United States Stove Company 4840 User Manual

OWNER’S OPERATION AND INSTRUCTION MANUAL

WALL MOUNTED PELLET UNIT

MODEL

4840

PATENT PENDING

SAFETY TESTED TO ASTM 1509-04 & ULC S-627-00

CAUTION!

Read All Instructions Carefully Before

Starting The Installation or Operating This

Heater.

Improper Installation Could Void Your

Warranty!

SAVE THIS MANUAL FOR FUTURE REFERENCE

THIS MANUAL WILL HELP YOU TO OBTAIN EFFICIENT, DEPENDABLE SERVICE FROM THE HEATER, AND

ENABLE YOU TO ORDER REPAIR PARTS CORRECTLY. KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

NOT RECOMMENDED AS PRIMARY HEAT SOURCE

UNITED STATES STOVE COMPANY

227 Industrial Park Road

P.O. Box 151

South Pittsburg, TN 37380

If this heater is not properly installed, a house ﬁ re may result. For your safety, follow the installation instructions. Contact your local building or ﬁ re ofﬁ cials about obtaining a permit, restrictions and installation

SAFETY NOTICE:

requirements in your area.

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852078B

SAFETY PRECAUTIONS

 IMPORTANT: Read this entire manual before installing and

operating this product. Failure to do so may result in property damage, bodily injury, or even death. Proper installation of this heater is crucial for safe and efﬁ cient operation. Never use make-shift compromises during the installation.

 Before installing your heater, you must perform an initial burn

in an OUTSIDE environment. Follow the Start-Up Procedure in the Operation section of this manual.

 This heater must be installed on an exterior wall to the outside.  Contact your local building ofﬁ cials to obtain a permit and

information on any additional installation restrictions or inspection requirements in your area.

 Save these instructions.. This manual has important operating

and maintenance instructions that you will need at a later time. Always follow the instructions in this manual.

 This heater is designed and approved for premium hardwood

pellet fuel only. Any other type of fuel burned in this heater will void the warranty and safety listing.

 Never use gasoline, gasoline-type lantern fuel, kerosene,

charcoal lighter ﬂ uid, or similar ﬂ ammable liquids to start or “freshen up” a ﬁ re in this heater. Keep all such liquids well away from the heater while it is in use.

 A working smoke detector must be installed in the same room

as this product.

 Do not unplug the heater if you suspect a malfunction. Turn

the ON/OFF SWITCH to ”OFF’ and contact your dealer.

 Do not operate your heater with the viewing or combustion

door open. The auger will not feed pellets under these circumstances and a safety concern may arise from sparks or fumes entering the room.

 Never disable or bypass the safety devices in this unit. Doing

so could result in damage to the unit or endanger yourself or someone else.

 Your heater requires periodic maintenance and cleaning (see

”MAINTENANCE ”). Failure to maintain your heater may lead to improper and/or unsafe operation.

 Never try to repair or replace any part of the heater unless

instructions for doing so are given in this manual. All other work should be done by a trained technician.

 Turn the heater OFF and allow to completely cool before

performing any maintenance.

 Disconnect the power cord before performing any

maintenance! NOTE: Turning the ON/OFF Switch to ”OFF” does not disconnect all power to the electrical components of the heater.

 Ashes must be disposed in a metal container with a tight

ﬁ tting lid. The closed container of ashes should be placed on a non-combustible surface or on the ground, well away from all combustible materials, pending ﬁ nal disposal.

 The exhaust system should be checked bi- monthly during the

burning season for any build-up of ﬂ yash, soot or creosote.

 HOT WHILE IN OPERATION. KEEP CHILDREN

CLOTHING AND FURNITURE AWAY. CONTACT MAY CAUSE SKIN BURNS. Do not touch the hot surfaces of

the heater. Educate all children on the dangers of a hightemperature heater. Young children should be supervised when they are in the same room as the heater.

 A power surge protector is required. This unit must be

plugged into a 110 - 120V, 60 Hz grounded electrical outlet. Do not use an adapter plug or sever the grounding plug. Do not route the electrical cord over the heater. Do not route the cord in foot trafﬁ c areas or pinch the cord under furniture.

 The heater will not operate during a power outage. If a power

outage does occur, check the heater for smoke spillage and open a window if any smoke spills into the room.

 Never block free airﬂ ow through the open vents of the unit.  Keep foreign objects out of the hopper.  The moving parts of this heater are propelled by high torque

electric motors. Keep all body parts away from the auger while the heater is plugged into an electrical outlet. These moving parts may begin to move at any time while the heater is plugged in.

 Do not place clothing or other ﬂ ammable items on or near

this heater.

 WARNING—DO NOT INSTALL THIS UNIT IN A

SLEEPING ROOM. CAUTION—The structural integrity of the mobile home floor, wall, and ceiling/roof must be maintained.

 This appliance is not intended for commercial use.  DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST

VENTING SYSTEM OF THIS UNIT.

 DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE

SERVING ANOTHER APPLIANCE.

 DO NOT USE CHEMICALS OR FLUIDS TO START THE

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

 DO NOT CONNECT TO OR USE IN CONJUNCTION

WITH ANY AIR DISTRIBUTION DUCTWORK UNLESS SPECIFICALLY APPROVED FOR SUCH INSTALLATIONS.

 The chimney connector shall not pass through an attic or roof

space, closet or similar concealed space, or a ﬂ oor, or ceiling. Where passage through a wall, or partition of combustible construction is desired, the installation shall conform to CANICSA-B365, Installation Code for Solid-Fuel-Burning Appliances and Equipment.

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SPECIFICATIONS

HEATING SPECIFICATIONS

Heat Output

Heating Capacity

Fuel Burn Rate

Burn Time (lowest setting) 35 hours

Hopper Capacity 28lbs

16,400 BTU/hr.

500 - 1,000 sq. ft.

3/4 - 2 1/2 lbs./hr.

BTU output will vary depending on the quality of fuel. Use PFI listed

fuels for the best results.

Heating capacity will vary depending on ﬂ oor plan layout of your

home, degree of insulation, and the outside temperature.

Pellet size may effect the actual rate of fuel feed and burn times. Fuel

feed rates may vary by as much as 20%. Use PFI listed fuel for best results.

DIMENSIONS

Height 27” [685.7 mm]

Width 36” [914.4 mm]

Depth of Unit 12.43” [315.77 mm]

Depth with Mounting Wall Bracket Approx. 14.27”

[362.4 mm]

Product Weight 185 lbs

1.84 [46.7] APPROX.

12.43 [315.7]

35.87 [911]

16.92

APPROX.

TOP VIEW

36.00 [914.4]

22.50 [571.5]

4.50 [114.2]

SIDE VIEW

22.25 [565.2]

FRONT VIEW

INTAKE/EXHAUST APPROXIMATE LOCATION DIMENSIONS

Back Side Left Edge to Center 29.34” [745.1 mm]

Back Side Top Edge to Center 10.97” [278.7 mm]

Diameter of Intake\Exhaust 5.25” [133.35 mm]

Diameter of Cut Out in Exterior Wall Refer for to Template

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ELECTRICAL SPECIFICATIONS

Electrical Rating 110-120 volt, 60Hz, 3.0Amp

Watts (operational) 175 approximately

Watts (igniter running) 425 approximately

FUEL CONSIDERATIONS

Your Pellet heater is designed to burn certified Premium Hardwood pellets that comply with Association of Pellet Fuel Industries standards. Pellets that are soft, contain excessive amounts of loose sawdust, have been, or are wet, will result in reduced performance. Failure to use proper fuel can affect the longevity of the appliance. Smaller pellets could affect feed rates. Store your pellets in a dry area and well away from the heater.

Do not use grates or other methods of supporting the fuel. Burn fuel in burnpot without modiﬁ cation.

Pellet Fuel Institute (PFI) Premium Standards

Min. Density 40 lbs. per cubic ft.

Size ¼” to 5/16” diameter, length

no greater than 1½”

Heat Output 8,200 BTU/lb

Moisture Content

Ash Content 1% by weight

Salt Content 300 parts per million or less

8% by weight or less

SAFETY AND COMPLIANCE

Your Pellet heater has been safety tested and listed to ASTM E 1509-04, UM-84 and ULC S627-00, by Intertek Testing Services in Portland, Oregon, USA.

MOBILE HOME INSTALLATION REQUIREMENTS

 WARNING!  DO NOT INSTALL IN A SLEEPING ROOM  CAUTION!  THE STRUCTURAL INTEGRITY OF THE MOBILE HOME FLOOR, WALL, AND CEILING/ROOF MUST

BE MAINTAINED.

• The heater must be permanently attached to the wall.

• The heater must be electrically grounded to the steel chassis of the mobile home with 8 GA copper wire using a serrated

or star washer to penetrate paint or protective coating to ensure grounding.

• When moving your mobile home, the heater must be removed while the mobile home is being relocated. After relocation,

heater may be reinstalled and securely fastened.

• Check with your local building ofﬁ cials as other codes may apply.

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STANDARD INSTALLATION

[152]

39.

2 [51]

87 [91012]

2 [51]

Floor Protector

6” [152mm]

18”

[457mm]

60”

[1.5M]

Floor Protector

Back Wall

J E F

# B D L

M M

Ceiling

 Read this entire manual before you install and use your pellet heater. Failure to follow instructions may result in property damage,

bodily injury, or even death!

 Before installing your heater, you must perform an initial burn in an OUTSIDE environment. Follow the Start-Up Procedure in

the Operation section of this manual.

Your pellet heater may be installed to code in either a conventional or mobile home (see SPECIAL MOBILE HOME REQUIREMENTS). It is recommended that only a authorized technician install your heater, preferably a National Fireplace Institute (NFI) certiﬁ ed specialist. This heater must be installed on an exterior wall to allow exhaust venting to meet the minimum required clearances. Once the desired location is selected, and before cutting a hole, check the outside of the structure for anything obstructing clearances to the exhaust vent. Also clear away leaves, shrubs/bushes, or trees that may be around the exhaust outlet.

Required Tools for installation:

1. Venting Kit

2. Power Drill

3. 7/32” drill bit to drill pilot holes

4. Wrench / Socket.

FLOOR PROTECTION

This heater must have a non-combustible floor protector (ember protection) installed beneath it if the ﬂ oor is of combustible material. If a ﬂ oor pad is used, it should be UL listed or equal. The ﬂ oor pad or non-combustible surface should be large enough to extend a minimum of 6-inches [152mm] in front and 2-inches [51mm] on each side of the heater.

Canadian Installations require a minimum of 450 mm [18”] beyond the front of the unit and 200mm [8”] beyond each side of the unit

A Floor Protector of 1/4 inch thick is recommended for this installation

5. Hammer

6. Knife

7. Pen

8. Noncombustible ﬂ oor protector

CLEARANCES TO COMBUSTIBLES

Combustible Clearance

Floor (Allow for brace) 8 inches [203mm]

Vent must meat minimum ground clearances

Left / Right 6 inches [152mm]

Ceiling (Allow for fuel loading)

Mantle / Sill 11 inches [279mm]

Front 60 inches [1.5M]

• Do not install heater where the exhaust will terminate in a window well or any opening below ground level.

• Special precautions may be required to prevent snow build-up within 12 inches of the air intake.

• Clearances around heater must provide adequate room for service, cleaning, and air circulation.

• Residential Garage Installation: The heater shall be located or protected so it is not subject to damage by a moving

vehicle. Use care when selecting a good location within the garage. DO NOT locate the heater where the discharge air will be directed onto a nearby parked vehicle. DO NOT store containers of paint, gasoline, or other ﬂ ammable liquids in the same area as the heater, inside or outside the home or structure.

General Installation Notes

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18 inches [457mm]

WALL INSTALLATION

• Select a wall to the exterior of the building. This wall should have the required clearance to combustibles inside and out as mentioned in this manual. Make certain that electrical wires, conduit, water or gas pipes do not pass through the area you have selected.

STEP: 1 MOUNT THE WALL PLATE

Note: Any material covering the wall (such as sheetrock) must not exceed 5/8” 16 mm).

Option 1: Mounting on a wood-stud wall

1. Locate the studs in exterior wall. Verify the center of the stud with an edge-to-edge stud ﬁ nder. Mark center point at predetermined height.

5/8”

[16mm]

2. At the wall height you determined in the previous step, place a small nail thru center triangle hole of bracket and align the wall mount against the wall. Level bracket and verify that pilot holes are centered on studs. Use a pencil to mark the screw hole locations, and intake/ exhaust thru hole then remove the wall plate.

3. Drill pilot holes to a depth of 3” (75 mm) using a 7/32” (5.5 mm) diameter drill bit.

4. Carefully cut intake/exhaust thru hole in exterior wall thru to the outside. (SEE VENT CLEARANCES SECTION TO INSURE PROPER INSTALLATION)

5. Realign the wall mount with the pilot holes and intake/exhaust thru hole. Insert 1/4” x 2” lag bolts with washers, and tighten the lag bolts until the washers are pulled ﬁ rmly against the wall mount and the wall mount is pulled ﬁ rmly against the exterior wall.

16”

[406mm]

[75mm]

3”

WARNING: AVOID POTENTIAL INJURIES OR PROPERTY DAMAGE! DO NOT OVER-

TIGHTEN THE LAG BOLTS.

Option 2: Mounting on a solid concrete or concrete block wall

1. Level the wall plate and mark the hole locations.

2. At the wall height you determined in the previous step, place a small nail thru center triangle hole of bracket and align the wall mount against the wall. Level bracket and verify that pilot holes are not located in the mortar of the cinder blocks. Use a pencil to mark the pilot hole locations, and intake/exhaust thru hole then remove the wall plate.

3. Drill pilot holes to a depth of 3” (75 mm) using a 1/2 in. (12.7 mm) diameter masonry drill bit.

4. Carefully cut intake/exhaust thru hole in exterior wall thru to the outside. (SEE VENT CLEARANCES SECTION TO INSURE PROPER INSTALLATION)

5. Insert 1/4” concrete wall anchors into the pilot holes and make sure that the anchors are seated ﬂ ush with the concrete surface.

6. Align the wall plate with the anchors. Place washers over the screw holes in the wall plate, insert 1/4” x 2” lag bolts through the washers, and then tighten the lag bolts until the washers are pulled ﬁ rmly against the wall plate and the wall mount is pulled ﬁ rmly against the exterior wall.

STEP: 2 MOUNTING THE HEATING UNIT TO THE WALL PLATE

Note: The Heating Unit is heavy. You will need assistance with this step.

1. After mounting Wall Plate to wall. Cut hole

2. Align intake/exhaust with hole in wall and carefully insert heating unit. Tilt top towards the wall and lower the Heating Unit onto the wall plate making sure that the hooks on the top of the left and right brackets slide over the top of the wall plate. Allow the Heating Unit to pivot parallel to the wall plate and lift to allow lower hooks to engage on the bottom of the Wall Mount.

3. Insert locking brackets into the lower slots of Heating Unit back mounting brackets. Tighten ¼-20 hex head bolts to lock Heating unit onto Wall Plate.

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