Heatiator BH60 User Manual

Installation & Operating Manual

The BH 105 Pellet Boiler

“Ce manuel est disponible en Français sur demande”

R9

SAFETY NOTICE

PLEASE READ THIS ENTIRE MANUAL BEFORE YOU INSTALL AND USE YOUR NEW BOILER. FAILURE TO FOLLOW
INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR EVEN DEATH.

FOR USE IN THE U.S. AND CANADA.

IF THIS PELLET BOILER IS NOT PROPERLY
INSTALLATION DIRECTIONS.

CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION
REQUIREMENTS IN YOUR AREA.

CONTACT YOUR LOCAL AUTHORITY (SUCH AS MUNICIPAL BUILDING DEPARTMENT, FIRE DEPARTMENT, FIRE
PREVENTION BUREAU, ETC.) TO DETERMINE THE NEED FOR A PERMIT.

CETTE GUIDE D’UTILISATION EST DISPONIBLE EN FRANCAIS. CHEZ VOTRE CONCESSIONNAIRE.

SAVE THESE INSTRUCTIONS

INSTALLED, A HOUSE FIRE MAY RESULT. FOR YOUR SAFETY, FOLLOW

#3-90-07205H

Hopper Lid

Latches

Hopper

Control Board Cover

Control Board

Combustion Blower

Combustion Blower Cover

Temperature / Pressure Gauge

Pressure Relief Valve

Aquastat Well

1-1/4” FMPT Supply

1-1/4” FMPT Return

Ash Door

Firebox Door

Access Cover To

Hopper / Swing Plate Knob

Access Cover To Secondary Ash Chamber

Blank Cover

(Removed w/ Domestic

Hot Water Option)

Vent Pip e

1/2” FMPT Boiler Drain

Viewing Glass

Parts Locations

3/4”

3

Table Of Contents

Warranty 5

Assembly 6

Venting 9

Installation 12

Operation 23

Maintenance 30

Troubleshooting 34

Atmospheric Conversion 35

Service Parts 36

Introduction

Appliance Certication.

Model: Pellet Burning Boiler - BH105
Test Lab: Omni-Test Laboratories, Inc.
Report #: 135-S-16-6
Type: Pellet Fueled Central/Supplementary For

Residential Use
Standard(s): CAN/CSA B366.1-M91, and
UL 391

Specications 42

Wiring Diagram 43

Note: This appliance is also approved for
installation into a shop.

Testing Label 45

Quick Reference Start-Up Back Cover

WARNING! RISK OF FIRE! Hearth & Home Technologies disclaims any responsibility for, and the warranty

and agency listing will be voided by the following actions:

DO NOT:

• Install or operate a damaged appliance

• Modify the appliance

• Install other than as instructed by Hearth & Home Technologies

• Operate the appliance without fully assembling all components

• Overretheappliance

• Install any component or part not approved by Hearth & Home Technologies

Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage.

Forassistanceoradditionalinformation,consultaqualiedinstaller,serviceagencyoryourdealer.

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

boiler. Failure to follow instructions may result in

property damage, bodily injury, or even death.

SAVE THESE INSTRUCTIONS

Hearth & Home Technologies, Inc.

352 Mountain House Road

Halifax, PA 17032

4

Warranty

ECO-CHOICE™ LIMITED WARRANTY

Hearth & Home Technologies Inc., on behalf of its Heatilator® brand (”HHT”), extends the following warranty for all
ECO-CHOICE™ furnace and boiler products (“Products”) that are purchased from an HHT authorized dealer.

Warranty Coverage: Subject to the conditions, exclusions and limitations set forth below, HHT warrants to the original
owner of the Products, and to any transferee taking ownership of the Products at the site of original installation within two
years following the date of original purchase, that the Products will operate free from defects in material and workman­ship under normal conditions and use, as described in the operating instructions furnished with the Product, during the
warranty period described below. HHT will, at its option, repair or replace any Product covered by this warranty that is
determined to be defective in material or workmanship.

Warranty Period: The warranty period runs for six years, except for mechanical and electrical components, which are
warranted for three years. The warranty period begins on the earlier of: (i) the date of invoice for the Product; (ii) in the

case of new home construction, the date of rst occupancy of the residence or six months after the date of sale of the Prod­uct by an HHT authorized dealer, whichever occurs rst; or (iii) the date 24 months following the date of Product ship-

ment from HHT, regardless of the invoice or occupancy date.

Warranty Conditions: This warranty applies only to Products: (i) installed, operated, and maintained as recommended in
the Product user’s manual; (ii) purchased through an HHT authorized dealer; (iii) while remaining at the site of original
installation; and (iv) that have not been altered after leaving the factory.

How to File a Claim: Claims must be made within the warranty period to the dealer who sold the Product. If that dealer
cannot provide the warranty service, contact the nearest HHT authorized dealer. Additional service fees may apply if you
are seeking warranty service from a dealer other than the dealer from whom you originally purchased the Product. Travel
and shipping charges for parts are not covered by this warranty.

Warranty Exclusions: This warranty does not cover the following: (1) consumable and normal wear items, including,
without limitation, ame guides, grates, coal bars, afterburner hoods, re brick, gaskets, paint, glass discoloration, burn­pot housing weldments, burnpot grate weldments (pellet or corn), burnpot front plates (pellet or corn), burnpot front plate

locks, corn auger extensions, ceramic inserts, and ceramic insert plates; (2) noise caused by minor expansion, contraction

or movement of parts; (3) damage resulting from: (i) failure to install, operate or maintain the Product according to the

installation and operating instructions and listing agent identication label furnished with the Product; (ii) failure to install

the Product according to local building codes; (iii) shipping or improper handling; (iv) abuse, misuse, continued operation
with damaged, corroded or failed components, accident, or incorrectly performed repairs; (v) environmental conditions,
inadequate ventilation, negative pressure or drafting caused by tightly sealed construction, insufcient make-up air sup­ply, or handling devices such as exhaust fans or forced air furnaces or other such causes; (vi) use of fuels other than those

specied in the operating instructions; (vii) installation or use of components or accessories not supplied with the Product
or authorized and approved in writing by HHT; (viii) modication of the product not expressly authorized and approved
by HHT in writing; or (ix) interruptions or uctuations of electrical power supply to the Product; (4) non-HHT compo-

nents or accessories used in conjunction with the Product; (5) the Products’ capability to heat a desired space; information
is provided to assist the consumer and the dealer in selecting the proper Product for the application; consideration must be

given to Product location and conguration, environmental conditions, insulation and air tightness of the structure; or (6)

additional or unusual utility bills incurred due to any malfunction or defect in Products.

Limitations of Liability: Repair or replacement in accordance with the provisions of this warranty will be the owner’s
exclusive remedy for and will constitute HHT’s sole obligation under this warranty, under any other warranty (express or
implied), or in contract, tort or otherwise. No employee, agent, dealer, or other person is authorized to give any warranty
on behalf of HHT. TO THE EXTENT ALLOWED BY LAW, HHT MAKES NO OTHER WARRANTY, EXPRESS OR
IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PUR­POSE. HHT WILL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES ARISING OUT
OF DEFECTS IN OR USE OF THE PRODUCTS. Some states do not allow exclusions or limitation of incidental or con-

sequential damages, so these limitations may not apply to you. This warranty gives you specic rights; you also may have

other rights, which vary from state to state. The duration of any implied warranty is limited to the duration of the warranty

period specied herein.

5

Assembly

Boiler Kit Materials: (Refer to page 2)

List of items contained within the boiler kit shipped with
the unit.
1 - Control board cover
1 - Access cover (Hopper Swing Plate Knob)
5 - Spring Handles

1 - 1/2” Boiler Drain
1 - 3/4” Safety Relief Valve
1 - 1/2” Aquastat Well
1 - 1/2” Dual Temperature/Pressure Gauge

1 - 100ft. Sensor Cable (Outdoor Air Sensor)
1 - Outdoor Air Sensor
1 - Flue Tunnel Weldment
1 - Combustion Blower Assembly
1 - Heat Shield (Comb. Blower)

2 - UY Connectors
2 - Terminals 1/4 Female
1 - #8 X 1/2” TEK
3 - 1/4-20 X 5/8” Wing Screw
4 - 1/4” Lock Washer
4 - 1/4-20 Nuts

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

Step 1: First install the ue tunnel weldment by
aligning the (4) studs with the (4) holes in the ash
chamber base. Fasten the (4) nuts and lock washers

provided, to the studs by removing the access cover on
the secondary ash chamber.

Step 2: Place the combustion motor onto the ue tunnel

weldment and tighten the (3) wing screws provided.
Step 3: Insert the Exhaust Sensing Probe (ESP) into the

1/8” hole provided on the ue pipe stub. Fasten with
the (1) #8x1/2” TEK screw also provided. ESP will be

taped to the sheet metal jacket for shipping purposes.

Step 4: Connect the ex conduit 90 degree elbow(Not

Shown) to the heat shield in the hole provided. Then
connect the (3) wires from the combustion blower with

the (3) wires in the ex conduit by using the push-on

connectors and matching the wire colors as follows:
Red to Black, White to White and Green to Green.
Step 5: Place Heat Shield over combustion blower and
align the swell latches with the holes in the sheet metal

and tighten.

NOTE: Refer to Fig’s 22, 23, and 24 located on page 31 of this manual.

6

Flue Tunnel Weldment

ESP

Combustion Blower

Heat Shield

Assembly

Refer to the illustration on page 3 to identify the compo­nents listed below:

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

located on the feeder cover.

2. Install the spring handles provided with the unit on the

ash door, rebox door and the heat exchanger cleanout rod

handles. (Fasten handles by turning them counterclockwise
and pushing inward simultaneously).

3. Install 3/4” MPT boiler drain in the tting as shown.

Note: Use pipe thread sealant or teon tape on ALL

threads before connections are made.

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

5. Install the 1/2” MPT aquastat well in tting as shown,

then place aquastat in the well and fasten with a zip tie. The
aquastat sensor is located under the top sheet metal jacket.

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

tting as shown.

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

nections at the boiler can be done with the two 1/4” female

push on connectors supplied.

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

Design:

The rst thing that needs to be done is deciding where and

how the boiler will be installed.

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

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

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

MINIMUM NON-COMBUSTIBLE FLOOR PROTECTION AREA

NON-COMBUSTIBLE

FLOOR PROTECTOR

40" USA

42" CANADA

55" USA & CAN

40" USA

42" CANADA

16" USA

18" CAN

55" USA & CAN

Floor Protection:

The striped area indicates the minimum required oor protec­tion area if the boiler is going to be placed on a combustible

oor. It requires 40” X 55”(US) or 42” X 55”(CAN) of non
combustible oor protection as shown. 16”(US) or 18”(CAN)
of the oor protection must be in front of the rebox door
as shown. Floor protection must be a minimum of 26 gauge

sheet metal. Floor protection must also be provided under any
horizontal run of vent pipe equal to the outside diameter of the

venting plus 2” to each side.

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

7

Assembly

INSTALLATION IS TO BE PERFORMED BY A
QUALIFIED INSTALLER.

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

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

8

Venting

Requirements for Terminating the Venting

WARNING: Venting terminals must not be recessed into

a wall or siding.

NOTE: Only PL vent pipe wall pass-throughs and re

stops should be used when venting through combustible
materials.
NOTE: Always take into consideration the effect the
prevailing wind direction or other wind currents will
cause with yash and /or smoke when placing the ter­mination.

In addition, the following must be observed:

A. The clearance above grade must be a minimum of

1

18”.
B. The clearance to a window or door that may be

opened must be a minimum of 48” to the side, 48”
below the window/door, and 12” above the window/

1

door.

C. A 12” clearance to a permanently closed window is

recommended to prevent condensation on the window.

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

minimum of 18”.

E. The clearance to an unventilated soft must be a
minimum of 12”.

F. The clearance to an outside corner is 11” from center
of pipe.

G. The clearance to an inside corner is 12”.
H. A vent must not be installed within 3 feet (90 cm)

above a gas meter/regulator assembly when measured
from the horizontal center-line of the regulator.

1

I. The clearance to service regulator vent outlet must be

a minimum of 6 feet.

1

J. The clearance to a non-mechanical air supply inlet
to the building or the combustion air inlet to any other

appliance must be a minimum of 48”.

1

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

1

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

M. The clearance under a veranda, porch, deck or

balcony must be a minimum of 12 inches.

1,2

1,3

(B Also

applies)

NOTE: The clearance to vegetation and other exterior

combustibles such as mulch is 36” as measured from the
center of the outlet or cap. This 36” radius continues to

grade or a minimum of 7 feet below the outlet.

1

Certain Canadian and or Local codes or regulations

may require different clearances.

2

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

3

Only permitted if veranda, porch, deck, or balcony is

fully open on a minimum of 2 sides beneath the oor.

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

= Vent terminal

9

= Air supply inlet

= Area where terminal is not permitted

Fig. 2

Fig. 3

Venting

Avoiding Smoke and Odors - Negative Pressure,
Shut-down and Electrical Power Failure.

To reduce the probability of back-drafting or burn
back in the pellet boiler during a power failure,
it must be able to draft naturally without exhaust

blower operation. Negative pressure in the house will
resist this natural draft if not accounted for during in­stallation. Heat rises in a house, and leaks out at upper
levels. This air must be replaced with air from outside

the dwelling, which normally ows into lower levels.
Vents and chimneys into basements and lower levels

can become the conduit for return air and reverse un­der these conditions.

Hearth & Home Technologies strongly recommends
the use of outside air in all pellet boiler installa-

tions, especially those on lower level and main oor

locations. Per national building codes, consideration
must be given to combustion air supply to all combus­tion appliances. Failure to supply adequate combustion
air for all appliance demands may lead to back-draft­ing of those and other appliances within the home.

To reduce the probability of reverse drafting dur­ing shut-down conditions, Hearth & Home Tech­nologies strongly recommends:

• Installing the pellet vent with a minimum vertical
run of 5 feet. Preferably terminating above the roof
line.

• Installing the outside air intake at least four feet
below the vent termination.
To prevent soot damage to exterior walls, and to pre­vent re-entry of soot or ash into the house:

• Maintain specied clearances to windows, doors

and air inlets, including air conditioners.

• Vents should not be placed below ventilated softs.

Run the vent above the roof.

• Avoid venting into alcove locations.

• Vents should not terminate under overhangs, decks

or onto covered porches.

• Maintain minimum clearance of 12” from the vent

termination to the exterior wall. Extending this dis­tance may be required if visual accumulation occurs.

10

Venting

Venting

Venting

Use 4” pellet vent pipe only.

A combustion blower is used to extract the combustion

gases from the rebox. This creates a negative pressure in
the rebox and a positive pressure in the venting system
as shown in Fig. 4. The longer the vent pipe and more
elbows used in the system, the greater the ow resistance.

Because of these facts we recommend using as few elbows
as possible and 30 feet or less of vent pipe. The maximum
horizontal run should not exceed 18 feet.

Be sure to use wall and ceiling pass through ttings

(which are approved for pellet vent pipe ) when going
through combustible materials. Be sure to use a starting
collar to attach the venting system to the stove. The start-

ing collar must be sealed to the stove ue collar with

high temp silicone caulking or aluminum tape, and

screwed into the stove ue collar at least three (3) places.

4” Type “L” or
“PL” Vent pipe

Fig. 5

This is the minimum venting conguration.

+

-

Fig. 4

Vent Pipe

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

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

joints within the structure should also be sealed with
silicone.

NOTE:Use only 4” diameter approved PELLET
venting system. Be sure to inspect and clean exhaust
venting system frequently.

The minimum vent conguration is a 90o or Tee on
a starter collar and a 24” length horizontal through an
exterior wall. A cap on the end should direct the ue

gasses down and away from the structure. See Fig. 5.

The maximum horizontal length is 18 feet. The
minimum termination height above the exterior grade

is 18”. The maximum total length of any conguration

is 30 feet*.

* ( see venting graph on page 9 for exceptions )

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

The venting graph allows for one(1) 90 deg. or Tee
tting in any conguration.

If more 90’s, T’s, or 45’s are needed, the total length

must be adjusted to allow for the added restriction.

Up to four (4) additional 90’s, Tee’s, or equivalent 45’s

can be added as long as the overall length is adjusted in
accordance with the values listed below.

( See the venting graph on page 10.)

Each Vertical ---- 90 deg. or T subtract 2.5 feet
Each Vertical ---- 45 deg. subtract 1.5 feet
Each Horizontal - 90 deg. or T subtract 5.0 feet
Each Horizontal - 45 deg. subtract 2.5 feet

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

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

11

Venting Installation

Chimneys taller than 20’ above the connection will

require a draft test to determine if the draft is too high.
Note: The high burn draft should not exceed .85 IWC.
Some form of a restrictor plate may be required at the

top of high chimneys to reduce the draft. See page 21

for the Draft Test procedure.

This boiler may be used and installed into an existing

masonry or Class A metal chimney.

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

The venting Can Not be installed in a chimney serv-

ing another appliance.

The chimney should be cleaned and or inspected before

installation of the venting.

NOTE: Use only 4” diameter approved pellet
venting system. Be sure to inspect and clean
exhaust venting system frequently.

INSTALLATION IS TO BE PERFORMED BY
A QUALIFIED INSTALLER.

DO NOT INSTALL A FLUE DAMPER IN THE
EXHAUST VENTING SYSTEM OF THIS UNIT.

DO NOT CONNECT THIS UNIT TO A
CHIMNEY FLUE SERVING ANOTHER
APPLIANCE.

INSTALL VENT WALL PASS-THROUGHS AT
CLEARANCES SPECIFIED BY THE VENT
MANUFACTURER

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

NOTE: Read and follow all of the vent pipe
manufacturers’ instructions on the proper
installation and support of the vent pipe. Adhere
to all clearances.

WARNING

KEEP COMBUSTIBLE MATERIALS SUCH
AS GRASS, LEAVES, ETC. AT LEAST 3 FEET
AWAY FROM THE POINT DIRECTLY UNDER
THE VENT TERMINATION. (BETWEEN THE
VENT AND THE GROUND)

CAUTION

KEEP COMBUSTIBLES AWAY

FROM FLUE OUTLET.

Other examples of possible installations of the venting.

Creosote - Formation and Need for Removal - When wood is burned slowly, it produces tar and other organic vapors,

which combine with expelled moisture to form creosote. The creosote vapors condense in the relatively cool chimney ue
of a slow-burning re. As a result, creosote residue accumulates on the ue lining. When ignited, this creosote makes an
extremely hot re. The pellet vent pipe should be inspected at least twice monthly during the heating season to determine
if a creosote buildup has occurred. If creosote has accumulated it should be removed to reduce the risk of a chimney re.

Guidance on minimizing creosote formation and the need for periodic creosote removal: The chimney should be

inspected during the heating season to determine if a creosote build-up has occurred. If a signicant layer of creosote has
accumulated (3mm or more) it should be removed to reduce the risk of a chimney re.

12

Inlet Cover part#
1-10-09542

Outside Air Pipe
Knockout

Feeder Cover

Fig. 7

Outside Air Inlet Pipe

Installation

Outside Air

To install outside air, use 2 3/4” I.D.galvanized
steel ex pipe, part # 2-00-08544 ( 12’ 6” length) or part
# 2-00-08545 ( 25’ length) See Fig. 6. There is a break-

away hole on the rear panel which must be removed

before connecting the ex pipe. See Fig. 7.

When the appliance is side wall vented: The air
intake is best located on the same exterior wall as the
exhaust vent outlet, and located lower on the wall than
the vent outlet.

When the appliance is roof vented: The air intake
is best located on the exterior wall oriented toward the

Fig. 6

prevailing wind direction during the heating season.

Never terminate the outside air above the vent pipe

outlet. The maximum length of this pipe is 20 feet. Inlet
cover part number 1-10-09542 should be used to keep
birds, rodents etc.out of the inlet pipe. See Fig.6.

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

The Outside Air knockout is located on the face of
the Feeder Cover. It is pre-cut except for several small

tabs. There is also a ller plate screwed to the inside

to cover the top of the hole after the Outside Air Pipe
has been installed. This will allow for removal of the
Feeder Cover without disconnecting the Outside Air
Pipe. See Fig. 7.

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

The Outside Air Intake Pipe is inside the Feeder

Cover and to the right of the feeder motor. The 2 3/4”
steel ex pipe is made to slide over the outside of the

Air Intake Pipe. See Fig. 8. It should be held into place
with some silicone, foil tape, or a hose clamp. (not
supplied)

13

Hopper/Feeder
Swing Plate
Knob

Heat Reclaiming Ventilation System (HRV)

When installing in a house with a Heat Reclaim-

ing Ventilation System (HRV) be sure the system is

balanced and is not creating a negative pressure in the
house.

Fig. 8

Main Wiring Installation

14

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

To install power to the boiler, rst remove the cover on the 4” X 4” junction box located on the back of the unit. There are several knockout

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

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

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

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

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

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

board properly. (Control board damage could occur).

Installing Duct

Installation

3/4”

NOTE: Cold return water temperature (Sustained temperatures below 140 degrees Fahrenheit) will lead to condensation in the

rebox.Thismoisturecanleadtocreosoteformation.Tohelpminimizemoistureandcreosote,itisstronglyrecommendedthat

some form of temperature balance is incorporated into the return water system.

NOTICE: When installing with the atmospheric conversion:Allofthepressurizedsystemcomponentsshownarenotnec-
essary. Air vents or bleeders will need to be removed from the plumbing system to prevent air from entering the lines. Control
Dipswitch #6 will need to be turned “ON”.

15

3/4”

Installing Duct/Air Conditioning

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

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

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

of the original boiler.

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

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

solid-fuel boiler.

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

6. Be capable of being installed without changing the function of the control or rewiring of the original boiler. A wiring interconnec­tion is permitted. The electrical system of both boilers shall be powered from a single branch circuit without exception.

(CAN/CSA-B366.1-M91)

7. Pertaining to CAN/CSA- B365-01, Have a clearly labelled device, located at each entrance to the boiler area, which can be thrown

to discontinue operation of the feed system.

Installation

NOTICE: When installing with the atmospheric conversion:Allofthepressurizedsystemcom-

ponents shown are not necessary. Air vents or bleeders will need to be removed from the plumbing
system to prevent air from entering the lines. Control Dipswitch #6 will need to be turned “ON”.

16

Installation

EXAMPLE OF TYPICAL TANKLESS DOMESTIC HOT WATER PIPING

INLET

AQUASTAT WELL LOCATION

HOSE BIB

OPTIONAL DOMESTIC
HOT WATER COIL

OUTLET

HOSE BIB TO
BACKFLUSH COIL
IF NEEDED

HIGH TEMPERATURE
WATER (IF NEEDED)

FLOW REGULATOR

MIXING VALVE

TEMPERED HOT WATER TO
SHOWERS AND FAUCETS

NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER
MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.

MIXING VALVE SET TO DESIRED WATER TEMPERATURE.

NORMALLY NOT MORE THAN 120 DEGREES.

SAFETY RELIEF VALVE

ISOLATION VALVE

COLD WATER SUPPLY

FLOW REGULATOR WILL NEED TO MATCH THE GPM RATING OF THE DOMESTIC COIL. (IF USING A DOMESTIC COIL, 4 GPM IS REQUIRED.)

FROM BOILER

CIRCULATOR

TO BOILER

EXAMPLE #1

EXAMPLES OF TYPICAL DOMESTIC HOT WATER STORAGE PIPING

EXAMPLE #2

FROM BOILER

COLD

HOT

DOMESTIC HOT
WATER STORAGE
HEATER

IN

OUT

CIRCULATOR

TO BOILER

COLD

HOT

DOMESTIC HOT
WATER STORAGE
HEATER

IN

OUT

NOTE: TYPICALLY, AS LONG AS THE WATER
TEMPERATURE NEEDED IS NOT MORE THAN
120 F, THE MIXING VALVE SHOWN ABOVE
(EXAMPLE 2) IS NOT NEEDED

HIGHER TEMPERATURE
WATER (IF NEEDED)

TEMPERED HOT WATER FOR
SHOWERS AND FAUCETS

MIXING VALVE

NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER
MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.

MIXING VALVE SET TO DESIRED WATER TEMPERATURE.
NORMALLY NOT MORE THAN 120 DEGREES.

17

Installation

TYPICAL BOILER HOT WATER PIPING SHOWING AIR REMOVAL SYSTEM, PROVISIONS FOR THE EXPANSION OF
WATER AND THE AUTOMATIC COLD WATER SUPPLY. ALSO SHOWN IS THE AUTOMATIC MIXING VALVE. THIS
COULD ALSO BE DONE BY (2) CLOSELY SPACED TEE'S. THE PROPER PIPING FOR THE INTENDED USE WILL BE
DETERMINED BY THE INSTALLING CERTIFIED PLUMBER OR HVAC CONTRACTOR.

SHUT-OFF
VALVE

UNION

SYSTEM SUPPLY 1-1/4"

* TEMPERATURE/PRESSURE
GAUGE

* AQUASTAT
WELL

* PRESSURE
RELIEF VALVE

AIR VENT

PIPE TO WITHIN 6" OF THE
FLOOR OR A FLOOR DRAIN

UNION

AIR SCOOP

EXPANSION TANK
(DIAPHRAGM TYPE)

SHUT-OFF VALVE

* BOILER DRAIN, 1/2" NPT MALE X

*BOILER DRAIN, 3/4” NPT MALE X

3/4" HOSE MALE (NOT SHOWN)

3/4” HOSE MALE (NOT SHOWN)

SENSING BULB

SYSTEM RETURN 1-1/4"

NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED
INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND
LOCATION WITHIN THE PIPING SYSTEM.

** THERMOMETER

SYSTEM SUPPLY 1-1/4"

AUTOMATIC
MIXING VALVE

PRESSURE REDUCING VALVE (PRV)
OR COMBINATION PRV AND
RELIEF VALVE

** THERMOMETER

SHUT-OFF VALVE

* ITEMS SUPPLIED

** OPTIONAL

COLD WATER
SUPPLY 1/2"

CHECK VALVE (OR BACKFLOW
PREVENTER IF REQUIRED)

NOTE: Cold return water temperature (Sustained temperatures below 140 degrees Fahrenheit) will lead to condensation in the

rebox.Thismoisturecanleadtocreosoteformation.Tohelpminimizemoistureandcreosote,itisstronglyrecommendedthat

some form of temperature balance is incorporated into the return water system.

NOTICE: When installing with the atmospheric conversion:Allofthepressurizedsystemcomponentsshownarenotnec-
essary. Air vents or bleeders will need to be removed from the plumbing system to prevent air from entering the lines. Control
Dipswitch #6 will need to be turned “ON”.

18

Installation

NOTE: Cold return water temperature (Sustained temperatures below 140 degrees Fahrenheit) will lead to condensation in the

rebox.Thismoisturecanleadtocreosoteformation.Tohelpminimizemoistureandcreosote,itisstronglyrecommendedthat

some form of temperature balance is incorporated into the return water system.

NOTICE: When installing with the atmospheric conversion:Allofthepressurizedsystemcomponentsshownarenotnec-
essary. Air vents or bleeders will need to be removed from the plumbing system to prevent air from entering the lines. Control
Dipswitch #6 will need to be turned “ON”.

19

Over Heat Safety Zone

OverHeat Safety Zone (Dump Zone): STRONGLY RECOMMENDED in all installations.

When the pellet boiler is operating at High burn, and all demand from the heating system stops, the control

will reduce the feed rate and shut down completely as necessary. This may take several minutes, and the remain-

ing heat may cause the water temperature to continue to rise. If the temperature gets too high, the OVERHEAT
SAFETY ZONE light on the control (see page 23) will illuminate, and the DARK BLUE circuit in the junction box
is energized(see wiring diagram). This circuit will ow 120V to operate a circulator pump installed to ow to the

overheat dump zone established in the original installation plan. If opening a zone valve is the chosen method of
dumping the excess heat, a voltage reduction relay will most likely be needed. If the water temperature continues
to rise to the risk of boiling point, the feed system will stop and the boiler will shut-down. A manual reset will then
be required to operate the boiler. Without a dump zone in place, the excess temperature will build pressure to the

point of opening the relief valve, or with the atmospheric conversion it will allow the water to boil and over-ow

the atmospheric tank. Both scenarios may create water damage and/or slip hazard.

The boiling temperature of water varies at different altitudes and atmospheric pressures. Therefore, at eleva-

tions above 3000 feet, and when using the atmospheric conversion, circuit board dipswitch #6 must be in the “ON”

position.

Power Failure / Heat Dissipation Loop

EXAMPLE OF PIPING IN ACCORDANCE
WITH (CAN/CSA-B366.1)
A POWER FAILURE HEAT DISSIPATION LOOP

BALANCING
VALVE

POWER FAILURE SYSTEM SUPPLY 3/4"

* TEMPERATURE/PRESSURE GAUGE

UNION

* AQUASTAT WELL

* PRESSURE RELIEF VALVE

SYSTEM SUPPLY

PIPE TO WITHIN
6" OF THE
FLOOR OR A
FLOOR DRAIN

UNION

(HIGH TEMPERATURE) BASEBOARD HEAT

120VAC,NORMALLY OPEN,FULL FLOW,
SOLENOID VALVE or EQUIVALENT

THE SOLENOID SHOULD BE
POWERED BY THE SAME
CIRCUIT AS THE BOILER

POWER FAILURE SYSTEM RETURN 3/4"

SHUT-OFF VALVE

SHUT-OFF VALVE

SYSTEM RETURN

MINIMUM OF 72" OF 3/4"
FINNED BASEBOARD
BASEBOARD MUST BE AT LEAST
24" HIGHER THAN BOILER FOR
PROPER GRAVITY FLOW

NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER

* ITEMS SUPPLIED

MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.

20 20

Installation

Draft Bolt Location

Viewing Window

Air wash Slot

Firebox Door

Draft Test Procedure

After the venting is completed, the rebox low draft

will need to be checked and possibly adjusted. After
removing the 3/8” bolt from the draft hole shown in Fig.

9, insert the draft meter tube. The appliance doors and

hopper lid must be latched during this test. (It is recom­mended that the draft meter have a scale of 0 to 1” WC.)

Air Wash Slot

Fig. 9

“Test”

Turn the feed adjuster to “Test”. this will start the
combustion blower and allow you to check and record
the High Draft ______ - IWC date _______ The
maximum draft must not exceed -.85” W.C. Some form
of vent restrictor may be needed. (There is no control
board adjustment for the High Draft)

After the rst 60 seconds the “Test” mode lowers the

combustion blower voltage to the Low Burn voltage.
During this lowered voltage cycle the Low Burn Draft
must be checked and adjusted if necessary. The recom-

mended low draft setting should be between -.25 & -.35

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

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

Don’t forget to turn the feed adjuster off of “Test”.

Covered

Low Draft

Adjustment Pot

Un-Covered

Fig. 10

Do not operate if the high draft exceeds -.85” W.C.

Excessive draft readings may be due to restriction in
the combustion air supply. Check for obstructions.

The Control

The boiler has the option to have the control panel
covered or un-covered See Fig. 11. There is a pair of
slots provided for each position. Simply move the cover
to the desired position by placing the tabs on the cover
in the proper slots.

CAUTION: Hot while in operation. Do not
touch. Keep children, clothing, furniture,
and other combustible material out of the
installation clearance area.

WARNING: Do not operate with the hopper

lid or re chamber or ash removal doors open.

21

Fig. 11

WARNING: Do not store fuel or other
combustible material within installation
clearance area.

Fuel Specications

Fuel and Fuel Storage

Pellet fuel quality can uctuate from manufacturer to

manufacturer, and even from bag to bag.
Hearth & Home Technologies recommends using only

fuel that is certied by the Pellet Fuels Institute (PFI).

Fuel Material

• Made from sawdust and/or other wood by-products

• Source material typically determines ash content

Higher Ash Content Material

• Hardwoods with high mineral content

• Bark and leaves as source material

• “Standard” grade pellets, corn and other biomass

Lower Ash Content Material

• Softwood; pine, r, etc.

• Materials with lower mineral content

• “Premium” grade pellets

CAUTION! Do not burn fuel that contains an additive;
(such as soybean oil)

• May cause hopper re

• Damage to product may result

Read the list of ingredients on the packaging. If you are
buying wood pellets, the only ingredient listed should be

wood ber or sawdust.

Clinkers
Minerals and other non-combustible materials, like sand,
will turn into a hard glass-like substance when heated.
Trees from different areas will vary in mineral content.
For this reason, some fuels will produce more clinkers
than others.

Performance

• Higher ash content requires more frequent mainte­nance.

• “Premium” grade pellets will produce the highest
heat output.

• Burning pellets longer than 1-1/2 inches (38mm)

can cause inconsistent feeding and/or ignition.

We recommend that you buy fuel in multi-ton lots
whenever possible. However, we do recommend try­ing different brands prior to purchasing multi-ton lots,
to ensure your satisfaction.

CAUTION! Tested and approved for use with wood
pellets ONLY. Burning of any other fuel will void your
warranty.

When changing from “Premium” grade pellets to a
“Standard” or “Economy” grade fuel, the FEED AD­JUSTER will likely need adjusted to a lower setting.
When under maximum demand, ensure there is no
unburned fuel being pushed into the ash pan.

Storage

• Wood pellets should be left in their original sealed
bag until ready to use, to prevent moisture.

• Do not store fuel within the specied clearance ar­eas, or in a location that will interfere with routine
cleaning and maintenance procedures.

Moisture
Always burn dry fuel. Burning fuel with high moisture
content takes energy to dry and tends to cool the appli­ance thus, robbing heat from your home. Damp pellet

fuel could turn back into sawdust which does not ow

properly through the feed system.
Size

• Pellets are either 1/4 inch or 5/16 inch (6-8mm) in

diameter

• Length should be no more than 1-1/2 inches (38mm)

• Pellet length can vary from lot to lot from the same

manufacturer

22

CAUTION

Tested and approved for use with wood pellets
ONLY. Burning of any other fuel will void your
warranty.

NOTICE

Hearth & Home Technologies is not responsible for
stove performance or extra maintenance required
as a result of using fuel with higher ash or mineral
content.

Operation

Power Light

Indicates power to the
control board.

Status Light

Will be lit anytime there is a
call for heat.

Overheat Safety Zone Light

Indicates elevated boiler
water temperature. Power

owing to Overheat circuit.

Combustion Blower Light

Indicates Power to
combustion blower

Feed Motor Light Indicates
Power to the feed motor.

Igniter Light

Indicates power to the igniter

Feed adjuster

Sets the maximum feed rate

Test

Combustion blower, feed motor
and safety dump zone are fully

energized for the rst minute.

Afterward, combustion blower
remains on low only.

Lighting Mode Selector

Switched between Auto and
Manual lighting

Mode Selector/Min Temp
Dial

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

Diagnostic Port

For diagnostic purposes only.
Requires special DDM monitor
supplied to trained technicians
exclusively.

Max Temp dial

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

Status light error messages:
3 Blinks: Indicates that the ESP (Exhaust Sensing Probe) has

gone out of range, too many times. May indicate axcessive
ash build-up in the exhaust stream. If the unit seems to be
operating normally, perform a manual reset by cycling the
main power off for a few seconds and re-connect.

4 Blinks: Indicates miscommunication with the aquastat, or
the sensor is not attached properly. May require a manual
reset.

5 Blinks: (In Auto Light Mode Only)

Indicates that the igniter has failed to light the re after 40

Minutes. To reset - Turn the Mode Selector/Min. Temp. to
OFF and then back to the desired temperature.

6 Blinks : Indicates that the control has calculated poor or

incomplete combustion occurring for 25 or more minutes.

A six blink status may be set if the stove is allowed to run
out of pellets. To reset, turn Mode Selector/Min Temp dial
to “OFF” then back on to the desired temperature. If the unit

was not out of pellets, see Troubleshooting section, Page 34,

for more details.

23

7 Blinks: Boiler water over heat safety shut down. This re­quires a manual reset by cycling the main power off for a few

seconds and re-connect. See explanation on page 20.

Mode Selector/Min. Temp.

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

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

See “Setting the boiler temperature” found on page 24.

OFF Mode

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

WATER TEMPERATURE

Operation

Setting The Boiler Temperature

Without the Outdoor Air Temperature Sensor
Installed

To set the maximum boiler water temperature, sim­ply turn the Max. Temp. water temperature dial to the
desired setting. The control and the boiler will then
perform to achieve and maintain the set temperature.
The Min. Temp. Knob is the boiler water tempera­ture minimum, or the lowest temperature the water
will go before the unit re-starts. Turning the knob fully
counter-clockwise is the “OFF” position, while turn-

ing the knob clockwise, past the 140 degree marking,

is the “ON” position..

With The Outdoor Air Temp - Sensor Installed

Maximum boiler temp setting is as described above.
The MIN. TEMP. knob in addition to being the
mode setting (on or off) now also has the function of
setting the minimum boiler water temperature. This
would be the lowest boiler water temperature that you
want to have based on the following factors.

1.) Outdoor Air Temperature (OAT)

2.) Domestic Hot Water Use

a.) Hot Water Coil Option
b.) Indirect Hot Water Storage

3.) Overall Volume of the Heating System

MAX. TEMP.

MIN. TEMP.

Control Board Operation

Aquastat Sensor - This sensor is located in the aqua-

stat well on the top of the water jacket. This sensor
along with the outdoor air sensor is what the control
board uses to regulate the feed rate based on these two
observed conditions. (Boiler Temp. & Outdoor Air
Temperature)
Outdoor Air Temp. Sensor (OAT) - This sensor is
located outside the building (on the north side of the
house and out of direct sunlight). The Outdoor Air
Sensor is used to perform hot water reset based on out­door air temperatures.

When the OAT sensor is installed, at 20° F. or below

(outside temperature), the boiler will operate at the
temperature set on the MAX. TEMP. knob. The boiler
water temperature will decrease by 1 degree F. for

every 1 degree F. in temperature rise (above 20°) of

the outdoor air.

NOTE: Pellet Boiler Outdoor Air Reset Operation
Graph located on page 23.

24

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

NOTE:

If the system is run at the lower temperature settings, con-

ditions of the rebox, boiler tubes, secondary ash chamber

and venting should be monitored closely. If conditions show
excess condensation, the boiler water minimum tempera­ture will need to be increased until condensation does not
occur. You should also consider some form of tempering of
the return water system. Discuss this with your plumber.

-45°

-40°

o

o

140

145

o

o

65

60

-35°

-30°

o

o

150

155

o

o

55

50

o

o

-25

-20

o

o

160

165

o

o

45

40

Operation

o

o

o

o

o

-15

-10

-5

0

o

o

180

185

o

o

25

20

0

o

185

o

15

o

o

170

175

o

o

30

o

0

0°

o

o

185

185

o

o

10

5

o

185

o

0

*

*

o

o

150

150

o

o

65

60

o

*

-30

o

o

150

150

o

o

55

50

o

o

-25

-20

o

o

155

160

o

o

45

40

o

o

-15

-10

o

o

165

170

o

o

30

o

o

-5

0

o

o

175

180

o

o

25

20

o

o

0

0

o

o

180

180

o

o

15

10

o

o

0

0

o

o

180

180

o

o

5

0

Pellet Boiler Outdoor Air Reset Operation

When the outdoor sensor is installed, at 20° F. or below OAT (Outdoor Air

Temperature), the boiler will operate at the temperature set on the Maximum

Temperature knob. The boiler water temperature will decrease by 1 degree for

every 1 degree in temperature rise of the Outside Air.

Example 1 OAT Water Temp Degree Change

o

o

Min set at 140

Max set at 185

35

o

o

Example 2 OAT Water Temp Degree Change

Min set at 150

Max set at 180

35

* No change in boiler temperature after reaching minimum setpoint temperature.

25

Scrape burnpot to remove any carbon
build-up that may have occurred

Operation

Starting A Fire Automatically

1. Turn Mode Selector to “OFF”.
This resets the control in addition to turning

it off.

2. Clean Burnpot with scraper, if necessary.

This is usually a weekly maintenance proce-

dure. Cleaning the burn pot with the scraper with
a small amount of new fuel in the bottom is not a
problem. First, scrape the ashes on the front of the
burn pot into the ash pan. Then scrape the hole grid
surface downward into the burn pot. When the stove
is ignited these scrapings will be pushed out by the
feeder.
The illustration at left shows the hopper swing plate
open for easy access to the burn pot. The burn pot

can also be reached through the rebox door.

NOTE: To minimize the amount of stress placed
on the hopper swing plate hinges, opening of the
hopper swing plate should be done with the least
amount of fuel in the hopper as possible.

26

3. Fill Hopper with pellets.

When lling the hopper check for excessive nes

in the bottom of the hopper. Fines are small pieces of

broken pellets (sawdust). Fines do not ow easily and

often build up on the hopper funnel bottom angles.

These nes can be pushed into the feeder opening
and then ll the hopper with pellets. As the system

works, they will be burned.

Operation

WATER TEMPERATURE

4. If Starting After an Empty Hopper, Turn Feed

Adjuster to “TEST” (for one 60 second cycle).

This will feed pellets into the auger tube and also
allow you to check the motors for operation. NOTE:

The auger motor will not operate with any of the
doors open.

5. Turn Feed Adjuster to #4.

If this is your rst re or you are trying differ-

ent pellets, set the feed adjuster to #4, This is an

average number for most pellets and may need to
be adjusted for your particular fuel. After you know
a feed rate setting that works well for your applica­tion, use that setting.
NOTE: You know your feed rate is too high when:
The overheat safety feature is energized each time
the heating zone demand turns off during a high burn.
OR, If unburned or partially burned pellets are found
in the ash pan.(this may also be an indication of a
burn pot in need of scraping.)

MAX. TEMP.

MIN. TEMP.

6. Flip the Igniter Switch up into the “AUTO”
position.

7. Turn the MAX. TEMP. Dial on the control

board to the desired temperature. This setting must

always be at least 5° F. higher than the MIN. TEMP.

setting.

WARNING: HOT WHILE IN OPERATION.
KEEP CHILDREN, CLOTHING, AND
FURNITURE AWAY. CONTACT MAY CAUSE
SKIN BURNS.

27

Operation

8. Turn the MIN. TEMP. Dial on the control board
to the desired Minimum temperature. This will start the
lighting process if the temperature at the aquastat sensor

is approximately 5° F. less than the set temperature on

the MAX TEMP. dial.
This is more than just an automatic ignition pellet

boiler. The automatic system will allow the re size to

be adjusted to match the heating needs and even put the

re out if necessary. If heat is needed after the re is out,
the boiler will automatically re-ignite and adjust the re

size to match the heating need.

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

Type of Fuel

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

kept, the more efcient the boiler will be.

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

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

Lighting A Fire Manually

Lighting the re manually will not be necessary unless

the igniter system fails.

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

6. Flip the Igniter Switch Down into the “MANUAL-

LIGHT” position. See Fig. 12.

Fig. 12

7. Open hopper swing plate as shown in Fig. 13 (See

“NOTE” on page 26.)

Fig. 13

8. Fill burnpot with pellets as shown.

See Fig. 14. Only ll level with the front edge.

( ------- DO NOT OVERFILL ------- )

Fig. 14

9. Have matches or other ignition source ready.

10. Turn Mode Selector to desired MIN TEMP setting.

This will start the combustion blower and allow the

ESP to control the re in relation to the MAX TEMP

Dial setting. (The MAX TEMP dial setting must always

be set above the MIN TEMP setting) Once the re is

well established the MAX TEMP dial can remain on
any temperature setting desired.

NOTE: When the Switch is set to Manual ignite position

the boiler will function as in auto ignite except the re will

not be allowed to go out. It will only be allowed to go to a
minimum burn rate between the times the aquastat is calling
for heat. This rate is about 1.1 pound of fuel per hour. If used
in the Manual ignite mode, be sure there is an overheat dump
zone in place. Note that if the dump zone does not provide

sufcient cooling, and the water temperature continues rising,

the feed motor will be forced to shut off. Because the unit is
in Manual Ignite mode, it will not re-ignite when the water
temperature cools below the control settings.

28

Operation

Fig. 15

NOTE: Stirring the starting gel into the pellets usually

allows the re to become established quicker.

CAUTION: A vapor ash could occur if too much

time is allowed to pass before lighting the starting gel.

11. Apply starting gel as shown in Fig.15

12. Light The Starting Gel With A Match.

13. Close The Doors

The re will light and the control will adjust the re

to the proper level according to the MAX TEMP dial
setting.

CAUTION: Care must be taken not to get starting gel
on your hands or clothing. Serious burns could occur
during the lighting process.

CAUTION: Never try to apply more starting gel to an

already burning re, or a re with smoldering pellets.

“NEVER USE GASOLINE, GASOLINE-TYPE
LANTERN FUEL, KEROSENE, CHARCOAL
LIGHTER FLUID, OR SIMILAR LIQUIDS TO
START OR “FRESHEN UP “ A FIRE IN THIS
APPLIANCE. KEEP ALL SUCH LIQUIDS WELL
AWAY FROM THE UNIT WHILE IN USE”.

NOTICE: When burning the boiler in the
manual ignition mode, there must be an
overheat dump zone incorporated into the
plumbing system.

If heating demand stops during manual operation, the
control will take the unit to low burn. If no heat is used
during this time, the water temperature will continue to
rise. When the temperature gets too high, the feeder will

be turned off and the re will go out. This will require a
manual re-start of the system. (see page 23 “7 Blinks”)

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

the following:

1. Call the re department.

2. Remove fuel from the burn pot using the burnpot

scraping tool to scrape the pellets into the ash pan.

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

4. Turn off circuit breaker at unit.

5. Do not use the unit until a qualied person has in-

spected your appliance and venting.

29

Fig. 16

Scrape the burnpot to remove any carbon
deposits which may have formed.

Scraping can be done while the boiler
is in operation, accessed through the

rebox door opening.

Maintenance

Burnpot Cleaning:

The burnpot should be cleaned no less than once a week.
For best operation the burnpot should be cleaned every time

the hopper is lled with pellets. The re does not have to be

out to scrape the burnpot although it is recommended the
boiler be on minimum burn at the time of cleaning.

Note: Scraping can be done while in operation if per-

formed through the rebox door opening. See Fig. 17

Use the at end of the scraper provided to scrape down

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

Note: Make a special effort to scrape the bottom inside
corners of the burnpot where the auger tube enters the
burnpot. Carbon deposits can build up over time in this

area that may cause a restriction to the ow of pellets into

the burnpot.

Note: An old long shank screwdriver with the end sharp-

Fig. 17

ened is an ideal aid in the removal of these deposits.

Fines area

30

Cleanout cover

Feeder cover

Fig. 19

Fig. 20

Fig. 18

Cleaning the Burnpot Air Chamber:

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

There is a cover on the front of the burnpot to gain access
to the air chamber. The cover is held into place by two thumb
screws. Loosen the thumb screws and remove the cover. See

Fig. 19. The air chamber can be cleaned of any ash that has

fallen through the holes during operation and cleaning. Also
at this time, remove the feeder assembly cover and remove

any nes that may have accumulated.

NOTE: ALWAYS REMEMBER TO CLOSE THE CLEA-

NOUT COVER AFTER CLEANING.

Feeder Chamber (Fig. 20):

This chamber may get a buildup of nes from the feeder

mechanism movement. This area should be checked and
cleaned at least once a year.

To remove the feeder cover:

• Loosen the 5/16” wing nut.

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

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

• Reinstall the cover making certain it is centered on the

feeder body and hand-tighten the wing nut.

Maintenance

Ash Door Handle

Ash Door

Ash Pan

Ash Pan Handle

WARNING! RISK OF FIRE!

• Ash, soot or creosote build-up may cause
overheating or re.

• Routine cleaning of heat exchangers and

venting is required.

Ash Removal

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

Open Ash Door

Lift the latch and open the door as shown in g. 21.

NOTE: Keep hopper lid, hopper swing plate, rebox

door and ash pan door closed during operation and
maintain all seals in good condition.

Remove Ash Pan

Always wear gloves to remove ash pan. Grab the ash

pan by the nger hold and pull it out of the boiler. Lift
the ash pan by the nger hold and use it for carrying the

ash pan. Close the ash door before disposing the ashes.

Fig. 21

Disposal of Ashes

Ashes should be placed in a steel container with a tight

tting lid. The closed container of ashes should be moved

outdoors immediately and placed on a non-combustible

oor or on the ground, well away from all combustible
materials, pending nal disposal. If ashes are disposed

of by burial in soil or otherwise locally dispersed, they
should be retained in the closed container until all cinders
have thoroughly cooled. Other waste shall not be placed
in this container.

Soot and Flyash: Formation and Need for
Removal

The products of combustion will contain small particles

of yash. The yash will collect in the exhaust venting
system and restrict the ow of the ue gases. Incomplete

combustion, such as occurs during startup, shutdown,
or incorrect operation of the room heater will lead to
some soot formation which will collect in the exhaust
venting system. The exhaust venting system should be
inspected at least twice monthly to determine if cleaning
is necessary. Pay particular attention to screening in the
vent cap. The screen, if present, will accumulate with
ashes rather quickly.

31

Fines Cleanout Cover

Maintenance

Heat Exchanger Cleanout Rod Handles

Firebox Door

Heat Exchanger Tube

Secondary Ash
Chamber Access Plate

Firebox Wall

Cleaning

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

efciency will be.

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

Start by actuating the (3) heat exchanger cleanout rods
by pulling and pushing these rods vigorously several

times. This action will remove any y ash built up on the

heat exchanger tubes. This can also be done at any time
during the operation of the boiler to maintain higher ef-

ciencies. Make sure that these rods are pushed in when

cleaning is completed.

Cleaning Steps

-Open the hopper swing plate to access burnpot and

also the rebox. With a wisp brush, wire brush, stiff
bristled paint brush or a soot vac, clean the rebox walls
and any y ash that has accumulated on the ledges of the

burnpot, or burnpot opening. At this time you can scrape

and clean the burnpot and nes cleanout area.

-Open rebox door and vacuum ash from ledges and

ash deector. You can also clean the rebox door viewing

glass using a typical glass cleaner and soft cloth.

Ash Door

-Open the ash door and remove the ash pan. Dispose

of any ash that has accumulated in the ash pan as well

as any y ash from within the ash pan area.

-Remove the (4) thumbscrews on the secondary

ash chamber access plate and remove it to access the

secondary ash chamber. Remove all y ash from this

area. This process should be done as needed.

-Inspect all sealing gaskets to ensure a proper seal

and re-install all components removed for cleaning.

CAUTION: Cleanout of the heat exchanger, ue

pipe, chimney, and combustion blower fan housing,
is especially important at the end of the heating
season to minimize corrosion during the summer
months, caused by accumulated ash.

NOTE: To minimize the amount of stress placed on
the hopper swing plate hinges, opening of the hopper
swing plate should be done with the least amount of
fuel in the hopper as possible.

32

Thumb Screws (3 Total)

Combustion
Blower Motor

Heat Shield

Latch

Fig. 22

Exhaust Probe

Fig. 23

Maintenance

The boiler MUST be OFF and COOL before you

should attempt to clean the combustion blower.

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

disconnected during the cleaning process.

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

See Fig. 23. Hold the motor head with one hand and the

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

Clean the blower fan blades and the blower plate

sealing overlap. See Fig. 24.

NOTE: Be careful not to bend the fan blades, this will
throw the fan blade out of balance or it may rub the inner
chamber, which may affect the performance of the boiler.

Any horizontal and vertical ue pipe directly above the unit

should be cleaned at this time

NOTE: The horizontal ue pipe directly above the boiler
is the rst place y ash will settle, due to the slowing of ue

gas velocity through horizontal pipe. Cleaning of horizon-

tal venting pipes is very important to the efciency of this

boiler.

Clean the ue outlet throat as well as the inner chamber
of the ue tunnel (this is the hole that goes up into the
ue pipe). See Fig. 24.

NOTE: The exhaust probe sensing tip extends into
this same area. CARE MUST BE TAKEN NOT TO
DAMAGE THE ESP DURING CLEANING. Bending

of the ESP will make it difcult to remove if it should

become necessary. See Fig. 23.

Sealing Overlap

5” Double
Bladed Fan

Fig. 24

Combustion Blower Cleaning

Remove the combustion blower heat shield. There are

two latches that hold the shield in place (See Fig. 22). Flip

the latches up and pull the shield away from the boiler.
It can not be fully removed, it can only be moved down
over the wire until it hangs on the junction box.

33

Clean the boiler blower plate, sealing overlap. See Fig

24. Make sure there are no y ash buildups that may
block the easy ow of ue gasses into the combustion
blower inlet hole. ( A ashlight may be necessary. )

Cleaning the Tube Heat Exchangers:

The heat exchanger tubes have external handles that

operate the cleaning mechanisms. See picture on page 32.

This cleaning should be done at least once a week,

although it can be done as often as desired. The cleaner

the heat exchangers are, the more efcient the boiler

will be. This cleaning can be done at any time and in

any mode of operation. During high re periods, the

cleaning rods may stick due to heat related expansion.

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

Troubleshooting

FEEDER DOES NOT FEED

1. No pellets in hopper.

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

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

remanually.

4.Somethingisrestrictingowinthehopperor

causing the slide plate to stick.

5. Feed motor has failed.

PARTIALLY BURNED PELLETS

1. Feed rate too high.

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

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

4. Combination of all the above.

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

neyre)

A 6 blink status may be caused by several
things:

1.Blockedorpartiallyblockedue.

2. Blocked or partially blocked inlet air.
a. Backdraft damper on the inlet pipe may be
stuck closed.
b. If outside air is installed, the inlet cover may
be blocked.

3. The air chamber under the burnpot may be

lledwithnesandsmallbitsofash.

4.Theholesintheburnpotmaybegettinglled

with ash or carbon buildup.

5. Combustion blower fan blades may need
cleaned.

6. There is no fuel in the hopper.

SMOKE SMELL

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

FIRE HAS GONE OUT

1. No pellets in hopper.

2. Draft setting is too low.

3.Somethingisrestrictingfuelow.

4. Feed motor or combustion blower has failed.

34

5. Power failure or blown fuse.

SMOKE IS VISIBLE COMING OUT OF VENT

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

LOW HEAT OUTPUT

1. Feed rate too low

2. Draft too low because of gasket leak.

3. Poor quality or damp pellets

4. Combination of 1 and 2.

Cleaning Burn Pot

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

you use a vacuum.

Carbon buildup can be scraped loose with

thereburningusingthespecialtoolprovided
withyourstove.Scrapetheoorandsidesofthe

burn pot. The carbon will be pushed out by the
incoming fuel. Always wear gloves to do this.

Removing Ashes

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

Maximum Feed Adjuster settings are not
needed in most cases. Operating in the normal
range (#4) is recommended when maximum heat
output is not required. The ESP prevents the

stovefrombeingover-red.

Keep the boiler free of dust and dirt.

Helpful Hints

Fuel

Pellet fuels are put into 3 categories in terms of
ash content. Premium at 1% or less, Standard at
3% or less and all others at 3% or more.

This unit is capable of burning all 3 categories
of pellets due to a patented feeder and burn pot
system.

It should be noted, however, that higher ash
content will require more frequent ash removal,
scraping of the burn pot, and may provide less
BTU’s per pound. Normally, standard and high ash
pellets cost less than premium pellets and can be
cost effective when burned in this boiler.

The moisture content must not exceed 8%.
Higher moisture will rob BTU’s and may not burn
properly.

Atmospheric Conversion

AtmosphericConversion:Item#1-00-232200,providesautomaticll,andconvertstheheating
systemplumbingfrompressurizedtoazeropressuresystem.Allowsforinstallationintomore
placeswherecodesandstandardsrestrictpressurizedsystems.Notethatwhenusingtheatmo-

spheric conversion, air bleeders and check valves may actually allow air into the lines. Another
reason it is important to have a licensed Plumber involved in each phase of your installation.

35

When using the atmospheric conversion, the circuit board dipswitch #6 must
be in the “ON” position. This will lower the overheat temperature parameters
to prevent boiling of the water. Since altitude affects the boiling point, it is also
recommended to set #6 to “ON” at elevations above 3000 ft.

Specications

36

BTU Input Range= 0, and 9350 to 113,900*

0 BTU if system is satised.

Min. Burn = 1.1 pound per hour

Max. Burn = 13.4 pounds per hour

* 8500 BTU per pound gures

Electrical 120 VAC 60 Hz

Combustion blower 1.4 AMP

Auger motor .7 AMP

Igniter element 3.6 AMP

Control board .05 AMP

Approximate operating wattage .2 KWH

6 AMP GLASS FUSE

Wiring Diagram

WHITE 11 PIN PLUG

2

EXHAUST PROBE

(ESP)

9

1

8

4

3

11

10

1

BROWN

3

PLUGGED

WHITE

4

5

WHITE

EMPTY

6

7

EMPTY

EMPTY

10911

8

BLACK

PART NO. 3-90-72194A

RED

YELLOW

DK BLUE

PELLET BOILER WIRING DIAGRAM

BROWN

AQUA TEMP SENSOR

WHITE

DARK BLUE

RED

3/8"FLEX CONDUIT

GREEN/YELLOW

ESP

BOARD

CONTROL

TCP

BLACK

GREEN/YELLOW WIRE

TWISTED WIRE

OUTDOOR AIR EXTENSION

120 VAC

YELLOW

YELLOW

SKY BLUE

SKY BLUE

WHITE

BLACK

N.O. CONTACTS

LOW PRESSURE SWITCH

IS GROUND BONDED TO

STOVE BODY

MOTOR WIRE MALE/FEMALE CONNECTION

450 WATT

IGNITER ELEMENT

IGNITER PUMP

FEEDER MOTOR

37

120 VAC 60 HZ

MAIN POWER

(SUPPLIED

BY OTHERS)

WHITE

BLACK

GREEN

4" SQUARE JUNCTION BOX

RED

WHITE

BROWN

BLACK

WHITE

WHITE

RED

DARK BLUE

AUX. OUTPUT (OVERHEAT ZONE)

PVC CORD MOTOR LEAD

5.3 AMPS ( ignition mode )

1.7 AMPS ( normal operation )

WHITE

GREEN/YELLOW

RED

WHITE

COMBUSTION MOTOR

120 VOLTS A.C. 60 HZ.

635 WATTS-

200 WATTS-

GREEN

3/8"FLEX CONDUIT

Power Failure Backup Supply

CORD CONNECTOR

POWER TO THE UPS / Plug UPS into here.

When current is present, will keep UPS in

Ready mode.

POWER FROM THE UPS / This plugs

into the UPS. When power fails, UPS

will supply current to the relay.

( UNINTERUPTED POWER SUPPLY / BATTERY BACK-UP )

UPS BACKUP FOR COMBUSTION MOTOR

“105 Series” PELLET BOILER

If using a standard UPS, it should

be rated at 650 or higher to

ensure that the combustion motor

operates until the fire is out.

CORD CONNECTOR

( approximately 20 minutes needed )

1/2" CONDUIT

receptacle on the UPS.

3

4

GREEN

MALE

16-3 AWG

PVC CORD

WHITE

BLACK

GREEN

1

5

2

6

DPDT RELAY flange mtd. -

GRAINGER # 2XCO2

FEMALE

16-3 AWG

PVC CORD

These cord tails can be made from an inexpensive 16/3 extension cord.

Make sure that the MALE end is long enough to reach the

WHITE

BLACK

GREEN

WHITE

WHITE

8 7

RED

RED

3838

3/8"FLEX CONDUIT

from control board

120 VAC power (by installer)

DARK BLUE

RED

GREEN

WHITE

BROWN

WHITE

WHITE

BLACK

WHITE

GREEN

GREEN/YELLOW

BLACK

WHITE

WHITE

RED

RED

RED

GREEN

WHITE

Relay enclosure box -

GRAINGER # 1EGH7

4" SQUARE JUNCTION BOX

to combustion motor

3/8"FLEX CONDUIT

Testing Label

BH105

BH105

Wood

SAMPLE LABEL ONLY

WARNING: Risk of fire - Do not operate with the flue draft

exceeding -.9 in Water Column / -224Pa.

39

ATTENTION: Risque de feu - Ne fonctionnez pas avec l'ébauche

deconduite de cheminée excédant -.9 " colonne de l'eau / -224Pa.

Hearth & Home Technologies, Inc.

Service Record / Notes

Date Of Service Performed By Description Of Service

40

Quick Reference ( Auto-Light )

1 Turn Mode Selector to OFF.

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

3 Scrape the air holes in the burnpot.**

4 Fill the hopper with pellets.

5 Turn Feed Adjuster to “Test”.*

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

7 Turn Feed Adjuster back to the #4 setting.

8 Turn the MAX TEMP dial to the desired temperature.

9 Turn MIN TEMP dial to the desired settings.*

10 Flip the igniter switch to Auto.*

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

temperature set on MAX TEMP dial..

*See the section on Operation for information

about Manual Lighting and Emergency Power.

**See the section on Maintenance for more details

about cleaning.

At Harman, we build each product to a standard, not a price.

Proudly Printed On 100% Recycled Paper

This powerful heating appliance boasts uncompromising
attention to detail and helps preserve our planet by using
environmentally responsible fuels.

(Signature of Boxer)

Your premium quality hearth product designed and assembled

by the experienced and skilled members at Harman in Halifax,

PA, USA.