Quadra-Fire CB1200I-B User Manual

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Owner’s Manual

DO NOT

DISCARD

Tested and

Listed by

Beaverton

Oregon USA

OMNI- Test Laboratories, Inc.

Installation and Operation

Model:

CB1200I-B

• Important operating and

maintenance instructions included.

CB1200-I PELLET INSERT

CAUTION

DO NOT DISCARD THIS MANUAL

•

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

Leave this manual with party responsible for use and operation.

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 am-

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

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

• Comply with all minimum clearances to com bustibles as specied. Failure to comply may cause house re.

CAUTION

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

WARNING

HOT! DO NOT TOUCH. SEVERE BURNS MAY RESULT. CLOTHING IGNITION MAY RESULT.

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

• Keep children away.

• CAREFULLY SUPERVISE children in same room as appliance.

• Alert children and adults to hazards of high temperatures.

• Do NOT operate with protective barriers open or removed.

• Keep clothing, furniture, draperies and other combustibles away.

CAUTION

Check building codes prior to installation.

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

• Consult local building, fire officials or authorities having jurisdiction about restrictions, installation inspection, and permits.

www.quadrare.com

7014-083C

October 26, 2006

CB1200-I Pellet Insert

and Welcome to the Quadra-Fire Family!

Senior

___________________________

Alan Trusler

Vice President

Dealer Channel

___________________________

Dan Henry

Vice President

Advanced Technolgies

_________________________

Jason Olmstead Vice President &

General Manager

___________________________

Steve Tate

Quadra-Fire

Brand Manager

Safety and clearance section located on inside of hopper lid./Serial Number section located under top on inside of hopper body.

La section se réfé dux distances et mescres de sécurité est située à l'intérieut du couvércle de la tré la bôitre à feu.

La section du numéro de série est située en dessous du couvercle à l'intérieur de la trémie.

Listed Solid Fuel Room Heater/Pellet Type Insert. Also suitable for Mobile Home Installation. This appliance has been tested and listed for use in Manufa ctured Homes in acco rdance with OAR 814-2 3-9000 through 814-23-909.

Listed by

Beaverton

Oregon USA

OMNI-Test Laboratories, Inc.

1200-I Pellet Insert

1445 Highway North, Colville, WA 99114

www.quadrafire.com

Tested to: ASTM E 1509, UL127, ULC S610, ULC C1482-M1990 Room Heating Pellet Burning Type, APFI, (UM) 84-HUD FOR USE

ONLY WITH PELLETIZED WOOD OR SHELLED FIELD CORN FUEL. Input Rating Maximum 5.5 lb fuel/hr. Electrical Rating:

115 VAC, 60 Hz, Start 4.1 Amps, Run 1.1 AMPS. Route power cord away from unit. Do not route cord under or in front of appliance.

DANGER:

Risk of e lectrical shock. Dis connect power s upply before

servicing. Replace glass only with 5mm ceramic available from your dealer. To start, s et thermostat above roo m temperature, the stove will ligh t 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.

Masonry or *Zero Clearance Minimum Clearances to Combustible

Maçonnene ou zéro distance foyer distances minimales à tout matériel combustible.

250-4594

U.S. ENVIRONMENTAL PROTECTION AGENCY OMNI Test Laboratories, Inc., Beaverton, Or Report/Rapport 061-S-12-2

This model is exempt from EPA certification under 40 CFR 60.531 by definition [Wood Heater (A) "Air-to-Fuel Ratio"].

250-4594

1200-I PELLET INSERT

A Louvers to combustible wall B Insert top to mantel C Front Facing D* Hearth Extension - Front E* Hearth Extension - Side

6” (152mm) 12” (305mm) 3” (76mm) 6" (152mm) 8” (203mm)

DO NOT REMOVE THIS LABEL / NE PAS ENLEVER L'ÉTIQUETTE

SERIAL NO.

NUMÉRO DU

Report Rapport #061-S-13-2

DO NOT REMOVE THIS LABEL / NE PAS ENLEVER L'ÉTIQUETTE

Made in China/Fait Aux Chine

Testé à: ASTM E 1509, UL127, ULC S610, ULC C1482-M1990 Room Heating Pellet Burning Type, APFI, (UM) 84-HUD POUR USAGE AVEC LES BOULETTES DE BOIS OU DE COMBUSTIBLE DE MAIS ÉCOSSÉ DES CHAMPS. Consommahon maximale à l'entrée (sans pertes) 2.5 kg/h. 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'a llumera automatiquement. Pour é teindre, 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'ouve rture et la por te des cendres fermées herm étiquement d urant l'opération.

Appareil de chauffage inséré de combustible solide/de type de boulettes. Accepté dans l'installation dans les maisons mobiles. Cet appareil a été testé et enregistré pour l

'usage dans les Maisons Mobiles en accord avec OAR 814-23-9000 jusqu'à 814-23-909.

*See hearth protection note above

A Lucarne au mur combustible B Dessus de l'insert à la tablette de cheminée C Revêtement facial D* Protechion de sol - frontal E* Protechon ole sol - côté

*Voir les notes sur la protechion ole sol ci-dessus.

152mm 305mm 76mm 152mm 203mm

QUADRA-FIRE

SIDE WALL

CAUTION:

HOT WHILE IN OPERATION DO NOT TOUCH. KEEP CHILDREN, CLOTHING AND FURNITURE AWAY. CONTACT MAY CAUSE SKIN BURNS. SEE NAMEPLATE AND INSTRUCTIONS. Operate this unit with fuel hopper lid closed. Failure to do so may result in emissions products' combustion from the hopper under certain conditions. Maintain hopper seal in good condition. Do no over fill the hopper.

ATTENTION:

CHAUD LORS DE L'OPÉRATION. NE PAS TOUCHER. GARDEZ LES ENFANTS ET LES VÊTEMENTS LOIN DE L'ESPACE DÉSIGNÉ DE L'INSTALLATION. LE CONTACT PEUT CAUSER DES BRÛLURES À LA PEAU. VOIR L'ÉTIQUETTE ET LES INSTRUCTIONS. Opérez cet appareil avec le couvercle de la trémie fermé. Le défaut de ne pas suivre les instructions peut résulter, sous certaines conditions, en une combustion des émissions des produits venant de la trémie. Ne pas remplir la trémie trop pleine.

O-T L

MANTEL

2006 2007 2008 JAN FEB MAR APR MAY JUNE JULY AUG SEPT OCT NOV DEC

SAMPLE

007C

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 replaces. And yet we are old-

meticulously fabricated and gold and nickel surfaces are hand-nished for lasting beauty and enjoyment. Our pledge to quality is completed as each model undergoes a quality control inspection. From design, to fabrication, to shipping: Our guarantee of quality is more than a word, it’s QuadraFire tradition, and we proudly back this tradition with a Limited Lifetime Warranty.

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.

fashioned when it comes to craftsmanship. Each unit is

With warm regards,

CLEARANCE TO COMBUSTIBLES LABEL LOCATED INSIDE HOPPER LID

SERIAL NUMBER & MANUFACTURE DATE LABEL LOCATED UNDER TOP ON INSIDE OF HOPPER BODY

Page 2

7014-083C

Test Lab & Report No.

Model Name

Manufactured Date

Serial Number

October 26, 2006

TABLE OF CONTENTS

Section 1: Listing and Code Approvals

A. Appliance Certications ......................4

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

C. Glass Specications ............................4

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

E. BTU & Efciency Specications ..........4

Section 2: Getting Started

A. Design, Installation & Location

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

B. Fire Safety ..........................................5

C. Tools & Supplies Needed ...................6

D. Measuring Standards..........................6

E. Inspect Appliance, Components

and Pre-Check List ............................. 6

Section 3: Dimensions & Clearances

A. Appliance Dimensions ........................7

B. Clearances to Combustibles

As A Built-In, UL and ULC ..................8

C. Clearances to Combustibles,

Masonry & Zero Clearance .................9

D. Minimum Opening for Factory

Built Fireplace .....................................9

E. Masonry Minimum Opening ................10

F. Floor Protection ..................................10

G. Calculating Alternate Floor

Protection Material ..............................10

H. Removing Floor of Factory Built

Fireplace .............................................11

CB1200-I Pellet Insert

Section 8: Operating Instructions

A. Fuel Size & Material ............................ 24

B. General Operation Information ...........24

C. Before Your First Fire .........................25

D. Fuel Adjustment Control Rod..............25

E. Starting Your First Fire ........................25

F. Fire Characteristics .............................25

G. Feed Rate Adjustment ....................... 25

H. Ignition Cycles ....................................25

I. Frequently Asked Questions...............26

Section 9: Troubleshooting ............................27-29

Section 10: Maintaining & Servicing Appliance

A. Proper Shutdown Procedure ...............30

B. General Maintenance & Cleaning ....... 0-2

C. High Ash Content Maintenance ..........2-

D. Igniter Replacement ............................ 

E. Glass Replacement .............................4

F. Bafe Removal ....................................34

Section 12: Reference Material

A. Component Functions.........................5-6

B. Component Locations .........................37

C. Exploded Drawings .............................7-8

D. Service Parts & Accessories...............9-41

E. Service & Maintenance Log ................42

F. Warranty Policy ...................................43

G. Contact Information ............................44

Section 4: Vent Information

A. Chimney & Exhaust Connections ........12

B. Venting Termination Requirements .... 12

C. Equivalent Feet of Pipe.......................1

D. Pipe Selection Chart ...........................1

Section 5: Venting Systems

A. Direct Connect with Outside Air ..........14

B. Direct Connect without Outside Air .....14

C. Full Reline with Outside Air .................15

Section 6: Mobile Home ..................................16

Section 7: Appliance Set-Up

A. Rear Shrould Installation ....................17-18

B. Outside Air Kit .....................................19

C. Adjustable Hopper Option...................19

D. Grille Installation .................................19

E. Adjustable Hearth Support..................20

F. Panel & Trim .......................................21-22

G. Log Set Placement ..............................2

H. Thermostat Installation ........................2

October 26, 2006

7014-083C

Page 

CB1200-I Pellet Insert

Listing and Code Approvals

A. Appliance Certication

MODEL: 1200-I Pellet Insert LABORATORY: OMNI Test Laboratories, Inc REPORT NO. 061-S-1-2 TYPE: Solid Fuel Room Heater/Pellet Type

Insert

STANDARD: ASTM E1509, ULC S628 and ULC/

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

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 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.

E. BTU & Efciency Specications

Emissions Rating: .9 grams/hr *BTU Output: 14,000 - 40,000 / hr Heating Capacity: up to 2,500 sq. ft. Hopper Capacity: 60-75 lbs Fuel: Wood Pellets or Shelled Corn Shipping Weight: 24 lbs

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

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

C. Glass Specications

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

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

ASTM E1509, (UM) 84-HUD, ULC/ORD-C-1482

D. Electrical Rating

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

Page 4

7014-083C

October 26, 2006

CB1200-I Pellet Insert

. Design, Installation & Location

Getting Started

Considerations

1. Appliance Location

Consideration must be given to safety, convenience, trafc ow, and the fact that the appliance will need a chimney and chimney connector. It is a good idea to plan your installation on paper, using exact measurements for clearances and oor protection, before actually beginning the installation. If you are not using an existing chimney, place the appliance where there will be a clear passage for a factory-built listed chimney through the outside wall or ceiling and roof.

Check with your local building code agency before you begin your installation. Be sure local building codes do not supersede UL specications and always obtain a building permit so that insurance protection benefits cannot be unexpectedly cancelled. If any assistance is required during installation, please contact your local dealer.

We recommend that a qualied building inspector and your insurance company representative review your plans before and after installation.

2. Thermostat Location

The thermostat’s location will have some effect on the appliance’s operation. When the thermostat is located close to the appliance, it may require a slightly higher temperature setting to keep the rest of the house comfortable. If the thermostat location is in an adjacent room or on a different oor level, you will notice higher temperatures near the appliance.

CAUTION

• Do NOT connect this unit to a chimney ue servicing another appliance.

• Do NOT connect to any air distribution duct or system.

B. Fire Safety

Maintain the designated clearances to combustibles. Insulation must not touch the chimney. You must maintain the designated air space clearance around the chimney. This space around a chimney is necessary to allow natural heat removal from the area. Insulation in this space will cause a heat buildup, which may ignite wood framing. NOTE:

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

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

1. Install at least one smoke detector on each oor of your home to ensure your safety. They should be located away from the heating appliance and close to the sleeping areas. Follow the smoke detector manufacturer’s placement and installation instructions, and be sure to maintain regularly.

2. A conveniently located Class A fire extinguisher to contend with small fires resulting from burning embers.

. A practiced evacuation plan, consisting of at least 2

escape routes.

4. A plan to deal with a hopper re as follows:

In the event of a hopper re:

a. Notify re department. b. Prepare occupants for immediate evacuation. c. Close all openings into the appliance. d. Unplug appliance. e. While awaiting re department, watch for ignition

of adjacent combustibles from overheated vent pipe, hot embers or sparks from the chimney.

f. Po ur a bucket of wat er int o the appli ance

hopper.

October 26, 2006

WARNING

Fire Risk.

• Do not operate appliance before reading and understanding operating instructions.

• Failure to operate appliance properly may cause a house re.

7014-083C

Page 5

CB1200-I Pellet Insert

Measure horizontal clearances from this surface

Measure vertical clearances from this surface

C. Tools And Supplies Needed

Tools and building supplies normally required for installation, unless installing into an existing

masonry replace:

Reciprocating Saw Hammer Phillips Screw driver Tape Measure

Safety Glasses Framing Square Electric Drill & Bits (1/4”)

1/4” Self-Tapping Screws Plumb Line Level Framing Material Hi-temp Caulking Material

May also need:

Vent Support Straps

Venting Paint Gloves

D. Measuring Standards

1. Pipe measurements are from center line to center line.

2. Vertical terminations are measured to top of pipe.

E. Inspect Appliance & Components and

Pre-Use Check List

1. Place the appliance in a location near the 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 followed.

4. This Owner’s Manual has been read.

5. Floor protection requirements have been met.

6. Venting is properly installed.

7. The proper clearances from the appliance and chimney to combustible materials have been met.

8. The masonry chimney is inspected by a professional and is clean, or the factory built metal chimney is installed according to the manufacturer’s instructions and clearances.

9. The chimney meets the required minimum height.

10.

11. Plated surfaces have been wiped clean, if

12. Thermostat or remote has been installed.

13. A power outlet is available nearby.

All labels have been removed from the glass door.

applicable.

Figure 6.1

Page 6

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.

7014-083C

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.

• Modi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.

• Ope r a t i n g ap p l i a nce wi thout fully as sembling all components.

• Do NOT Overre.

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

October 26, 2006

Dimensions and Clearances

0" (762mm)

22" (559mm)

19-1/2" (495mm)

11"

(279mm)

11"

(279mm)

25-1/2"

(648mm)

12"

(05mm)

13"

(0mm)

10-/4"

(27mm)

(Hopper Up)

(Hopper Down)

22" (559mm)

29-1/4" (74mm)

8-/4"

(222mm)

40" (1016mm)

1" (0mm)

12" (05mm)

28-1/2" (724mm)

10-/4"

(27mm)

A. Appliance Dimensions

CB1200-I Pellet Insert

Figure 7.1 - Top View

Figure 7.2 - Front View

Panel A B

Standard 0 inches (762mm) 40 inches (1016mm)

Large  inches (88mm) 50 inches (1270mm)

October 26, 2006

Figure 7.3 - Side View

7014-083C

Page 7

CB1200-I Pellet Insert

12 in

Rear Shroud

6 in

Shown with Hopper Extended

Optional Outside Air

Combustible Mantel

B. Clearance To Combustibles, UL and ULC

AS A BUILT-IN

Rear Shroud Kit, Part 811-0680 is Required for Built-In Installation

(see pages 17-18 for installation instructions)

0 INCH (0mm) CLEARANCE TO EXPOSED SECTION AND FACE TRIM

Figure 8.1

A Top of Shroud Top Vent .0 76

Rear Vent 0 0 B Sides of Inside Shroud Top or Rear Vent 0 0 C Back of Inside Shroud Top Vent 2.5 64

Rear Vent 0 0

D Vent Pipe to Combustible Top or Rear Vent .0 76

E From Outside Edge of

Panel Set to Combustibles

INSTALLED AS A BUILT-IN UNIT

Shown with Rear Vent and Optional Outside Air

Inches Millimeters

0 0

WARNING

Fire Risk. Comply with all minimum clear-

ances to combustibles as specied.

Failure to comply may cause house re.

Figure 8.2

Page 8

NOTE:

• Illustrations reect typical installations

and are FOR DESIGN PURPOSES ONLY.

• Illustrations/diagrams are not drawn to

7014-083C

scale.

• Actual installation may vary due to

individual design preference.

October 26, 2006

SIDE WALL

MANTEL

Face Trim

C. Minimum Clearances To Combustibles for

Masonry and Zero Clearance Fireplaces

CB1200-I Pellet Insert

Inches Millimeters

A Louvers to combustible

side wall

B Insert top to mantel 12 305 C Front Facing 3 76 D Hearth Extension - Front 6 153 E Hearth Extension - Sides 8 20

6 153

Figure 9.1

D. Minimum Opening for Masonry and Zero

Clearance Fireplaces for Built-In Using Rear Shroud

NOTE: A Quadra-Fire oor protector (Part 811-070) is

available through your dealer to be used as a oor protector for the section under the insert body only. Floor protection to front and sides of insert unit must be supplied in addition to this part.

Inches Millimeters

A Rear Width 22 558 B Depth 15-1/2 393

Height - Top Vent 25-1/2 647

Height - Rear Vent 22-1/2 571

D Front Width 29-1/4 743

*The size of your oor protector choice must be

added to this dimension. If using Quadra-Fire oor protector, Part 811-070, allow 1-1/2” (8mm).

Figure 9.2

October 26, 2006

7014-083C

Page 9

CB1200-I Pellet Insert

E. Masonry Minimum Opening

Location Inches Millimeters

A Rear Width 22 558 B Depth 13 330 C Height - Top Vent 19-1/2 495 D Front Width 29-1/4 743

F. Floor Protection

1. Zero Clearance Installations* It is necessary to install a oor protection of non-combus-

tible material with a R value of .0 (1 inch [25mm] minimum thickness with a “k” value of 0.58) or a 1 inch (25mm) air space between insert base and hearth.

2. Non-Zero Clearance Installations* A non-combustible oor protector is required with a mini-

mum R value of .0 (1 inch [25mm] minimum thickness with a “k” value of 0.58) extending 6 inches (15mm) in front of the insert and 8 inches (20mm) to each side of the door opening.

* See alternate oor protection worksheet.

G. Calculating Alternate Floor Protection Material

Thermal Conductivity: k value

The k value indicates the amount of heat (in BTU’s) that will ow in 1 hour through 1 square foot of a uniform material 1 inch thick for each degree (F) of temperature difference from one side of the material to the other. The LOWER the k factor means less heat is being conducted through the non-combustible material to the combustible material beneath it. The k value of a material must be equal or smaller then the required k value to be acceptable. (BTU) (inch) (foot2 (hour) (oF)

Thermal Resistance: R value

The R value is a measure of a material’s resistance to heat transfer. R value is convenient when more than one material is used since you can add the R values together, whereas you can not do this for k value. The HIGHER the R factor means less heat is being conducted through the non-combustible material to the combustible material beneath it. The R value of a material must be equal or larger then the required R value to be acceptable.

Converting k to R:

Divide 1 by k and multiply the results times the thickness in inches of the material.

R = 1/k x inches of thickness

Converting R to k:

Divide the inches of thickness by R.

k = inches of thickness/R

Calculations:

Example: Floor protection requires k value of 0.84 and /4 inch thick.

Alternative material has a k value of 0.6 and is /4 inch thick.

Divide 0.6 by .75 = k value of 0.80. This k value is smaller than

0.84 and therefore is acceptable.

Page 10

7014-083C

October 26, 2006

Mark area of floor to cut

Starter hole

Keep sharp edge of metal floor away from power cord

H. Removing Metal Floor of Factory-Built

Firebox

• The rebrick (refractory), glass doors, screen rails, screen mesh and log grates can be removed from a factory-built rebox in order to gain minimum insert opening requirements.

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

• The metal oor of the factory-built rebox may be removed to facilitate the installation of the insert only when a 1 inch (25mm) airspace is provided between the insert and the oor of outer wrap.

• If the oor is made of thin metal, we recommend using a Quarda-Fire oor protector, Part 811-070, which is available through your dealer.

CB1200-I Pellet Insert

Figure 11.3. Place the insert into the fac-

tory-built rebox. 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.

Figure 11.1. Measure and mark the metal oor for cutting. With a drill, make a starter hole in each corner.

Figure 11.2. Using a saws-all, cut out the oor.

October 26, 2006

7014-083C

Page 11

CB1200-I Pellet Insert

Vent Information

A. Chimney and Exhaust Connection

1. Chimney & Connector: Use  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 ue connector. A Quadra-Fire Outside Air Kit must be used with manufactured home installations.

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

listed double wall ue connector to Class A listed metal chimneys, or masonry chimneys meeting national and/or local codes for solid fuel appliances.

4. INSTALL VENT AT CLEARANCES SPECIFIED BY THE VENT MANUFACTURER.

5. Secure exhaust venting system to the appliance with at

least  screws. Also secure all connector pipe joints with at least  screws through each joint.

NOTE: All pipe must be welded seam pipe whenever possible. Seal pipe joints with high temperature silicone (500°F [260°C] minimum rated only).

NOTE: If burning shelled eld corn, you must use approved venting speci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.

WARNING

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

B. Venting Termination Requirements

CAUTION

Do not terminate vent in any enclosed or semi-enclosed

area such as a carport, garage, attic, crawl space, under a sun deck or porch, narrow walkway or closely fenced area, or any location that can build up a concentration of fumes such as a stairwell, covered breezeway, etc.

1. Termination must exhaust above air inlet elevation. It is

recommended that at least 60 inches (1524mm) of vertical pipe be installed when appliance is vented directly through a wall. This will create a natural draft, which will help prevent the possibility of smoke or odor venting into the home during a power outage. It will also keep exhaust from causing a nuisance or hazard by exposing people or shrubs to high temperatures. The safest and preferred venting method is to extend the vent vertically through the roof.

2. Distance from doors and opening windows, or gravity or

ventilation air inlets into building:

a. Not less than 48 inches (1219mm) below; b. Not less than 48 inches (1219mm) horizontally

from;

c. Not less than 12 inches (05mm) above.

. Distance from permanently closed windows:

a. Not less than 12 inches (05mm) below, horizontally

from or above.

4. Distance between bottom of termination and grade

should be 12 inches (05mm) 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 (214mm) 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 softs.

• Clearance of a termination cap above electrical service will be 12 inches (05mm) minimum.

• Location of the vent termination must not obstruct or interfere with access to the electrical service.

Page 12

7014-083C

October 26, 2006

CB1200-I Pellet Insert

3 in. or 4 in. (76mm or 102mm) Diameter Pipe

Equivalent Pipe

Length In Feet

ALTITUDE IN THOUSANDS OF FEET

1 2 3 4 5 6 7 8 9 10

4 in. (102mm) Diameter Pipe Only

2 ft.

 ft.

2 ft.

C. Equivalent Feet of Pipe

The table below can help you calculate the equivalent feet of pipe which is a method used to determine pellet vent size. See

Figure 13.1

Example of 3 Elbow-Rear Vent Termination Calculation

Pellet Venting

Component

90o Elbow or Tee 45o Elbow

Horizontal Pipe

Vertical Pipe

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to the owner’s information manual provided with this appliance. For assistance or additional information consult a qualied installer, service agency or your dealer.

# of

Elbows

Feet of

3 X 5 15

Multiplied ByEquivalent

Pipe

X 3 7 X 1 7 2 X 0.5 1

Total Equivalent Feet 23

Feet

Components

Equivalent Feet

Note: This is a generic example and is not intended to represent any specic fuel type.

Figure 13.1

D. Pipe Selection Chart

The chart will help you in determing proper venting size according to the equivalent feet of pipe calcuated above and the altitude above sea level of this installation. See Figure 13.2.

Locate the calculated equivalent feet of pipe on the vertical left side of the chart. Move to the right horizontally on the chart until you reach your altitude above sea level.

If you fall below the diagonal line,  or 4 inch (76 to 102mm) pipe may be used. If it is anywhere above the diagonal line, a 4 inch (102mm) diameter pipe is requried.

The chart reveals that a 90° elbow is 5 times as restrictive to the ow of exhaust gases under positive pressure as 1 foot of horizontal pipe, and a foot of horizontal pipe is twice as restrictive as a foot of vertical pipe.

Figure 13.2

October 26, 2006

7014-083C

Page 1

CB1200-I Pellet Insert

Outside Air through Rear Wall

Venting Systems

A. Direct Connect With Outside Air

NOTE: In Canada, only a full reline is

allowed per ULC S-628, ORD ULC C1482.

NOTE; Use metal plate

around exhaust vent pipe and seal all edges with non-ammable insulation such as berglass, mineral wool or ceramic material.

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

Direct Connect Without Outside Air

Figure 14.1

NOTE:

• Illustrations re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.

CAUTION

Never draw outside combustion air from:

• Wall, oor or ceiling cavity

• Enclosed space such as an attic or garage

Page 14

7014-083C

Figure 14.2

WARNING

Fire Risk. Inspection of Chimney:

• Masonry chimney must be in good condition.

• Meets minimum standard of NFPA 211

• Factory-built chimney must be 6 inch (152mm)

UL10 HT.

NOTE:

In Canada, where passage through a wall or partition of combustible construction is desired, the installation shall conform to CAN/CSA-B65.

October 26, 2006

C. Full Reline With Outside Air

Outside Air Termination

Chimney Top

Outside Air through Rear Wall

Exit through the

Ash Clean-Out of

Masonry Chimney

12” (05mm) min. below

12” (05mm) min. above

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

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

CB1200-I Pellet Insert

NOTE: Check clearances carefully for this

type of installation to ensure adequate room for outside air venting.

NOTE: In Canada, only a full reline is allowed per ULC S-628, ORD ULC C1482.

CAUTION

Check building codes prior to installation.

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

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

Figure 15.1

October 26, 2006

7014-083C

Page 15

CB1200-I Pellet Insert

Spark Arrestor Cap

Roof Flashing

Storm Collar

Joist Shield/Firestop

Double Wall Pellet Vent

Mobile Home

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.

. The appliance must be secured to the mobile home

structure by bolting it to the oor (using lag bolts). Use the same holes that secured the appliance to the shipping pallet.

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

CAUTION

Maintain structural integrity of mobile home:

• Floor, wall, ceiling and/or roof. Do NOT cut through:

• Floor joist, wall studs or ceiling trusses.

• Any supporting material that would affect the structural integrity.

5. Refer to Clearances to Combustibles and oor pro-

tection requirements on pages 8 & 9 for listings to combustibles and appropriate chimney systems.

6. Use silicone to create an effective vapor barrier at the location where the chimney or other component penetrates to the the exterior of the structure.

7. Follow the chimney manufacturer’s instructions when installing the vent system for use in a mobile home.

8. Installation shall be in accordance with the Manufacturers Home & Safety Standard (HUD) CFR 280, Part

24.

WARNING

Installation must comply with Manufactured Home and Safety Standard (HUD), CFR 280, Part 24.

WARNING

Never install in a sleeping room.

Figure 16.1

Page 16

7014-083C

October 26, 2006

Appliance Set-Up

Knock-Out Rear

ent Access

Outside Air V

ent

Pipe Access

Right Corner

Left Corner

Top Vent Opening

Left Corner

Filler Piece

REAR SHROUD TOP

VENT PART 811-0650

Vertical Exhaust Transition Pipe

Top Vent Adapter

Filler Piece

Left Corner

Piece

Rear Shroud

Top Vent

A. Rear Shroud Installation

1. Top Vent Installations Parts Required:

Part 811-0680, Rear Shroud Kit. Includes: Six galvanized steel shroud pieces, two cover plates and fastener package.

Part 811-0650, Rear Shroud Top Vent Includes: Vent pipe and two 1/4 - 20 x /4" bolts with nuts.

Part 811-0660, " Top Vent Adapter or Part 811-0670, 4” Top Vent Adapter

2. Rear vent installations Parts Required:

Part 811-0680, Rear Shroud Kit.

Part 811-0690, Rear Vent Kit

Includes: Rear Vent Adapter and fastener package.

CB1200-I Pellet Insert

Tools Required:

Electric drill, 1/8" drill bit, Phillips screw driver, /8" wrench & 7/16" wrench, (7/16" socket wrench & high temperature silicone adhesive are also required for rear vent installations).

1. Remove the top vent adapter from the vertical exhaust

2. Use 2 screws to attach left corner ller piece of rear

. Use (2) 1/4 - 20 x /4" bolts with nuts to install rear

4. Install the left shroud panel corner at  points, 2 screws

October 26, 2006

Complete the following procedures, based on your venting installation, prior to installing the rear shroud kit. (Note: All photos depict top vent

installation).

Top Vent Installation Preparation

transition pipe. Figures 17.2 and 17.5.

shroud to the insert hopper. Figures 17.1 and 17.2.

shroud top vent to the exhaust transition. See boxed area in Figure 17.3. (Circled area, top vent adapter, will be installed later).

into back of hopper and 1 down into the ller piece).

Figure 17.4

7014-083C

Figure 17.1

Figure 17.2 Figure 17.3

Figure 17.4

Figure 17.5

Page 17

CB1200-I Pellet Insert

Left Corner

Piece

Attach right corner piece to side panel first.

Right Corner Piece

Right Side

Rear Panel

Outside Air Cover Plate

Knock-Out

Plate

Rear Panel

Left Side

Drill Holes

Rear Panel

Drill Holes

Rear Vent Installation Preparation:

1. Remove the ENTIRE exhaust blower housing by remov-

ing the 4 nuts using a 7/16" socket wrench. Set the nuts aside for later use.

2. Remove the 4 screws and remove the vertical exhaust transition pipe exhaust blower housing.

. Remove any silicone sealant remaining on the blower

housing.

4. Attach the rear vent adapter to the exhaust blower housing with 4 screws. Figure 18.2.

5. Apply a bead of high temperature silicone adhesive around the juncture of the blower housing and rear vent adapter, smoothing it around the joint to ensure that a good seal is made.

6. Re-install the exhaust blower housing (now with rear vent adapter attached) with the 4 nuts previously removed in Step 1.

7. Use 2 screws to attach left corner ller piece of rear shroud to the insert hopper. Figures 17.1 & 17.2 on page 17.

8. Install the left shroud corner with 2 screws into the hopper body and 1 down into ller piece. Figure 18.1.

9. Install cover plate over top vent opening using 4 screws.

Assemble the right corner and right panel pieces using 4 screws prior to attaching to insert. Figure 18.4.

After assembly,

attach the right shroud panel/corner

assembly to the insert with  screws across the bottom and 1 on the side. Figure 18.4.

Figure 18.3

Figure 18.4

piece

Figure 18.1

Installing Rear Shroud

Figure 18.2

Top Vent Applications: Leave knock-out plate in place. Figure 18.3

Rear Vent Applications: Clip corners of knock-out plate,

remove and discard, prior to assembling rear shroud kit.

1. Install rear panel using 4 screws along bottom and 2 screws

into the left shroud corner piece at the top. Figure 18.3.

2. If your installation does not include an outside air kit, attach cover plate with 4 screws.

.

Attach left shroud panel using seven screws,  on top and bottom and 1 along the side. Figure 18.3.

Page 18

Attaching Shroud to Hopper Body:

6. Beginning at the right shroud panel drill into hopper body through the  pre-drilled openings and the 2 pre-drilled openings on the rear shroud panel. Figure 18.5. Continue around to left shroud corner panel at the 2 pre-drilled openings. Figure 18.6. Secure with screws to insert.

7. For Top Vent Installation:

Install  inch or 4 inch (76 or 102mm) top vent adapter.

See circled area in Figure 17.3 on page 17. NOTE: This adapter may be attached to outside venting prior to latching it on to the top vent pipe.

Figure 18.5

Figure 18.6

7014-083C

October 26, 2006

CB1200-I Pellet Insert

Flex Hose

Hose Clamp

Collar

ssembly

Trim Ring

Hose Clamp

Termination Cap Assembly

Attach hose clamp to

intake air collar

Outside air

flex pipe

Bag Support Shelf

B. Outside Air Kit Instructions

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

1 hose clamp and 1 rodent screen. Tools Needed: Phillips head screw driver; wire cutters;

hole saw or jig saw.

1. Measure distance from oor to air vent opening in appli ance and mark location on wall.

2. Use saw to cut opening in wall. Cut a 2-1/2 to  inches (64-76mm) opening on inside wall and a  to -1/2 inch (76-89mm) opening on outside of house.

. Use hose clamp to secure ex pipe to collar assembly.

4. Slide trim ring over 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, oor or ceiling cavity

• Enclosed space such as an attic or garage

C. Adjustable Hopper Options

Depending on your installation, the hopper can be vertically adjusted up to a maximum of -1/2 inches (89mm) and will hold an additional 15 lbs of fuel.

To adjust hopper:

1. Using a Phillips head screw drive, remove all the screws from the top of the hopper securing the top hopper piece to the bottom hopper piece and insert body.

2. Adjust upward a maximum of -1/2 inches (89mm).

. Mark location for new holes and drill new holes.

4. Secure hopper pieces together using screws removed in step one.

5. See drawing on page 7, Figure 7.3.

D. Optional Grille Installation

1. Remove grille from packaging.

2. Lift top up.

. Align the  holes in the insert with the holes in the grille.

4. Use a Phillips screw driver to secure in place. It will be necessary to go through the hole in the bag support shelf to gain access to the screw. Figure 19.3.

5. Lower the top into position.

Figure 19.1

Figure 19.2

October 26, 2006

7014-083C

Figure 19.3

Page 19

CB1200-I Pellet Insert

DOUBLE-SIDED TAPE

EXPLODED VIEW OF SCISSORS

SCREWS ARE CIRCLED

Decorative tile

may be installed

INSTALL FRONT TRIM LAST.

CORNERS OVERLAP SIDE

TRIM PIECES

EXPAND SCISSORS TO DESIRED HEIGH T

CUT TOP EDGE OF TRIM,

NOT BOTTOM EDGE

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 screw driver, sheet metal shears, measuring tape, gloves

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

loose when shipped. Figure 20.1.

Expand scissors to desired height. Tighten screws to hold in place using Phillips head screw driver. Figure 20.2.

. 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.

Figure 20.3.

4. Using sheet metal shears, cut trim along the marked edge. The cut edge ts under lip of top trim, so it allows for some variance in your straight edge.

Figure 20.1

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

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

7. Once you are satised with the positioning, remove trim and set aside.

8. 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.

9. There are  holes in the back ange of the top to secure it to the wall if necessary. Use the appropriate fastener for the type of wall material, i.e., brick, sheetrock, etc.

NOTE: /8 inch (9.5mm) thick tile or like material can be

cut to size and t under lip of top trim edge for a decorative touch. Figure 20.3.

Figure 20.2

Figure 20.3

Page 20

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

Injury can occur.

WARNING

7014-083C

October 26, 2006

F. Panel and Trim Set

Top Trim

Corner Bracket

Left Trim

Right Trim

Right

Left

*Right Side

*Left Side

Top Panel

Standard Size: 30”H x 40” W (762mm x 1016mm) Large Size: 33” H x 50” W (838mm x 1270mm)

Included in Kit: 2 side panels, 1 top panel, 2 side trim, 1 top trim, 2 corner brackets and fastener package.

Tools Needed: Phillips and at head screw drivers.

1. Unpack and lay out parts face down (anges up) on a non-

abrasive surface as shown in Figure 21.1. Install (1) 8-2 x /8” screw into bottom tab of side panel.

2. Set the large hole at bottom of side curtain over screw

installed in Figure 21.2. Stand assembly on end and attach and install (1) 8-2 x /8” screw through tab in side panel and curtain. Lay face down as shown in Figure 21.3

. Align top panel to side panel setting clearance hole over

screw head in side panel/curtain assembly.

4. Install (2) 8-2 x /8” screws through holes in side panel into top panel. Complete for both sides.

CB1200-I Pellet Insert

Figure 21.3

Figure 21.1

Figure 21.2

*Right and left side curtains are shipped with the insert.

Figure 21.4

Figure 21.5

October 26, 2006

7014-083C

Figure 21.6

Page 21

CB1200-I Pellet Insert

View of "L" Bracket

installed

F. Panel and Trim Set (Cont’d)

7. Hold side curtains in open position and lower panel set over insert setting lower edge of top panel in slot between hopper lid and panel support as shown in Figure 22.1. Place existing screw head (installed in Figure 21.2) into locator hole in oor of insert. See Figure 22.2.

8. Lift hopper lid and press down on panel top while installing (4) 8-2 x /8” screws into holes in panel support. (If screws have been factory installed, tighten to secure panel to panel support.) Return hopper lid to closed position.

9. Install a corner bracket on each side trim piece. Slide brackets into top trim from each side and secure with athead screwdriver. Attach trim assembly to panel set as follows:

a. Ensure that brackets face towards the back.

b. Align trim assembly to panel set sides and slide

down.

Figure 22.3

Figure 22.1

Figure 22.2

Figure 22.4

Figure 22.5- Completed View

Page 22

7014-083C

October 26, 2006

CB1200-I Pellet Insert

LOCATING PINS

Charred Areas in the Back

Right Twig

Left Twig

Front Log

Terminal Block

Center 2 Screws for

Thermostat Wires

Power Outlet

G. Optional Log Set Placement Instructions

CAUTION

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

1. Place the front log in rst as shown in log between repot and face of appliance with charred area surrounding repot.

2. Set the left and right twigs onto the log, placing the holes in the base of twigs over the locating pins in log. See Figure 23.2. Ensure that the charred ends are facing the repot.

Figure 23.1. Place

H. Thermostat Installation

1. A 12 volt AC thermostat is required to operate this pellet appliance. You may use the included wall mount thermostat or purchase an optional programmable thermostat or remote control. The included thermostat is equipped with an adjustable heat anticipator. The current rating is .05 amps. The anticipator needs to be adjusted to the lowest setting available.

2. When mounting a thermostat on a wall, be sure to follow your thermostat installation instructions carefully.

NOTE: Thermostat must be mounted level for 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.

. Open right side plane to access a 4 screw terminal block

located on the bottom right hand side next to the power cord inlet. The center 2 screws are for the thermostat wires. The outer 2 are the mounting screws for the terminal block. Figure 23.1.

Figure 23.1

Figure 23.2

NOTE:

Due to the abrasive nature of a pellet appliance 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 23.3

CAUTION

Shock hazard.

• Do NOT remove grounding prong from plug.

• Plug directly into properly grounded  prong receptacle.

• Route cord away from appliance.

•

Do NOT route cord under or in front of appliance.

October 26, 2006

7014-083C

Page 2

CB1200-I Pellet Insert

Heat Output Switch

Reset Button

Red Call Light

Fuse

Control Box

Red / Green

Light

Blue

Blinking

Light

Fire Risk.

WARNING

• High ash fuels, or lack of maintenance, can cause the ﬁrepot to ﬁll with ash and clinker. If the ﬁrepot ﬁlls to the top, immediately shut down the unit and clean.

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

Operating Instructions

A. Fuel Size And Material

1. Wood Pellets

Fuel pellets are made from sawdust or wood by-products. If the source material is hardwood, they can have a higher mineral content, creating more ash. Fuels containing bark will also have higher ash content. Minerals and other noncombustible materials such as sand will turn into a hard, glass-like substance called a clinker when heated to the extreme temperatures our repot reaches. This is what forms clinkers in the bottom of the repot. Trees from different areas will vary in mineral content. That is why some fuels produce more clinkers than others. Pellets are manufactured in either 1/4 inch or 5/16 inch (6-8mm) diameter and should be no more than 1-1/2 inches (38mm) in length. Pellet lengths may even vary by lot from the same manufacturer which is why the feed rate may need to be adjusted occasionally. If you burn pellets longer than 1-1/2

inches (38mm) you may have an inconsistent fuel feed rate and/or missed ignitions.

Pellet fuel quality can greatly uctuate. We recommend using premium grade fuel with ash content less than 1%. Even in some fuel labeled “premium” ash content can vary from bag to bag and possibly exceed 1%. High ash fuel, or lack of maintenance, can cause the repot to ll up and thus create a potential for smoking, sooting and possible hopper res.

Always burn dry fuel. Burning fuel with high moisture content takes heat from the fuel and tends to cool the appliance, robbing heat from your home. Damp pellet fuel can clog the feed system.

We recommend that you buy fuel in multi-ton lots whenever possible. Buying large quantities of fuel at once will greatly reduce the number of times the feed adjustments will need to be made. However, we do recommend trying various brands before purchasing multi-ton lots to ensure your satisfaction.

B. General Operating Information

1. Thermostat Calls For Heat

The appliance is like most modern furnaces; when the thermostat calls for heat, your appliance will automatically light and deliver heat. When the room is up to temperature and the thermostat is satised, the red call light will shut off and the appliance will shut down. Figure 24.1.

2. Heat Output Controls

This appliance is equipped with a heat output control switch that has three settings or burn rates; low, medium and high. The appliance will turn on and off as the thermostat demands. When the thermostat calls for heat, the appliance will always start up on High. After burning approximately 4 minutes, the appliance will then burn at the rate at which it was originally set. If the appliance is set at one of the lower settings, it will run quieter but takes longer to heat up an area than if it were set at a higher burn rate. Regardless of the burn rate, when the area is warm enough to satisfy the thermostat, the appliance will shut off.

Figure 24.1

2. Shelled Field Corn

Shelled eld corn can be an efcient and economical fuel. We recommend using a 50-50 blend of corn and wood pellets. The only change in operation; 1) the feed rate may require a slight adjustment and 2) repot will require more frequent cleanings. The BTU output varies slightly compared to pellets, depending on the quality of the corn used. In cases where it is acceptable for the appliance to run full time, 100% corn will work after the re has been started using wood pellets.

Page 24

7014-083C

WARNING

Fire Risk.

Keep combustible materials, gasoline and other ammable vapors and liquids clear of appliance.

• Do NOT store ammable materials in the appliance’s vicinity.

• Do NOT use gasoline, lantern fuel, kerosene, charcoal lighter uid or similar liquids to start or “freshen up” a re in this heater.

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

• Combustible materials may ignite.

October 26, 2006

CB1200-I Pellet Insert

C. Before Your First Fire

1. First, make sure your appliance has been properly installed and that all safety requirements have been met. Pay particular attention to the re protection, venting and thermostat installation instructions.

2. Double check that the ash pan and rebox are empty!

. Check the position of the thermocouple, located above

the repot, and make sure that it protrudes approximately /4 inch (19mm) into the repot.

4. Close the front door.

CAUTION

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

Missed ignitions can occur.

D. Fuel Adjustment Control Rod

The set screw is located at the bottom of the hopper and set loose at the factory so the fuel adjustment control rod will slide by only loosening the wing nut. Do not re-tighten bottom set screw.

E. Starting Your First Fire

1. A thermostat is required for proper operation of this appliance, except for corn. At this time, 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 10 minutes even though the thermostat is not calling for heat. This is normal.

. L

ocate the heat output control switch on the right side behind the right side panel. 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 right side behind the right side panel. This indicates the thermostat is calling for heat. See Figure 24.1 on page 24.

The fuel feed system and the igniter should

5. For your rst re it will be necessary to press the reset button approximately 2 minutes after start-up and again at 4 minutes. This will ll the feed system and allow the appliance to begin dropping pellets. Continue pushing the reset button until you detect that pellets are being delivered into the repot. The appliance will continue to run as long as the thermostat is calling for heat.

6. Once the appliance has ignited, let the it burn for approximately 15 minutes, then set the thermostat to the desired room temperature. Adjust the heat output control switch to the desired setting.

now

be on.

F. Fire Characteristics

A properly adjusted re with the heat output control switch set on “HIGH” has a short active ame pattern that extends out of the repot approximately 4 to 6 inches (102-105mm). If the re has tall ames with black tails and seems somewhat lazy, the feed rate will need to be reduced. If the re is not 4 inches to 6 inches (102-105mm) tall, increase the feed rate. A medium and low setting will give a shorter ame. The ame will rise and fall somewhat. This is normal.

G. Feed Rate Adjustment Instructions

The feed adjustment control rod is factory set, and should be adequate for most fuels. 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 adjustment to take effect.

llow 15 minutes for feed

1. Open the hopper lid and locate the fuel adjustment control rod.

2. Loosen the wing nut on the rod.

. Adjust the fuel adjustment control rod towards the "+"

symbol to increase the feed rate and ame height or towards the "-" symbol, to decrease the feed rate and flame height. Make approximately 1/2 inch (1mm) movements of rod at a time.

4. Re-tighten the wing nut.

H. Ignition Cycles

1. During each ignition cycle, it is normal to see some smoke in the rebox. The smoke will stop once the 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.

. Occasionally the appliance may run out of fuel and shut

itself down. When this happens, the red call light will be on. To restart it, 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 re shortly. If not, follow the instructions “Starting Your First Fire”.on this page.

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.

October 26, 2006

7014-083C

Page 25

CB1200-I Pellet Insert

Back side of Firepot

Firepot floor left open

WARNING

Fire Risk Do NOT operate appliance:

• With appliance door open.

• Firepot oor open.

• Cleaning slide plates open. Do NOT store fuel:

• Closer than required clearances to com-

bustibles to appliance

• Within space required for loading or ash removal.

Figure 25.1 - DO NOT LEAVE FIREPOT FLOOR OPEN

I. Frequently Asked Questions

ISSUES SOLUTIONS

1. Metallic noise. 1. Noise is caused by metal expanding and contracting as

it heats up and cools down, similar to the sound produced by a furnace or heating duct. This noise does not affect the operation or longevity of your appliance.

2. Ash buildup on glass. 2. This is normal. Clean the glass.

. Glass has turned dirty. . Excessive build up of ash. The lower burn settings will

4. Fire has tall ames with black tails and is lazy. 4. The feed rate needs to be reduced or the repot needs

5. Smokey start-up or puffs of smoke from the airwash. 5. Either the repot is dirty or there is too much fuel at

produce more ash, the higher burn settings produce less. The more it burns on low the more frequent cleaning of the glass is required.

cleaning. Heat exchanger or exhaust blower needs cleaning.

start-up and not enough air. Close down feed rate 1/4 inch (6mm) at a time until this no longer happens.

6. Large ame at start-up. 6. This is normal. Flame will settle down once the re is established.

Page 26

7014-083C

October 26, 2006

Troubleshooting

CB1200-I 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 quali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 qualied service technician.

Symptom

Plug in appliance - No response.

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

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

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

Possible Cause Corrective Action

No current to outlet.

.7 amp fuse defective.

# snap disc tripped or defective.

Control box defective.

Out of fuel.

#2 snap disc may be defective.

Vacuum switch not closing, no vacuum.

Control box defective.

Firepot clean-out plate not closed.

Firepot is dirty (missed ignition).

Firepot clean-out plate not closed.

Firepot is dirty.

Ignition hole blocked.

Check circuit breaker at service panel.

Replace fuse.

Reset or replace snap disc.

Replace control box.

Check hopper. Fill with fuel.

Replace snap disc.

Check exhaust blower is plugged in and operating. Check vacuum switch is plugged in. Check vacuum hose is in good condition, clear and connected at both ends. Check thermocouple is in good condition and plugged in properly. Make sure venting system is clean. Make sure front door is closed.

Replace control box.

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

Clean repot. Make sure there is no clinker in the repot.

Clinkers may have to be broken up with repot scraper tool or other means.

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

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

Scrape with solid piece of wire.

Igniter not working.

Control box defective.

Slow or smoky start-up. Firepot clean-out plate not closed.

Firepot is dirty.

Excessive amount of fuel at start-up.

October 26, 2006

7014-083C

Remove ash pan to see if igniter is glowing red on start-up. Check igniter wires for good connection. Replace igniter using 1/4 inch male /female spade connectors.

Replace control box.

Check that repot clean-out is fully closed.

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

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

Page 27

CB1200-I 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, rebox, heat exchanger, exhaust blower and venting.

Out of fuel.

#2 snap disc may be defective.

Check hopper, ll with fuel.

Replace snap disc. Firebox door must be closed securely.

No call light. Appliance does not begin start sequence.

Appliance fails to shut off.

Vacuum switch not closing. No vacuum.

Feed system jammed or blocked.

Empty hopper of fuel. Use a wet/dry vacuum cleaner to remove remaining fuel, from hopper, including feed tube. Check feed chute for obstructions. Loosen 2 screws and jiggle feed assembly.

Feed spring not turning with feed motor.

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

Feed motor defective or not plugged in.

Check connections on feed motor, replace if defective.

Thermostat not set to a high enough temperature.

Snap Disc # tripped.

No power.

Fuse blown.

Connections at thermostat and/or appliance not making proper contact.

Defective thermostat or thermostat wiring.

Adjust thermostat above room temperature.

Reset snap disc.

Connect to power.

Replace fuse.

Check connections at thermostat and appliance.

Replace thermostat or wiring. NOTE: To test thermostat and wiring, use a jumper wire at the thermostat block on the appliance to by-pass thermostat and wiring.

Control box defective.

Replace control box.

Call light on. Turn thermostat off.

If call light does not go out, disconnect thermostat wires from appliance. If call light does go out, thermostat or wires are defective.

Page 28

7014-083C

October 26, 2006

Symptom Possible Cause Corrective Action

Convection blower fails to start.

No call light.

#1 snap disc defective.

CB1200-I Pellet Insert

Defective control box.

Replace snap disc.

Exhaust blower fails to start or does not shut off.

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

Blower not plugged in.

Blower is defective.

Control box is defective.

Blower not plugged in.

Blower is clogged with ash.

Blower is defective.

Control box is defective.

Dirty appliance. Poor fuel quality, high ash content.

Firepot clean-out plate not completely closed.

Check that blower is plugged into wire harness.

Replace blower.

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

ness.

Clean exhaust system.

Replace blower.

Replace control box.

Clean appliance, including repot, heat exchangers and venting system. Remove stainless steel bafe from rebox to clean ash from on top of bafe. Clean behind rear brick panels. Change fuel brand to premium.

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

Excessive amount of fuel.

Nuisance shutdowns. Low ame.

Sawdust buildup in hopper.

Feed motor is reversing.

Defective thermocouple.

Defective control box.

Firepot more than 1/2 full

Appliance calls for heat. Call light illuminates.

Thermocouple is defective or not properly

plugged in. Exhaust blower starts. No feed or igniter.

Defective control box

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

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

Clean hopper, see page 32.

Check for good connections between feed motor and wire harness.

Replace thermocouple.

Replace control box. See pages 32 & 33 for detailed instructions

for “High Ash Fuel Content Maintenance”.

Check connections on thermocouple or replace if defective. A ashing yellow light on the control box indicates a problem with the thermocouple.

Replace control box.

October 26, 2006

7014-083C

Page 29

CB1200-I Pellet Insert

Clinker

Maintaining & Servicing Your Appliance

A. Proper Shutdown Procedure

CAUTION

Shock and Smoke Hazard

• Turn down thermostat, let appliance completely cool and exhaust blower must be off. Now you can unplug appliance before servicing.

• Smoke spillage into room can occur if appliance is not cool before unplugging.

• Risk of shock if appliance not unplugged before servicing appliance.

B. General Maintenance

1. Types of Fuel

Depending on the type of fuel you are burning will dictate how often you have to clean your repot. If the fuel you are burning has a high dirt or ash content or you are burning shelled eld corn, it may be necessary to clean the repot more than once a day. Dirty fuel will cause clinkers to form in the repot. A clinker is formed when dirt, ash or a non-burnable substance is heated to 2000°F (109°C) and becomes glass-like. See “C” in this section for more details on fuels with high ash content.

Figure 30.1 - Clinker

2. Cleaning Firepot with Cleaning Rod & Firepot Scraper

• Frequency: Daily or more often as needed

• By: Homeowner

• Task:

a. The appliance must be in complete shutdown and cool

and the exhaust blower off. If you are just cleaning the repot, there is no need to unplug the appliance.

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

to help shake debris loose. If rod is hard to pull, it may be necessary to use your repot scraper to chip away material that has built up on the bottom plate of the repot and to push out any clinkers. Larger clinkers may have to be removed from the top of the repot. Corn clinkers can be especially difcult to break up.

c. The repot oor plate must be fully closed when

nished.

3. Cleaning Ash Pan

• Frequency: As needed

• By: Homeowner

• Task:

Locate the ash pan underneath the repot and using a

slight pull up and out remove the ash pan. Empty into a non-combustible container and re-install ash pan.

See Disposal of Ashes on page 31.

4. Ash Removal from Firebox

• Frequency: Weekly or as needed

• By: Homeowner

• Task:

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

cleaning so allow the appliance to completely cool. Frequent cleaning of the ash in the 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 immediatley shut it off to start the exhaust blower on its cycle time. It will pull y ash out the exhaust instead of into the room.

c. Open door. Remove ash with an ash vacuum or whisk

broom and small dust pan.

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

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

See Disposal of Ashes on page 31.

Page 0

WARNING

Fire Risk.

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

7014-083C

WARNING

Disposal of Ashes

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

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

October 26, 2006

CB1200-I Pellet Insert

6. Disposal of Ashes

• Frequency: As needed

• By: Homeowner

• Task:

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

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 Heat Exchanger Chambers

• Frequency: Weekly or as needed

• By: Homeowner

• Task:

The amount of ash buildup in the repot 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 y ash out the exhaust instead of into the room.

b. To access the cleaning rods lift the hopper lid. Both

black bent handle pull rods are located close to the face of the appliance to the left and right side.

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

approximately 20 inches (508mm). Slide the rods OUT and IN a couple of times.

8. Cleaning Beneath Heat Exchanger

• Frequency: Monthly or after burning 1 ton of fuel

• By: Homeowner

• Task:

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 bafe. This will require removing the bafe. Please refer to page 34 for instruc- tions on removing the bafes.

9. Cleaning Exhaust Path

• Frequency: Yearly or as needed

• By: Homeowner

• Task:

a. Appliance must be completely cool before cleaning

glass.

b. Open the hinged access door on the left of the

insert.

c. Reach in and unlatch the trap door that is connected

to the rear of exhaust blower.

d. Use a small vacuum hose attachment to clean

area.

e. Re-latch and close trap door.

NOTE:

There are heavy duty vacuum cleaners specically

designed for solid fuel appliance cleaning.

10. Cleaning the Glass

• Frequency: As needed

• By: Homeowner

• Task:

a. Appliance must be completely cool before cleaning

glass.

b. Use a damp paper towel or any nonabrasive glass

cleaner. Wipe off with dry towel.

CAUTION

Handle glass assembly with care.

When cleaning glass:

• Avoid striking, scratching or slamming glass.

• Do NOT use abrasive cleaners.

• Use a hard water deposit glass cleaner on white lm.

• Refer to maintenance instructions.

• Do NOT clean glass when hot.

October 26, 2006

• Do NOT operate with glass cracked, broken or scratched.

7014-083C

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.

Page 1

CB1200-I Pellet Insert

11. Door Latch Inspection

• Frequency: Periodically

• By: Homeowner

• Task:

To adjust, open the latch and pivot the holding rod out. Loosen the jam nut on the rod. With a Phillips head screw driver, turn the rod clockwise to tighten. The latch handle should snap securely in place when adjusted properly. After adjusting the latch, be sure to tighten the jam nut on the rod to hold the adjustment.

12. Door Gasket Inspection

• Frequency: Periodically

• By: Homeowner

• Task:

To inspect the door rope (gasket), open the door and see that the door rope extends approximately 1/8" (mm) to /16" (9.5mm) from the door rope channel. It should show signs of compaction all the way around the door where the rope contacts the face of the insert. Conrm there are no air leaks.

13. Cleaning the Hopper

• Frequency: Monthly or after burning 1 ton of fuel

• By: Homeowner

• Task:

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 repot. This can result in nuisance shutdowns and mis-starts.

a. The appliance must be in complete shutdown. Allow

the appliance to completely cool down.

b Empty the hopper of any remaining pellets.

c. Vacuum the hopper and feed tube.

14. Cleaning Exhaust Blower - Requires No Lubrication

• Frequency: Yearly or as needed

• By: Quality Service Technician/Homeowner

• Task:: Contact your local dealer.

15. Cleaning Convection Blower - Requires No Lubrication

• Frequency: Yearly or as needed

• By: Qualied Service Technician

• Task: Contact your local dealer.

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

• Frequency: Yearly or as needed

• By: Qualied Service Technician/Homeowner

• Task:

The products of combustion will contain small particles of y ash. The y ash will collect in the exhaust venting system and restrict the ow of the 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 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.

C. High Ash Fuel Content Maintenance

• Frequency: As needed

• By: Homeowner

• Task:

Poor quality pellet fuel, or lack of maintenance, can create conditions that make the repot ll quickly with ashes and clinkers. This condition makes the appliance susceptible to overlling the repot with pellets which may result in smoking, sooting and possible hopper res. Figure 33.1 shows an example where the repot overlls, pellets back up into the feed tube and ash has accumulated in the rebox. On page  Figure 33.2 illustrates an inefcient and non-economical method of burning of fuel caused by poor quality pellet fuel. Figure 33.3 is showing the correct ame size when good quality, premium pellet fuel is burned.

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

IMMEDIATE ATTENTION AND CLEANING IS REQUIRED.

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

• Shut down the unit by turning down the thermostat and allow unit to completely cool down. (Do not unplug the unit, it can cause smoke spillage in the room).

• Pull the heat exchanger cleaning rods. Section

10.7

• Empty the repot. Section 10.2

• Clean the rebox. Section 10.4

• Empty the ash pan Section 10.3

• Dispose of the ashes. Section 10.6

• Restart the appliance with premium grade fuel.

Page 2

7014-083C

October 26, 2006

Ash Build Up in Firebox

Pellets Back Up In Feed Tube

Firepot Overfills

Tall, Lazy Flame, Orange in Color

Incorrect

Correct Flame Size, Yellow/White in Color

Correct

Figure 33.1

Igniter

Igniter Bracket

Thumb Screw

Fire Risk.

WARNING

• High ash fuels, or lack of maintenance, can cause the ﬁrepot to ﬁll with ash and clinker. If the ﬁrepot ﬁlls to the top, immediately shut down the unit and clean.

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

Figure 33.2

CB1200-I Pellet Insert

D. Igniter Replacement

Figure 33.4

a. Shut down the appliance by turning down the thermostat

and let the appliance completely cool down. After the appliance has cooled down, unplug it and remove the ash pan.

b. The wire leads to the igniter are connected to the wire

harness with 1/4 inch male / female spade connectors. These wires will pull forward approximately 4 to 5 inches (102mm to 127mm). Disconnect the spade connections and remove the igniter from the chamber. Loosen the thumb screw and slide igniter out.

c. Install new igniter into the chamber and tighten the

thumb screw. Re-connect the wires to the 2 leads with the spade connectors.

d. Push excess wire leads to take-up the 4 to 5 inches

(102mm to 107mm) previously pulled out. This will keep the wires out of the way of the ash pan. Double check that the igniter wires are clear of any movement, i.e. ash pan, repot cleaning rod, etc.

f. Re-install the ash pan and re-connect the power.

Figure 33.3

October 26, 2006

7014-083C

Page 

CB1200-I Pellet Insert

Top & Bottom Frame

Door Latch

Side Frame

Center Posts

Glass

Remove Door Latch First

and then Side Frame

Door Frame shown with no Glass or Glass Frames

Remove 5 nuts from Bottom Frame

Top & Bottom Frame

Door Latch

Side Frame

Center Posts

Glass

Remove Door Latch First

and then Side Frame

Door Frame shown with no Glass or Glass Frames

Remove 5 nuts from Bottom Frame

E. 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

Remove door from appliance and place face down on

•

a protected surface to avoid scratching the door.

Remove all door rope.

•

Replacing Center Glass

NOTE: DO NOT LET Air Wash Spacers fall down from

top frame when removing and replacing center glass.

1. Using a nut driver remove the (5) bottom nuts and

remove the bottom glass frame. Figure 34.2.

2. Slightly bend up and out of the way the 2 center posts and slide the glass out the bottom.

. Slide new glass in, reposition the 2 center posts and

re-install bottom glass frame.

4. Re-rope the door.

Figure 34.1

Replacing Side Glass NOTE: When removing the side glass with the door

latch, you must remove the door latch rst

before removing the side frame. Use a powered Phillips head screw driver to remove the 4 screws.

1. Remove side glass frame.

2. Loosen the top and bottom frame and slightly bend up and out of the way.

. Slide glass out the side and slide new glass in.

4. Re-install the side glass frame and tighten the top and bottom frames.

5. Re-install the door latch, if applicable, and re-rope the door.

Figure 34.2

F. Bafe Removal

1. Allow appliance to cool completely.

2. Open glass door.

. Grab the bottom of the bafes and pull up to dislodge

from hook attachment.

4. Use a standard screw driver to unlatch the covers beneath the bafes of each side.

5. Re-install in reverse order.

Page 4

7014-083C

October 26, 2006

Reference Materials

CB1200-I Pellet Insert

A. Component Function

1. Control Box

a. The control box is located on right side of appliance,

behind the right side panel.

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 200oF (9°C) in the repot. and will turn red when it reaches 600oF (15°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 1 blink every 10 seconds for 60 seconds and then will stop.

NOTE:

Do NOT open the control box. This will void the warranty. If you need to plug in or remove the control box you must 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 heated air through the heat exchange system into the room.

3. Exhaust Blower

The exhaust blower is mounted on the left side of the appliance behind the left side panel. It is accessible either when the insert is pulled out onto the hearth or from both hinged side openings. 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 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 repot.

5. Firepot

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

6. Fuse

The fuse is located on the right side of the appliance behind the side panel. The fuse will blow should a short occur and shut off power to the appliance.

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

7. Heat Exchangers

The heat exchangers transfer heat from the exhaust system into convection air. There are 2 clean out rods located under the heat exchangers.

8. Heat Output Switch

The heat output switch is located on the right side of rebox, behind right side panel. The function of the heat output switch is to regulate the burn rates; low, medium and high settings.

9. Igniter

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

10. Junction Box And Wiring Harness

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

11. Power Supply

The power outlet is located on the right side of the appliance. Check the wall receptacle for 120 volt, 60 Hz (standard current). Make sure the outlet is grounded and has the correct polarity. A good surge protector is recommended. When operating with a generator you need at least 600 watts of power, or with an inverter at least 800 watts of power, available for the appliance during the start cycle.

12. Red Call Light

The red call light is on the right side behind the right side panel. The function of the red call light is to indicate that the thermostat is calling for heat.

13. Reset Button

The reset button is located on the right side of firebox behind right side panel. The function of the reset button is to momentarily open the thermostat circuit, which restarts the system.

14. Thermocouple

The thermocouple is located on top of the 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 have been obtained.

15. Thermostat

The appliance is designed to run on a 12 volt AC thermostat. The heat anticipator, if present, should be set on the lowest setting available.

October 26, 2006

7014-083C

Page 5

CB1200-I Pellet Insert

5678

BURN R ATE

LIGHT

P.B.

ORANGE

PURPLE

BLUE

VAC.

SWITCH

T/C

RED

BLACK

ACCY

JUMPER

4 5 6

AUG.

CAP.

ORANGE

CONV. BLOWER

BLK

WHITE

BLK

POWER IN (BLK)

BLK

RED

YELLOW

PURPLE

ORANGE

RED

BLUE

GRAY

WHITE

BLACK

HI-TEMP

T.C .

FUSE

YELLOW

NEUTRAL IN (WHT)

NEUTRAL AUGER (WHT)

NEUTRAL CONV (WHT)

NEUTRAL COMB (WHT)

NEUTRAL IGN (HT)

IGNITER (HT)

AUGER MOTOR (RED/WHT)

AUGER MOTOR (BLK)

COMB BLOWER (BLU)

T-STAT CONN (YEL) T-STAT CONN

SNAP DISC #2 (YEL)

SNAP DISC # (GRAY)

SNAP DISC #1 (PUR)

GRAY

16. Snap Disc #1 (Convection Blower) 125°F

Snap disc #1 is located on the right side of the 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.

17.

Snap Disc #2 (Fuel Delivery Interrupt) 200°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 overre condition should occur or if the convection blower should fail to operate. If this occurs the snap disc with automatically reset itself.

18.

Snap Disc #3 (Burn Back Protector) 250°F

Snap disc # is mounted on the right side of the auger tube just below feed motor and has a reset button. To access it remove the right side panel. If the 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.

19. Vacuum Switch

The vacuum switch is located at the rear of the appliance. This switch turns the feed system on when vacuum is present in the 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 rebox door is open.

20. Wiring Harness

See Figure 36.1 below

Figure 36.1

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CB1200-I Pellet Insert

Terminal Block

Center 2 Screws for

Thermostat Wires

Power Outlet

Heat Output

Switch

Reset Button

Red Call Light

Fuse

Control Box

Blue Blinking Light

Red/ Green

Light

6

Exhaust

Blower

Convection

Blower

Exhaust Transition Assembly

B. Component Locations

Figure 37.1

Beginning Manufacture Date: April 8, 1999

Figure 37.4 - Door, Face, Glass, & Latch Assembly

Nbr Description Part Number

11 Door Frame MBK: 410-600

Gold: 410-550 Nickel: 510-550

12 Glass Assembly, Center 510-5400

13 Glass Assembly, Sides 510-5410

1 Glass Frame Post 410-6240 2 Glass Frame Side 410-4740

14 Door Latch Bracket 410-4912

3 Glass Frame Spacer 410-6250 4 Glass Frame, Top & Bottom 410-4730 5 Hinge, Female 450-2910

Figure 37.2

C. Exploded Views

October 26, 2006

Figure 37.3 - Firepot Assembly

Glass Size Center: 13-7/8” wide x 11” high Glass Size Sides: 5-1/8” wide x 11” high

Nbr Description Part Number

40 Firepot Pull Rod (Linkage) 812-4140

42 Igniter Bracket Not Replaceable

7014-083C

7 Thumb Screw 7000-22 43 Igniter (Heating Element) 7000-226 41 Firepot, EZ Clean 812-51 39 Thermocouple Holder 812-171

8 Thermocouple 812-0210

Thermocouple Cover 812-122

6

Page 7

CB1200-I Pellet Insert

2

2

6

Beg. Manufacture Date: July, 2005

Figure 38.1

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CB1200-I Pellet Insert

D. Service Parts and Accessories

IMPORTANT: This is dated information. The most current information is located on the quadra-re web site at

www.Quadrare.Com. When ordering, supply serial and model numbers to ensure correct part.

SCHEMATIC LIST

Nbr Description

11 Door Frame (Black, Gold or Nickel)

12 Glass, Center

13 Glass, Side 14 Door Latch 15 Grille, Louver, Top (Black, Gold or Nickel)

16 Ashpan Door (Panel, Front Access)

17 Ashpan 18 Ash Catcher (Ash Lip) 19 Heat Exchanger Tubes

20 Power Outlet & Thermostat Block

21 Curtain, Side, Right

22 Latch, Draw ()

Heat Shield Extension, Top

2

24 Junction Box

25 Control Box

26 Vacuum Switch

27 Hopper, Top

Nbr Description

28 Feed Motor Cover

29 Feed Motor & Spring Assembly

30 Heat Exchanger Cleaning Rods

31 Blower, Convection

Exhaust Adapter Assembly

2

33 Exhaust Transition Assembly

34 Blower, Exhaust

35 Curtain, Side, Left

Thermocouple Cover

6

37 Gasket, Blower, Exhaust

38 Mount, Door Hinget

39 Thermocouple Holder

40 Firepot Pull Rod Assembly

41 Firepot, EZ Clean

42 Igniter Bracket

43 Igniter (Heating Element)

SERVICE PARTS

Item # Part Descsription, Alphabetical Order SKU

18 Ash Catcher (Ash Lip) 410-7830 17 Ash Pan 812-410

16 Ash Pan Door (Panel, Access Front) 410-7900

Bafe, Left 812-4200

Bafe, Right 812-4210

31 Blower, Convection 812-4900 34 Blower, Exhaust 812-81

Component Pack (Includes repot scrapper, touch-up paint, power cord & wiring harness to the thermostat and manual, owner’s manual, label “Caution Fireplace Altered” warranty card, consumer’s view card and “How-To-Operate” DVD)

26 Control Box SRV7000-205

28 Cover, Feed Motor, Top 410-7920 35 Curtain, Side, Left 812-410

21 Curtain, Side, Right 812-420 14 Door Latch Bracket 410-4912

Exhaust Plenum Clean-Out Plate 410-7910 Exhaust Adapter Assembly 510-5330

2 33 Exhaust Transition Assembly 510-5340

Feed Motor 812-4421

29 Feed Motor Capacitor Jumper 20-2150

812-40

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CB1200-I Pellet Insert

Item # Part Descsription, Alphabetical Order SKU

Feed Spring Only 812-600

Firepot Bolt, 1-1/4” long 225-0120

Firepot Floor (Slide Plate) 414-0290

Firepot Nut, 1/4-20 226-0090

40 Firepot Pull Rod Assembly (Linkage) 812-4140 41 Firepot, EZ Clean 812-51

Fuse .7 amp, Junction Box 812-080

Gasket (Rope), Door 842-250

Gasket, 1200 ft per roll, /8”

Gasket, 500 ft per roll, 1/2” 240-0940

37 Gasket, Blower, Exhaust 240-0812

Gasket, Exhaust Blower (Round White) between blower & housing 812-4710 Gasket, Firepot 510-0530

Gasket, Flue Flange 240-0850

Gasket, Tadpole, 10 ft 842-510

12 Glass Assembly, Center 510-5400 13 Glass Assembly, Side, 1 pc 510-5410

Grille, Bar Bottom 410-8330

2

Heat Sheld Extension, Top 410-7860

Hinge, Hopper Lid 200-2200

27 Hopper Top 410-7960

Igniter Wire (5 ft) & 4 Ceramic Nuts 812-4520

43 Igniter, Loop (Heating Element) 7000-226

24 Junction Box & Wire Harness SRV7000-155

Knob, Firepot Pull Rod 200-081

22 Latch, Draw 229-0640

Latch, Magnet 229-061

38 Mount, Door Hinge 410-7290

Mount, Feed Motor 410-7172

Mount, Hopper Lid Support, Left 410-8200 Mount, Hopper Lid Support, Right 410-7410

Mount, hopper Lid Support, Top 410-7560 Outside Air Collar Assembly 7001-045 Outside Air Termination Cap 7001-044

Power Cord 812-1180

Snap Disc, #1, Convection Blower, 125 degree 20-0470

Snap Disc, #2, 200 degree 20-0900

Snap Disc, #, Manual Reset, 250 degree 20-1290

Thermocouple 812-0210

42 Thermocouple Bracket Not Replaceable

6

Thermocouple Cover 812-122

Thermocouple Holder 812-171

Thumb Screw 7000-22

26 Vacuum Switch 7000-166

240-0880

Page 40

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CB1200-I Pellet Insert

Item No. Accessories Part No.

Door Assembly, Black DR-CB12-MBK

Door Assembly, Gold DR-CB12-GD

Door Assembly, Nickle DR-CB12-NL Floor Protector 811-0730

Grille, Louver, Black LVGRL-CB12-MBK

Grille, Louver, Gold LVGRL-CB12-GD

Grille, Louver, Nickel LVGRL-CB12-NL

Log Set,  pieces Outside Air Kit 811-0700

Panel & Trim Set, Small, 0” h x 40” w, Gold SP-CB12I040-GD

Panel & Trim Set, Small, 0” h x 40” w, Nickel SP-CB12I040-NL

Panel & Trim Set, Large, ” h x 50” w, Gold SP-CB12I50-GD

Rear Shroud Kit 811-0680

Rear Top Vent Kit 811-0690

Top Vent Kit, Rear Shroud 811-0650

Top Vent Adapter,  inch

Top Vent Adapter, 4 inch 811-0670

Thermostat, Mechanical 812-760

Thermostat, Programmable #9600 811-0520

Vent Adapter,  inch to 4 inch Zero Clearance Adjustable Trim Support, 2 inch to 10 inch 841-1000

811-0592

811-0660

811-0720

Appliance Part No.

CB1200-I Insert, No Door or Grille (order door & grille separately) CB1200I-B

October 26, 2006

7014-083C

Page 41

CB1200-I Pellet Insert

E. Service And Maintenance Log

Date of Service Performed By Description of Service

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CB1200-I Pellet Insert

Lifetime Warranty

F. Warranty Policy

LIMITED LIFETIME WARRANTY

The Hearth & Home Technologies limited Lifetime Warranty guarantees that the following components will work as designed for the lifetime of the stove or Hearth & Home Technologies will repair or replace them. These items include but are not limited to steel and cast iron components, all gas burners, gas logs, combustion chambers, heat exchanger systems, stainless steel rebox components, plating, doors, glass damaged by thermal breakage, steel bafe supports, steel and ceramic bafes and manifold tubes. Labor is for the rst ve years.

THREE YEAR WARRANTY

Our pellet repots are covered under Hearth & Home Technologies three-year warranty program. Labor is for  years.

TWO YEAR WARRANTY

All electrical components such as but not limited to blowers, wiring, vacuum switches, speed controls, control boxes, thermodisc switches, pilot assembly, gas valves, thermostats and remotes are covered under Hearth & Home Technologies two-year warranty program. Effective April, 2005 igniters are also covered under the two year warranty. Labor is for two years.

ONE YEAR WARRANTY

Porcelain and Powder Coat nishes are warranted against manufacturer defects for one year. Labor to repair or replace these parts is covered for one year, reimbursed per our warranty service fee schedule.

CONDITIONS

This warranty is non-transferable and is made to the original retail purchaser only provided that the purchase was made through an authorized dealer of Hearth & Home Technologies. It must be installed and operated at all times in accordance with the Installation and Operating Instructions furnished with this product, as well as any applicable local and national codes. Any alteration, willful abuse, accident, or misuse of the product shall nullify this warranty.

Labor to repair or replace items covered under the limited Lifetime Warranty will be covered for the rst ve years per our warranty service fee reimbursement schedule. Parts covered under the limited Lifetime Warranty will be covered for the lifetime of the appliance up to a maximum of ten (10) years after Hearth & Home Technologies discontinues the model and two (2) years for optional accessories. Adjustments, regular maintenance, cleaning and temporary repairs do not qualify for a service call fee and will not be covered. The replacement of consumer replaceable items and installation of upgraded component parts do not quality for a service call fee, and will not be covered.

This limited Lifetime Warranty does not extend to or include surface nish on the appliance, door gasketing, glass gasketing, glass, rebrick, pellet logs, kaowool or other ceramic insulating materials. It does not cover installation or operational-related problems such as overring, use of corrosive driftwood, downdrafts or spillage caused by environmental conditions, nearby trees, buildings, hilltops, mountains, inadequate venting or ventilation, excessive offsets, or negative air pressures caused by mechanical systems such as furnaces, fans, clothes dryers, etc.

Any installation, construction, transportation, or other related costs or expenses arising from defective part(s), repair, replacement, etc., will not be covered by this warranty, nor will Hearth & Home Technologies assume responsibility for them. Further, Hearth & Home Technologies will not be responsible for any incidental, indirect, or consequential damages, except as results in damage to the interior or exterior of the building in which this appliance is installed. This limited Lifetime Warranty does not apply to the venting components, hearth components or other accessories used in conjunction with the installation of this product not manufactured by Hearth & Home Technologies

This warranty is void if the stove has been overred or operated in atmospheres contaminated by chlorine, uorine, or other damaging chemicals, the stove is subjected to prolonged periods of dampness or condensation, or there is any damage to the stove or other components due to water or weather damage which is the result of, but not limited to, improper chimney or venting installation. Hearth & Home Technologies may, at its discretion, fully discharge all obligations with respect to this warranty by either repairing or replacing the unit, or refunding the wholesale price of the defective part(s).

This limited Lifetime Warranty is effective on all appliances sold after May 1, 2002 and supersedes any and all warranties currently in existence.

Policy 250-8620 Rev K

October 26, 2006

7014-083C

Page 4

CONTACT INFORMATION:

Hearth & Home Technologies

1445 North Highway

Colville, WA 99114

Division of HNI INDUSTRIES

www.quadrare.com

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

For the number of your nearest Quadra-Fire dealer

please call 1-800-926-4356

CAUTION

Do NOT discard this manual.

• Important operating and maintenance instructions included.

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

• Leave this manual with party responsible for use and operation.

Your Records for Model:

CB1200-I Pellet Insert

WHERE PURCHASED:

SERIAL NUMBER: __________________

DATE PURCHASED: __________________

DATE INSTALLED: __________________

This product may be covered by one or more of the following patents: (United States) 459510, 4686807, 4766876, 47922, 481154, 5000162, 5016609, 5076254, 51184, 5191877, 521895, 526471, 52856, 541794, 54798, 5429495, 5452708, 5542407, 560107, 561487, 564740, 5688568, 5762062, 5775408, 5890485, 591661, 594127, 5947112, 5996575, 600674, 6019099, 6048195, 605165, 6145502, 6170481, 627588, 6296474, 674822, 641079, 649226, 6484712, 654698, 6550687, 6601579, 6672860, 668802B2, 6715724B2, 6729551, 6761, 6748940, 6748942, 6769426, 6774802, 679602, 6840261, 6848441, 686064, 6866205, 6869278, 6875012, 6880275, 690809, 6919884, D20652, D445174, D46246; (Canada) 1297749, 2195264, 2225408, 21972; (Australia) 780250, 78040, 1418504 or other U.S. and foreign patents pending.

_______________________________________

TELEPHONE: __________________

Page 44

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Quadra-Fire CB1200I-B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual