Quadra-Fire CASTILEI-MBK User Manual

CASTILE PELLET INSERT

R

Owner’s Manual

Installation and Operation

Model:

CASTILEI-MBK
CASTILEI-PMH
CASTILEI-CSB
CASTILEI-CWL

DO NOT DISCARD THIS MANUAL

• Important operating and
maintenance instruc­tions included.

WARNING

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 fl am-

mable vapors and liquids in the vicinity of this
or any other appliance.

• Do not overfi re - If any external part starts to
glow, you are overfi ring. Reduce feed rate.
Overfi ring will void your warranty.

• Comply with all minimum clearances to com­bustibles as specifi ed. Failure to comply may
cause house fi re.

•

NOTICE

Read, understand and
follow these instruc­tions for safe installa­tion and operation.

Hot glass will cause burns.

• Do not touch glass until it is cooled

• NEVER allow children to touch glass

• Keep children away

• CAREFULLY SUPERVISE children in same room as
fi replace.

• Alert children and adults to hazards of high
temperatures.

High temperatures may ignite clothing or other

fl ammable materials.

• Keep clothing, furniture, draperies and other fl ammable
materials away.

Tested and

Listed by

•

Leave this manual with
party responsible for use
and operation.

WARNING

HOT SURFACES!

Glass and other surfaces are
hot during operation AND
cool down.

O-T L

C

-

Portland

Oregon USA

US

DO NOT

DISCARD

CAUTION

Tested and approved for wood pellets and shelled
fi eld corn fuel only. Burning of any other type of fuel
voids your warranty.

www.quadrafi re.com

Check building codes prior to installation.

• Installation MUST comply with local, regional, state and national

• Consult local building, fi re offi cials or authorities having jurisdic-

7022-122

CAUTION

codes and regulations.

tion about restrictions, installation inspection, and permits.

January 19, 2011

Castile Pellet Insert

R

and Welcome to the Quadra-Fire Family!

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 fi replaces. And yet we are old-fashioned when it comes to
craftsmanship. Each unit is meticulously fabricated and surfaces
are hand-fi nished for lasting beauty and enjoyment. Our pledge
to quality is completed as each model undergoes a quality control
inspection.

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.

NOTE: Consult insurance carrier, local building inspector, fi re
offi cials or authorities having jurisdiction over restrictions,
installation inspection and permits.

LOCATION: Riveted to appliance behind left side panel. Remove cast side and swing label forward

Test Lab &

Serial Number

Castile Pellet Insert-B

1445 Highway North, Colville, WA 99114

DO NOT REMOVE THIS LABEL

NE PAS ENLEVER L'ÉTIQUETTE

SAFETY LABEL / ÉTIQUETTE DE SÉCURITÉ

Appareil de chauffage inséré de combustible solide/de type de boulettes. “Pour Usage Avec Bois Solide et
Champ de Maïs égrené Seulement”. Accepté dans l'installation dans les maisons mobiles. Cet appareil a
été testé et enregistré pour l
814-23-909.

Testé à: ASTM #1509-04, ULC S628-93, ULC/ORD-C1482-M1990 Room Heating. Pellet Burning Type, UM)
84-HUD POUR USAGE AVEC LES BOULETTES DE BOIS.

appareil se conforme avec la norme de l’Association Canadienne de normalisation (CSA) B415.1 ainsi que le Titre 40 du
Code Fédéral de Régulations des États-Unis, partie 60, sous-partie AAA. Accréditations OMNI-Test Laboratories : Le
Conseil Canadien des Normes (CCN/SCC), l’Institue des Standards Nationaux Américain (ANSI) et l’Agence de Protection
Environnemental (EPA).

Puissance de Rendement: 30,000 BTU/HR

Puissance Électrique: 115 VAC, 60 Hz, Début 4.1 Amps, Courir 1.1 Amps,
Éloignez le fil électrique de l'appareil. Ne pas faire passer le fil électrique au dessus ou en dessous de l'appareil.
DANGER: Il y a risque de décharge électrique. Déconnectez le fil électrique de la prise de contact avant le service.
Remplacez la vitre seulement avec une vitre céramique de 5 mm disponible chez votre fournisseur.
Pour allumer, monter la température du thermostat au dessus de la température de la pièce, le poêle s'allumera
automatiquement. Pour éteindre, descendre la température du thermostat en dessous de la température de la pièce.
Pour des instructions supplémentaires, référez vous au manuel du propriétaire. Gardez la porte d'ouverture et la porte
des cendres fermées hermétiquement durant l'opération.

I

nstallez et utilisez en accord avec les instructions d'installation et d'opération du fabricant. Contactez le bureau
de la construction ou le bureau des incendies au sujet des restrictions et des inspections d'installation dans votre
voisinage. Ne pas obstruez l'espace en dessous de l'appareil.

A

VIS - Pour Les Maisons Mobiles: Ne pas installer dans une chambre à coucher. Un tuyau extérieur de
combustion d'air doit être installé et ne doit pas être obstrué lorsque l'appareil est en usage. La structure
intégrale du plancher, du plafond et des murs de la maison mobile doit être maintenue intacte.
Référez vous aux instructions du fabricant et des codes locaux pour les précautions requises pour passer une
cheminée à travers un mur ou un plafond combustibles, et les compensations maximums.
Inspectez et nettoyez la cheminée fréquemment.

Ne pas connecter cet appareil à une cheminée servant un autre appareil.

Utilitsez le syst

'usage dans les Maisons Mobiles en accord avec OAR 814-23-9000 jusqu'à

OMNI-Test Laboratories, Inc. a déterminé que cet

PRÉVENTION DES FEUX DE MAISON

SAMPLE

è

me de ventilation de 3 or 4 inch (76-102mm) de diametre de type “L” ou “PL”.

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS

Masonry or Zero Clearance

Dégagement de la maçonnerie ou Dégagement zéro

Maximum Mantel Depth - 10 inches

A

0 in. 0mm

B

12 in. 305mm

C

0 in. 0mm

D

0 in. 0mm

E

6 in. 152mm

F

6 in. 152mm

Profondeur Maximale Mantel - 254mm

Mantel/Manteau

B

A

Sidewall / Mur Latéral

C

Insert

Insére

F

ESPACES LIBRES MINIMUM DES MATÉRIAUX COMBUSTIBLES:

AS A BUILT-IN UNIT

Fascia or Trim

E

Garniture
de façade

D

G

I

0 in. Clearance To Exposed Section and Face Trim / Espace libre
de 0 mm de la section exposée et de la garniture du devant.

Listed Solid Fuel Room Heater/Pellet Type Insert. “For Use with Solid Wood Fuel and
Shelled Field Corn Only”.
tested and listed for use in Manufactured Homes in accordance with OAR 814-23-9000

through 814-23-909.
Tested to: ASTM E1509-04, ULC S628-93, ULC/ORD-C1482-M1990 Room Heating Pellet
Burning Type, (UM) 84-HUD FOR USE

Laboratories, Inc. has determined that this appliance complies with Canadian Standards
Association (CSA) B415.1 and Title 40 of the U.S. Code of Federal Regulations, Part 60,
SubPart AAA.OMNI-Test Laboratories Accrediations: The Standards Council of Canada,
the American National Standards Institute, and the U.S. Environmental Protection Agency.
Input Rating: 30,000 BTU/HR.
Electrical Rating:
Route power cord away from unit. Do not route cord under or in front of appliance.

DANGER:

Replace glass only with 5mm ceramic available from your dealer.
To start, set thermostat above room temperature, the stove will light automatically. To
shutdown, set thermostat to below room temperature. For further instruction refer to owner's
manual.
Keep viewing and ash removal doors tightly closed during operation.

Install and use only in accordance with manufacturer's installation and operating instructions.

Contact local building or fire officials about restrictions and inspection in our area.

WARNING: FOR MOBILE HOMES: Do not install appliance in a sleeping room. An outside

combustion air inlet must be provided. The structural integrity of the mobile home floor, ceiling

and walls must be maintained.

Refer to manufacturer's instructions and local codes for precautions required for passing

chimney through a combustible wall or ceiling. Inspect and clean vent system frequently in

accordance with manufacturer's instructions.

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

Use a 3 or 4 inch (76-102mm) diameter type "L" or "PL" venting system.

Report No.

Also suitable for Mobile Home Installation. This appliance has been

ONLY WITH PELLETIZED WOOD.

115 VAC, 60 Hz, Start 4.1 Amps, Run 1.1 Amps.

Risk of electrical shock. Disconnect power supply before servicing.

PREVENT HOUSE FIRES

COMME APPAREIL INSÉRÉ

G

I

H

J

H

K

2 in. (51mm)*

2.5 in. (64mm)**

H 2 in. (51mm)
I 4 in. (102mm)
J 3 in. (76mm)

*Top Vent /
**

Rear Vent

Model

OMNI-Test

Des Conduits Du Haut

/ Des Conduits Arrières

Mfg By: Mfg Date

SERIAL NO.

/ NUMÉRO DU SÉRIE

00702300000

O-T L

US

C

OMNI-Test Laboratories, Inc.

imported parts.

Fabriqué par

Portland

Oregon USA

7022-121

Tested and

Listed by

Report / Rapport
#061-S-77d-6.2

Made in U.S.A. of US and

États-Unis-d’Amérique par des

pièces d’origine américaine et

pièces importées.

Manufactured by:

www.quadrafire.com

2010 2011 2012

JAN FEB MAR JAN FEB MAR

APR MAY JUNE

JULY AUG SEPT

OCT NOV DEC

R

:

Page 2

7022-122

January 19, 2011

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Castile Pellet Insert

Safety Alert Key:

• DANGER! Indicates a hazardous situation which, if not avoided will result in death or serious injury.

• WARNING! Indicates a hazardous situation which, if not avoided could result in death or serious injury.

• CAUTION! Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

• NOTICE: Indicates practices which may cause damage to the fi replace or to property.

TABLE OF CONTENTS

Section 1: Listing and Code Approvals

A. Appliance Certifi cations ......................4

B. Mobile Home Approved ......................4

C. Glass Specifi cations ............................4

D. Electrical Rating ..................................4

E. BTU & Effi ciency Specifi cations ..........4

Section 2: Getting Started

A. Design, Installation & Location

Considerations ....................................5

B. Locating Your Appliance & Chimney ..6

C. Draft ....................................................6

D. Negative Pressure ..............................6

E. Avoiding Smoke & Odors....................7

F. Fire Safety ..........................................8

G. Tools & Supplies Needed ...................8

H. Inspect Appliance, Components

and Pre-Burn List ................................8

Section 3: Dimensions & Clearances

A. Appliance Dimensions ........................9

B. Clearances to Combustibles

As A Built-In, UL and ULC ..................10

C. Clearances to Combustibles,

Masonry & Zero Clearance .................11

D. Minimum Opening for Masonry and

Factory-Built Fireplace ........................11

E. Floor Protection ..................................11

F. Prefabricated Metal Chimney ..............11

G. Removing Floor of Factory Built

Fireplace .............................................12

H. Altering Factory-Built Fireplace ...........12

Section 4: Vent Information

A. Chimney & Exhaust Connections ........13

B. Venting Termination Requirements ....13

C. Pellet Venting Chart ............................14

Section 5: Venting Systems

A.

B. Full Reline with Outside Air-Vertical ....16

Full Reline with Outside Air-Horizontal

15

Section 6: Mobile Home .................................. 17

Section 7: Appliance Set-Up

A. Leveling System .................................18

B. Outside Air Kit .....................................18

C. Door Handle Removal ........................19

D. Door Removal .....................................19

E. Adjustable Hearth Support ..................19

F. Hearth Support, Standard Surround ...20-21

G. Surround & Trim Set, Econo ...............21

H. Surround Cast Trim Set ......................22

I. Log Set Placement ..............................22

J. Thermostat Installation ........................24

Section 8: Operating Instructions

A. Combustible & Non-Combustible ........25

B. Fuel Material & Fuel Storage ..............25

C. General Operation Information ...........26

D. Before Your First Fire .........................26

E. Clear Space ........................................26

F. Starting Your First Fire ........................27

G. Fire Characteristics .............................27

H. Feed Rate Adjustment .......................27

I. Ignition Cycles ....................................28

J. Frequently Asked Questions...............28

Section 9: Troubleshooting ............................29-31

Section 10: Maintaining & Servicing Appliance

A. Proper Shutdown Procedures .............32

B. Quick Reference Maintenance Chart ..32

C. General Maintenance & Cleaning .......32-35

D. High Ash Content Maintenance ..........36

E. Combustion Blower Replacement .......37

F. Convection Blower Replacement ........37

G. Igniter Replacement ............................38

H. Glass Replacement .............................38

I. Baffl e & Brick Removal .......................39-40

Section 12: Reference Material

A. Component Functions.........................40-42

B. Component Locations .........................43

C. Exploded Drawings .............................44

D. Service Parts & Accessories ...............45-50

E. Maintenance & Service Log ................51-52

F. Homeowner’s Notes ............................53

G. Warranty Policy ...................................54-55

H. Contact Information .............................56

January 19, 2011

7022-122

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Castile Pellet Insert

Listing and Code Approvals

1

R

A. Appliance Certifi cation

MODEL: Castile Pellet Insert-B
LABORATORY: OMNI Test Laboratories, Inc
REPORT NO. 061-S-77d-6.2
TYPE: Solid Fuel Room Heater/Pellet Fuel

Burning Type Insert

STANDARD: ASTM E1509-2004, ULC S628-93 and

ULC/ORD-C1482-M1990 Room Heater
Pellet Fuel Burning Type and (UM) 84­HUD, Mobile Home Approved

NOTE: This installation must conform with local codes. In
the absence of local codes you must comply with the ASTM

E1509-2004, ULC S628-93, ULC/ORD-C-1482-M1990,
(UM) 84-HUD

The Castile Pellet Insrt by Quadra-Fire is exempt from Envi­ronmental Protection Agency certifi cation under 40 CFR

60.531 y defi nition [Wood Heater (A) “Air to Fuel Ratio].

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 fl oor, 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.

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

E. BTU & Effi ciency Specifi cations

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: 252 lbs

*BTU output will vary, depending on the brand of fuel you
use in your appliance. Consult your Quadra-Fire dealer
for best results.

WARNING! Risk of Fire! Hearth & Home Technologies dis­claims any responsibility for, and the warranty and agency
listing will be voided by the below actions.

DO NOT:

• Install or operate damaged appliance

• Modify appliance

• Install other than as instructed by Hearth & Home

Technologies

• Operate the appliance without fully assembling all

components

• Overfi re

• Install any component not approved by Hearth &

Home Technologies

• Install parts or components not Listed or approved.

• Disable safety switches

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

For assistance or additional information, consult a qualifi ed
installer, service agency or your dealer.

0.7 grams/hr

on climate zone

C. Glass Specifi cations

This appliance is equipped with 5mm ceramic glass.
Replace glass only with 5mm ceramic glass. Please contact
your dealer for replacement glass.

D. Electrical Rating

115 VAC, 60 Hz, Start 4.1 Amps, Run 1.1 Amps

NOTE: Some generator or battery back-up systems may
not be compatible with the micro-processor electron­ics on this appliance. Please consult the power supply
manufacturer for compatible systems.

Page 4

7022-122

NOTE: Hearth & Home Technologies, manufacturer of
this appliance, reserves the right to alter its products,
their specifi cations and/or price without notice.

Quadra-Fire is a registered trademark of Hearth & Home
Technologies.

January 19, 2011

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Castile Pellet Insert

2

A.Design, Installation & Location Considerations

1. Appliance Location

NOTICE: Check building codes prior to installation.

• Installation MUST comply with local, regional, state and
national codes and regulations.

• Consult insurance carrier, local building inspector, fi re
offi cials or authorities having jurisdiction over restrictions,
installation inspection and permits.

Getting Started

Since pellet exhaust can contain ash, soot or sparks, you
must consider the location of:

• Windows

• Air Intakes

• Air Conditioner

• Overhang, soffi ts, porch roofs, adjacent walls

• Landscaping, vegetation
When locating vent and venting termination, vent above

roof line when possible.
It is a good idea to plan your installation on paper, using
exact measurements for clearances and fl oor protection,
before actually beginning the installation

Consideration must be given to:

• Safety, convenience, traffi c fl ow

• Placement of the chimney and chimney connector.

• If you are not using an existing chimney, place the appli-

Warning! Risk of Fire Damaged parts could impair safe
operation. Do NOT install damaged, incomplete or substitute

components.

CAUTION! If burning shelled fi eld corn, you must use ap-

proved venting specifi cally designed for corn to prevent corro-
sion or degradation. Follow the instructions from the venting
manufacturer.

ance where there will be a clear passage for a factory­built listed chimney through the ceiling and roof.

• Installing an optional outside air kit would affect the loca-

tion of the vent termination.

NOTICE: Locating the appliance in a location of
considerable air movement can cause intermittent smoke
spillage from appliance. Do not locate appliance near:

• Frequently open doors

• Central heat outlets or returns

Location NOT recommended:

• Not the highest point of the roof

• Wind loading possible

Windward

Recommended:

Outside Air Intake
on windward side

Figure 5.1

Recommended Location:

• Above peak

Marginal Location:

• Below peak

Recommended:

• Insulated exterior chase
in cooler climates

Recommended Location:

• Above peak

• Inside heated space

Multi-level Roofs

Marginal Location:

• Wind loading possible

Location NOT recommended:

• Too close to tree

• Below adjacent structure

• Lower roof line

• Avoid outside wall

Leeward

NOT recommended:
Outside Air Intake
on leeward side

January 19, 2011

7022-122

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Castile Pellet Insert

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B. Locating Your Appliance & Chimney

Location of the appliance and chimney will affect
performance.

• Install through the warm airspace enclosed by the building
envelope. This helps to produce more draft, especially
during lighting and die-down of the fi re.

• Penetrate the highest part of the roof. This minimizes the
effects of wind loading.

• Locate termination cap away from trees, adjacent
structures, uneven roof lines and other obstructions.

• Minimize the use of chimney offsets.

• Consider the appliance location relative to fl oor and ceiling
and attic joists.

CAUTION

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

• DO NOT CONNECT TO ANY AIR DISTRIBUTION DUCT
OR SYSTEM.

May allow fl ue gases to enter the house

C. Draft

Draft is the pressure difference needed to vent appliances
successfully. When an appliance is drafting successfully, all
combustion byproducts are exiting the home through the
chimney.

Considerations for successful draft include:

• Preventing negative pressure

• Location of appliance and chimney
To measure the draft or negative pressure on your appliance

use a magnahelic or a digital pressure gauge capable of
reading 0 - .25 inches of water column (W.C.).

The appliance should be running on high for at least 15
minutes for the test.

With the stove running on high you should have a negative
pressure equal to or greater than the number given in the
chart below. If you have a lower reading than you fi nd on the
chart, your appliance does not have adequate draft to burn
the fuel properly.

D. Negative Pressure

WARNING! Risk of Asphyxiation! Negative pressure can
cause spillage of combustion fumes and soot.

Negative pressure results from the imbalance of air avail­able for the appliance to operate properly. It can be stron­gest in lower levels of the house.

Causes include:

• Exhaust fans (kitchen, bath, etc.)

• Range hoods

• Combustion air requirements for furnaces, water heaters
and other combustion appliances

• Clothes dryers

• Location of return-air vents to furnace or air conditioning

• Imbalances of the HVAC air handling system

• Upper level air leaks such as:

- Recessed lighting

- Attic hatch

- Duct leaks

To minimize the effects of negative air pressure:

• Install the outside air kit with the intake facing prevailing
winds during the heating season

• Ensure adequate outdoor air for all combustion appliances
and exhaust equipment

• Ensure furnace and air conditioning return vents are not
located in the immediate vicinity of the appliance

• Avoid installing the appliance near doors, walkways or
small isolated spaces

• Recessed lighting should be a “sealed can” design

• Attic hatches weather stripped or sealed

• Attic mounted duct work and air handler joints and seams
taped or sealed

NOTICE: Hearth & Home Technologies assumes no

responsibility for the improper performance of the chimney

system caused by:

• Inadequate draft due to environmental conditions

• Downdrafts

• Tight sealing construction of the structure

• Mechanical exhausting devices

Minimum Vacuum Requirements: .095

Page 6

7022-122

January 19, 2011

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Castile Pellet Insert

E. 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 appliance during power failure or shut down con­ditions, 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 in the pellet appliance installation.

Heat rises in the house and leaks out at upper levels. This
air must be replaced with cold air from outdoors which
fl ows into lower levels of the house.

Vents and chimneys into basements and lower levels of the
house can become the conduit for air supply and reverse
under these conditions.

Outside Air

An outside air kit is recommended in all installations. The
Outside Air Kit must be ordered seperately.

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 backdrafting of those and other
appliances.

Vent Confi gurations

To reduce 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 (1.52m). Preferably terminating above the roof
line.

• Installing the outside air kit at least 4 feet (1.22m)
below the vent termination.

To prevent soot damage to exterior walls of the house and
to prevent re-entry of soot or ash into the house:

• Maintain specifi ed clearances to windows, doors and
air inlets, including air conditioners.

• Vents should not be placed below ventilated soffi 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 6 inches (152mm)
from the vent termination to the exterior wall. If you
see deposits developing on the wall, you may need to
extend this distance to accommodate your installation
conditions.

When the appliance is roof vented (strongly recommended):

The air intake is best located on the exterior wall ori­ented towards the prevailing wind direction during the
heating season.

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 exhaust vent outlet.

The outside air supply kit can supply most of the demands
of the pellet appliance, but consideration must be given to
the total house demand.

House demand may consume the air needed for the appli­ance. It may be necessary to add additional ventilation to
the space in which the pellet appliance is located.

Consult with your local HVAC professional to determine
the ventilation demands for your house.

January 19, 2011

7022-122

Page 7

Castile Pellet Insert

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F. Fire Safety

To provide reasonable fi re safety, the following should be
given serious consideration:

• Install at least one smoke detector on each fl oor of your
home.

• Locate smoke detector away from the heating appliance
and close to the sleeping areas.

• Follow the smoke detector manufacturer’s placement and
installation instructions and maintain regularly.

• Conveniently locate a Class A fi re extinguisher to contend
with small fi res.

• In the event of a hopper fi re:

• Evacute the house immediately.

• Notify fi re department.

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.

• Modifi cation 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 Overfi re.

Or any such action that may cause a fi re hazard.

G. Tools And Supplies Needed

Tools and building supplies normally required
for installation, unless installing into an existing
masonry fi replace:

Reciprocating Saw

Hammer

Phillips Screw driver
Tape Measure
Plumb Line
Level
Framing Material
Non-Combustible Sealant
Material

Gloves
Safety Glasses
Framing Square
Electric Drill & Bits)
1/4” Self-Tapping Screws

May also need:
Vent Support Straps
Venting Paint

H. Inspect Appliance & Components

• Remove appliance and components from packaging
and inspect for damage.

• Report to your dealer any parts damaged in shipment.

• Read all the instructions before starting the instal-

lation. Follow these instructions carefully during
the installation to ensure maximum safety and
benefi t.

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.

Pre-Burn Check List

1. Place the appliance in a location near the

fi nal 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 fol-

lowed.

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 profes-

sional 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. A power outlet is available nearby.

14. A good quality surge protection is highly recom-

All labels have been removed from the glass

door.

applicable.

mended to protect the electronics.

Page 8

7022-122

January 19, 2011

R

Dimensions and Clearances

3

A. Appliance Dimensions

27-7/8 in. (707mm)

23-3/8 in. (594mm)

(203mm)

Castile Pellet Insert

8 in.

32-1/4 in. (819mm)

Figure 9.1 - Top View

24-3/4 in.

(629mm)

9-3/4 in.

(249mm)

Figure 9.2 -Side View

A

13 in.

(330mm)

19 in.

(483mm)

2 in.

(51mm)

January 19, 2011

B

Figure 9.3- Front View

Overall Size A B

Metal Surround w/Cast Trim, STD 42-1/2 in. (1080mm) 30 in. (762mm)
Metal Surround w/Cast Trim, LRG 48 in. (1219mm) 34 in. (864mm)
Metal Surround w/Standard Trim, STD 43 in. (1092mm) 31 in. (787mm)
Metal Surround w/Standard Trim, LRG 51 in. (1294mm) 34 in. (864mm)

7022-122

Page 9

Castile Pellet Insert

R

B. Clearance To Combustibles, UL and ULC

AS A BUILT-IN

A

C

0 in. Clearance To Exposed Section And Face Trim

Figure 10.1

A Top of Hopper Top Vent 2.0 51

B Side of Hopper Top or Rear Vent 2.0 51
C Back of Hopper Top or Rear Vent 4.0 102
D Vent Pipe to Combustible Top or Rear Vent 3.0 76

Must be installed in a non-tapered enclosure.

Rear Vent 2.5 64

NOTE: All Clearances are Minimum Clearances

C

B

D

B

Inches Millimeters

Shown with Rear Vent and Outside Air

Combustible

Mantel

INSTALLED AS A BUILT-IN UNIT

12 in

(305mm)

Top Vent:
2 in. (51mm)

Rear Vent:

2.5 in (64mm)

Back of Hopper:
4 in (102mm)

Vent Pipe to
Combustibles:
3 in (76mm)

6 in

(152mm)

Outside Air

WARNING

Fire Risk.
Comply with all minimum clear-

ances to combustibles as speci­fi ed.

Failure to comply may cause
house fi re.

NOTE:

• Illustrations refl ect typical installations
and are FOR DESIGN PURPOSES
ONLY.

• Illustrations/diagrams are not drawn to
scale.

• Actual installation may vary due to
individual design preference.

Figure 10.2

Page 10

7022-122

January 19, 2011

R

Castile Pellet Insert

C. Masonry and Factory-Built Fireplaces

Maximum Mantel Depth: 12 inches (305mm)

Mantel

B

C

Side Wall

A

F

E

D

Figure 11.1

Inches Millimeters

Insert side to combustible side wall 16 406

A

Insert top to mantel 12 305

B

Insert top to maximum. 2-1/4 inch

C

(57mm) face trim
Insert side to maximum. 2-1/4 inch

D

(57mm) face trim

4-3/4 121

10 254

D. Minimum Opening for Masonry and

Factory-Built Fireplaces

B

D

Figure 11.2

Location Inches Millimeters

A Rear Width 23-5/8 600
B Depth 17 432
C Height 21-1/4 540
D Front Width 28-1/8 714

C

A

Face
Trim

E. Floor Protection

Inches Millimeters

E Floor protection hearth extension from

door opening

F Floor protection to the side of door

opening

6 152

6 152

F. Prefabricated Metal Chimney

The chimney can be new or existing, masonry or prefabricated
and must meet the following minimum requirements:

• Must be minimum 6 inch (152mm) inside diameter of
high temperature chimney listed to UL 103 HT (2100
or ULC-S628.

• Must use components required by the manufacturer for
installation.

• Must maintain clearances required by the manufacturer
for installation.

• Refer to manufacturers instructions for installation

•This insert is listed to UL 1482 Standard and is approved
for installation into listed factory-built zero

clearance fi re-

places listed to UL 127 conforming to the following speci­fi cations and instructions:

•The original factory-built zero clearance fi replace chim­ney cap must be re-installed after installing the approved
chimney liner meeting type UL 103 HT requirements
(2100°F) per UL 1777.

•If the chimney is not listed as meeting HT requirements,
or if the factory built fi replace was tested prior to 1998, a
full height listed chimney liner must be installed from the
appliance fl ue collar to the chimney top.

•The liner must be securely attached to the insert fl ue collar
and the chimney top.

•The air fl ow of the factory-built zero-clearance fi replace
system must not be altered. The fl ue liner top support
attachment must not reduce the air fl ow for the existing
air-cooled chimney system.

•No dilution air is allowed to enter the chimney.

1. Secure the fi replace damper in the open position. If

this cannot be accomplished, it will be necessary to
remove the damper.

2. Seal damper area of chimney around chimney
connector with a high temperature sealant or seal
insert against the face of the fi replace.

3. Both methods must be removable and replaceable
for cleaning and re-installation.

o

F)

January 19, 2011

7022-122

Page 11

Castile Pellet Insert

G.

Removing Metal Floor of Factory-Built Fireplace

R

• The fi rebrick (refractory), glass doors, screen rails, screen

mesh and log grates can be removed from a factory-built fi re-
box in order to gain minimum insert opening requirements.

• Any smoke shelves, shields and baffl es may be removed
from a factory-built fi rebox if attached with mechanical fas­teners.

• The metal fl oor of the factory-built fi replace 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 fl oor of
outer wrap.

• This should have prior approval from authority having juris­diction. Upon removal, the factory built fi replace is no longer
considered a UL 127 Listed fi replace, only a metal box.

• Ensure the metal box is supported to hold weight of the chim­ney and the insert. Maintain clearances to combustibles.

The following is only one example as there are many different
models of factory-built fi replaces.

Starter hole

Mark area of
floor to cut

Figure 12.1. Measure and mark the metal fl oor for cutting. With
a drill, make a starter hole in each corner.

In Figure 2.3 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: If the fl oor 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. Ensure
that the leveling bolt is positioned over the 2 x 4 before level­ing the insert.

H. Altering the Factory-Built Fireplace

• The fireplace must not be altered, except for the

exceptions listed below. Do not removal the bricks and
mortar from the existing fi replace.

The following modifi cations are premissible:

• Removal of damper or locked in open position

• Removal of smoke shelf or baffl e

• Removal of ember catches

• Removel of fi re grate

• Removal of view screen/curtain

• Removal of doors

• External trim pieces which do not affect the operation
of the fi replace may be removed providing they can be
stored on or within the fi replace for reassembly if the
insert is removed.

• The permanent metal warning label provided must be
attached to the back of the fi replace, with screws or
nails, stating that the fi replace may have been altered
to accommodate the insert, and the fi replace must be
returned to original condition befor use as a conventional
fi replace. Figure 12.4.

• If the hearth extension is lower than the fireplace
opening, the portion of the insert extending onto the
hearth must be supported.

• Manufacturer designed adjustable support kit can be
ordered from your dealer.

• Final approval of this installation type is contingent upon
the authority having jurisdiction.

Figure 12.2. Using a saws-all, cut out the fl oor.

Figure 12.3. Using a saws-all, cut out the fl oor.

Page 12

7022-122

NOTE: Refer to chimney liner manufacturer for rec­ommendations on supporting the liner. Installation
into fi replaces without a permit will void the listing

WARNING

THIS FIREPLACE MAY HAVE BEEN ALTERED
TO ACCOMMODATE AN INSERT. IT MUST BE
RETURNED TO ITS ORIGINAL CONDITION
BEFORE USE AS A SOLID FUEL BURNING
FIREPLACE.

Figure 12.4

250-2061

250-2061

January 19, 2011

R

Vent Information

4

A. Chimney and Exhaust Connection

Castile Pellet Insert

B. Venting Termination Requirements

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 fl ue connector. A Quadra-Fire outside air kit must
be used with manufactured home installations.

3. Residential: Use 24 gauge single wall fl ue connector or

Listed double wall fl ue connector to Class A Listed metal
chimneys, or masonry chimneys meeting International Build­ing Code (ICC) standards 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.

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

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

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 fi eld corn, you must use approved
venting specifi cally designed for corn. Follow the instruc-
tions 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.

•

Follow venting manufacturer’s clearances

and instructions when installing venting system.

WARNING

Vent surfaces get HOT, can cause burns if
touched. Non-combustible shielding or guards
may be required.

NOTICE: In Canada when using a factory-built chim-

ney it must be safety listed, Type UL103 HT (2100oF)

o

[1149
S629M, STANDARD FOR 650oC FACTORY-BUILT
CHIMNEYS.

C] CLASS “A” or conforming to CAN/ULC-

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 strongly 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 sof­fi ts.

• 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.

January 19, 2011

7022-122

Page 13

Castile Pellet Insert

Minimum Vertical Vent for One Elbow

Horizontal Run, (ft)

Minimum Vertical Vent for Two Elbows
Length of Horizontal Sections, (ft)

Minimum Vertical Vent for Three Elbows

024681012

Length of Horizontal Sections (ft)

C. Pellet Venting Charts

The maximum horizontal venting allowed with no vertical vent­ing attached is 48 inches (1219mm) including one 90° elbow
or two 45° elbows. This is our recommended horizontal vent­ing installation. Addition of any horizontal venting beyond
48 inches (1219mm) Hearth & Home Technologies strongly
recommends a minimum of 60 inches (1524mm) of additional
vertical vent. Horizontal sections of vent pipe should have a
1/4 inch (6.35mm) rise per foot.

R

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.

Hearth & Home Technologies recommends any installation
requiring more than two 90° elbows, or more than 15 feet
(4.5m) of venting to use 4 inch (102mm) vent.

ONE 90º ELBOW

Total

Horizontal

Total Minimum Vent

Horizontal Vertical Diameter

Minimum

Vertical
403
553
663
773
884
994

10 10 4
11 11 4
12 12 4
13 13 4
14 14 4
15 15 4
16 16 4
17 17 4
18 18 4
19 19 4

Vent

Diameter

TWO 90º ELBOWS

253
363
473
583
693
7104
8114
9124

10 13 4
11 14 4
12 15 4
13 16 4
14 17 4
15 18 4

Minimum Vertical Rise

Figure 14.1

Rise, (ft)

Minimum Vertical

45° elbow is equivalent to 1 foot of straight pipe
90° elbow is equivalent to 3 feet of straight pipe

Minimum Vertical Vent for One Elbow

20

15

10

(ft)

5

0

0 5 10 15 20

Horizontal Run (FT)

Minimum Vertical Vent for Two Elbows

20

15

10

5

0

0 5 10 15

Length of Horizontal Sections (FT)

THREE 90º ELBOWS

Total Minimum Vent

Horizontal Vertical Diameter

2114
3124
4134
5144
6154
7164
8174
9184

10 19 4
11 2 0 4

NOTICE: These are guidelines for successful venting of your pellet appliance. The more vertical rise you can obtain in
your system, the better it will perform. Horizontal vent runs can accumulate ash and will need to be cleaned more often.
Try to keep them as short as possible.

Page 14

Figure 14.2

Minimum Vertical Vent for Three Elbows

25

20

15

(ft)

10

5

0

Minimum Vertical Rise

Length of Horizontal Sections (FT)

Figure 14.3

7022-122

January 19, 2011

5

R

Castile Pellet Insert

Venting Systems

A. Full Reline With Horizontal Outside Air

CAUTION

Never draw outside combustion air from:

• Wall, fl oor or ceiling cavity

• Enclosed space such as an attic or garage

NOTE; Use metal plate around
exhaust vent pipe and seal all
edges with non-flammable insu­lation such as , mineral wool or
ceramic.

WARNING

Fire Risk.
Inspection of Chimney:

• Masonry chimney must be in good condition.

• Meets minimum standard of NFPA 211

• Factory-built chimney must be a minimum 6 inch
(152mm) UL103 HT.

Do not use high temperature
caulking materials to seal any
edge to prevent future service­ability.

Figure 15.1

Figure 15.1

NOTE:

In Canada, where passage through a wall or partition of
combustible construction is desired, the installation shall
conform to CAN/CSA-B365.

Outside Air through Rear
Wall (Horizontal)

NOTE:

• Illustrations refl ect typical installations and are FOR
DESIGN PURPOSES ONLY.

• Illustrations/diagrams are not drawn to scale.

• Actual installation may vary due to individual design

preference.

January 19, 2011

7022-122

Page 15

Castile Pellet Insert

C. Full Reline With Vertical Outside Air

R

NOTE: Check clearances carefully for this type of
installation to ensure adequate room for outside air
venting.

12” (305mm)
min. above

12” (305mm)
min. below

NOTE; Use metal
plate around
exhaust vent pipe
and seal all edges
with non-flammable
insulation such as
mineral wool or
ceramic.

CAUTION

Check building codes prior to installation.

• Installation MUST comply with local, regional, state and
national codes and regulations.

• Consult local building, fi re offi cials or authorities having
jurisdiction about restrictions, installation inspection,
and permits.

NOTE: In Canada, only a full reline is allowed per
ULC S628-93, ORD ULC C1482-M1990.

NOTE: In Canada this fi replace insert must be installed
with a continous chimney liner a 6 inch (152mm) in
diameter extending from the fi replace insert to the top
of the chimney. The chimney liner must conform to the
Class 3 requirments of CAN/ULC-S635, Standard for
Lining Systems for Existing Masonry or Factory-Built
Chimneys and Vents, or CAN/ULC-S640, Standard for
Lining Systems for New Masonry Chimneys.

Do not use high
temperature caulk­ing materials to seal
any edge to prevent
future serviceability

Figure 16.1

Outside Air

Termination

at

Chimney Top

Page 16

7022-122

January 19, 2011

R

o

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 fl oor (using lag bolts). Use
the same holes that secured the appliance to the ship­ping pallet with a minimum of two attachment points.

4. The appliance must be grounded with #8 solid copper
grounding wire or equivalent, terminated at each end
with an NEC approved grounding/bonding connector.

Castile Pellet Insert

CAUTION

THE STRUCTURAL INTEGRITY OF THE MANUFAC­TURED HOME FLOOR, WALL AND CEILING/ROOF MUST
BE MAINTAINED.

Do NOT cut through:

• Floor joist, wall, studs or ceiling trusses.

• Any supporting material that would affect the structural
integrity.

Spark Arrestor Cap

Storm Collar

Roof Flashing

5. Refer to clearances to combustibles and fl oor protection

requirements on pages 9 to 11 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

Asphyxiation Risk.

NEVER INSTALL IN A SLEEPING ROOM.
Consumes oxygen in the room.

Joist Shield/Firestop

Figure 16.1

Approved Class “L”
“PL” Pellet Vent

January 19, 2011

7022-122

Page 17

Castile Pellet Insert

Appliance Set-Up

7

R

A. Leveling System

The leveling bolts are located at the rear of the appliance.
To access the bolts, remove the side access panels. Reach
in and turn the bolt to the desired height to level the appli­ance. Shown in Figures 18.1 and 18.2.

Leveling Bolt on each Side

Figure 18.1

B. Outside Air Kit Instructions

Parts Included in Kit: 1 piece of 2 inch x 3 ft. fl ex hose,

2 hose clamps, 1 collar assembly, 1 termination cap
assembly, 1 trim ring, fasteners and air intake channel
(discard).
Tools Needed: Phillips head screwdriver; wire cutters;
hole saw or jig saw.

1. Measure distance from fl oor to air vent opening in appli­ance and mark location on wall.

2. 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.

3. Use hose clamp to secure fl ex pipe to collar assembly.

4. Slide trim ring over fl ex pipe and run pipe through wall.

5. Attach hose to outside termination cap with second
hose clamp.

6. Secure termination cap to outside surface.

7. Secure trim ring to interior wall.

CAUTION

Never draw outside combustion air from:

• Wall, fl oor or ceiling cavity

• Enclosed space such as an attic or garage

Page 18

Figure 18.2

Air Intake Channel (Discard)

Collar
Assembly

2 inch diameter Flex Pipe

Hose Clamp

Flex Hose

7022-122

Leveling Bolt

Attach Termination
Cap to Exterior Wall

Trim Ring

Hose Clamp

Termination
Cap Assembly

January 19, 2011

R

Castile Pellet Insert

C. Door Handle Removal

1. Open the outer door.

2. Unlatch and open the fi rebox door.

3. Continue to turn handle until it is free from the fi rebox

door.

D. Door Removal

1. Open the outer door.

2. Unlatch and open the fi rebox door.

3. Lift the fi rebox door up, freeing it from the fi rebox hinges.

E. Adjustable Hearth Support

Size: 9”d x 45”w, 2” to 10” Height Adjustment

Included in Kit: (1) trim top, (1) trim front, (2) trim sides,

double-sided tape (already installed)
Tools Needed: Phillips head screwdriver, sheet metal

shears, measuring tape, gloves

fastener for the type of wall material, i.e., brick, sheet­rock, etc.

NOTE: 3/8 inch (9.5mm) thick tile or like material can be
cut to size and fi t under lip of top trim edge for a decora­tive touch. Figure 20.3.

EXPLODED VIEW OF SCISSORS

SCREWS ARE CIRCLED

DOUBLE-SIDEDTAPE

DOUBLE-SIDEDTAPE

Figure 19.1

EXPAND SCISSORS TO DESIRED HEIGHT

1. The 10 screws on each set of scissors will already be

loose when shipped. Figure 19.1.

2. Expand scissors to desired height. Tighten screws to
hold in place using Phillips head screwdriver.

3. Measure front and side trims to required height
to cover scissors and mark pieces for cutting. Cut
excess material from top of trim’s edge, not bottom.
This edge will be sharp; wear gloves to prevent injury
to your hands. The cut edge fi ts under lip of top trim,
so it allows for some variance in your straight edge.

Figure 19.2.

4. The double-sided tape that holds front and side trims
to scissors has a powerful bonding adhesive. Adjust­ments are extremely diffi cult once trim has adhered to
tape. Do a dry run fi rst without removing paper from
tape.

5. Place cut edge of trim under top lip and into position
on scissors. Place side pieces on fi rst and then front
piece. The front piece overlaps side pieces.

6. Once you are satisfi ed with the positioning, remove
trim and set aside.

Figure 19.2

Figure 19.3

INSTALL FRONT TRIM LAST.

CORNERS OVERLAP SIDE

TRIM PIECES

CUT TOP EDGE OF TRIM,

NOT BOTTOM EDGE

Decorative tile

may be installed

7. Remove the paper from double-sided tape that is
to accept trim side. Align side and then press hard
against tape to secure side piece. Repeat for other
side. Install front trim piece last.

8. There are 3 holes in the back fl ange of the top to
secure it to the wall if necessary. Use the appropriate

January 19, 2011

7022-122

WARNING

Sheet metal trim edges will be sharp.
For safety purposes wear gloves.

Injury can occur.

Page 19

Castile Pellet Insert

F. Hearth Support For Standard Surround Only

First

Install Sides

R

Figure 20.1 - Assembled View

1

2

3

Figure 20.2

Item Description

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

Install Front Last

NOTE: Manually

pre-shape sides before

installing

Bend top and bottom tabs toward inside

8

7

6

5

4

Figure 20.3

Turn right side up and attach top cast ring

Figure 20.4

Alignment

Hole

Panel Extension

Figure 20.5

Cast Trim Footer

1. Remove contents from box and lay on protective surface to

avoid scratching the paint.

2. Lay hearth support’s front and sides face down. Bend the

tab down toward the inside.
The side pieces are shipped fl at. It

3.

is much easier to manually
fl ex the sides into a bowed position before installing.
Lay 1 cast ring face up, which

4.

will become the bottom ring when

installed. Attach the 2 sides FIRST and then the front piece.

Figure 20.3.

5. Now turn the cast ring right side up

and attach the top cast

ring . Figure 20.4.

6. Attach the hearth support’s panel extensions. Figure 20.5

7. Attach cast footers. Figure 20.6.

8. Place the assembled hearth support under the insert. Figure

20.7.

Page 20

7022-122

Figure 20.6

Panel Leg

Figure 20.7

January 19, 2011

R

Castile Pellet Insert

F. Hearth Support (Cont’d)

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

Panel Extension

Figure 21.1

8. If power enters appliance on the left side: The cord will
have to be routed through the back of the insert. When
routing the power cord, keep cord lying fl at as possible,
keeping the cord away from all exhaust surfaces and
moving parts. After routing, install cord restraint and
press into the left side panel.

9. Slide surround over the top of the insert into

place.

Surround attaches to bottom and top of insert sides with
the supplies 1/4 inch screws.

10. Plug cord into inlet on junction box routing the wire as
shown in Figure 21.3.

11. Install plug into unused hole.

12 in (305mm)

G. Surround & Trim Set, Econo

Included in Surround Kit:

top piece and fastener package.
Included in Basic Trim Kit: 2 side pieces, left and right, top

piece and “L” brackets.

Tools Needed: 4-6 inch long Philips head screwdriver,
pliers and fl at head screwdriver

1. Lay surround face down on a fl at protected surface
to prevent scratching.

2. Using the Philips head screwdriver attach the side
surrounds to the top surround using 2 sheet metal
screws provided with the kit on each side.

3. Assemble the trim with the two corner brackets
provided.

4. Slide the assembled trim over the assembled
surround set.

5. Remove the cast sides before attaching the surround
and trim. Lift up the top to expose the thumb screws
that secure the cast sides. Remove the thumb screw
and top bracket and then remove the cast side.
NOTE: The right cast side bracket has the hopper
cut out switch attached. Remove the retainer from
the right side and allow to hang down into the insert
or disconnect the switch when removing side.

6. Install the power cord in the surround.

7. If power enters the appliance on the right side:
Using the pliers, attach cord restraint 12 inches from
the female end of the cord and then press into the
right side panel. Figure 21.2.

2 side pieces, left and right,

Figure 21.2

Plug Cord into Junction Box

Figure 21.3

Back of Top Panel

Screws

Back of Side Panel

Figure 21.4

January 19, 2011

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Page 21

Castile Pellet Insert

R

G. Surround & Trim Set, Econo (Cont’d)

View of "L" Bracket

installed

Figure 22.1

Thumb
Screw

Bracket

Surround Set
attaches to top
and bottom of
insert sides.

Figure 22.2

H. Surround and Cast Trim Set

Included in Surround Kit: (2) side surrounds, left and

right; (1) surround top; (1) fastener package.

Included in Cast Trim Kit:

cast trim header; (2) cast trim footers, left and right
Tools Needed: 4-6 inch long Philips head screwdriver, pliers

and fl at head screwdriver.

1. Place the peel and stick round felt vibration insulation
pads on the front side in each corner of the top metal
piece and on the back side in each corner of the top cast
piece. Figure 23.1 on page 23

2. Lay surround face down on a fl at protected surface to
prevent scratching.

3. Using the Philips screwdriver attach the side surrounds
to the top surround using 2 sheet metal screws provided
with the kit on each side.

(2) cast trim legs, left and right; (1)

4. Assemble Cast Trim and attach to surround:
a) Place corresponding cast trim pieces (2 cast trim sides

and 1 cast trim header) underneath the surround set, also
face down. Align the holes in the metal pieces with the 5
bosses on the top cast piece and 2 bosses on each side
piece. Figure. 22.1.

b) Attach the magnets to the magnet brackets with one

countersink screw each. Attach magnet and bracket to
the metal surround sides with magnet facing the front as
shown in Figure. 23.2 on page 23.

c) Place cast footers under metal sides aligning the top and

bottom holes.

d) The 9 mounting clips are shipped in one long strip. Use

your hands or pliers to break them apart.

e) Each clip has a clearance notch to allow room for the cast

on the boss. Place the clips over the boss so that the
notch is facing the outer edge of the surround. Figure

23.3 on page 23.

f) It is best to install all of the 1/4-20 screws only half way

at fi rst to allow for adjustments. After adjustment tighten
the 2 screws in each footer fi rst and then work your way
around to the rest.

5. Remove the cast sides before attaching the surround
and trim. Lift up the top to expose the thumb screws that
secure the cast sides. Remove the thumb screw and top
bracket and then remove the cast side. NOTE: The right
cast side bracket has the hopper cut out switch attached.
Remove the retainer from the right side and allow to hang
down into the insert or disconnect the switch when remov­ing side.

6. Install the power cord in the surround.

7. If power enters the appliance on the right side: Using
the pliers, attach cord restraint 12 inches from the female
end of the cord and then press into the right side panel.

Figure 21.2 on page 21.

8. If power enters appliance on the left side: The cord will
have to be routed through the back of the insert. When
routing the power cord, keep cord lying fl at as possible,
keeping the cord away from all exhaust surfaces and
moving parts. After routing, install cord restraint and press
into the left side panel.

9. Slide surround over the top of the insert into place. Sur­round attaches to bottom and top of insert sides with the
supplies 1/4 inch screws.

10. Plug cord into inlet on junction box routing the wire as
shown in Figure 21.3 on page 21.

11. Install plug into unused hole.

Page 22

CAUTION

Do not pick up assembled appliance by corners.
It is too heavy and may damage the surrounds.
Pick up from center.

7022-122

January 19, 2011

R

Castile Pellet Insert

H. Surround and Cast Trim Set (Cont’d)

(4) Felt Vibration Insulation Pads

Secure
Surrounds to
Cast Trim Kit

Attach Magnet
before installing
Cast Footers

Cast Footers,
Left & Right

Magnet Installed

Figure 23.1

Clearance Notch

I. Optional Log Set Placement Instructions

CAUTION

Logs are FRAGILE. Use extreme care when handling or
cleaning logs.

Two Piece Log Set Installation

1. Open door to expose the fi rebox.

2. Install the left log fi rst and then the right log. Figure 23.1

3. Lean the logs against the cast iron brick in the back of
the fi rebox.

4. Push the logs to the far left and far right against the
sides of the fi rebox. Figure 23.2.

5. To clean the logs, use a vaccum cleaner and a soft
brush attachment or a paint brush.

Back
of
Side
Piece

Magnet Attached - Faces Front

Figure 23.2

Surround Set
attaches to top
and bottom of
insert sides.

Figure 23.5

Figure 23.3

Thumb
Screw

Bracket

Figure 23.6

NOTE:

Due to the abrasive nature of a pellet appliance fi re, the
logs are not covered under warranty. Any placement vari­ation other than shown here can cause excessive heat
and shall void the appliance warranty.

Figure 23.4

January 19, 2011

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Page 23

Castile Pellet Insert

J. 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 accu-

rate 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 tem-

perature in your home.

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 appli-

ance.

R

Firepot Cleaning Rod

Figure 24.1

Heat Output
Switch

Reset Button

Fuse

Red Call
Light

Blue Light

Red/Green/Amber Light

Junction Box

Control Box

Power Cord
Outlet

Thermostat
Block

Page 24

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January 19, 2011

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Operating Instructions

8

A. Combustible/Non-Combustible Materials

• Combustible Material

Material made of or surfaced with wood, compressed
paper, plant fi bers, plastics, or any material capable
of igniting and burning, whether fl ame-proofed or not,
plastered or unplastered.

• Non-combustible Material
Material which will not ignite and burn. Such materials are

those consisting entirely of steel, iron, brick, tile, slate,
glass or plasters, or any combination thereof.

• Non-combustible Sealant Material
Sealants which will not ignite and burn: Rutland, Inc.

Fireplace Mortar #63, Rutland 76R, Nufl ex 304, GE
RTV106 or GE RTB116 (or equivalent).

B. Fuel Material and Fuel Storage

Pellet fuel quality can greatly fl uctuate. We recommend that
you buy fuel in multi-ton lots whenever possible. However,
we do recommend trying various brands before purchasing
multi-ton lots to ensure your satisfaction.

Fuel Material

• Made from sawdust or wood by-products

• Shelled fi eld corn

• Depending on the source material it may have a high
or low ash content.

Higher Ash Content Material

• Hardwoods with a high mineral content

• Fuel that contains bark

• Standard grade pellets, high ash pellets or shelled fi eld

corn

Lower Ash Content Material

• Most softwoods

• Fuels with low mineral content

• Most premium grade pellets

Shelled Field Corn

• Moisture content must be 15% or less

• Corn must be free of debris. Never burn corn straight
from the fi eld it will clog the auger mechanism

• Corn with excessive grain dust must be screened by
sifting with 3/16 (4.76mm) inch mesh screening

• Do not use corn that contains additives such as oils or
meals or has been chemically treated with pesticides. It
will void your warranty and destroy the exhaust system.

Castile Pellet Insert

Clinkers
Minerals and other non-combustible materials such as sand

will turn into a hard, glass-like substance called a clinker
when heated in the fi repot.

Trees from different areas will vary in mineral content. That
is why some fuels produce more clinkers than others.

Moisture
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.

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 lengths can vary from lot to lot from the same
manufacturer

• Due to length variations, the feed rate may need adjusting
occasionally

Performance

• Higher ash content and burning corn requires the fi repot
and the ash drawer to be emptied more frequently

• Hardwoods require more air to burn properly

• Premium wood pellets produce the highest heat output

• Burning pellets longer than 1-1/2 inches (38mm) can cause
an inconsistent fuel feed rate and/or missed ignitions or
jammed auger.

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

CAUTION! Tested and approved for wood pellets and
shelled fi eld corn. Burning of any other type of fuel voids

your warranty

Storage

• Wood pellets should be left in their original sealed bag until

using to prevent moisture absorption

• Shelled corn should be stored in a tight container to prevent

it from absorbing moisture from damp or wet fl oors

• Do not store any pellet fuel within the clearance

requirements or in an area that would hinder routine
cleaning and maintenance

WARNING

Fire Risk.

• High ash fuels, or lack of maintenance, can
cause the fi repot to fi ll with ash and clinker. If the
fi repot fi lls to the top, immediately shut down the
appliance and clean.

• Failure to do so could result in smoking, sooting
and possible hopper fi res.

January 19, 2011

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Page 25

Castile Pellet Insert

C. 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
satisfi ed, the red call light will shut off and the appliance will shut
down. The red call light is located behind the right 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.

Figure 26.1.

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.

R

WARNING

Fire Hazard.
Keep combustible materials, gasoline
and other fl ammable vapors and liquids
clear of appliance.

• Do NOT store fl ammable 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.

• DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS
SUCH AS GASOLINE, NAPHTHA OR ENGINE OIL.

• DO NOT USE CHEMICALS OR FLUIDS TO START THE
FIRE.

• Keep all such liquids well away from the heater while it is in
use.

• Combustible materials may ignite.

D. 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 drawer and fi rebox are empty!

3. Close the front door.

Figure 26.1

High
Med

Low

Reset
Button

CAUTION

Tip of thermocouple must be in contact with the
inside end of the thermocouple cover.

Missed ignitions can occur.

E. Clear Space

WARNING! RISK OF FIRE! Do NOT place combustible
objects in front or to the sides of the appliance. High tempera­tures may ignite clothing, furniture or draperies.

Mantel:

objects on mantel or hearth. Heat may damage these

NOTICE: Clearances may only be reduced by means approved
by the regulatory authority having jurisdiction.

WARNING! RISK OF FIRE! Keep combustible materials,

gasoline and other fl ammable vapors and liquids clear of
appliance.

• Do NOT store fl ammable materials in the appliance’s vicin-

• Do NOT use gasoline, lantern fuel, kerosene, charcoal lighter

Keep all such liquids well away from the heater while it is in use
as combustible materials may ignite.

Avoid placing candles and other heat-sensitive

objects.

ity.

fl uid or similar liquids to start or “freshen up” a fi re in this
heater.

Page 26

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January 19, 2011

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Castile Pellet Insert

F. Starting Your First Fire

1. A thermostat is required for proper operation of this
appliance, except for corn. At this time, fi ll 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 on the lower right
side of the fi rebox behind decorative front door. 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 access panel.
This indicates the thermostat is calling for heat. Figure

27.1.

4.

The fuel feed system and the igniter should

now

be on.

5. For your fi rst fi re it will be necessary to press the reset
button once per minute until pellets start to drop into the
fi repot, then press button 1 more time. This will fi ll 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.

NOTE: We recommend the use of a 50-50 blend of corn
and wood pellets. The only change in operation is that the
feed rate may require a slight adjustment. If the appliance is
running all of the time, 100% corn will work after the fi re has
been started using wood pellets.

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.

G. Fire Characteristics

A properly adjusted fi re with the heat output control switch
set on “HIGH” has a short active fl ame pattern that extends
out of the fi repot approximately 4 inches (102mm).

If the fi re has tall fl ames with black tails and seems somewhat
lazy, the feed rate will need to be reduced.

If the fi re is not 4 inches (102mm) tall, increase the feed rate.
A medium and low setting will give a shorter fl ame. The fl ame
will rise and fall somewhat. This is normal.

H. Feed Rate Adjustment Instructions

The feed adjustment control rod is factory set, and should be
adequate for most fuels. T
loosening the wing 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 screw. Figure 27.2.

2. Adjust the fuel adjustment control rod towards to the right
and up to increase the feed rate and fl ame height or to
the left and down to decrease the feed rate and fl ame
height.

3. Re-tighten the wing screw.

Push down
to Decrease

he control rod will slide by only

Wing Screw

Control Rod

Pull up to
Increase

pot Cleaning Rod

Figure 27.1

January 19, 2011

Heat Output
Switch

Reset Button

Fuse

Red Call
Light

Red/Green/Amber Light

Junction Box

7022-122

Control Box

Blue Light

Thermostat
Block

Figure 27.2

Power Cord
Outlet

Page 27

Castile Pellet Insert

I. Ignition Cycles

1. At the beginning of each ignition cycle, it is normal to see
some smoke in the fi rebox. The smoke will stop once
the fi re 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. See Figure 27.1 on page 27.

To restart it, fi ll the hopper and press the reset button.
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 fi re shortly.

If not, follow the instructions on page 27, “Starting Your
First Fire”.

R

WARNING

Fire Risk
Do NOT operate appliance:

• With appliance door open.

• Firepot fl oor 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 28.1 - DO NOT LEAVE FIREPOT FLOOR OPEN

J. 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. White ash buildup on glass. 2. This is normal. Clean the glass using any non-abrasive
glass cleaner.

3. Glass has buildup of black soot 3. Excessive build-up of ash. See solution #4. 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. 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.

5. Fire has tall fl ames with black tails and is lazy. 4. The feed rate needs to be reduced or the fi repot needs
cleaning. Heat exchanger or exhaust blower needs
cleaning.

6. Smokey start-up or puffs of smoke from the airwash. 5. Either the fi repot 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 fl ame at start-up. 6. This is normal. Flame will settle down once the fi re is
established.

Page 28

7022-122

January 19, 2011

9

R

Troubleshooting

Turn down thermostat and let the appliance completely cool.

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
qualifi ed service person in the diagnosis of a problem and the corrective action to be taken.
This troubleshooting guide can only be used by a qualifi ed service technician.

Exhaust blower must be off.

Unplug appliance before servicing.

Symptom

Plug in appliance - No
response.

Call light on. No fi re.
No fuel in fi repot.

Call light on. No fi re.
Partially burned fuel in
fi repot.

Call light on. No fi re.
Unburned pellets in
fi repot.

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.

The ignition hole between the igniter bracket
and fi repot is 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 fi repot clean-out plate is fully
closed.

Clean fi repot. Make sure there is no clinker
in the fi repot. See page 32.

Clinkers may have to be broken up with
fi repot clean-out tool or other means.

Check that fi repot clean-out plate is fully
closed.

Clean fi repot. Make sure there is not a
clinker in the fi repot. Clinkers may have to
be pushed out of fi repot with fi repot clean­out tool or other means.

Scrape with solid piece of wire or fi repot
tool.

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.

January 19, 2011

7022-122

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 fi repot clean-out is fully closed.
Clean fi repot. Make sure there is not a

clinker in the fi repot. Clinkers may have
to pushed out of fi repot with fi repot clean­outool or other means.

Reduce feed rate using feed rate adjust­ment control rod located inside hopper.

Page 29

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, fi rebox, heat
exchanger, exhaust blower and venting.

Out of fuel.
#2 snap disc may be defective.

Check hopper, fi ll with fuel.
Replace snap disc.

R

No call light. Appliance
does not begin start
sequence.

Vacuum switch not closing. No vacuum.

Feed system jammed or blocked.

Feed spring not turning with feed motor.

Feed motor defective or not plugged in.

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.

Firebox door must be closed securely.
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 fi rebox
causing loss of vacuum.

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.

Check that set screw is tight on feed
spring shaft at end of feed motor.

Check connections on feed motor, replace
if defective.

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.

Appliance fails to shut
off.

Page 30

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.

7022-122

January 19, 2011

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Symptom Possible Cause Corrective Action

Convection blower fails to
start.

#1 snap disc defective.

Blower not plugged in.

Castile Pellet Insert

Replace snap disc.

Check that blower is plugged into wire har­ness.

Blower is defective.

Control box is defective.

Exhaust blower fails to

Blower not plugged in.

start or does not shut off.

Blower is clogged with ash.

Blower is defective.

Control box is defective.

Large, lazy fl ame, orange
color. Black ash on glass.

Dirty appliance.
Poor fuel quality, high ash content.

Firepot clean-out plate not completely
closed.

Excessive amount of fuel.

Nuisance shutdowns. Low fl ame.

Replace blower.

Replace control box.
Check that blower is plugged into wire har-

ness.

Clean exhaust system.

Replace blower.

Replace control box.
Clean appliance, including fi repot, heat

exchangers and venting system. Remove
stainless steel baffl e from fi rebox to clean
ash from on top of baffl e. Clean behind rear
brick panels. Change fuel brand to pre­mium.

Check that fi repot clean-out plate is fully
closed.

Reduce feed rate using feed rate adjustment
control rod located inside hopper.

Increase feed by opening feed rate adjust­ment control rod located inside hopper.

Appliance calls for heat.
Call light illuminates.
Exhaust blower starts.
No feed or igniter.

Hopper lid not closed all
the way

Sawdust buildup in hopper.

Feed motor is reversing.

Defective thermocouple.

Defective control box
Firepot more than 1/2 full

Thermocouple is defective or not properly
plugged in.

Defective control box
Switch or magnet is out of adjustment

(auger will not function)

Clean hopper, see page 35.

Check for good connections between feed
motor and wire harness.

Replace thermocouple.

Replace control box.
See page 36 for detailed instructions for

“High Ash Fuel Content Maintenance”
Check connections on thermocouple or

replace if defective.
A fl ashing yellow light on the control box
indicates a problem with the thermocouple.

Replace control box.
Close the lid. If that doesn’t work, adjust or

replace the switch or magnet

January 19, 2011

7022-122

Page 31

Castile Pellet Insert

Maintaining & Servicing Your Appliance

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.

Follow the detailed instructions found in this
section for each step listed in the chart below.

B. Quick Reference Maintenance Chart

R

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 fi repot.

If the fuel you are burning has a high dirt or ash content or you
are burning shelled fi eld corn, it may be necessary to clean the
fi repot more than once a day.

Dirty fuel will cause clinkers to form in the fi repot. A clinker is
formed when dirt, ash or a non-burnable substance is heated
to 2000F (1093C) and becomes glass-like. See “D” page 36
in this section for more details on fuels with high ash content.

Clinker

Figure 32.1 - Clinker

Cleaning or Inspection

Ash Pan Every 5 bags of fuel depend-

ing on the fuel type or ash
build-up

Ash Removal from Firebox Every 5 bags or more fre-

quently 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 Every 25 bags or more fre-

quently 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 - hardwood Every 3 bags OR X
Firepot - Burning pellets - softwood Every 5 bags OR X
Firepot - Burning Corn Every 1 bag OR X
Glass When clear view of fi repot

becomes obscure
Heat Exchanger & Drop Tube Every 5 bags of fuel OR X
Hopper Every 50 bags 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

OR X

NOTICE: These are recommendations. Clean more frequently if you encounter heavy build-up of ash at

the recommended interval or you see soot coming from the vent. Not properly cleaning your

appliance on a regular basis will void your warranty.

Page 32

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January 19, 2011

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Castile Pellet Insert

2. Cleaning Firepot with Cleaning Rod & Firepot
Clean-Out Tool

• Frequency: Daily or more often as needed

• By: Homeowner

a. The appliance must be in complete shutdown and

cool and the exhaust blower off. NOTE: If you are
just cleaning the fi repot, there is no need to unplug the

insert.

b. Pull fi repot cleaning rod OUT and IN a couple of times

to help shake debris loose. See Figure 43.3 on page

43.

If rod is hard to pull, it may be necessary to use your

fi repot clean-out tool to chip away material that has built
up on the bottom plate of the fi repot and to push out any
clinkers. Larger clinkers may have to be removed from
the top of the fi repot. Corn clinkers can be especially
diffi cult to break up.

c. The fi repot fl oor plate must be fully closed when fi nished.

See Figure 28.1 on page 28.

3. Ash Removal from Firebox

• Frequency: Weekly or 5 bags or more frequently
depending on ash build-up

• By: Homeowner

a. There must not be any hot ashes in the fi rebox during

cleaning so allow the appliance to completely cool.
The fi rebox ash should be removed every time the
exhaust path is cleaned. Frequent cleaning of the ash
in the fi rebox will help slow down the build-up of ash
in the exhaust blower and vent system.

b. Plug in your appliance, if unplugged, and turn the

thermostat on and immediately shut it off to start the
exhaust blower on its cycle time. It will pull fl y ash out
the exhaust instead of into the room.

c. Open door. There are 2 cleaning slide plates to the

left and right of the fi repot with fi nger holes. Pull both
slide plates out and sweep the remaining ash from the
fi rebox into the 2 open holes. A paint brush works well
for this. Close slide plates.

d. This ash is deposited in the same ash drawer as the

fi repot debris. The ash drawer should be emptied
every time you clean the fi rebox. Remember to place
the ash and debris into a metal or non-combustible
container.

e. The 2 cleaning slide plates must be fully closed when

cleaning is complete.

4. Cleaning Ash Drawer

• Frequency: Weekly or every 5 bags or more
frequently depending on ash build

• By: Homeowner

Locate the ash drawer underneath the firepot and

slide the ash drawer straight out. Empty into a non­combustible container and re-install ash drawer.

5. Disposal of Ashes

• Frequency: As needed

• By: Homeowner

Ashes should be placed in a metal container with a
tight-fi tting lid. The closed container of ashes should
be placed on a non-combustible fl oor or on the ground,
well away from all combustible materials, pending fi nal
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.

WARNING

Disposal of Ashes

• Ashes should be placed in metal container
with tight fi tting lid.

• Ashes should be retained in closed container
until all cinders have thoroughly cooled.

WARNING

Fire Risk

• NEVER pull fi repot cleaning rod or cleaning
slide plates when appliance is operating. Hot
pellets may fall into ashpan and may start a
fi re or have mis-starts due to lack of vacuum.

WARNING

Fire Risk.

• The cleaning slide plates must be fully
CLOSED when appliance is operating. Hot
pellets may fall into ash pan and start a fi re.

January 19, 2011

7022-122

Page 33

Castile Pellet Insert

R

6. Cleaning Heat Exchanger Tubes

• Frequency: Weekly or every 5 bags of fuel

• By: Homeowner

T

he amount of ash buildup in the fi rebox 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 fl y ash out the exhaust instead
of into the room.

b. Locate the 2 exposed rods directly underneath the heat

exchanger tubes. Figure 34.1.

c. To clean, pull the rods straight out until it stops,

approximately 8 inches (203mm). Slide the rods OUT
and IN a couple of times.

10 Heat Exchanger Tubes

8. Cleaning the Glass

• Frequency: When clear view of the fi repot is obscure

• By: Homeowner

a. Appliance must be completely cool before cleaning

glass.
b. Vacuum fl y ash from the glass and door rope.
c. 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 fi lm.

• Refer to maintenance instructions.

Cleaning Rods

Figure 34.1

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. Cleaning Beneath Heat Exchanger

• Frequency: Monthly or every 1 ton of fuel

• By: Homeowner

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. The ash will be resting on the
back of the baffl e.

This will require removing the baffl e and cast brick set.
Please refer to pages 39 & 40 for a detailed explanation of
removing the baffl e and brick set.

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.

9. Door Latch Inspection

• Frequency: Prior to heating season

• By: Homeowner

The door latch is non-adjustable but the gasketing between
the glass and fi rebox should be inspected periodically to make
sure there is a good seal.

NOTE: There is no gasket on the bottom of glass.

NOTE: Hearth & Home Technologies recommends

using a heavy duty vacuum cleaners specifi cally
designed for solid fuel appliance cleaning.

Page 34

7022-122

January 19, 2011

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Castile Pellet Insert

10. Cleaning the Hopper

• Frequency: Monthly or every 50 bags 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 fi repot. This can result in
nuisance shutdowns and mis-starts.

1. The appliance must be in complete shutdown. Allow the
appliance to completely cool down.

2 Empty the hopper of any remaining pellets.

3. Vacuum the hopper and feed tube.

11. Cleaning Exhaust Blower - Requires No Lubrication

• Frequency: Yearly or as needed

• By: Quality Service Technician/Homeowner

a. Remove left & right cast brick. The exhaust blower

is behind the right cast brick. Vacuum this area
thoroughly. See pages 39 & 40 for removing the cast
bricks. Re-install cast bricks when done.

14. Preparing Firebox for Non-Burn Season

• Frequency: At the end of the heating season

• By: Homeowner

a. Be sure the appliance is allowed to cool, has been

unplugged and the exhaust blower is off.
Remove all ash from the fi rebox and vacuum thoroughly.

b.

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 specifi -

cially for heating appliances.

12. Cleaning Convection Blower - Requires No
Lubrication

• Frequency: Yearly or as needed

• By: Qualifi ed Service Technician

• Task: Contact your local dealer.

13. Soot and Fly Ash: Formation & Need for Removal
in Exhaust Venting System.

• Frequency: Yearly or more frequently depending on

ash build-up

• By: Qualifi ed Service Technician/Homeowner

The products of combustion will contain small particles
of fl y ash. The fl y ash will collect in the exhaust venting
system and restrict the fl ow of the fl ue 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 (chimney) 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.

January 19, 2011

7022-122

Page 35

Castile Pellet Insert

D. High Ash Fuel Maintenance

• Frequency: When the ash build-up exceeds more

than half way up the fi repot.

• By: Homeowner

Poor quality pellet fuel, or lack of maintenance, can create
conditions that make the fi repot fi ll quickly with ashes and
clinkers.

This condition makes the appliance susceptible to overfi ll­ing the fi repot with pellets which may result in smoking,
sooting and possible hopper fi res. Figure 36.1 shows an
example where the fi repot overfi lls, pellets back up into the
feed tube and ash has accumulated in the fi rebox.

An ineffi cient and non-economical method of burning of
fuel caused by poor quality pellet fuel

36.2.

The correct fl ame size when good quality, premium pellet
fuel is burned is shown in Figure 36.3.

If the ash buildup exceeds the half way point in the fi repot

IMMEDIATE ATTENTION AND CLEANING IS REQUIRED.

is shown in Figure

Firepot Overfills

Ash Build Up in Firebox

Figure 36.1

Incorrect

R

Pellets Back Up
In Feed Tube

WARNING

Fire Risk.

• High ash fuels, or lack of maintenance, can

cause the 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.

Tall, Lazy Flame, Orange in Color

Figure 36.2

Correct

Correct Flame Size, Yellow/White in Color

Figure 36.3

Page 36

7022-122

January 19, 2011

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Castile Pellet Insert

E. Combustion Blower Replacement

1. If you have adequate clearance you will not have to
remove the panel set and disconnect fl ue, if not then
you will have to remove the panel set and disconnect
the fl ue.

2. Pull appliance out onto the hearth.

3. Remove right cast side.

4. Disconnect the white and blue wires from the blower.

5. Remove blower mounting screws (not housing bolts),
Figure 37.1, from blower housing and remove blower.
The replacement blower is shipped with a housing.
If you do not need the housing, discard it. If you do
need to the replace the housing you will also need
to replace the gasket. See Service Parts List for the
part number.

6. Re-install in reverse order.

F. Convection Blower Replacement

1. The blower is located at the bottom rear of the insert.
If an outside air kit is also installed, you will fi rst need
to remove the outside air fl ange by removing the 2
screws using a Phillips head screwdriver. You do not
need to remove the fl ex pipe from the fl ange.

2. If you have adequate clearance you will not have to
remove the panel set and disconnect fl ue, if not then
you will have to remove the panel set and disconnect
the fl ue.

3. Pull appliance out onto the hearth.

4. Remove left cast side.

5. Disconnect the wires from the blower. The wires
coming from the wiring harness are purple & white and
the wires from the blower are black.

6. The blower is held in place with a wing screw.

7. Re-install in reverse order.

Figure 37.1

Housing Bolts

(Do Not Remove)

Wing Screw

Figure 37.2

Blower

Screws

January 19, 2011

7022-122

Page 37

Castile Pellet Insert

R

G. Igniter Replacement

Igniter Bracket

Thumb Screw

Figure 38.1

1. 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 drawer.

2. 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 (102mm to 127mm) through the grommet
at the back of the ash drawer chamber. Disconnect
the spade connections and remove the igniter from the
chamber. LooseN the thumb screw and slide igniter
out.

3. Install new igniter into the chamber and tighten the
thumb screw. Re-connect the wires to the 2 leads with
the spade connectors.

4. Push excess wire leads back through the grommet, one
wire at a time, to take-up the 4 to 5 inches (102mm to
127mm) previously pulled out. This will keep the wires
out of the way of the ash drawer. Double check that
the igniter wires are clear of any movement, i.e. ash
drawer, fi repot cleaning rod, cleaning slide plates, etc.

5. Re-install the ash drawer and then re-install the side
panel and re-connect the power.

Igniter

H. 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

1. Open the face and remove door from the appliance
by lifting door off of hinge pin and and lay on a fl at
surface face down.

2. 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.

3. Remove old glass and replace with new glass.

4. Slide the retainer rod into the top hole fi rst, and then

line up the bottom crimped end with the hole in the
door. The crimped end must be parallel with the glass
in order to insert it into place. Figure 38.2.

Slide this
end in first

Glass ships
with Gasket
Installed

Rope Retainer Rods

Gasket

Crimped end must
be paralle with the
glass

Page 38

Figure 38.2

7022-122

January 19, 2011

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Castile Pellet Insert

I. Baffl e & Brick Set Removal

1. Follow proper shutdown procedures in Section 10.

2. The top baffl e 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 baffl e by fi rst pulling the baffl e forward
until back edge drops down. Then slide baffl e back and
down until the front edge clears the shelf that it had been
resting on.

3

. The top baffl e 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 fl ush with the fi rebox.
Rotate the inside edge of the brick forward and remove
brick. Repeat for left brick. Figure 39.2.

Figure 39.1.

Re-installing Baffl e & 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 39.4.

The brick will be fl ush against the back wall and notches

2.

exposed in the side bracket. Figure 39.5.

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

39.1 and 39.2.

4. Repeat for left brick.

5.

Insert baffl e into top front inside the fi rebox and pull for­ward. Then raise up the bottom end and insert baffl e tab
into slot on the top of the right bracket to lock into place.
Figure 39.3. Place the left side hook at the bottom of the
baffl e over the top edge of brick for stability. Figure 37.4.

6.

The baffl e does not completely cover the top of the fi rebox.
There is an opening on the left as shown in Figure 40.5 on

page 40.
NOTE: Improper installlation can cause poor appli-

ance performance.

Figure 39.1

Remove Right
& Left Brick

Figure 39.2

Exhaust Area

Tabs

Figure 39.4

Brick is flush against back wall

Right Brick

Removed

Notches
exposed

Vacuum

Figure 39.3

January 19, 2011

7022-122

Figure 39.5

Page 39

Castile Pellet Insert

Re-installing Baffl e & Brick Set (Cont’d)

Lift brick, pull forward at an angle
and drop down into notches

R

Figure 40.1

Figure 40.4

Figure 40.5

Hook on
left side

Tab on
right side

Figure 40.2

Figure 40.3

Page 40

7022-122

January 19, 2011

R

Reference Materials

Castile Pellet Insert

11

A. Component Function

1. Control Box

a. The control box is located on lower right side of

appliance, 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
4 blinks every 10 seconds for 60 seconds (depending
upon setting) 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 fi rst 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 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 side panel. 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 behind the fi rebox 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 fi repot at a set rate. The feed motor starts
and stops every 7 seconds.

5. Firepot

The fi repot is made of high quality ductile iron and has a
cleaning pull-out rod. The fl oor of the fi repot opens for
cleaning when you pull out the rod. Be sure that the fl oor
returns to a completely closed position or your appliance
will not operate properly.

6. Fuse

The fuse is located on the side of the junction box near the
red call light. The fuse will blow should a short occur and

January 19, 2011



F (93C) in the fi repot.



When describing the location of a component
part it is always AS YOU FACE THE FRONT
OF THE APPLIANCE.

shut off power to 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
fi rebox, behind the front access door and above the reset
button. The function of the heat output switch is to regulate
the burn rates; low, medium and high settings.

9. Hopper Switch

The hopper switch is located in the upper right hand corner,
outside of the hopper. This switch is designed to shut down
the feed motor whenever the hopper lid is opened.

10. Igniter

The igniter is mounted on the base of the fi repot. Combustion
air travels over the red hot igniter creating super heated air
that ignites the pellets.

11. Junction Box And Wiring Harness

The junction box is located on the lower right side of the
appliance, behind the left front access door. The junction box
and wiring harness are replaced as one component.

12. Power Supply

The power outlet is located on the lower right side of the
appliance on the front of 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 a least 600 watts of power, or with an
inverter at least 800 watts of power available for the appliance
during the start cycle.

13. Red Call Light

The red call light is on the top of the junction box by the
fuse. The function of the red call light is to indicate that the
thermostat is calling for heat.

14. Reset Button

The reset button is located on the lower right side of fi rebox
in behind the access door and below the heat output control
switch. The function of the switch is to momentarily open the
thermostat circuit, which restarts the system.

15. Thermocouple

The thermocouple is located on top of the fi repot 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

7022-122

Page 41

Castile Pellet Insert

R

have been obtained.

16. 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.

17. Snap Disc #1 (Convection Blower) 110°F

Snap disc #1 is located on the right side of the fi rebox. 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 if the stove is powered up.

18.

Snap Disc #2 (Fuel Delivery Interrupt) 250°F

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 overfi re condition should occur or if the
convection blower should fail to operate. If this occurs the

snap disc with automatically reset itself.

19.

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 side panel. If the fi re 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. Power is always present at snap disc #3 if
the stove is powered up.

20. Vacuum Switch

The vacuum switch is located on the lower right side of the
appliance behind left access panel. This switch turns the
feed system on when vacuum is present in the fi rebox. 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 fi rebox door is open.

21. Wiring Schematic

See Figure 42.1 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

Reset

Button

Vacuum

Switch

Hopper

Switch

Fuse

Snap

Disc #2

Capacitor

Snap

Disc #1

Feed

Motor

Convection

Blower

Exhaust
Blower

Figure 42.1

Page 42

7022-122

January 19, 2011

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Castile Pellet Insert

B. Component Locations

10 Heat Exchanger Tubes

Cleaning Rods

Figure 43.1 - Cleaning Rods & Heat
Exchanger Tubes

RIGHT SIDE

Feed Motor

Figure 43.2

Convection Blower

Heat Output
Switch

Combustion Blower

Vacuum Switch

Leveling Bolt

Red Call
Light

Fuse

Control Box

Power Cord
Outlet

Blue Light

Red/Green/Amber Light

January 19, 2011

Firepot Cleaning Rod

Figure 43.3

Reset Button

7022-122

Thermostat
Block

Junction Box

Page 43

R

Service Parts

Castile Insert

Castile Pellet Insert

Beginning Manufacturing Date: Jan 2011

Ending Manufacturing Date: Active

CASTILEI-MBK, CASTILEI-PMH, CASTILEI-CSB CASTILEIW-CWL

1

3

5

6

7

8

2

4

35

36

9

34

37

32

31

30

29

11

13

15

14

12

10

16

21

17

18

19

20

27

28

25

26

24

23

Part number list on following pages.

Figure 44.1

Page 44

7022-122

22

01/11

January 19, 2011

R

Service Parts

Beginning Manufacturing Date: Jan 2011

Ending Manufacturing Date: Active

IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement
parts for your appliance please provide model number and serial number. All parts listed
in this manual may be ordered from an authorized dealer.

ITEM DESCRIPTION COMMENTS PART NUMBER

Matte Black 7022-129BK

1 Top Cast - Must specify color

2 Handle Cover Plate SRV7022-144
3 Heat Shield, Top SRV7022-143
4 Hinge Assembly, Top 7036-006P
5 Side Cast Hook SRV7022-137

Thumb Screw, 1/4-20 x 1/2 Pkg of 10 7000-617/10 Y

6 Side - Must specify color

7 Glass Assembly, Side, 1 Piece - 5-7/8 in. W x 9 in. H Interchangeable 414-5380 Y

Gasket, Channel 1/8 x 1-1/4 10 Ft. 7000-377/10 Y

8 Backer, Side Window Interchangeable 414-0280
9 Door Hinge Assembly SRV7022-012

Hinge, Door, Male 450-2810

10 Defl ector, Bottom Airwash 413-0680

11 Baffl e Assembly 7001-034 Y

12 Door Rope, 7/8” 8 Ft 842-2350
13 Brick, Left / Right, Cast 414-0270
14 Brick, Center, Cast 414-0260
15 Ash Pan Assembly SRV414-6240

16 Plate, Ash Cleanout 7001-186
17 Magnet Round SRV7000-140 Y
18 Bracket, Magnet 414-0930

19 Wire Harness SRV414-1040 Y
20 Control Board 3 Speed SRV7000-205 Y

Fuse, 8 Amp, Control Box

21 Face Hinge SRV7022-138

22 Face - Must specify color

Porcelain 7022-129POR
Powder Coat 7022-129PWD

Matte Black 414-0050BK
Porcelain Color 414-0050POR
Powder Coat 414-0050PWD

Pkg of 1 812-3780 Y
Pkg of 10 812-3780/10 Y

Matte Black 414-0040BK
Porcelain Color 414-0040POR
Powder Coat 414-0040PWD

Castile Insert

Stocked
at Depot

Additional service part numbers appear on following page.

January 19, 2011

7022-122

01/11

Page 45

R

Service Parts

Beginning Manufacturing Date: Jan 2011

Ending Manufacturing Date: Active

Castile Insert

IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement
parts for your appliance please provide model number and serial number. All parts listed
in this manual may be ordered from an authorized dealer.

ITEM DESCRIPTION COMMENTS PART NUMBER

Stocked

at Depot

#23 Door Assembly

23.3

23.2

23.1

23.4

23.5

23.6

23 Door Assembly SRV7021-007

23.1 Door Latch Assembly 7021-006

23.2 Door Frame SRV7021-114

23.3 Screw, Pan Head Philips, 10/32 x 1/4 Pkg of 24 229-1230/24 Y

23.4 Hinge, Female 450-2910

23.5 Glass Assembly (w/gasket) 17-1/4” W x 11-5/8” H 7001-038 Y
Gasket, Tadpole 842-5130 Y
Tape, 1/2” x 1/16 10 Ft 240-0290/10 Y
Tape, Door Corner SRV7027-227

23.6 Retainer, Rope 7001-192 Y

24 Vacuum Switch SRV7000-531 Y
25 Corner Post SRV7022-104

26

Bolt, GRD 2 Tap 3/8 x 4

223-0140

27 Snap Disc, 110-20 SRV230-1220 Y

#28 Feed Assembly

28.2

28.1

28.3

28.4

28.5

28.6

28.7

28.8

28 Feed Assembly 812-4760

28.1 Screw, 8-32 x 3/8 PH,TF Pkg of 40 225-0500/40

28.2 Feed Motor 812-4421 Y

28.3 Collar, Set, 7/8 229-0520

28.4 Bearing, Feed System, Nylon SRV7000-598

28.5 Feed Motor Bracket Assembly 7001-039

28.6 Gasket, Feed Motor 240-0731 Y

28.7 Feed Spring Assembly SRV7001-046 Y

28.8 Set Screw 5/16-18 x 1/4 Pkg of 25 225-0550/25 Y

Additional service part numbers appear on following page.

Page 46

7022-122

January 19, 2011

01/11

R

Service Parts

Beginning Manufacturing Date: Jan 2011

Ending Manufacturing Date: Active

IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement
parts for your appliance please provide model number and serial number. All parts listed
in this manual may be ordered from an authorized dealer.

ITEM DESCRIPTION COMMENTS PART NUMBER

29 Blower, Exhaust Combustion 812-4400 Y

Gasket, Exhaust Combustion Blower (between…)

30 Exhaust Transition Assembly 414-5100

Latch, Draw 229-0230

31 Gasket, Flue Adapter 7036-180 Y
32 Exhaust Adapter Assembly SRV414-5850
33 Blower Retainer SRV7058-148
34 Snap Disc, #2 SRV7000-268 Y
35 Snap Disc, Manual Reset, # 3 SRV230-1290 Y
36 Blower, Convection 812-4900 Y
37 Feed Adjustment Plate SRV7022-119

...Housing & Stove
...Housing & Motor

Castile Insert

240-0812 Y
812-4710 Y

Stocked

at Depot

#38 Firepot and Associted Parts

38.1 Firepot Pull Rod Assembly 414-5270 Y

Spring, Firepot 200-2050
Washer, 1/4 Sae Pkg of 24 28758/24 Y

38.2 Thermocouple Cover 812-4920 Y

38.3 Thermocouple Clamp SRV7001-203

38.4 Thermocouple 812-4470 Y

38.5 Firepot Assembly SRV414-5200 Y

Bushing, Firepot 410-8320
Floor, Firepot 414-0290 Y

38.6 Gasket, Firepot 240-0930 Y
Nut, Lock 1/4-20 Pkg of 25 226-0090/25 Y
Bolt, Firepot, 1-1/4” Long Pkg of 25 225-0120/25 Y

38.7 Wing Thumb Screw 8-32 x 1/2 Pkg of 24 7000-223/24 Y

38.8 Heating Element Assembly 18” (Loop Igniter)

Additional service part numbers appear on following page.

38.1

38.5

38.6

38.7

38.2

38.3

38.4

38.8

Pkg of 1 SRV7000-462 Y
Pkg of 10 SRV7000-462/10 Y

January 19, 2011

7022-122

01/11

Page 47

R

Service Parts

Beginning Manufacturing Date: Jan 2011

Ending Manufacturing Date: Active

IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement
parts for your appliance please provide model number and serial number. All parts listed
in this manual may be ordered from an authorized dealer.

ITEM DESCRIPTION COMMENTS PART NUMBER

Mahogany SRV7022-023
Component Pack Assembly (Includes Firepot Cleanout
Tool, Touch-Up Paint, Power Cord, Thermostat Wire
Harness, Owners Manual, Warranty Card, “How-To” Dvd

Cleanout Tool 414-1140 Y
Dvd Original Energy Insert 7000-441

Paint Touch-Up

Power Cord 812-1180 Y
Harness, Thermostat Wire 230-0810

Fuse, 7 Amp, Junction Box Pkg of 10 812-0380/10 Y
Hose, Vacuum, 5/32 Id 3 Ft SRV240-0450 Y
Magnetic Switch 7000-375
Wire Harness, Hopper Switch SRV414-1220

Matte Black SRV7022-020

Sienna Bronze SRV7022-021

Willow SRv7022-022

Matte Black 812-0910

Mahogany 855-1450 Y

Sienna Bronze TOUCHUP-CSB

Willow TOUCHUP-CWL

Castile Insert

Stocked

at Depot

OPTIONAL ACCESSORIES

Adjustable Hearth Support - 12” x 50”, 2-10” H ADJSPT-12
Damper, 3 Inch - Tall Vertical Installs Only PEL-DAMP3 Y
Damper, 4 Inch - Tall Vertical Installs Only PEL-DAMP4
Log Set LOGS-30-OE Y

Log Rear, Left 7050-144
Log Rear, Right 7050-143

Outside Air Kit, Rear 811-0872

Channel, Air Intake 413-7040
Cover, Outside Air Kit, Floor 411-1071
Hose, Alum Flex, 2 Inch x 3 Ft 3 Ft 200-0860
Outside Air Cap Assembly 7001-044
Outside Air Collar Assembly 7001-045
Trim Plate, Outside Air Kit 412-7100

Surround Trim Assembly 43 X 31

Surround Trim Assembly 51 X 34

Additional service part numbers appear on following page.

Black TRIMKIT-4331-BK

Gold TRIMKIT-4331-GD

Nickel TRIMKIT-4331-NL

Black TRIMKIT-5134-BK

Gold TRIMKIT-5134-GD

Nickel TRIMKIT-5134-NL

Page 48

7022-122

01/11

January 19, 2011

R

Service Parts

Beginning Manufacturing Date: Jan 2006

Ending Manufacturing Date: Active

IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement
parts for your appliance please provide model number and serial number. All parts listed
in this manual may be ordered from an authorized dealer.

ITEM DESCRIPTION COMMENTS PART NUMBER

Surround, Basic, Large SP-CSTLI5134

Component Pack SRV7022-055

Surround, Basic, Standard SP-CSTLI4331

Component Pack SRV7022-055

Surround, Standard

Component Pack SRV7022-054
Surround, Standard
Thermostat, Mechanical 812-3760
Thermostat, Programmable 811-0520
Trim Cast Matte Black 811-0930

Footer, Left 414-7090MBK
Footer, Right 414-7100MBK
Header 414-7110MBK
Trim Leg, Left 414-7120MBK
Trim Leg, Right 414-7130MBK

Trim Cast Mahogany 811-0960

Footer, Left 414-7090PMH
Footer, Right 414-7100PMH
Header 414-7110PMH
Trim Leg, Left 414-7120PMH
Trim Leg, Right 414-7130PMH

Trim Cast Sienna Bronze TR-CAST-CSB

Footer, Left 414-7090CSB
Footer, Right 414-7100CSB
Header 414-7110CSB
Trim Leg, Left 414-7120CSB
Trim Leg, Right 414-7130CSB

Trim Cast Willow TR-CAST-CWL

Footer, Left 414-7090CWL
Footer, Right 414-7100CWL
Header 414-7110CWL
Trim Leg, Left 414-7120CWL
Trim Leg, Right 414-7130CWL

Trim Support, adjustable (standard panel surround only) Zero Clearance 811-0980

Use With Cast Trim SP-CSTLI4230-CM

Use With Cast Trim SP-CSTLI4834-CM

Castile Insert

Stocked

at Depot

Additional service part numbers appear on following page.

January 19, 2011

7022-122

01/11

Page 49

R

Service Parts

Beginning Manufacturing Date: Jan 2006

Ending Manufacturing Date: Active

IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement
parts for your appliance please provide model number and serial number. All parts listed
in this manual may be ordered from an authorized dealer.

ITEM DESCRIPTION COMMENTS PART NUMBER

FASTENERS

Avk Rivnut Repair Kit RIVNUT-REPAIR Y
Bolt, Hex Head, 1/4-20 X 1 Pkg of 10 25221A/10 Y
Bumper, Rubber Pkg of 12 SRV224-0340/12 Y
Leveling Bolt Pkg of 25 220-0080/25 Y
Nut, Capped, Push, 1/4 Pkg of 24 7000-157/24 Y
Nut, Ser Flange Small 1/4-20 Pkg of 24 226-0130/24 Y
Nut, Wing, 8-32 Pkg of 24 226-0160/24 Y
Screw Flat Head 1/4-20 Pkg of 24 7000-130/24 Y
Screw, 1/4-20X3/8 Phillips Button Head Pkg of 24 7000-401/24 Y
Screw, Flat Head Philips 8-32X1/2 Pkg of 12 220-0490/12 Y
Screw, Machine Screw 1/4-20X5/8 Pkg of 24 220-0440/24 Y
Screw, Pan Head Philips 8-32 X 3/8 Pkg of 40 225-0500/40 Y
Screw, Pan Head Philips Tc 8-32X1/2 Pkg of 25 220-0030/25 Y
Screw, Pan Head Philips, 10/32 X 1/4 Pkg of 24 229-1230/24 Y
Screw, Sheet Metal #8 X 1/2 S-Grip Pkg of 40 12460/40 Y
Speed Nut 5/16 Pkg of 24 7000-422/24 Y
Thumb Screw, 1/4-20 X 1/2 Pkg of 10 7000-617/10 Y
Washer, 1/4 Sae Pkg of 24 28758/24 Y
Wing Thumb Screw 8-32X1/2 Pkg of 24 7000-223/24 Y

Castile Insert

Stocked
at Depot

Page 50

7022-122

01/11

January 19, 2011

R

E. Service And Maintenance Log

Date of Service Performed By Description of Service

Castile Pellet Insert

January 19, 2011

7022-122

Page 51

Castile Pellet Insert

E. Service And Maintenance Log (Cont’d)

Date of Service Performed By Description of Service

R

Page 52

7022-122

January 19, 2011

R

F. Homeowner’s Notes

Castile Pellet Insert

January 19, 2011

7022-122

Page 53

4

W

W

a

f

T
g
t

g

y

y p

p

y

y

y

y

y p

Castile Pellet Insert

R

Hearth & Home Technologies Inc.

LIMITED LIFETIME WARRANTY

earth & Home Technologies Inc., on behalf of its hearth brands (”HHT”), extends the following warranty for
HT gas, wood, pellet, coal and electric hearth appliances that are purchased from an HHT authorized dealer.

ARRANTY COVERAGE:

HT warrants to the original owner of the HHT appliance at the site of installation, and to any transferee taking ownership

f the appliance at the site of installation within two years following the date of original purchase, that the HHT appliance

ill be free from defects in materials and workmanship at the time of manufacture. After installation, if covered compo-

ents manufactured by HHT are found to be defective in materials or workmanship during the applicable warranty period,

HT will, at its option, repair or replace the covered components. HHT, at its own discretion, may fully discharge all of its

bligations under such warranties by replacing the product itself or refunding the verified purchase price of the product
tself. The maximum amount recoverable under this warranty is limited to the purchase price of the product. This warranty
s subject to conditions, exclusions and limitations as described below.

ARRANTY PERIOD:

arranty coverage begins on the date of original purchase. In the case of new home construction, warranty coverage

begins on the date of first occupancy of the dwelling or six months after the sale of the product by an independent,

uthorized HHT dealer/ distributor, whichever occurs earlier. The warranty shall commence no later than 24 months

ollowing the date of product shipment from HHT, regardless of the installation or occupancy date. The warranty period for

parts and labor for covered components is produced in the following table.

he term “Limited Lifetime” in the table below is defined as: 20 years from the beginning date of warranty coverage for
as appliances, and 10 years from the beginning date of warranty coverage for wood, pellet, and coal appliances. These

ime periods reflect the minimum expected useful lives of the designated components under normal operating conditions.

Warranty Period HHT Manufactured Appliances and Venting

Parts Labor Gas Wood Pellet

EPA

Wood

Coal Electric Venting

Components Covered

All parts and material except as

1 Year

XXXXXXX

covered by Conditions,

Exclusions, and Limitations

listed

XXX

2 years

XXXXX Factor

X Molded refractor

3 years

ears 1 year X X Castings and baffles

5

X Fire

7 years 3 years X X X

10

ears

1 year X Burners, logs and refractory

Igniters, electronic components,

lass

and

-installed blowers
anels

ots and burnpots

Manifold tubes,

HHT chimne

and termination

Limited

Lifetime

021-645C 12-29-10 Page 1 of 2

Page 54

3 years X X X X X Firebox and heat exchanger

90 Days

XXXXXXX

See conditions, exclusions, and limitations on next page.

7022-122

All replacement parts

be

ond warrant

eriod

January 19, 2011

R

I

W



Castile Pellet Insert

WARRANTY CONDITIONS:

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IRUSDUWVDUHQRWFRYHUHGE\WKLVZDUUDQW\

WARRANTY EXCLUSIONS:

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This warranty is void if:

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LIMITATIONS OF LIABILITY:

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4021-645C 12-29-10 Page 2 of 2

January 19, 2011

7022-122

Page 55

R

CONTACT INFORMATION:

Hearth & Home Technologies

1445 North Highway

Colville, WA 99114

Division of HNI INDUSTRIES

www.quadrafi re.com

Please contact your Quadra-Fire dealer with any questions or concerns.

For the number of your nearest Quadra-Fire dealer

visit our website at www.quadrafi re.com

NOTICE

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.

DO NOT

DISCARD

We recommend that you record the following pertinent
information for your CASTILE PELLET INSERT

Date purchased/installed:

Serial Number: Location on appliance:

Dealership purchased from: Dealer phone:

Notes:

This product may be covered by one or more of the following patents: (United States) 6830000 and 5582117 or other U.S. and
foreign patents pending.

Page 56

7022-122

January 19, 2011