting to keep the rest of the house comfortable. If the
thermostat location is in an adjacent room or on a different
floor level, you will notice higher temperatures near the
appliance.
B. Fire Safety
Maintain the designated clearances to combustibles. Insulation must not touch the chimney. You must maintain the
designated air space clearance around the chimney. This
space around a chimney is necessary to allow natural heat
removal from the area. Insulation in this space will cause
a heat buildup, which may ignite wood framing. NOTE:
Clearances may only be reduced by means approved
by the regulatory authority having jurisdiction.
To provide reasonable fire safety, the following should be
given serious consideration:
1. Install at least one smoke detector on each floor of
your home to ensure your safety. They should be
located away from the heating appliance and close
to the sleeping areas. Follow the smoke detector
manufacturer’s placement and installation instructions,
and be sure to maintain regularly.
2. A conveniently located Class A fire extinguisher
to contend with small fires resulting from burning
embers.
3. A practiced evacuation plan, consisting of at least 2
escape routes.
4. A plan to deal with a hopper fire as follows:
In the event of a hopper fire:
a. Evacuate the house immediately.
b. Notify fire department.
WARNING
CAUTION
• Do NOT connect this unit to a chimney flue servicing
another appliance.
• Do NOT connect to any air distribution duct or system.
September 1, 2008
250-7251F
Fire Risk.
• Do not operate appliance before reading
and understanding operating instructions.
• Failure to operate appliance properly may
cause a house fire.
Page 5
Castile Pellet Insert
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C. Tools And Supplies Needed
Tools and building supplies normally required
for installation, unless installing into an existing
masonry fireplace:
Reciprocating Saw
Hammer
Phillips Screwdriver
Tape Measure
Safety Glasses
Framing Square
Electric Drill & Bits (1/4”)
1/4” Self-Tapping Screws
Plumb Line
Level
Framing Material
Hi-temp Caulking Material
May also need:
Vent Support Straps
Venting Paint
Gloves
WARNING
Inspect appliance and components for
damage. Damaged parts may impair safe
operation.
• Do NOT install damaged components.
• Do NOT install incomplete components.
• Do NOT install substitute components.
Report damaged parts to dealer.
WARNING
Fire Risk.
Hearth & Home Technologies disclaims any
responsibility for, and the warranty will be
voided by, the following actions:
• Installation and use of any damaged appliance.
• Modification of the appliance.
• Installation other than as instructed by Hearth & Home
Technologies.
• Installation and/or use of any component part not approved
by Hearth & Home Technologies.
• Operating appliance without fully assembling all
components.
• Do NOT Overfire.
Or any such action that may cause a fire hazard.
D. Inspect Appliance & Components and
Pre-Use Check List
1. Place the appliance in a location near the
final installation area and follow the procedures below:
2. Open the appliance and remove all the parts
and articles packed inside the Component
Pack. Inspect all the parts and glass for shipping damage. Contact your dealer if any irregularities are noticed.
3. All safety warnings have been read and followed.
4. This Owner’s Manual has been read.
5. Floor protection requirements have been met.
6. Venting is properly installed.
7. The proper clearances from the appliance and
chimney to combustible materials have been
met.
8. The masonry chimney is inspected by a professional and is clean, or the factory built metal
chimney is installed according to the manufacturer’s instructions and clearances.
9. The chimney meets the required minimum
height.
10.
11. Plated surfaces have been wiped clean, if
12. Thermostat or remote has been installed.
13.
All labels have been removed from the glass
door.
applicable.
A power outlet is available nearby.
Page 6
250-7251F
September 1, 2008
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Dimensions and Clearances
3
A. Appliance Dimensions
Castile Pellet Insert
23-7/16"
(595mm)
32-5/16"
(821mm)
28-1/16"
(713mm)
8"
(203mm)
11-1/16"
(281mm)
43-1/2"
(1105mm)
Figure 7.2- Front ViewFigure 7.1 - Top View
42-1/2"
(1080mm)
30"
(762mm)
30-3/8"
(772mm)
Height Width
Panel Size inch mm inch mm
Small Cast 30 762 42-1/2 1078
Large Cast 34 864 48 1219
Small Econo 30 762 40 1016
NOTE: All views are shown with Panel
& Cast Trim Set installed.
10-3/16"
(259mm)
24-3/4"
(629mm)
9-13/16"
(249mm)
Figure 7.3 -Side View
13-1/16"
(332mm)
9-3/16"
(234mm)
2.0"
24-3/16"
(3614mm)
19.0"
(483mm)
12-3/4"
(324mm)
(51mm)
September 1, 2008
250-7251F
Page 7
Castile Pellet Insert
B. Clearance To Combustibles, UL and ULC
AS A BUILT-IN
R
Figure 8.1
A
D
B
C
B
C
0” (0mm) Clearance To Exposed Section And Face Trim
Inches Millimeters
A Top of Hopper Top or Rear Vent 0 0
B Side of Outside Skin Top or Rear Vent 0 0
C Back of Hopper Top Vent 2.5 64
Rear Vent 0 0
D Vent Pipe to Combustible Top or Rear Vent 3.0 76
E Front Panel Edge Top or Rear Vent 0 0
E
INSTALLED AS A BUILT-IN UNIT
Shown Optional Outside Air
12 in
(305mm)
6 in
(153mm)
Outside
Air
WARNING
Fire Risk.
Comply with all minimum clearances
to combustibles as specified.
Failure to comply may cause house
fire.
NOTE:
• Illustrations reflect typical installations
and are FOR DESIGN PURPOSES
ONLY.
• I
llustrations/diagrams are not drawn to
scale.
• Actual installation may vary due to
individual design preference.
Figure 8.2
Page 8
250-7251F
September 1, 2008
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C. Masonry and Zero Clearance Fireplaces
MANTEL
B
C
SIDE WALL
Castile Pellet Insert
Inches Millimeters
A Insert side to combustible
side wall
B Insert top to mantel 12 305
C Insert top to face trim 0 0
D Insert side to face trim 0 0
00
A
Figure 9.1
F
E
D
D. Floor Protection
Inches Millimeters
E Floor protection hearth extension
6 152
from door opening
F Floor protection to the side of door
6 152
opening
E. Minimum Opening for Masonry and Zero
Clearance Fireplaces
Figure 9.2
September 1, 2008
Location Inches Millimeters
A Rear Width 23-7/16 595
B Depth 18 for Zero Clearance
14 for Masonry
B
C
A
C Height 19-1/4 if drop down
21-1/4 if flush or
hearth mount
457
356
489
540
D Front Width 28-1/4 718
D
250-7251F
Page 9
Castile Pellet Insert
F. Removing Metal Floor of Factory-Built Firebox
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• The firebrick (refractory), glass doors, screen rails, screen
mesh and log grates can be removed from a factory-built
firebox in order to gain minimum insert opening requirements.
• Any smoke shelves, shields and baffles may be removed
from a factory-built firebox if attached with mechanical fasteners.
• The metal floor of the factory-built firebox may be removed
to facilitate the installation of the insert only when a 1/4
(6mm) inch airspace is provided between the insert and
the floor of outer wrap.
The following is only one example as there are many different models of factory-built fireplaces.
Starter hole
Mark area of
floor to cut
Use 2 x 4 from insert
packaging to support insert
Figure 10.3. If the floor is made of thin metal,
we recommend using the 2 x 4 from the insert
packaging to support the insert. The 2 x 4
may need to be cut to the appropriate size.
Keep sharp edge of
metal floor away from
power cord
Figure 10.1. Measure and mark the metal
floor for cutting. With a drill, make a starter
hole in each corner.
Figure 10.2. Using a saws-all, cut out the
floor
Figure 10.4. Place the insert into the factory-built firebox. Ensure that the power
cord can not be damaged by the sharp metal
edge. You may need to cut out a notch to
accommodate the cord.
NOTE: Ensure that the leveling leg is positioned over the 2 x 4 before leveling the
insert. See page 16, for detailed instructions
on how to adjust the leveling legs.
Page 10
250-7251F
September 1, 2008
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Vent Information
4
A. Chimney and Exhaust Connection
1. Chimney & Connector: Use 3 or 4 inch (76-102mm)
diameter type "L" or "PL" venting system. It can be vented
vertically or horizontally.
2. Mobile Home: Approved for all Listed pellet vent. Use
Listed double wall flue connector. A Quadra-Fire outside
air kit must be used with manufactured home installations.
3. Residential: Use 24 gauge single wall flue connector
or a Listed double wall flue connector to Class A Listed
metal chimneys, or masonry chimneys meeting national
and/or local codes for solid fuel appliances.
4. INSTALL VENT AT CLEARANCES SPECIFIED BY THE
VENT MANUFACTURER.
5.
Secure exhaust venting system to the appliance with at
least 3 screws. Also secure all connector pipe joints with
at least 3 screws through each joint.
NOTE: All pipe must be welded seam pipe whenever possible. Seal pipe joints with high temperature silicone (500°F
[260°C] minimum rated only).
NOTE: If burning shelled field corn, you must use approved
venting specifically designed for corn. Follow the instructions from the venting manufacturer.
WARNING
Fire Risk.
• Only LISTED venting components may be
used.
• NO OTHER vent components may be used.
Substitute or damaged vent components may
impair safe operation.
WARNING
Vent surfaces get HOT, can cause burns
if touched. Non-combustible shielding or
guards may be required.
Castile Pellet Insert
B. Venting Termination Requirements
CAUTION
Do not terminate vent in any enclosed or semi-enclosed
area such as a carport, garage, attic, crawl space, under a
sun deck or porch, narrow walkway or closely fenced area,
or any location that can build up a concentration of fumes
such as a stairwell, covered breezeway, etc.
1. Termination must exhaust above air inlet elevation. It is
recommended that at least 60 inches (1524mm) of vertical pipe be installed when appliance is vented directly
through a wall. This will create a natural draft, which
will help prevent the possibility of smoke or odor venting
into the home during a power outage. It will also keep
exhaust from causing a nuisance or hazard by exposing
people or shrubs to high temperatures. The safest and
preferred venting method is to extend the vent vertically
through the roof.
2. Distance from doors and opening windows, or gravity or
ventilation air inlets into building:
a. Not less than 48 inches (1219mm) below;
b. Not less than 48 inches (1219mm) horizontally
from;
c. Not less than 12 inches (305mm) above.
3. Distance from permanently closed windows:
a. Not less than 12 inches (305mm) below, horizontally
from or above.
4. Distance between bottom of termination and grade
should be 12 inches (305mm) minimum. This is conditional upon plants in the area, and nature of grade
surface. The grade surface must be a non-combustible
material (i.e., rock, dirt). The grade surface must not be
lawn. Distance between bottom of termination and public
walkway should be 84 inches (2134mm) minimum.
5. Distance to combustible materials must be 24 inches
(610mm) minimum. This includes adjacent buildings,
fences, protruding parts of the structure, roof overhang,
plants and shrubs, etc.
6. Termination Cap Location (Home Electrical Service)
• Side-to-side clearance is to be the same as minimum
clearance to vinyl inside corners.
•
Clearance of a termination cap below electrical service
shall be the same as minimum clearance to vinyl soffits.
• Clearance of a termination cap above electrical service
will be 12 inches (305mm) minimum.
• Location of the vent termination must not obstruct or
interfere with access to the electrical service.
September 1, 2008
250-7251F
Page 11
Castile Pellet Insert
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C. Equivalent Feet of Pipe
The table below can help you calculate the equivalent feet
of pipe which is a method used to determine pellet vent size.
Figure 12.1.
Example of 3 Elbow-Rear Vent Termination Calculation
2 ft.
3 ft.
2 ft.
2 ft.
Pellet Venting
Component
90o Elbow or Tee
45o Elbow
Horizontal Pipe
Vertical Pipe
WARNING
Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage. Refer
to the owner’s information manual provided with this appliance. For assistance or additional information consult a
qualified installer, service agency or your dealer.
# of
Elbows
Feet of
3X5 15
Note: This is a generic example and is not
intended to represent any specific fuel type.
MultipliedByEquivalent
Pipe
X 3
7X 1 7
2X 0.5 1
Total Equivalent Feet 23
Feet
Components
Equivalent Feet
Figure 12.1
D. Pipe Selection Chart
The chart will help you in determing proper venting
size according to the equivalent feet of pipe calcuated
above and the altitude above sea level of this installation. Figure 12.2.
Locate the calculated equivalent feet of pipe on
the vertical left side of the chart. Move to the right
horizontally on the chart until you reach your altitude
above sea level.
If you fall below the diagonal line, 3 or 4 inch (76 to
102mm) pipe may be used. If it is anywhere above
the diagonal line, a 4 inch (102mm) diameter pipe is
required.
The chart reveals that a 90° elbow is 5 times as restrictive to the flow of exhaust gases under positive pressure as 1 foot of horizontal pipe, and a foot of horizontal
pipe is twice as restrictive as a foot of vertical pipe.
Equivalent Pipe
Length In Feet
Figure 12.2
30
20
10
0
4 in. (102mm) Diameter Pipe Only
3 in. or 4 in. (76mm or 102mm) Diameter Pipe
1 2 3 4 5 6 7 8 9 10
ALTITUDE IN THOUSANDS OF FEET
Page 12
250-7251F
September 1, 2008
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Venting Systems
5
A. Direct Connect With Outside Air
NOTE: In Canada, only a full reline is
allowed per ULC S-628, ORD ULC C1482.
B.
NOTE; Use metal plate
around exhaust vent pipe
and seal all edges with
non-flammable insulation
such as fiberglass, mineral
wool or ceramic material.
Do not use high temperature caulking materials to
seal any edge to prevent
future serviceability.
Castile Pellet Insert
Direct Connect Without Outside Air
Outside Air
through
Rear Wall
Figure 13.1
NOTE:
• Illustrations reflect typical installations and are FOR
DESIGN PURPOSES ONLY.
• I
llustrations/diagrams are not drawn to scale.
• Actual installation may vary due to individual design
preference.
CAUTION
Never draw outside combustion air from:
• Wall, floor or ceiling cavity
• Enclosed space such as an attic or garage
Figure 13.2
WARNING
Fire Risk.
Inspection of Chimney:
• Masonry chimney must be in good condition.
• Meets minimum standard of NFPA 211
Factory-built chimney must be 6 inch (152mm)
•
UL103 HT.
NOTE:
In Canada, where passage through a wall or partition of
combustible construction is desired, the installation shall
conform to CAN/CSA-B365.
September 1, 2008
250-7251F
Page 13
Castile Pellet Insert
C. Full Reline With Outside Air
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NOTE; Use metal
plate around
exhaust vent pipe
and seal all edges
with non-flammable
insulation such as
fiberglass, mineral
wool or ceramic.
12” (305mm)
min. above
12” (305mm)
min. below
NOTE: Check clearances carefully for this
type of installation to ensure adequate room
for outside air venting.
CAUTION
Check building codes prior to installation.
• Installation MUST comply with local, regional,
state and national codes and regulations.
• Consult local building, fire officials or authorities having jurisdiction about restrictions,
installation inspection, and permits.
NOTE:
allowed per ULC S-628, ORD ULC C1482.
In Canada, only a full reline is
Do not use high
temperature caulking materials to
seal any edge to
prevent furture
serviceability.
Outside Air
Termination
at
Chimney Top
Figure 14.2
Page 14
Exit through the
Ash Clean-Out of
Masonry Chimney
Outside Air
through
Rear Wall
250-7251F
September 1, 2008
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Mobile Home
6
A. Mobile Home Installation
You must use a Quadra-Fire Outside Air Kit for installation in a mobile home.
1. An outside air inlet must be provided for the combustion
air and must remain clear of leaves, debris, ice and/or
snow. It must be unrestricted while the appliance is
in use to prevent room air starvation which causes
smoke spillage. Smoke spillage can also set off smoke
alarms.
2. The combustion air duct system must be made of
metal. It must permit zero clearance to combustible
construction and prevent material from dropping into
the inlet or into the area beneath the dwelling and
contain a rodent screen.
3. The appliance must be secured to the mobile home
structure by bolting it to the floor (using lag bolts). Use
the same holes that secured the appliance to the shipping pallet.
4. The appliance must be grounded with #8 solid copper
grounding wire or equivalent, terminated at each end
with an NEC approved grounding device.
Castile Pellet Insert
CAUTION
Maintain structural integrity of mobile home:
• Floor, wall, ceiling and/or roof.
Do NOT cut through:
• Floor joist, wall studs or ceiling trusses.
• Any supporting material that would affect the structural
integrity.
Spar rrestor ap
Storm ollar
Roof las i g
5. Refer to clearances to combustibles and floor protection
requirements on pages 8 & 9 for listings to combustibles and appropriate chimney systems.
6. Use silicone to create an effective vapor barrier at
the location where the chimney or other component
penetrates to the the exterior of the structure.
7. Follow the chimney manufacturer’s instructions when
installing the vent system for use in a mobile home.
8. Installation shall be in accordance with the Manufacturers Home & Safety Standard (HUD) CFR 3280, Part
24.
WARNING
Installation must comply with Manufactured Home and
Safety Standard (HUD), CFR 3280, Part 24.
WARNING
Never install in a sleeping room.
oist S ield irestop
Figure 15.1
ppro ed lass L
or L ellet e t
September 1, 2008
250-7251F
Page 15
Castile Pellet Insert
Appliance Set-Up
7
A. Reversible Top or Rear Flue Adapter
Top Vent Installation
1. Release ammo can latches on each side. Figure 16.1.
2. Place the reversible adapter in the correct position for your
installation.
3. Make sure BOTH latches are in position before securing
them.
Rear Vent Installation
1. Remove the 90
packaging.
2.
Attach the 90o adapter onto the vent adapter, using the 3
screws provided. You will need to pre-drill the holes for screw
placement. Be sure to adjust the 90
position for venting before drilling.
3. Silicone the pipe joints according to the Note below.
o
adapter and installation screws from the
o
adapter to the desired
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B. Leveling System
The back legs are adjustable to allow for customized fit
into zero clearance boxes.
1. Loosen 2 top screws and remove 2 bottom screws.
2. Adjust leg to desired height. Leg can slide up (shorter)
or down (longer) to level the insert.
3. Tighten 2 top screws.
4. Drill 2 holes for the bottom 2 screws and re-install
screws. Figure 16.5.
Loosen top 2 screws and remove
bottom 2. Adjust leg to desired height.
NOTE: All pipe must be sealed using welded
seam pipe whenever possible. Seal pipe joints
with high temperature silicone, minimum rate of
0
F (2600C).
500
Ammo Can Latches
Figure 16.1 - Top Vent
Figure 16.4
Drill 2 holes and
re-install bottom 2
screws
Figure 16.2 - Rear Vent
Page 16
screw
Figure 16.3 - Rear Vent
250-7251F
Figure 16.5
September 1, 2008
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Castile Pellet Insert
C. Outside Air Kit Instructions
Parts Included in Kit: 1 piece of 2 inch x 3 ft. flex hose, 2
hose clamps, 1 collar assembly, 1 termination cap assembly, 1 trim ring, fasteners.
Tools Needed: Phillips head screwdriver; wire cutters;
hole saw or jig saw.
1. Attach collar assembly to appliance. Figure 17.1.
Measure distance from floor to air vent opening in
appliance and mark location on wall.
3. Use saw to cut opening in wall. Cut a 2-1/2 to 3 inch
(64-76mm) opening on inside wall and a 3 to 3-1/2
inch (76-89mm) opening on outside of house.
4. Use hose clamp to secure flex pipe to collar assembly.
5. Slide trim ring over flex pipe and run pipe through
pre-cut hole in back of appliance and through the
wall.
6. Attach hose to outside termination cap with second
hose clamp.
7. Secure termination cap to outside surface.
8. Secure trim ring to interior wall.
D. Zero Clearance Trim Support Instructions
NOTE: Only for use on small size panels.
Figure 17.2 - Assembled View
8
7
6
5
4
CAUTION
Never draw outside combustion air from:
• Wall, floor or ceiling cavity
• Enclosed space such as an attic or garage
Trim Ring
Hose Clamp
Collar
Assembly
Flex Hose
Hose Clamp
Termination
Cap Assembly
Figure 17.3
Item Description
1
2
3
1 Front, 3 inch
2 Front, 5 inch
3 Cast Ring, Top & Bottom, Interchangeable
4 Side, 5 inch
5 Side, 3 inch
6 Panel Extension, 5 inch
7 Panel Extension, 3 inch
8 Panel Extension, Base Plate Only
Figure 17.1
September 1, 2008
250-7251F
Page 17
Castile Pellet Insert
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D. Zero Clearance Trim Support (Cont’d)
Kit Includes: See Page 17
Tools Needed: Phillips head screwdriver
1.
Remove contents from box and lay on protective surface
to avoid scratching the paint.
2. Lay zero clearance front and sides face down. Bend the
tab down toward the inside.
3.
The side pieces are shipped flat. It
flex the sides into a bowed position before installing.
4.
Lay 1 cast ring face up, which
when installed. Attach the 2 sides FIRST and then the front
piece. Figure 18.1.
5. Now turn the cast ring right side up
ring . Figure 18.2.
6. Attach the zero clearance panel extensions. Figure 18.3
7. Attach cast footers. Figure 18.4.
8. Place the assembled zero clearance trim support under
the insert. Figure 18.5.
is much easier to manually
will become the bottom ring
and attach the top cast
T
Figure 18.4
L
Figure 18.5
Install Front Last
Bend top and bottom tabs toward inside
Figure 18.1
Turn right side up and attach top cast rin g
Figure 18.2
Alignment
Hole
First
Install Sides
OT
-
Base Plate Only Installation
Parts Needed: (1) cast ring (2) base zero clearance panel
extensions. Discard balance of parts.
Tools Needed: Phillips head screwdriver
1. Attach base zero clearance panel extensions to cast
ring.
2. Place assembly under appliance.
Cast Trim Footer
Panel Leg
Zero Clearance
Panel Extension
Figure 18.6
Figure 18.3
Page 18
Zero Clearance Panel Extension
250-7251F
September 1, 2008
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Castile Pellet Insert
E. Panel Set And Cast Trim Set
Included in Panel Kit: (2) side panels, left and right; (1)
panel top; (1) fastener package.
Included in Cast Trim Kit:
cast trim header; (2) cast trim footers, left and right; (1) fastener
package.
Tools Needed: Powered Phillips head screw driver
1. Remove contents from box being careful not to scratch or
damage the cast trim pieces.
2. Lay the panel set face down on protective covering to prevent
scratching the painted surface.
3. Secure the panels legs to top panel with the screws provided.
4. Now bend the tabs down toward the backside of the panel set,
5 on top and 2 on each leg. Leave the panel set face down.
5. Place the corresponding cast trim pieces ( 2 cast trim legs and
1 cast trim header) underneath the panel set, also face down.
6. Place washer provided over tab and secure the trim and panel
together with screw. Continue for all tabs.
7. Secure cast footers with screws.
8. Remove both left and right cast sides from insert,
28A, 28B and 28C on page 28.
9. Slide panel and trim over the top of the insert into place matching
the mounting tabs on the panel with the slots on the insert.
(2) cast trim legs, left and right; (1)
See Figures
F. Panel & Trim Set, Econo
Included in Panel & Trim Kit:
screws; (1) trim set, 3 piece; (2) side panels; (1) top panel;
(4) screws;
Tools Needed: Powered Phillips head screw driver
1. Secure the top panel to the panel sides with the
screws provided. Figure 19.3.
2. Assemble the gold trim with the (2) corner brackets
provided. Figure 19.4.
3. Slide the assembled trim over the assembled panel
set.
4. Slide panel and trim over the top of the insert into
place matching the mounting tabs on the panel with
the slots on the insert.
Back of Top Panel
(2) corner brackets and set
Screws
CAUTION
• Do NOT pick up assembled unit by corners.
• It is too heavy and may damage the panels.
• Pick up from center.
2. Bend tabs down
1. Screw panels
together
3. Install Cast Trim Header
Figure 19.1
1. Screw panels
together
2. Bend tabs
down
Mounting tabs on each panel leg
to match up with slots on insert.
Back of Side Panel
Figure 19.3
View of "L" Bracket
installed
Figure 19.4
September 1, 2008
Figure 19.2 - Completed View
of Panel Set & Cast Trim Set
250-7251F
Page 19
Castile Pellet Insert
G. Optional Log Set Placement Instructions
CAUTION
Logs are FRAGILE. Use extreme care when handling or
cleaning logs.
Four Piece Log Set Installation
1. Open the hinged cast face and open the glass door
assembly.
2. Positioning the logs.
Place the right rear log as shown. There is a notch in
the bottom of the log for clearance for the thermocouple and thermocouple cover (ceramic protection tube).
Figure 20.1
Continue placing the last 3 logs around the firepot as
show in Figures 20.2, 20.3 and 20.4. Be careful not to
block the drop tube in the back of the firebox where pellets feed into the firepot.
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Figure 20.3
Thermocouple
Cover
Figure 20.1
Drop Tube
Notch
Figure 20.4
Top Log Installation
Place the log over the firepot. The charred
area on the log is turned toward the back, not
the front.
The log will be about 2-1/2 inches (64mm)
above the firepot when in place. It must rest
on the 3 logs in a stable position to prevent it
from falling into the firepot. Figure 20.5.
Figure 20.2
NOTE:
Due to the abrasive nature of a pellet appliance fire, the
logs are not covered under warranty. Any placement variation other than shown here can cause excessive heat and
shall void the appliance warranty.
Page 20
250-7251F
Figure 20.5
September 1, 2008
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H. Thermostat Installation
1. A 12 volt AC thermostat is required to operate this
pellet appliance. You may use the included wall mount
thermostat or purchase an optional programmable
thermostat or remote control. The included thermostat
is equipped with an adjustable heat anticipator. The
current rating is .05 amps. The anticipator needs to
be adjusted to the lowest setting available.
2. When mounting a thermostat on a wall, be sure to follow
your thermostat installation instructions carefully.
NOTE: Thermostat must be mounted level for accurate readings. The thermostat should be mounted
on an inside wall and not in direct line with the
appliance convection air. Remove any packaging
from inside the thermostat before using.
NOTE: If the thermostat is located too close to
the appliance, you may need to set the temperature setting slightly higher to maintain the desired
temperature in your home.
3. There is a 4 screw terminal block located on the junction box to the left of the power cord inlet. The center
2 screws are for the thermostat wires. The outer 2 are
the mounting screws for the terminal block. Figure
21.1.
Castile Pellet Insert
CAUTION
Shock hazard.
• Do NOT remove grounding prong from plug.
• Plug directly into properly grounded 3 prong
receptacle.
• Route cord away from appliance.
•
Do NOT route cord under or in front of appliance.
Figure 21.1
eat tp t
Sit
Reset tto
se
Red all
Lig t
Red ree mber Lig t
tio o
o trol o
o er ord
tlet
l e Lig t
T ermostat
lo
September 1, 2008
250-7251F
Page 21
Castile Pellet Insert
Operating Instructions
8
A. Fuel Size And Material
1. Wood Pellets
Fuel pellets are made from sawdust or wood by-products. If the
source material is hardwood, they can have a higher mineral
content, creating more ash. Fuels containing bark will also have
higher ash content. Minerals and other non-combustible materials
such as sand will turn into a hard, glass-like substance called
a clinker when heated to the extreme temperatures our firepot
reaches. This is what forms clinkers in the bottom of the firepot.
Trees from different areas will vary in mineral content. That is
why some fuels produce more clinkers than others. Pellets are
manufactured in either 1/4 inch or 5/16 inch (6-8mm) diameter and
should be no more than 1-1/2 inches (38mm) in length. Pellet
lengths may even vary by lot from the same manufacturer which
is why the feed rate may need to be adjusted occasionally. If you
burn pellets longer than 1-1/2 inches (38mm) you may have
an inconsistent fuel feed rate and/or missed ignitions.
Pellet fuel quality can greatly fluctuate. We recommend using
premium grade fuel with ash content less than 1%. Even in some
fuel labeled “premium” ash content can vary from bag to bag
and possibly exceed 1%. High ash fuel, or lack of maintenance,
can cause the firepot to fill up and thus create a potential for
smoking, sooting and possible hopper fires.
Always burn dry fuel. Burning fuel with high moisture content
takes heat from the fuel and tends to cool the appliance,
robbing heat from your home. Damp pellet fuel can clog the
feed system.
We recommend that you buy fuel in multi-ton lots whenever
possible. Buying large quantities of fuel at once will greatly
reduce the number of times the feed adjustments will need to
be made. However, we do recommend trying various brands
before purchasing multi-ton lots to ensure your satisfaction.
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B. General Operating Information
1. Thermostat Calls For Heat
The appliance is like most modern furnaces; when the thermostat
calls for heat, your appliance will automatically light and deliver
heat. When the room is up to temperature and the thermostat
is satisfied, the red call light will shut off and the appliance will
shut down. The red call light is located behind the left access
panel.
2. Heat Output Controls
This appliance is equipped with a heat output control switch that
has three settings or burn rates; low, medium and high. The
appliance will turn on and off as the thermostat demands. When
the thermostat calls for heat, the appliance will always start up
on High. After burning approximately 4 minutes, the appliance
will then burn at the rate at which it was originally set. If the
appliance is set at one of the lower settings, it will run quieter
but takes longer to heat up an area than if it were set at a higher
burn rate. Regardless of the burn rate, when the area is warm
enough to satisfy the thermostat, the appliance will shut off.
Heat Output
Switch
Right
Side
Ash Pan
Reset Button
WARNING
Fire Risk.
• High ash fuels, or lack of maintenance, can
cause the firepot to fill with ash and clinker. If the
firepot fills to the top, immediately shut down the
appliance and clean.
• Failure to do so could result in smoking, sooting
and possible hoper fires.
2. Shelled Field Corn
Shelled field corn can be an efficient and economical fuel. We
recommend using a 50-50 blend of corn and wood pellets. The
only change in operation; 1) the feed rate may require a slight
adjustment and 2) firepot will require more frequent cleanings.
The BTU output
on the quality of the corn used. In cases where it is acceptable
for the appliance to run full time, 100% corn will work after the
fire has been started using wood pellets.
Page 22
varies slightly compared to pellets, depending
250-7251F
Figure 22.1
WARNING
Fire Risk.
Keep combustible materials, gasoline and other
flammable vapors and liquids clear of appliance.
• Do NOT store flammable materials in the appliance’s
vicinity.
• Do NOT use gasoline, lantern fuel, kerosene, charcoal
lighter fluid or similar liquids to start or “freshen up” a fire in
this heater.
• Keep all such liquids well away from the heater while it is in
use.
• Combustible materials may ignite.
September 1, 2008
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C. Before Your First Fire
1. First, make sure your appliance has been properly
installed and that all safety requirements have been met.
Pay particular attention to the fire protection, venting and
thermostat installation instructions.
2. Double check that the ash pan and firebox are empty!
3. Check the position of the thermocouple, located above
the firepot, and make sure that it protrudes approximately
3/4 inch (19mm) into the firepot.
4. Close the front door.
CAUTION
Tip of thermocouple must be in contact with the inside
end of the thermocouple cover.
Missed ignitions can occur.
D. Starting Your First Fire
1. A thermostat is required for proper operation of this
appliance, except for corn. At this time, fill the hopper
with pellets, set the thermostat to its lowest setting. Plug
the power cord into nearby outlet.
2. The exhaust blower will stay on for approximately 18
minutes even though the thermostat is not calling for
heat. This is normal.
3.
Locate the heat output control switch behind the right face
on the lower right side of the firebox. Set to the HIGH
setting and then adjust the thermostat to its highest setting.
The red call light will be on which is located on the top of
the junction box behind the right cast side. This indicates
the thermostat is calling for heat. Figure 23.1.
4.
The fuel feed system and the igniter should
5. For your first fire it will be necessary to press the reset
button once a minute until pellets start to drop into the
firepot, then press button 1 more time. This will fill the
feed system and allow the appliance to begin dropping
pellets. The appliance will continue to run as long as the
thermostat is calling for heat.
6. Once the appliance has ignited, let it burn for approximately
15 minutes, then set the thermostat to the desired room
temperature. Adjust the heat output control switch to the
desired setting.
now
be on.
Castile Pellet Insert
Red Call
Light
Fuse
Heat Output
Switch
Reset Button
Junction Box
Figure 23.1
Control Box
Power Cord
Outlet
Blue Light
Red/Green Light
Thermostat
Block
F. Feed Rate Adjustment
The fuel adjustment control rod is factory set, and should be
adequate for most fuels.
The set screw is located at the bottom of the hopper and
set loose at the factory so the fuel adjustment control rod
will slide by only loosening the wing nut. Do not re-tighten
bottom set screw.
However, if the flame height is too high or too low, you will
need to adjust the feed rate. Wait until the appliance has been
burning for 15 minutes before making your adjustments and
a
llow 15 minutes for feed adjustment to take effect. Make
adjustments in approximately 1/2 inch increments.
1. Loosen the wing nut. Figure 23.2.
2. Adjust the fuel adjustment control rod towards the
"+" symbol to increase the feed rate and flame height or
towards the "-" symbol, to decrease the feed rate and flame
height.
3. Re-tighten the wing nut.
Wing Nut
E. Fire Characteristics
A properly adjusted fire with the heat output control switch
set on “HIGH” has a short active flame pattern that extends
out of the firepot approximately 4 inches (102mm). If the fire
has tall flames with black tails and seems somewhat lazy, the
feed rate will need to be reduced. If the fire is not 4 inches
(102mm) tall, increase the feed rate. A medium and low
setting will give a shorter flame. The flame will rise and fall
somewhat. This is normal.
September 1, 2008
250-7251F
"-"
"+"
Page 23
Castile Pellet Insert
G. Iginition Cycles
1. During each ignition cycle, it is normal to see some smoke
in the firebox. The smoke will stop once the fire starts.
2. The convection blower will automatically turn on after your
appliance has reached the set temperature. This blower
transfers heat from your appliance into the room, and will
continue to run after the thermostat has stopped calling
for heat until the appliance has cooled down.
3. Occasionally the appliance may run out of fuel and shut
itself down. When this happens, the red call light will
be on. To restart it, fill the hopper and press the reset
button. See Figure 21.1 on page 21. When you press
the reset button the red call light will go out. Release the
button and the light will come back on. You should see
a fire shortly. If not, follow the instructions on page 23,
“Starting Your First Fire”.
CAUTION
Odors and vapors released during initial operation.
• Curing of high temperature paint.
• Open windows for air circulation.
Odors may be irritating to sensitive individuals.
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WARNING
Fire Risk
Do NOT operate appliance:
• With appliance door open.
• Firepot floor open.
• Cleaning slide plates open.
Do NOT store fuel:
• Closer than required clearances to combustibles to appliance
• Within space required for loading or ash
removal.
Back side of Firepot
Firepot floor left open
Figure 24.1 - DO NOT LEAVE FIREPOT FLOOR OPEN
H. Frequently Asked Questions
ISSUES SOLUTIONS
1. Metallic noise. 1. Noise is caused by metal expanding and contracting as
it heats up and cools down, similar to the sound produced by a furnace or heating duct. This noise does not
affect the operation or longevity of your appliance.
2. Ash buildup on glass. 2. This is normal. Clean the glass.
3. Glass has turned dirty. 3. Excessive build up of ash. The lower burn settings will
produce more ash, the higher burn settings produce
less. The more it burns on low the more frequent cleaning of the glass is required.
4. Fire has tall flames with black tails and is lazy. 4. The feed rate needs to be reduced or the firepot needs
cleaning. Heat exchanger or exhaust blower needs
cleaning.
5. Smokey start-up or puffs of smoke from the airwash. 5. Either the firepot is dirty or there is too much fuel at
start-up and not enough air. Close down feed rate 1/4
(6mm) inch at a time until this no longer happens.
6. Large flame at start-up. 6. This is normal. Flame will settle down once the fire is
established.
Page 24
250-7251F
September 1, 2008
9
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Troubleshooting
Castile Pellet Insert
With proper installation, operation, and maintenance your appliance will provide years
of trouble-free service. If you do experience a problem, this troubleshooting guide
will assist a qualified service person in the diagnosis of a problem and the corrective
action to be taken. This troubleshooting guide can only be used by a qualified service
technician.
Symptom
Plug in appliance - No
response.
Call light on. No fire.
No fuel in firepot.
Call light on. No fire.
Partially burned fuel in
firepot.
Call light on. No fire.
Unburned pellets in
firepot.
Possible Cause Corrective Action
No current to outlet.
.7 amp fuse defective.
#3 snap disc tripped or defective.
Control box defective.
Out of fuel.
#2 snap disc may be defective.
Vacuum switch not closing, no vacuum.
Control box defective.
Firepot clean-out plate not closed.
Firepot is dirty (missed ignition).
Firepot clean-out plate not closed.
Firepot is dirty.
Ignition hole blocked.
Check circuit breaker at service panel.
Replace fuse.
Reset or replace snap disc.
Replace control box.
Check hopper. Fill with fuel.
Replace snap disc.
Check exhaust blower is plugged in and
operating.
Check vacuum switch is plugged in.
Check vacuum hose is in good condition,
clear and connected at both ends.
Check thermocouple is in good condition
and plugged in properly.
Make sure venting system is clean.
Make sure front door is closed.
Replace control box.
Check that firepot clean-out plate is fully
closed.
Clean firepot. Make sure there is no clinker
in the firepot.
Clinkers may have to be broken up with
firepot scraper tool or other means.
Check that firepot clean-out plate is fully
closed.
Clean firepot. Make sure there is not a
clinker in the firepot. Clinkers may have to
be pushed out of firepot with firepot scraper
tool or other means.
Scrape with solid piece of wire.
Igniter not working.
Control box defective.
Slow or smoky start-up. Firepot clean-out plate not closed.
Firepot is dirty.
Excessive amount of fuel at start-up.
September 1, 2008
250-7251F
Remove ash drawer to see if igniter is
glowing red on start-up.
Check igniter wires for good connection.
Replace igniter using 1/4 inch (6mm) male
/female spade connectors.
Replace control box.
Check that firepot clean-out is fully closed.
Clean firepot. Make sure there is not a
clinker in the firepot. Clinkers may have to
pushed out of firepot with firepot scraper
tool or other means.
Reduce feed rate using feed rate adjustment control rod located inside hopper.
Page 25
Castile Pellet Insert
Symptom Possible Cause Corrective Action
Slow or smoky start-up
(Cont’d)
Feed system fails to
start.
Dirty exhaust and/or venting system. Check for ash build up in appliance,
including behind rear panels, firebox, heat
exchanger, exhaust blower and venting.
Out of fuel.
#2 snap disc may be defective.
Check hopper, fill with fuel.
Replace snap disc. Firebox door must be
closed securely.
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No call light. Appliance
does not begin start
sequence.
Appliance fails to shut
off.
Vacuum switch not closing. No vacuum.
Check exhaust blower is plugged in and
operating.
Check vacuum switch is plugged in.
Check vacuum hose is in good condition,
clear and connected at both ends.
Check thermocouple is in good condition
and plugged in properly.
Make sure venting system is clean.
NOTE: High winds blowing into the venting system can pressurize the firebox
causing loss of vacuum.
Feed system jammed or blocked.
Empty hopper of fuel. Use a wet/dry
vacuum cleaner to remove remaining fuel,
from hopper, including feed tube.
Check feed chute for obstructions.
Loosen 2 screws and jiggle feed assembly.
Feed spring not turning with feed motor.
Check that set screw is tight on feed
spring shaft at end of feed motor.
Feed motor defective or not plugged in.
Check connections on feed motor, replace
if defective.
Thermostat not set to a high enough temperature.
Snap Disc #3 tripped.
No power.
Fuse blown.
Connections at thermostat and/or appliance not
making proper contact.
Defective thermostat or thermostat wiring.
Adjust thermostat above room temperature.
Reset snap disc.
Connect to power.
Replace fuse.
Check connections at thermostat and
appliance.
Replace thermostat or wiring.
NOTE: To test thermostat and wiring, use
a jumper wire at the thermostat block on
the appliance to by-pass thermostat and
wiring.
Control box defective.
Replace control box.
Call light on. Turn thermostat off.
If call light does not go out, disconnect
thermostat wires from appliance. If call
light does go out, thermostat or wires are
defective.
Page 26
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September 1, 2008
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Symptom Possible Cause Corrective Action
Convection blower fails to
start.
No call light.
#1 snap disc defective.
Castile Pellet Insert
Defective control box.
Replace snap disc.
Exhaust blower fails to
start or does not shut off.
Large, lazy flame, orange
color. Black ash on glass.
Blower not plugged in.
Blower is defective.
Control box is defective.
Blower not plugged in.
Blower is clogged with ash.
Blower is defective.
Control box is defective.
Dirty appliance.
Poor fuel quality, high ash content.
Firepot clean-out plate not completely
closed.
Check that blower is plugged into wire harness.
Replace blower.
Replace control box.
Check that blower is plugged into wire harness.
Clean exhaust system.
Replace blower.
Replace control box.
Clean appliance, including firepot, heat
exchangers and venting system. Remove
stainless steel baffle from firebox to clean
ash from on top of baffle. Clean behind rear
brick panels. Change fuel brand to premium.
Check that firepot clean-out plate is fully
closed.
Excessive amount of fuel.
Nuisance shutdowns. Low flame.
Sawdust buildup in hopper.
Feed motor is reversing.
Defective thermocouple.
Defective control box
Firepot more than 1/2 full
Appliance calls for heat.
Call light illuminates.
Thermocouple is defective or not properly
plugged in.
Exhaust blower starts.
No feed or igniter.
Defective control box
Reduce feed rate using feed rate adjustment
control rod located inside hopper.
Increase feed by opening feed rate adjustment control rod located inside hopper.
Clean hopper, see page 31.
Check for good connections between feed
motor and wire harness.
Replace thermocouple.
Replace control box.
See page 31 for detailed instructions for
“High Ash Fuel Content Maintenance”
Check connections on thermocouple or
replace if defective.
A flashing yellow light on the control box
indicates a problem with the thermocouple.
Replace control box.
September 1, 2008
250-7251F
Page 27
Castile Pellet Insert
Maintaining & Servicing Your Appliance
R
10
A. Proper Shutdown Procedure
CAUTION
Shock and Smoke Hazard
• Turn down thermostat, let appliance completely
cool and exhaust blower must be off. Now you
can unplug appliance before servicing.
• Smoke spillage into room can occur if appliance
is not cool before unplugging.
• Risk of shock if appliance not unplugged before
servicing appliance.
.
B. Quick Reference Maintenance Chart
C. General Maintenance
1. Types of Fuel
Depending on the type of fuel you are burning will dictate
how often you have to clean your firepot.
If the fuel you are burning has a high dirt or ash content
or you are burning shelled field corn, it may be necessary
to clean the firepot more than once a day.
Dirty fuel will cause clinkers to form in the firepot. A clinker
is formed when dirt, ash or a non-burnable substance is
heated to 2000°F (1093°C) and becomes glass-like. See
“C” page 32 in this section for more details on fuels with
high ash content.
li er
Figure 27.1 - Clinker
Cleaning or Inspection
Ash Pan Every 5 bags of fuel OR X
Ash Removal from Firebox More frequently depending on
the fuel type or ash build-up
Beneath Heat Exchanger Every 1 ton of fuel OR X
Blower, Combustion (Exhaust) More frequently depending on
the fuel type
Blower, Convection More frequently depending on
the fuel type
Door Latch Inspection Prior to heating season OR X
Exhaust Path More frequently depending on
ash build-up
Firebox - Prepare for Non-Burn Season At end of heating season OR X
Firepot - Burning pellets Every 3 bags OR X
Firepot - Burning Corn Every 1 bag OR X
Glass When clear view of firepot
becomes obscure
Heat Exchanger & Drop Tube Every 1 ton of fuel OR X
Hopper Every 1 ton of fuel or when
changing fuel types
Top Vent Adapter More frequently depending on
the fuel type or ash build-up
Venting System More frequently depending on
the fuel type
Frequency Daily Weekly Monthly Yearly
OR X
OR X
OR X
OR X
OR X
OR X
OR X
OR X
Page 28
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September 1, 2008
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Castile Pellet Insert
2. Remove Cast Sides for Cleaning & Maintenance
a. Loosen screw on top right corner directly under the cast
top, but do not remove. Figure 28.1.
b. With thumb, press upward on the frame to relieve the
pressure on the cast side. Figure 28.2.
c. Slide the cast side downward as shown in Figure 28.3.
(The top has been removed to show the details.
d. Lay sides on protective padding to avoid scratching the
paint or chipping the porcelain.
e. Repeat for the other side.
To p
Front
Right
Cast
Side
Figure 29.1
3. Cleaning Firepot with Cleaning Rod & Firepot
Scraper
• Frequency: Daily or more often as needed
• By: Homeowner
a. The appliance must be in complete shutdown and cool
and the exhaust blower off. If you are just cleaning the
firepot, there is no need to unplug the appliance.
b. Pull firepot cleaning rod OUT a couple of times to help
shake debris loose. See Figure 30.1 on page 30. If rod
is hard to pull, it may be necessary to use your firepot
clean-out tool to chip away material that has built up
on the bottom plate of the firepot and to push out any
clinkers. Larger clinkers may have to be removed from
the top of the firepot. Corn clinkers can be especially
difficult to break up.
c. The firepot floor plate must be fully closed when
finished. See Figure 24.1 on page 24.
WARNING
Fire Risk
• NEVER pull firepot cleaning rod or cleaning
slide plates out when appliance is operating.
• The cleaning slide plates must be fully
CLOSED when appliance is operating.
•. Hot pellets may fall into ashpan and start a fire
or mis-starts due to lack of vacuum.
Flex frame upward with thumb
to relieve pressure on cast side.
Figure 29.2
Figure 29.3
CAST
SIDE
4. Ash Removal from Firebox
• Frequency: Weekly or more frequently depending on
ash build-up.
• By: Homeowner
a. Allow the appliance to completely cool down. There
must not be any hot ashes in the firebox during
cleaning. Turn the thermostat on and then immediately
off to start the exhaust blower on its cycle time. It will
pull fly ash out the exhaust instead of into the room.
b. Frequent cleaning of the ash in the firebox will help
slow down the build-up of ash in the exhaust blower
and vent system.
c. Open door. There are 2 cleaning slide plates to the
left and right of the firepot with finger holes. Pull both
slide plates out and open the glass door and sweep the
remaining ash from the firebox into the 2 open holes.
A paint brush works well for this. Close slide plates.
d. This ash is deposited in the same ash pan as the
firepot debris. The ash pan should be emptied every
time you clean the firebox. Remember to place the ash
and debris into a metal or non-combustible container.
See Disposal of Ashes.
September 1, 2008
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Castile Pellet Insert
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5. Cleaning Ash Pan
• Frequency: Weekly or every 5 bags of fuel
• By: Homeowner
Locate the ash pan underneath the firepot. Open the
bottom ash door and slide the ash pan straight out.
Empty into a non-combustible container and re-install
ash pan. See Disposal of Ashes.
6. Cleaning Heat Exchanger Chambers & Drop Tube
• Frequency: Monthly or every 1 ton of fuel
• By: Homeowner
WARNING
Heat exchanger cleaning rods may be warm
to the touch. For safety purposes wear
gloves.
Do not pull heat exchanger cleaning rods
while appliance is operating.
Push cleaning rods IN when done, DO NOT
leave cleaning rods OUT. Injury can occur.
7. Disposal of Ashes
• Frequency: As needed
• By: Homeowner
Ashes should be placed in a metal container with a
tight-fitting lid. The closed container of ashes should
be placed on a non-combustible floor or on the ground,
well away from all combustible materials, pending final
disposal.
If the ashes are disposed of by burial in soil or otherwise
locally dispersed, they should be retained in the
closed container until all cinders have been thoroughly
cooled.
10 Heat Exchanger Tubes
CLEANING RODS
Figure 30.1
The amount of ash buildup in the firepot will be a good
guide to determine how often you should clean the heat
exchangers.
a. Allow the appliance to completely cool down before
pulling the cleaning rods. Turn the thermostat on and
then immediately off to start the exhaust blower on its
cycle time. It will pull fly ash out the exhaust instead
of into the room. Open the cast front door to access
the 2 cleaning rods. See Figure 29.1 on page 29.
b. Locate the 2 rods directly underneath the heat
exchanger tubes. Rods are bent at a 90° angle for
easy handling.
c. To clean, pull the rods straight out until it stops,
approximately 10 inches (254mm). Slide the rods
OUT and IN a couple of times.
WARNING
Disposal of Ashes
• Ashes should be placed in metal container
with tight fitting lid.
• Ashes should be retained in closed container
until all cinders have thoroughly cooled.
8. Cleaning Beneath Heat Exchanger
• Frequency: Monthly or after burning 1 ton of fuel
• By: Homeowner
a.
Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off
b. A more thorough cleaning is needed to remove the
excess ash that is left behind from the use of the
cleaning rods for the heat exchanger tubes.
c. The ash will be resting on the back of the baffle.
This will require removing the cast baffle. Please
refer to page 33 for a detailed explanation of removing the baffle.
NOTE:
There are heavy duty vacuum cleaners specifically
designed for solid fuel appliance cleaning.
9. Cleaning the Exhaust Path
• Frequency: Yearly or more frequently depending on
ash build-up.
• By: Homeowner
a. Appliance must be completely cool.
b.
Open cast front door. Remove right brick and thoroughly
vacuum the area and continue throughout the rest of
the firebox. See Figure 33.3 on page 33.
c. Replace right brick and close cast front door.
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Castile Pellet Insert
10. Cleaning the Hopper
• Frequency: Monthly or after burning 1 ton of fuel
• By: Homeowner
After burning approximately 1 ton of fuel you will need to
clean the hopper to prevent sawdust build-up.
A combination of sawdust and pellets on the auger
reduces the amount of fuel supply to the firepot. This
can result in nuisance shutdowns and mis-starts.
a. The appliance must be in complete shutdown. Allow
the appliance to completely cool down.
b. Empty the hopper of any remaining pellets.
c. Vacuum the hopper and feed tube.
11. Soot and Fly Ash: Formation & Need for Removal
in Exhaust Venting System.
• Frequency: Yearly or more frequently depending on
ash build-up.
• By: Qualified Service Technician/Homeowner
Be sure the appliance is allowed to cool, has been unplugged
and the exhaust blower is off.
The products of combustion will contain small particles of fly
ash. The fly ash will collect in the exhaust venting system
and restrict the flow of the flue gases.
At start-up if there is incomplete combustion, or if there is a
shutdown or incorrect operation of the appliance it will lead
to some soot formation. This will collect in the exhaust venting system.
The venting system may need to be cleaned at least once a
year or more often depending upon the quality of your fuel
or if there is a lot of horizontal pipe sections. Ash will build
up more quickly in the horizontal sections.
12. Cleaning the Glass
• Frequency: When clear view of the firepot becomes
obscure
• By: Homeowner
a. Appliance must be completely cool before cleaning
glass.
b. Use a damp paper towel or any non-abrasive glass
cleaner. Wipe off with dry towel.
CAUTION
Handle glass assembly with care.
When cleaning glass:
• Avoid striking, scratching or
slamming glass.
• Do NOT clean glass when hot.
• Do NOT use abrasive cleaners.
• Use a hard water deposit glass cleaner on white film.
• Refer to maintenance instructions.
13. Cleaning Convection Blower - Requires No
Lubrication
• Frequency: Yearly or as needed
• By: Qualified Service Technician
a. The appliance must be in complete shutdown and
completely cooled.
b. Remove both the left and right cast sides.
c. Use either a can of compressed air or an air com-
pressor.
d. Reach as far back as possible and spray com-
presssed air liberally from both sides at the blower.
This will remove any lint or dust build-up on the
impellers.
14. Cleaning Exhaust Blower - Requires No
Lubrication
• Frequency: Yearly or as needed
• By: Qualified Service Technician
• Task: Contact your local dealer.
15. Door Latch Inspection
• Frequency: Prior to heating season
• By: Homeowner
The door latch is non-adjustable but the gasketing between
the glass and firebox should be inspected periodically to
make sure there is a good seal.
NOTE: There is no gasket on the bottom of glass.
WARNING
Handle glass with care.
• Inspect the gasket to ensure it is
undamaged.
• Do NOT strike, slam or scratch glass.
• Do NOT operate appliance with glass
assembly removed.
• Do NOT operate with glass cracked, broken or
scratched.
September 1, 2008
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Page 31
Castile Pellet Insert
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16. Door Gasket Inspection
• Frequency: Monthly or after burning 1 ton of fuel
• By: Homeowner
To inspect the door rope (gasket), open the door and see
that the door rope extends approximately 1/8 to 3/16 inch
(3 to 9.5mm) from the door rope channel.
It should show signs of compaction all the way around the
door where the rope contacts the face of the insert.
17. Preparing Firebox for Non-Burn Season
• Frequency: Yearly
• By: Homeowner
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off.
b.
Remove all ash from the firebox and vacuum thoroughly.
c. Paint all exposed steel, including cast-iron.
•
Use the Touch-Up paint supplied with the appliance;
or;
• Purchase paint from your local dealer.
• Must use a high-temperature paint made specificially for heating appliances.
D. High Ash Fuel Content Maintenance
• Frequency: When the ash build-up exceeds more
than half way up the firepot.
• By: Homeowner
Poor quality pellet fuel, or lack of maintenance, can create
conditions that make the firepot fill quickly with ashes and
clinkers.
This condition makes the appliance susceptible to overfilling
the firepot with pellets which may result in smoking, sooting
and possible hopper fires. Figure 32.1 shows an example
where the firepot overfills, pellets back up into the feed tube
and ash has accumulated in the firebox.
An inefficient and non-economical method of burning of fuel
caused by poor quality pellet fuel
The correct flame size when good quality, premium pellet
fuel is burned is shown in Figure 32.3.
If the ash buildup exceeds the half way point in the firepot
IMMEDIATE ATTENTION AND CLEANING IS REQUIRED.
is shown in Figure 32.2.
WARNING
Fire and Smoke Risk.
• High ash fuels or lack of maintenance
can cause firepot to overfill. Follow
proper shutdown procedure if ash buildup
exceeds half way point in firepot.
• Failure to do so could result in smoking,
sooting and possible hopper fires.
Figure 32.1
Tall, Lazy Flame, Orange in Color
Figure 32.2
Correct Flame Size, Yellow/White in Color
Incorrect
Correct
Figure 31.1
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250-7251F
Figure 32.3
September 1, 2008
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Castile Pellet Insert
E. Igniter Replacement
Igniter Bracket
Thumb Screw
Figure 33.1
a. Shut down the appliance by turning down the thermostat
and let the appliance completely cool down. After the
appliance has cooled down, unplug it and remove the
ash pan.
b. The wire leads to the igniter are connected to the wire
harness with 1/4 inch (6mm) male / female spade
connectors. These wires will pull forward approximately
4 to 5 inches (102 to 127mm). Disconnect the spade
connections and remove the igniter from the chamber.
Loosen the thumb screw and slide igniter out.
c. Install new igniter into the chamber and tighten the
thumb screw. Re-connect the wires to the 2 leads with
the spade connectors.
d. Remove the right cast side and pull the wire leads
back toward the rear of the appliance to take-up the 4
to 5 inches (102mm to 107mm) previously pulled out.
This will keep the wires out of the way of the ash pan.
Double check that the igniter wires are clear of any
movement, i.e. ash pan, firepot cleaning rod, cleaning
slide plates, etc.
f. Re-install the ash pan and then re-install the cast side
panel and re-connect the power.
Igniter
F. Glass Replacement
WARNING
• Glass is 5mm thick high temperature heatresistant ceramic glass.
• DO NOT REPLACE with any other material.
• Alternate material may shatter and cause
injury
a. Open hinged cast face and lift door assembly off
from the insert and lay on a flat surface face down.
b. Using a screwdriver, tap the bottom of the rope
retainer rod to push it up out of the hole. The top
end of the rod will slide up. Swing the rod toward
you from the bottom and remove the rod. Repeat
for other side.
c. Remove old glass and replace with new glass.
d. Slide the retainer rod into the top hole first, and then
line up the bottom crimped end with the hole in the
door. The crimped end must be paralle with the glass
in order to insert it into place. Figure 33.2.
Rope Retainer
Rods
Slide this
end in first
Glass
Crimped end
at the bottom
September 1, 2008
250-7251F
Crimped end must be
parallel with the glass
Figure 33.2
Page 33
Castile Pellet Insert
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G. Baffle & Brick Set Removal
1. Follow proper shutdown procedures on
The top baffle has a hook on the bottom left side that
rests on the top lip of the cast brick. There is a tab on
the bottom right side that hooks into the side bracket.
Remove the top baffle by first pulling the baffle forward
until back edge drops down. Then slide baffle back until
the front edge clears the shelf that it had been resting on.
Figure 34.1.
3
. The top baffle must be removed before you can remove
the right and left brick. Remove the right brick by holding top lip of brick and lifting up, then push outside edge
back. Slide brick to the right until it is flush with the firebox.
Rotate the inside edge of the brick forward and remove
brick. Repeat for left brick. Figure 34.2.
Hook on
left side
Tab on
right side
Page 28.
Re-installing Baffle & Brick Set
1. Place right brick in behind the right bracket, and then
slide to the left so the tabs are behind the center brick.
Figure 34.4
The brick will be flush against the back wall and notches
2.
exposed in the side bracket. Figure 34.5.
3. Lift slightly and pull the right edge of the brick forward until
it stops and then drops down into both top and bottom
notches of right bracket and locks into place. Figures
35.1 and 35.2.
4. Repeat for left brick.
5. Insert baffle into top front inside the firebox and pull forward. Then raise up the bottom end and insert baffle tab
into slot on the top of the right bracket to lock into place.
Figure 35.3. Place the left side hook at the bottom of
the baffle over the top edge of brick for stability. Figure
35.4.
6. The baffle does not completely cover the top of the firebox. There is an opening on the left as shown in Figure
35.5.
Figure 34.1
Remove Right
& Left Brick
Figure 34.2
Exhaust Area
Vacuum
Right Brick
Removed
Ta bs
Figure 34.4
Brick is flush against back wall
Notches
exposed
Figure 34.5
Page 34
Figure 34.3
250-7251F
September 1, 2008
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Re-installing Baffle & Brick Set (Cont’d)
Lift brick, pull forward at an angle
and drop down into notches
Castile Pellet Insert
Figure 35.1
Figure 35.4
Hook on
left side
Tab on
right side
Figure 35.2
Figure 35.3
Figure 35.5
September 1, 2008
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Page 35
Castile Pellet Insert
Reference Materials
R
11
A. Component Function
1. Control Box
a. The control box is located on lower right side of
appliance, behind cast side on top of the junction
box.
b. There is a light located inside of the control box. The
internal light will turn green when the appliance has
reached a temperature of 200
and will turn red when it reaches 600oF (315°C).
c. There is also an internal blue light located in the upper
left corner of the control box. When you plug in the
appliance the blue light will automatically start blinking
6 blinks every 10 seconds for 60 seconds and then will
stop.
NOTE:
Do NOT open the control box. This will void the
warranty. If you need to plug in or remove the control
box you must first unplug the appliance.
2. Convection Blower
The convection blower is mounted at the bottom rear of the
appliance. There are 2 impellers, one on each side of the
motor. The convection blower pushes heated air through the
heat exchange system into the room.
3. Exhaust Blower
The exhaust blower is mounted on the right side of the
appliance behind the right cast side. The exhaust blower is
designed to pull the exhaust from the appliance and push it
out through the venting system.
4. Feed System
The feed system is located on the right side and can be
removed as an entire assembly. The assembly includes
the feed motor, mounting bracket, bearing and feed spring
(auger). The hollow feed spring (auger) pulls pellets up the
feed tube from the hopper area and drops them down the
feed chute into the firepot.
5. Firepot
The firepot is made of high quality ductile iron and has a
cleaning pull-out rod. The floor of the firepot opens for
cleaning when you pull out the rod. Be sure that the floor
returns to a completely closed position or your appliance will
not operate properly.
6. Fuse
The fuse is located on the right side behind the control box.
The fuse will blow should a short occur and shut off power
to the appliance.
ο
F (93°C) in the firepot.
When describing the location of a component
part it is always AS YOU FACE THE FRONT
OF THE APPLIANCE.
7. Heat Exchangers
The heat exchangers transfer heat from the exhaust system
into convection air. There are 2 clean out rods located under
the heat exchangers.
8. Heat Output Switch
The heat output switch is located on the lower right side of
firebox, behind the right face above the reset button. The
function of the heat output switch is to regulate the burn rates;
low, medium and high settings.
9. Igniter
The igniter is mounted on the base of the firepot. Combustion
air travels over the red hot igniter creating super heated air
that ignites the pellets.
10. Junction Box And Wiring Harness
The junction box is located behind right cast side of the
appliance. The junction box and wiring harness are replaced
as one component.
11. Power Supply
The power outlet is located behind the right cast side of the
appliance behind the thermostat block on the junction box.
Check the wall receptacle for 120 volt, 60 Hz (standard
current). Make sure the outlet is grounded and has the correct
polarity. A good surge protector is recommended. When
operating with a generator you need at least 600 watts of
power, or with an inverter at least 800 watts of power available
for the appliance during the start cycle.
12. Red Call Light
The red call light is located behind the fuse behind the right
cast side. The function of the red call light is to indicate that
the thermostat is calling for heat.
13. Reset Button
The reset button is located on the lower right side of firebox
behind right face and below the heat output control switch. The
function of the switch is to momentarily open the thermostat
circuit, which restarts the system.
14. Thermocouple
The thermocouple is located on top of the firepot inside
the thermocouple cover (ceramic protection tube). The
thermocouple sends a millivolt signal to the control box
indicating the preset temperatures of the green and red lights
have been obtained.
15. Thermostat
The appliance is designed to run on a 12 volt AC thermostat.
The heat anticipator, if present, should be set on the lowest
setting available.
Page 36
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September 1, 2008
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Castile Pellet Insert
16. Snap Disc #1 (Convection Blower) 110°F
Snap disc #1 is located behind the right cast side of the firebox
above the red call light. There are 2 purple wires connected
to it. This snap disc turns the convection blower on and off as
needed. Power is always present at snap disc #1.
Snap Disc #2 (Fuel Delivery Interrupt) 250°F
17.
Snap disc #2 is located on the back side of the feed drop
tube. There is 1 orange wire and 1 black wire connected to
it. This snap disc will turn off the feed system, which will turn
off the appliance if an overfire condition should occur or if the
convection blower should fail to operate. If this occurs the
snap disc with automatically reset itself.
18.
Snap Disc #3 (Burn Back Protector) 250°F
Snap disc #3 is mounted on the back of the auger tube in the
center of the appliance and has a reset button. To access
it remove the right cast side. If the fire tries to burn back
into the feed system or push exhaust up the feed tube, this
snap disc will shut the entire system off. This disc must be
manually reset.
19. Vacuum Switch
The vacuum switch is located at the back of the appliance.
This switch turns the feed system on when vacuum is present
in the firebox. The vacuum switch is a safety device to shut
off the feed motor if the exhaust or the heat exchanger
system is dirty or plugged or if the firebox door is open.
20. Wiring Harness
See Figure 37.1 below
Thermocouple
Yellow
Red
Black
White
Red
Black
Black
White
Red
Purple
Gray
Blue
Black
Black
Igniter
Burn
Selector
Light
Call
Thermostat
Block
Snap
Disc #3
Yellow
Reset
Button
Blue
Yellow
Gray
Male
White
Female
Vacuum
Switch
Disc #2
Fuse
Snap
Capacitor
Snap
Disc #1
Feed
Motor
Convection
Blower
Exhaust
Blower
Receptacle
Figure 37.1
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Castile Pellet Insert
B. Component Locations
Feed Motor
Convection Blower
Exhaust
Blower
R
10 Heat Exchanger Tubes
CLEANING RODS
Figure 38.2 - Cleaning Rods & Heat Exchanger Tubes
Figure 38.1 - Blowers & Feed Motor
eat tp t
Sit
Red all
Lig t
se
o trol o
o er ord
tlet
l e Lig t
Red ree mber Lig t
Figure 38.3
Page 38
Reset tto
250-7251F
tio o
T ermostat
lo
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Castile Pellet Insert
C. Exploded Views
6
Glass
7
1
2
GLASS SIZE: 11-5/8” wide x 17-1/4” high
Figure 38.1 - Door, Glass, & Handle Assembly
Beg. Manufacture Date: July, 2005
Item Description Part Number
1
Screw 10-32 x 5/16 PH PHL MS ZC
2 Screw 1/4-20 x 5/8 TH PHL 220-0440
3 Door Latch Assembly 413-5200
4 Glass Assembly 7001-038
5 Rope Retainer 7001-192
5
4
3
6 Hinge, Female 450-2910
7 Door 414-0400
229-1230
13
8
9
10
Figure 38.2 - Firepot Assembly
12
27
Item Description Part Number
8 Firepot Pull Rod Assy 414-5270
9 Igniter Bracket not sellable
10 Thumb Screw 7000-223
11 Thermocouple Clamp 7001-203
11
26
12 Thermocouple 812-4470
13 Thermocouple Cover 812-1322
26 Firepot SRV414-5200
27 Igniter SRV7000-226
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Castile Pellet Insert
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41
42
40
2
6
4
44
2
4
1
0
46
4
2
26
4
2
2
2
24
1
2
4
22
4
0
21
1
201
Figure 40.1
# Description # Description # Description # Description
18 Face, Cast 27 Igniter 36 Exhaust Transition 46 Trim, Cast, Header
19 Glass, Side Window 28 Brick, Center, Cast 37 Exhaust Adapter,
Top/Rear
20 Side, Cast 29 Brick, Side, Cast 38 Blower, Convection 48 Trim, Cast, Leg, Left
21 Panel, Side, Right
(not sellable)
22 Trim, Cast, Footer, Right 31 Control Box 40 Vacuum Switch 50 Trim, Cast Footer, Left
Trim, Cast, Leg, Right 32 Snap Disc #3 41 Hopper Back
23
24 Hopper Top Slide, Right 33 Snap Disc #1 42 Hopper (not sellable) 52 Snap Disc #2
25 Door & Glass Assembly 34 Outerskin, Interchangeable 44 Baffle 53 Bracket, Hinge
26 Firepot 35 Blower, Exhaust 45 Panel, Top (not sellable) 54 Hopper Top Slide, Left
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30 Junction Box 39 Feed Motor Assembly 49 Panel, Side, Left
(not sellable)
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47 Top, Cast
(not sellable)
51 Side Glass Backer
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Castile Pellet Insert
D. Service Parts and Accessories
IMPORTANT: THIS IS DATED INFORMATION. The most current information is located on the Quadra-Fire
web site at www.quadrafire.com. When ordering, supply serial and model numbers to ensure correct service
parts.
Item # Part Description, Alphabetical Order Part Number
Ash Pan 414-0130
44 Baffle Assembly UK-30KPEL
38 Blower, Convection 812-4900
35 Blower, Exhaust with Gasket & Housing 812-4400
Bracket, Hinge SRV414-0610
28 Brick, Center, Cast 414-0260
29 Brick, Side, Cast, (interchangeable) 414-0270
Call Light, Fluorescent SRV7000-122
Component Pack (Includes firepot scraper, touch-up paint, power cord & wiring harness
to thermostat and manual, owner’s manual, warranty card, consumer’s view card and
“How-to-Operate” DVD
31 Control Box SRV7000-205
25 Door Assembly with Glass
& Gasket
3 Door Latch Assembly 413-5200
18 Face, Cast, Matte Black 414-0040BK
18 Face, Cast, Porcelain (specify color) 414-0040POR
19 Face, Cast, Powder Coat, (specific color) 414-0040PWD
39 Feed Assembly 414-5400
Feed Motor Bracket Assembly 7001-039
Feed Motor Only w/capacitor 812-4421
Feed Spring Only 812-3600
Firepot Bottom Slide Plate 414-0290
8 Firepot Pull Rod Assembly 414-5270
26 Firepot, EZ Clean SRV414-5200
Fuse, .7 amp, Junction Box 812-0380
Gasket, Exhaust Blower (Round White) between blower & housing 812-4710
Gasket, Firepot 240-0930
Gasket, Tadpole, 10 feet 842-5130
4 Glass Assembly with Gasket for Door 7001-038
19 Glass Assembly, side (interchangeable) 414-5380
Heat Ouptut Control Switch, (Rocker Switch), 3 position 812-3500
Hopper Top Slide Assembly, Left 414-5180
Hopper Top Slide Assembly, Right 414-5170
27 Igniter, Loop (Heating Element) SRV7000-226
30 Junction Box & Wiring Harness SRV414-0720
Magnet Bracket 414-0930
Magnet SRV7000-140
MBK: 414-5390
PMH: 414-5460
CCR: 414-5480
CLG: 414-5410
CME: 414-5420
CSB: 414-5510
CWL: 414-5520
414-5190
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Castile Pellet Insert
Item # Part Description, Alphabetical Order SKU
Power Cord 812-1180
20 Side, Cast, Matte Black 414-0050BK
20 Side, Cast, Porcelain, (specifiy color) 414-0050POR
20 Side, Cast, Powder Coat, (specific color) 414-0050PWD
33 Snap Disc #1, 110 degree 230-1220
52 Snap Disc #2, 250 degree, automatice reset 230-1290
32 Snap Disc #3, 250 degree, manual reset SRV7000-268
13 Thermocouple Cover 812-1322
12 Thermocouple, 14 inches 812-4470
11 Thermocouple Clamp 7001-203
10 Thumb Screw for Igniter, pkg of 24 7000-223/24
47 Top, Cast, Matte Black 414-0060BK
47 Top Cast, Porcelain (specify color) 414-0060POR
47 Top, Cast, Powder Coat (specific color) 414-0060PWD
47 Vacuum Switch, Rectangular SRV7000-447
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Item No. Accessories, Alphabetical Order Part No.
Adjustable Hearth Support, 12 inches x 50 inches, 2 inches to 10 inches high ADJSPT-12
Log Set, 4 piece 811-0852
Log, Top, (to cover firepot) 811-0900
Outside Air Kit 811-0872
Panel Set, Small, 30” w x 42-1/2” h (use with cast trim) 811-0910
Panel Set, Large, 34” w x 48” h (use with cast trim) 811-0920
Panel & Trim Set, Econo, Small, 30” w x 40” h 811-0990
Thermostat, Mechanical 812-3760
Thermostat, Programmable, #9600 811-0520
Trim, Panel, Cast, Matte Black, MBK 811-0930
Trim, Panel, Cast, Porcelain, Mahogany, PMH 811-0960
Trim, Panel, Cast, Powder Coat, Sienna Bronze TR-CAST-CSB
Trim, Panel, Cast, Powder Coat, Willow TR-CAST-CWL
Zero Clearance Adjustable Trim Support (only fits small size panels) 811-0980
Item No. Appliance Part No.
Castile Insert, Matte Black 810-02901
Castile Insert, Porcelain, Mahogany 810-03201
Castile Insert, Powder Coat, Sienna Bronze CASTINS-CSB
Castile Insert, Powder Coat, Willow CASTINS-CWL
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E. Service And Maintenance Log
Date of Service Performed By Description of Service
Castile Pellet Insert
September 1, 2008
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Castile Pellet Insert
E. Service And Maintenance Log (Cont’d)
Date of Service Performed By Description of Service
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F. Homeowner’s Notes
Castile Pellet Insert
September 1, 2008
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Castile Pellet Insert
G. Warranty Policy
Hearth & Home Technologies LIMITED WARRANTY
Hearth & Home Technologies (“HHT”) and its respective brands extends the following warranty for HHT gas, wood,
pellet and electric appliances purchased from an authorized HHT dealer and installed in the United States of America or
Canada. Warranty starts with date of purchase by the original owner (End User) except as noted for replacement parts.
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Warranty Period
Parts Labor Gas Wood Pellet
HHT Manufactured Appliances and Venting
EPA
Wood
Electric Venting
Components Covered
All Parts and Material Except
1 Year XXXXXX
as covered by Conditions,
Exclusion, and Limitations
listed
Igniters, Electronic Compo-
nents, and Glass
2 years
XX
XXXX Blowers
X Molded Refractory Panels
3 years X Firepots
5 years 3 years X X Castings & Baffles
7 years 3 years X X X
10
years
1 year X
Firebox, HHT Chimney, Termi-
nation & Heat Exchanger
Burners, Logs & Refractory
Limited
Lifetime
1 year X
Firebox & Heat Exchanger
90 Days XXXXXX All Replacement Parts
See Conditions, Exclusions, and limitations. 9-01-08
CONDITIONS, EXCLUSIONS & LIMITATION OF LIABILITY
This warranty applies to the original owner and is transferable up to two years from date of purchase to the new
homeowner, provided the purchase was made through an authorized dealer or distributor of HHT, and the appliance
remains in its original place of installation.
The maximum amount recoverable under this warranty is limited to the purchase price of the product.
In no event shall HHT be liable for any incidental or consequential damages caused by defects in the product.
Adjustments, regular maintenance, cleaning and temporary repairs, or the failure to duplicate the problem in the home
is not covered under this warranty.
This limited warranty does not extend to or include surface finish on the appliance or terminations, door gasketing,
glass gasketing, glass discoloration, firebrick, pellet logs, kaowool or other ceramic insulating materials. Rust and/or
corrosion on any of the metal surfaces, cast iron components, baffles, firepots, doors, or firebox area are not covered
by this warranty.
Noise resulting from minor expansion, contraction, or movement of certain parts is normal and complaints related to
this noise are not covered by this warranty.
4021-645A 09-01-08
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Castile Pellet Insert
Hearth & Home Technologies LIMITED WARRANTY (Cont’d)
HHT’s obligation under this warranty does not extend to damages resulting from: (1) installation, operation or main-
tenance of the appliance not in accordance with the installation instructions; operating instructions and the listing
agent identification label furnished with the appliance; (2) installation which does not comply with local building codes;
(3) shipping, improper handling, improper operation, abuse, misuse, accident or unworkmanlike repairs; (4) environmental conditions, inadequate ventilation or drafting caused by tight sealing construction of the structure or handling
devices such as exhaust fans or forced air furnaces or other such causes; (5) use of fuels other than those specified
in the operating instructions; (6) installation or use of components not supplied with the appliance or any other components not expressly authorized and approved by HHT; and/or (7) modification of the appliance not expressly authorized and approved by HHT in writing.
This warranty does not apply to non-HHT venting components, hearth components or other accessories used in con-
junction with the installation of this product.
This warranty is void if the appliance has been over-fired or operated in atmospheres contaminated by chlorine,
fluorine, or other damaging chemicals the appliance is subject to prolonged periods of dampness or condensation, or
there is any damage to the appliance or other components due to water or weather damage which is the result of, but
not limited to, improper chimney or venting installation.
HHT’s liability under this warranty is limited to the replacement and repair of defective components or workmanship
during the applicable period. HHT may fully discharge all of its obligations under such warranties by repairing the
defective component(s) at HHT’s discretion. Shipping costs are not covered under this warranty.
Some states do not allow exclusions or limitation of incidental or consequential damages, so those limitations may not
apply to you. This warranty gives you specific rights; you may also have other rights, which vary from state to state.
EXCEPT TO THE EXTENT PROVIDED BY LAW, HHT MAKES NO EXPRESS WARRANTIES OTHER THAN THE
WARRANTY SPECIFIED HEREIN. THE DURATION OF ANY IMPLIED WARRANTY IS LIMITED TO DURATION OF
THE WARRANTY SPECIFIED ABOVE.
This Limited Warranty is effective on all HHT appliances sold after September 01, 2008 and supersedes any and all warranties currently in existence.
If warranty service is needed, you should contact your installing dealer. If the installing dealer is unable to provide necessary parts or components, contact the nearest authorized HHT dealer or supplier.
c
September 1, 2008
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O T T O T O :
Hearth & Home Technologies
1445 North Highway
Colville, WA 99114
Division of HNI INDUSTRIES
Please contact your Quadra-Fire dealer with any questions or concerns.
For the number of your nearest Quadra-Fire dealer
please visit our web site at www.quadrafire.com
CAUTION
Do NOT discard this manual.
• Important operating and maintenance
instructions included.
• Read, understand and follow these instructions for safe installation and operation.
• Leave this manual with party responsible
for use and operation.
Your Records for Model:
Castile Pellet Insert
WHERE PURCHASED:
SERIAL NUMBER: __________________
DATE PURCHASED: __________________
DATE INSTALLED: __________________
This product may be covered by one or more of the following patents: (United States) 4593510, 4686807, 4766876, 4793322, 4811534,
5000162, 5016609, 5076254, 5113843, 5191877, 5218953, 5263471, 5328356, 5341794, 5347983, 5429495, 5452708, 5542407,
5601073, 5613487, 5647340, 5688568, 5762062, 5775408, 5890485, 5931661, 5941237, 5947112, 5996575, 6006743, 6019099,
6048195, 6053165, 6145502, 6170481, 6237588, 6296474, 6374822, 6413079, 6439226, 6484712, 6543698, 6550687, 6601579,
6672860, 6688302B2, 6715724B2, 6729551, 6736133, 6748940, 6748942, 6769426, 6774802, 6796302, 6840261, 6848441, 6863064,
6866205, 6869278, 6875012, 6880275, 6908039, 6919884, D320652, D445174, D462436; (Canada) 1297749, 2195264, 2225408,
2313972; (Australia) 780250, 780403, 1418504 or other U.S. and foreign patents pending.
_______________________________________
_______________________________________
_______________________________________
TELEPHONE: __________________
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