R
CASTILE PELLET INSERT
Portland
Oregon USA
Tested and
Listed by
Owner’s Manual
Installation and Operation
O-T L
C
US
OMNI-Test Laboratories, Inc.
Models:
810-02901 (MBK)
810-03201 (PMH)
CASTINS-CSB
CASTINS-CWL
CAUTION
DO NOT DISCARD THIS MANUAL
• Leave this manual
with party respon-
sible for use and
operation.
• Read, understand and
follow these instruc-
tions for safe installa-
tion and operation.
• Important operating and
maintenance instruc-
tions included.
WARNING
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.
HOT SURFACES!
Glass and other surfaces are
hot during operation AND
cool down.
Hot glass will cause burns.
•
•
•
•
Do not touch glass until it is cooled
NEVER allow children to touch glass
Keep children away
CAREFULLY SUPERVISE children in same room as
fireplace.
Alert children and adults to hazards of high
temperatures.
• Do not store or use gasoline or other flam-
mable vapors and liquids in the vicinity of this
or any other appliance.
• Do not overfire - If any external part starts to
glow, you are overfiring. Reduce feed rate.
Overfiring will void your warranty.
•
High temperatures may ignite clothing or other
flammable materials.
• Comply with all minimum clearances to com-
bustibles as specified. Failure to comply may
cause house fire.
•
Keep clothing, furniture, draperies and other flammable
materials away.
CAUTION
Check building codes prior to installation.
CAUTION
•
Installation MUST comply with local, regional, state
and national codes and regulations.
Tested and approved for wood pellets and shelled
field corn fuel only. Burning of any other type of fuel
voids your warranty.
•
Consult local building, fire officials or authorities having
jurisdiction about restrictions, installation inspection,
and permits.
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Castile Pellet Insert
Safety Alert Key:
•
•
•
•
DANGER! Indicates a hazardous situation which, if not avoided will result in death or serious injury.
WARNING! Indicates a hazardous situation which, if not avoided could result in death or serious injury.
CAUTION! Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE: Indicates practices which may cause damage to the fireplace or to property.
TABLE OF CONTENTS
Section 1: Listing and Code Approvals
A. Appliance Certifications ......................4
B. Mobile Home Approved ......................4
C. Glass Specifications............................4
D. Electrical Rating..................................4
E. BTU & Efficiency Specifications..........4
Section 7: Appliance Set-Up
A. Reversible Top & Rear Flue Adapter ....18
B. Leveling System .................................18
C. Outside Air Kit.....................................19
D. Zero Clearance Trim Support .............19-20
E. Panel Set & Cast Trim ........................21
F. Panel & Trim Set Econo .....................21
G. Log Set Placement..............................22
H. Thermostat Installation........................23
Section 2: Getting Started
A. Design, Installation & Location
Considerations....................................5
B. Locating Your Appliance & Chimney..6
C. Draft....................................................6
D. Negative Pressure ..............................6
E. Fire Safety ..........................................7
F. Tools & Supplies Needed...................7
G. Inspect Appliance, Components
and Pre-Use Check List......................7
Section 8: Operating Instructions
A. Fuel Size, Material & Storage .............24
B. General Operation Information...........25
C. Before Your First Fire .........................25
D. Starting Your First Fire........................25
E. Fire Characteristics.............................25
F. Feed Rate Adjustment .......................26
G. Ignition Cycles ....................................26
H. Frequently Asked Questions...............27
Section 3: Dimensions & Clearances
A. Appliance Dimensions ........................8
B. Clearances to Combustibles
Section 9: Troubleshooting ............................28-30
As A Built-In, UL and ULC ..................9
C. Clearances to Combustibles,
Masonry & Zero Clearance.................10
D. Floor Protection ..................................10
E. Minimum Opening for Factory-
Built Fireplace .....................................10
F. Removing Floor of Factory-Built
Fireplace .............................................11
G. Prefabricated Metal Chimney..............12
H. Altering Factory-Built Fireplace...........12
Section 10: Maintaining & Servicing Appliance
A. Proper Shutdown Procedures.............31
B. Quick Reference Maintenance Chart..31
C. General Maintenance & Cleaning.......32-35
D. High Ash Content Maintenance ..........35
E. Igniter Replacement............................36
F. Glass Replacement.............................36
G. Baffle & Brick Removal .......................37-38
Section 12: Reference Material
Section 4: Vent Information
A. Component Functions.........................39-40
B. Component Locations.........................41
C. Exploded Drawing...............................42
D. Service Parts & Accessories...............43-47
E. Service & Maintenance Log................48-49
F. Warranty Policy...................................50-51
G. Contact Information.............................52
A. Chimney & Exhaust Connections........13
B. Venting Termination Requirements....13
C. Equivalent Feet of Pipe.......................14
D. Pipe Selection Chart...........................14
Section 5: Venting Systems
A. Full Reline with Outside Air-Horizontal 15
B. Full Reline with Outside Air-Vertical....16
Section 6: Mobile Home..................................17
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Castile Pellet Insert
Listing and Code Approvals
1
E. BTU & Efficiency Specifications
A. Appliance Certification
MODEL:
Castile Pellet Insert
Particulate Emis-
sions Rating:
0.7 grams/hr
LABORATORY: OMNI Test Laboratories, Inc
REPORT NO.
061-S-42-2
*BTU Output:
8,000 - 30,000 / hr
TYPE:
Solid Fuel Room Heater/Pellet Fuel
Burning Type Insert
Heating Capacity:
up to 1,500 sq. ft. depending
on climate zone
Hopper Capacity:
Fuel:
45 lbs
STANDARD:
ASTM E1509-95, ULC S628-93 and
ULC/ORD-C1482-M1990 Room
Heater Pellet Fuel Burning Type and
(UM) 84-HUD, Mobile Home Approved
Wood Pellets or Shelled Corn
260 lbs
Shipping Weight:
Colorado:
Approved 11-15-02
*BTU output will vary, depending on the brand of fuel you
use in your appliance. Consult your Quadra-Fire dealer
for best results.
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 used.
WARNING! Risk of Fire! Hearth & Home Technologies dis-
claims any responsibility for, and the warranty and agency
listing will be voided by the above actions.
The structural integrity of the mobile home floor, ceiling, and
walls must be maintained.
DO NOT:
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.
• Install or operate damaged appliance
• Modify appliance
• Install other than as instructed by Hearth & Home
Technologies
• Operate the appliance without fully assembling all
components
A Quadra-Fire Outside Air Kit must be installed in a mobile
home installation. You must order the Outside Air Kit sepa-
rately.
• Overfire
Note: The appliance is also approved for installation
• Install any component not approved by Hearth &
Home Technologies
into a shop.
• Install parts or components not Listed or approved.
Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage.
C. Glass Specifications
For assistance or additional information, consult a qualified
installer, service agency or your dealer.
This appliance is equipped with 5mm ceramic glass. Replace
glass only with 5mm ceramic glass. Please contact your
dealer for replacement glass.
NOTE: Hearth & Home Technologies, manufacturer of
this appliance, reserves the right to alter its products,
their specifications and/or price without notice.
NOTE: This installation must conform with local codes.
In the absence of local codes you must comply with the
ASTM E1509-95, ULC S628-93, ULC/ORD-C-1482-
M1990 and (UM) 84-HUD
Quadra-Fire is a registered trademark
of Hearth & Home Technologies.
D. Electrical Rating
115 VAC, 60 Hz, Start 4.1 Amps, Run 1.1 Amps
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Castile Pellet Insert
Getting Started
2
Since pellet exhaust can contain ash, soot or sparks, you
must consider the location of:
A
.
Design, Installation & Location Considerations
• Windows
1. Appliance Location
• Air Intakes
NOTICE: Check building codes prior to installation.
• Air Conditioner
•
Installation MUST comply with local, regional, state and
national codes and regulations.
• Overhang, soffits, porch roofs, adjacent walls
• Landscaping, vegetation
•
Consult insurance carrier, local building inspector, fire
officials or authorities having jurisdiction over restrictions,
installation inspection and permits.
When locating vent and venting termination, vent above
roof line when possible.
It is a good idea to plan your installation on paper, using
exact measurements for clearances and floor protection,
before actually beginning the installation
Warning! Risk of Fire Damaged parts could impair safe
operation. Do NOT install damaged, incomplete or substitute
components.
Consideration must be given to:
CAUTION! If burning shelled field corn, you must use ap-
proved venting specifically designed for corn to prevent corro-
sion or degradation. Follow the instructions from the venting
manufacturer.
• Safety, convenience, traffic flow
• Placement of the chimney and chimney connector.
• If you are not using an existing chimney, place the appli-
ance where there will be a clear passage for a factory-
built listed chimney through the ceiling and roof.
NOTICE: Locating the appliance in a location of
considerable air movement can cause intermittent smoke
spillage from appliance. Do not locate appliance near:
• Installing an optional outside air kit would affect the loca-
tion of the vent termination.
•
•
Frequently open doors
Central heat outlets or returns
Recommended Location:
• Above peak
• Inside heated space
Recommended Location:
• Above peak
Marginal Location:
Wind loading possible
•
Marginal Location:
• Below peak
Location NOT recommended:
• Not the highest point of the roof
• Wind loading possible
Location NOT recommended:
• Too close to tree
• Below adjacent structure
• Lower roof line
• Avoid outside wall
Recommended:
• Insulated exterior chase
in cooler climates
Windward
Leeward
Multi-level Roofs
Recommended:
Outside Air Intake
on windward side
NOT recommended:
Outside Air Intake
on leeward side
Figure 5.1
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Castile Pellet Insert
B. Locating Your Appliance & Chimney
D. Negative Pressure
Location of the appliance and chimney will affect
performance.
WARNING! Risk of Asphyxiation! Negative pressure can
cause spillage of combustion fumes and soot.
•
Install through the warm airspace enclosed by the building
envelope. This helps to produce more draft, especially
during lighting and die-down of the fire.
Negative pressure results from the imbalance of air avail-
able for the appliance to operate properly. It can be stron-
gest in lower levels of the house.
•
•
Penetrate the highest part of the roof. This minimizes the
effects of wind loading.
Causes include:
Locate termination cap away from trees, adjacent
structures, uneven roof lines and other obstructions.
•
•
•
Exhaust fans (kitchen, bath, etc.)
Range hoods
•
•
Minimize the use of chimney offsets.
Combustion air requirements for furnaces, water heaters
and other combustion appliances
Consider the appliance location relative to floor and ceiling
and attic joists.
•
•
•
•
Clothes dryers
Location of return-air vents to furnace or air conditioning
Imbalances of the HVAC air handling system
Upper level air leaks such as:
- Recessed lighting
CAUTION
•
•
DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE
SERVICING ANOTHER APPLIANCE.
- Attic hatch
DO NOT CONNECT TO ANY AIR DISTRIBUTON DUCT
OR SYSTEM.
- Duct leaks
To minimize the effects of negative air pressure:
•
•
•
•
Install the outside air kit with the intake facing prevailing
winds during the heating season
C. Draft
Draft is the pressure difference needed to vent appliances
successfully. When an appliance is drafting successfully, all
combustion byproducts are exiting the home through the
chimney.
Ensure adequate outdoor air for all combustion appliances
and exhaust equipment
Ensure furnace and air conditioning return vents are not
located in the immediate vicinity of the appliance
Considerations for successful draft include:
•
•
Preventing negative pressure
Avoid installing the appliance near doors, walkways or
small isolated spaces
Location of appliance and chimney
•
•
•
Recessed lighting should be a “sealed can” design
Attic hatches weather stripped or sealed
NOTICE: Hearth & Home Technologies assumes no
responsibility for the improper performance of the chimney
system caused by:
Attic mounted duct work and air handler joints and seams
taped or sealed
•
•
•
•
Inadequate draft due to environmental conditions
Downdrafts
Tight sealing construction of the structure
Mechanical exhausting devices
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Castile Pellet Insert
F. Tools And Supplies Needed
E. Fire Safety
To provide reasonable fire safety, the following should be
given serious consideration:
Tools and building supplies normally required
for installation, unless installing into an existing
masonry fireplace:
• Install at least one smoke detector on each floor of your
home.
Reciprocating Saw
Hammer
Safety Glasses
Framing Square
• Locate smoke detector away from the heating appliance
and close to the sleeping areas.
Phillips Screw driver
Tape Measure
Plumb Line
Electric Drill & Bits (1/4”)
1/4” Self-Tapping Screws
• Follow the smoke detector manufacturer’s placement and
installation instructions and maintain regularly.
Level
May also need:
Vent Support Straps
Venting Paint
• Conveniently locate a Class A fire extinguisher to contend
with small fires.
Framing Material
Hi-temp Caulking Material
Gloves
•
In the event of a hopper fire:
• Evacute the house immediately.
• Notify fire department.
G. Inspect Appliance & Components and
Pre-Use Check List
1.
2.
Place the appliance in a location near the
final installation area and follow the proce-
dures below:
WARNING
Inspect appliance and components for
damage. Damaged parts may impair safe
operation.
Open the appliance and remove all the parts
and articles packed inside the Component
Pack. Inspect all the parts and glass for ship-
ping damage. Contact your dealer if any irregu-
larities are noticed.
•
•
•
Do NOT install damaged components.
Do NOT install incomplete components.
Do NOT install substitute components.
Report damaged parts to dealer.
3.
All safety warnings have been read and fol-
lowed.
4.
5.
6.
7.
This Owner’s Manual has been read.
Floor protection requirements have been met.
Venting is properly installed.
WARNING
Fire Risk.
The proper clearances from the appliance and
chimney to combustible materials have been
met.
Hearth & Home Technologies disclaims any
responsibility for, and the warranty will be
voided by, the following actions:
8.
The masonry chimney is inspected by a profes-
sional and is clean, or the factory built metal
chimney is installed according to the manufac-
turer’s instructions and clearances.
•
•
•
Installation and use of any damaged appliance.
Modification of the appliance.
Installation other than as instructed by Hearth & Home
Technologies.
Installation and/or use of any component part not approved
by Hearth & Home Technologies.
Operating appliance without fully assembling all
components.
9.
The chimney meets the required minimum
height.
•
•
•
10.
11.
All labels have been removed from the glass
door.
Do NOT Overfire.
Plated surfaces have been wiped clean, if
applicable.
Or any such action that may cause a fire hazard.
12.
13.
14.
Thermostat or remote has been installed.
A power outlet is available nearby.
Agood quality surge protection is highly recom-
mended to protect the electronics.
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Dimensions and Clearances
3
A. Appliance Dimensions
28-1/16 in.
(713mm)
43-1/2 in.
(1105mm)
23-7/16 in.
42-1/2 in.
(595mm)
(1080mm)
8 in.
(203mm)
11-1/16 in.
(281mm)
30-3/8 in.
(772mm)
30 in.
(762mm)
32-5/16 in.
(821mm)
Figure 8.1 - Top View
Figure 8.2- Front View
Height
Width
13-1/16 in.
(332mm)
10-3/16 in.
(259mm)
Panel Size
Small Cast
Large Cast
Small Econo
inch mm inch mm
30
34
30
762 42-1/2 1078
864
762
48
40
1219
1016
24-3/16 in./
(614mm)
19.0 in.
(483mm)
NOTE: All views are shown with Panel
& Cast Trim Set installed.
24-3/4 in.
(629mm)
12-3/4 in.
(324mm)
9-3/16 in.
(234mm)
2.0 in. (51mm)
9-13/16 in.
(249mm)
Figure 8.3 -Side View
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B. Clearance To Combustibles, UL and ULC
AS A BUILT-IN
A
C
D
B
B
C
E
0” (0mm) Clearance To Exposed Section And Face Trim
Figure 9.1
Inches
Millimeters
A
Top of Hopper
Top or Rear Vent
Top or Rear Vent
Top Vent
0
0
0
0
B
C
Side of Outside Skin
Back of Hopper
2.5
0
64
0
Rear Vent
D
E
Vent Pipe to Combustible
Front Panel Edge
Top or Rear Vent
Top or Rear Vent
3.0
0
76
0
INSTALLED AS A BUILT-IN UNIT
Shown Optional Outside Air
WARNING
Fire Risk.
Comply with all minimum clearances
to combustibles as specified.
Failure to comply may cause house
fire.
12 in
(305mm)
6 in
(153mm)
NOTE:
•
Illustrations reflect typical installations
and are FOR DESIGN PURPOSES
ONLY.
•
•
Illustrations/diagrams are not drawn to
scale.
Actual installation may vary due to
individual design preference.
Outside
Air
Figure 9.2
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Castile Pellet Insert
C. Masonry and Zero Clearance Fireplaces
Inches Millimeters
A Insert side to combustible
side wall
MANTEL
0
0
B Insert top to mantel
C Insert top to face trim
D Insert side to face trim
12
0
305
0
B
C
0
0
D
A
E
F
Figure 10.1
D. Floor Protection
Inches
Millimeters
E
F
Floor protection hearth extension
from door opening
6
152
Floor protection to the side of door
opening
6
152
E. Minimum Opening for Masonry and Zero
Clearance Fireplaces
Location
Rear Width
Depth
Inches
Millimeters
A
B
23-7/16
595
18 for Zero Clearance
14 for Masonry
457
356
C
C
D
Height
19-1/4 if drop down
21-1/4 if flush or
hearth mount
489
540
B
A
D
Front Width
28-1/4
718
Figure 10.2
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F. Removing Metal Floor of Factory-Built Firebox
•
The firebrick (refractory), glass doors, screen rails, screen
mesh and log grates can be removed from a factory-built
firebox in order to gain minimum insert opening require-
ments.
Use 2 x 4 from insert
packaging to support insert
•
•
Any smoke shelves, shields and baffles may be removed
from a factory-built firebox if attached with mechanical fas-
teners.
The metal floor of the factory-built firebox may be removed
to facilitate the installation of the insert only when a 1/4
(6mm) inch airspace is provided between the insert and
the floor of outer wrap.
Figure 11.3. If the floor is made of thin metal,
we recommend using the 2 x 4 from the insert
packaging to support the insert. The 2 x 4
may need to be cut to the appropriate size.
The following is only one example as there are many dif-
ferent models of factory-built fireplaces.
Starter hole
Keep sharp edge of
metal floor away from
power cord
Mark area of
floor to cut
Figure 11.1. Measure and mark the metal
floor for cutting. With a drill, make a starter
hole in each corner.
Figure 11.4. Place the insert into the fac-
tory-built firebox. Ensure that the power
cord can not be damaged by the sharp metal
edge. You may need to cut out a notch to
accommodate the cord.
NOTE: Ensure that the leveling leg is posi-
tioned over the 2 x 4 before leveling the
insert. See page 18, for detailed instructions
on how to adjust the leveling legs.
Figure 11.2. Using a saws-all, cut out the
floor
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H. Altering the Factory-Built Fireplace
G. Prefabricated Metal Chimney
•
The fireplace must not be altered, except for the
exceptions listed below. Do not removal the bricks and
mortar from the existing fireplace.
The chimney can be new or existing, masonry or prefabricated
and must meet the following minimum requirements:
•Must be minimum 6 inch (152mm) inside diameter of
o
The following modifications are premissible:
high temperature chimney listed to UL 103 HT (2100 F)
or ULC-S628.
• Removal of damper or locked in open position
• Removal of smoke shelf or baffle
• Removal of ember catches
• Removel of fire grate
• Removal of view screen/curtain
• Removal of doors
•Must use components required by the manufacturer for
installation.
•Must maintain clearances required by the manufacturer
for installation.
•Refer to manufacturers instructions for installation
•
•
External trim pieces which do not affect the operation
of the fireplace may be removed providing they can be
stored on or within the fireplace for reassembly if the insert
is removed.
•This insert is listed to UL 1482 Standard and is approved
for installation into listed factory-built zero clearance fire-
places listed to UL 127 conforming to the following speci-
fications and instructions:
The permanent metal warning label provided must be
attached to the back of the fireplace, with screws or
nails, stating that the fireplace may have been altered to
accommodate the insert, and must be returned to original
condition for use as a conventional fireplace. Figure
11.1
•The original factory-built clearance fireplace chimney
cap must be re-installed after installing the approved
chimney liner meeting type UL 103 HT requirements
(2100°F) per UL 1777.
•If the chimney is not listed as meeting HT requirements,
or if the factory built fireplace was tested prior to 1998, a
full height listed chimney liner must be installed from the
appliance flue collar to the chimney top.
•
If the hearth extension is lower than the fireplace opening,
the portion of the insert extending onto the hearth must
be supported.
•
•
Manufacturer designed adjustable support kit can be
ordered from your dealer.
•The liner must be securely attached to the insert flue collar
and the chimney top.
Final approval of this installation type is contingent upon
the authority having jurisdiction.
•The air flow of the factory-built zero-clearance fireplace
system must not be altered. The flue liner top support
attachment must not reduce the air flow for the existing
air-cooled chimney system.
NOTE: Refer to chimney liner manufacturer for recom-
mendations on supporting the liner. Installation into
fireplaces without a permit will void the listing
•No dilution air is allowed to enter the chimney.
1. Secure the fireplace damper in the open position. If
this cannot be accomplished, it will be necessary to
remove the damper
WARNING! Risk of Fire!
2. Seal damper area of chimney around chimney
connector with a high temperature sealant or seal
insert against the face of the fireplace.
Follow venting manufacturer’s clearances and instructions
when installing venting system.
3. Both methods must be removable and replaceable
for cleaning and re-installation.
NOTICE: In Canada when using a factory-built chim-
o
ney it must be safety listed, Type UL103 HT (2100 F)
o
[1149 C] CLASS “A” or conforming to CAN/ULC-
o
S629M, STANDARD FOR 650 C FACTORY-BUILT
CHIMNEYS.
WARNING
THIS FIREPLACE MAY HAVE BEEN ALTERED
TO ACCOMMODATE AN INSERT. IT MUST BE
RETURNED TO ITS ORIGINAL CONDITION
BEFORE USE AS A SOLID FUEL BURNING
FIREPLACE.
250-2061
250-2061
Figure 121
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Vent Information
4
B. Venting Termination Requirements
A. Chimney and Exhaust Connection
CAUTION
1. Chimney & Connector: Use 3 or 4 inch (76-102mm)
diameter type "L" or "PL" venting system. It can be vented
vertically or horizontally.
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.
2. Mobile Home: Approved for all Listed pellet vent. If using
the 3 inch (76mm) vertical Top Vent Adapter Kit or the 3
to 6 inch (76-152mm) Top Vent OffsetAdapter, use Listed
double wall flue connector. A Quadra-Fire Outside Air Kit
must be used with manufactured home installations.
1. Termination must exhaust above air inlet elevation. It
is recommended that at least 60 inches (1.5m) of verti-
cal 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.
3. Residential: The 3 inch (76mm) vertical Top VentAdapter
Kit and the 3 to 6 inch (76-152mm) Top Vent OffsetAdapter
are tested to use 24 gauge single wall flue connector or
Listed double wall flue connector to Class A Listed metal
chimneys, or masonry chimneys meeting International
Conference of Building Officials (ICBO) standards for solid
fuel appliances.
4. INSTALL VENT AT CLEARANCES SPECIFIED BY THE
VENT MANUFACTURER.
2. Distance from doors and opening windows, or gravity or
5. Secure exhaust venting system to the appliance with at
least 3 screws. Also secure all connector pipe joints with
at least 3 screws through each joint.
ventilation air inlets into building:
a. Not less than 48 inches (1.2m) below;
b. Not less than 48 inches (1.2m) horizontally from;
c. Not less than 12 inches (305mm) above.
6. DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST
VENTING SYSTEM OF THIS UNIT.
3. Distance from permanently closed windows:
7. DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE
SERVING ANOTHER APPLIANCE.
a. Not less than 12 inches (305mm) below, horizontally
from or above.
NOTE: All pipe must be welded seam pipe whenever pos-
sible. Seal pipe joints with high temperature silicone (500°F
[260°C] minimum rated only). Do not put silicone inside
of pipe.
4. Distance between bottom of termination and grade
should be 12 inches (305mm) minimum. This is con-
ditional 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 (2.13m) minimum.
NOTE: If burning shelled field corn, you must use approved
venting specifically designed for corn. Follow the instruc-
tions from the venting manufacturer.
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.
WARNING
Fire Hazard.
•
Only LISTED venting components may be
6. Termination Cap Location (Home Electrical Service)
used.
•
•
•
•
Side-to-side clearance is to be the same as minimum
clearance to vinyl inside corners.
•
NO OTHER vent components may be used.
Substitute or damaged vent components may
impair safe operation.
Clearance of a termination cap below electrical service
shall be the same as minimum clearance to vinyl soffits.
Clearance of a termination cap above electrical service
will be 12 inches (305mm) minimum.
WARNING
Vent surfaces get HOT, can cause burns if
touched. Noncombustible shielding or guards
may be required.
Location of the vent termination must not obstruct or
interfere with access to the electrical service.
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WARNING
C. Equivalent Feet of Pipe
Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage. Refer
to the owner’s information manual provided with this appli-
ance. For assistance or additional information consult a
qualified installer, service agency or your dealer.
The table below can help you calculate the equivalent feet
of pipe which is a method used to determine pellet vent size.
Figure 14.1.
Example of 3 Elbow-Rear Vent Termination Calculation
Pellet Venting
Component
# of
Elbows
Feet of Multiplied Equivalent
Components
Equivalent Feet
2 ft.
Pipe
By
Feet
o
90 Elbow or Tee
3
X
5
15
o
45 Elbow
X
3
Horizontal Pipe
Vertical Pipe
7
2
X
1
7
1
3 ft.
X
0.5
Total Equivalent Feet
23
2 ft.
Note: This is a generic example and is not
intended to represent any specific fuel type.
2 ft.
Figure 14.1
D. Pipe Selection Chart
30
20
The chart will help you in determing proper vent-
ing size according to the equivalent feet of pipe
calcuated above and the altitude above sea level
of this installation. Figure 14.2.
4 in. (102mm) Diameter Pipe Only
Example 1
Equivalent Pipe
Length In Feet
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.
Example 2
10
If you fall below the diagonal line, 3 or 4 inch (76
to 102mm) pipe may be used. If it is anywhere
above the diagonal line, a 4 inch (102mm) diameter
pipe is required.
3 in. or 4 in. (76mm or 102mm) Diameter Pipe
0
1
2
3
4
5
6
7
8
9
10
ALTITUDE IN THOUSANDS OF FEET
The chart reveals that a 90° elbow is 5 times as
restrictive to the flow of exhaust gases under posi-
tive pressure as 1 foot of horizontal pipe, and a
foot of horizontal pipe is twice as restrictive as a
foot of vertical pipe.
Figure 14.2
Example 1: If the equivalent length of pipe is 23 feet with altitude of
8,000 feet you must use 4 inch (102mm) diameter type “L” or “PL”
vent.
Example 2: If the equivalent length of pipe is 12 feet with altitude of
6,000 feet you may use 3 or 4 inch (76 to 102mm) diameter type “L”
or “PL” vent
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Venting Systems
5
A. Full Reline With Outside Air - Horizontal
WARNING
Fire Risk.
Inspection of Chimney:
CAUTION
• Masonry chimney must be in good condition.
• Meets minimum standard of NFPA 211
Never draw outside combustion air from:
• Factory-built chimney must be a minimum 6 inch
(152mm) UL103 HT.
•
•
Wall, floor or ceiling cavity
Enclosed space such as an attic or garage
NOTE; Use metal plate around
exhaust vent pipe and seal all
edges with non-flammable insu-
lation such as fiberglass, mineral
wool or ceramic.
Do not use high temperature
caulking materials to seal any
edge to prevent furture service-
ability.
Outside Air through Rear
Wall (Horizontal)
Figure 15.1
NOTE:
•
Illustrations reflect typical installations and are FOR
DESIGN PURPOSES ONLY.
Illustrations/diagrams are not drawn to scale.
Actual installation may vary due to individual design
preference.
NOTE:
In Canada, where passage through a wall or partition of
combustible construction is desired, the installation shall
conform to CAN/CSA-B365.
•
•
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B. Full Reline With Outside Air - Vertical
NOTE: In Canada only a full reline is allowed per ULC
NOTE: Check clearances carefully for this type of instal-
S628, ORD ULC C1482-M1990.
lation to ensure adequate room for outside air venting.
305mm min.
above
305mm min.
below
NOTE; Use metal plate around
exhaust vent pipe and seal all
edges with non-flammable insula-
tion such as fiberglass, mineral
wool or ceramic.
Outside Air
Termination
at
Chimney Top
(Vertical)
Do not use high temperature caulk-
ing materials to seal any edge to
prevent furture serviceability.
Figure 16.1
NOTE: In Canada this fireplace insert must be installed
with a continous chimney liner a 6 inch (152mm) in diam-
eter extending from the fireplace insert to the top of the
chimney. The chimney liner must conform to the Class
3 requirments of CAN/ULC-S635, Standard for Lining
Systems for Extising Masonry or Factory-Built Chimneys
and Vents, or CAN/ULC-S640, Standard for Lining Sys-
tems for New Masonry Chimneys.
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.
•
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Castile Pellet Insert
Mobile Home
6
A. Mobile Home Installation
CAUTION
You must use a Quadra-Fire Outside Air Kit for instal-
lation in a mobile home.
THE STRUCTURAL INTEGRITY OF THE MOBILE HOME
FLOOR, WALL AND CEILING/ROOF MUST BE MAIN-
TAINED
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.
Do NOT cut through:
•
•
Floor joist, wall, studs or ceiling trusses.
Any supporting material that would affect the structural
integrity.
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.
Spark Arrestor Cap
3. The appliance must be secured to the mobile home
structure by bolting it to the floor (using lag bolts). Use
the same holes that secured the appliance to the ship-
ping pallet.
Storm Collar
Roof Flashing
4. The appliance must be grounded with #8 solid copper
grounding wire or equivalent, terminated at each end
with an NEC approved grounding device.
5. Refer to clearances to combustibles and floor protection
requirements on pages 9 & 10 for listings to combus-
tibles and appropriate chimney systems.
Joist Shield/Firestop
Approved Class “L”
or “PL” Pellet Vent
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.
Figure 17.1
8. Installation shall be in accordance with the Manufactur-
ers Home & Safety Standard (HUD) CFR 3280, Part
24.
WARNING
Installation must comply with Manufactured Home and
Safety Standard (HUD), CFR 3280, Part 24.
WARNING
Asphyxiation Risk.
NEVER INSTALL IN A SLEEPING ROOM.
Consumes oxygen in the room.
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Castile Pellet Insert
Appliance Set-Up
7
B. Leveling System
A. Reversible Top or Rear Flue Adapter
Top Vent Installation
The back legs are adjustable to allow for customized fit
into zero clearance boxes.
1. Release ammo can latches on each side. Figure 18.1.
1. Loosen 2 top screws and remove 2 bottom screws.
2. Place the reversible adapter in the correct position for your
installation.
2. Adjust leg to desired height. Leg can slide up (shorter)
or down (longer) to level the insert.
3. Make sure BOTH latches are in position before securing
them.
3. Tighten 2 top screws.
Rear Vent Installation
4. Drill 2 holes for the bottom 2 screws and re-install
o
screws. Figure 18.5.
1. Remove the 90 adapter and installation screws from the
packaging.
o
2. Attach the 90 adapter onto the vent adapter, using the 3
screws provided. You will need to pre-drill the holes for screw
placement. Be sure to adjust the 90 adapter to the desired
Loosen top 2 screws and remove
bottom 2. Adjust leg to desired height.
o
position for venting before drilling.
3. Silicone the pipe joints according to the Note below.
NOTE: All pipe must be sealed using welded
seam pipe whenever possible. Seal pipe joints
with high temperature silicone, minimum rate of
5000F (2600C).
Ammo Can Latches
Figure 18.4
Drill 2 holes and
re-install bottom 2
screws
Figure 18.1 - Top Vent
Figure 18.5
screw
Figure 18.3 - Rear Vent
Figure 18.2 - Rear Vent
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C. Outside Air Kit Instructions
D. Zero Clearance Trim Support Instructions
Parts Included in Kit: 1 piece of 2 inch x 3 ft. flex hose, 2
hose clamps, 1 collar assembly, 1 termination cap assem-
bly, 1 air intake channel, 1 trim ring, fasteners. NOTE:
Discard air intake channel, it is not used on this appliance.
NOTE: Only for use on small size panels.
Tools Needed: Phillips head screwdriver; wire cutters;
hole saw or jig saw.
1. Attach collar assembly to appliance. Figure 19.1.
Measure distance from floor to air vent opening in
appliance and mark location on wall.
Figure 19.2 - Assembled View
3. Use saw to cut opening in wall. Cut a 2-1/2 to 3 inch
(64-76mm) opening on inside wall and a 3 to 3-1/2
inch (76-89mm) opening on outside of house.
8
7
4. Use hose clamp to secure flex pipe to collar assem-
bly.
6
5. Slide trim ring over flex pipe and run pipe through
pre-cut hole in back of appliance and through the
wall.
5
4
6. Attach hose to outside termination cap with second
hose clamp.
7. Secure termination cap to outside surface.
8. Secure trim ring to interior wall.
1
2
3
CAUTION
Never draw outside combustion air from:
Figure 19.3
•
•
Wall, floor or ceiling cavity
Enclosed space such as an attic or garage
Item
Description
1
2
3
4
5
6
7
8
Front, 3 inch
Front, 5 inch
Cast Ring, Top & Bottom, Interchangeable
Side, 5 inch
Side, 3 inch
Panel Extension, 5 inch
Panel Extension, 3 inch
Panel Extension, Base Plate Only
Air Intake Channel
(Discard)
Termination
Trim Ring
Cap Assembly
Flex Hose
Hose Clamp
Collar
Assembly
Hose Clamp
Figure 19.1
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D. Zero Clearance Trim Support (Cont’d)
Cast Trim
Footer
1. Remove contents from box and lay on protective surface
to avoid scratching the paint.
2. Lay zero clearance front and sides face down. Bend the
tab down toward the inside.
3. The side pieces are shipped flat. It is much easier to
manually flex the sides into a bowed position before
installing.
Figure 20.4
4. Lay 1 cast ring face up, which will become the bottom ring
when installed. Attach the 2 sides FIRST and then the
front piece. Figure 20.1.
5. Now turn the cast ring right side up and attach the top cast
ring . Figure 20.2.
Panel Leg
6. Attach the zero clearance panel extensions. Figure
20.3
7. Attach cast footers. Figure 20.4.
8. Place the assembled zero clearance trim support under
the insert. Figure 20.5.
Figure 20.5
Base Plate Only Installation
Parts Needed: (1) cast ring (2) base zero clearance panel
extensions. Discard balance of parts.
NOTE: Manually
pre-shape sides before
Install Front Last
installing
Tools Needed: Phillips head screwdriver
Bend top and bottom tabs toward inside
1. Attach base zero clearance panel extensions to cast
ring.
Figure 20.1
2. Place assembly under appliance.
Cast Trim Footer
Panel Leg
Turn right side up and attach top cast rin g
Figure 20.2
Zero Clearance
Panel Extension
Figure 20.6
Alignment
Hole
Zero Clearance Panel Extension
Figure 20.3
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F. Panel & Trim Set, Econo
E. Panel Set And Cast Trim Set
Included in Panel Kit: (2) side panels, left and right; (1)
panel top; (1) fastener package.
Included in Panel & Trim Kit: (2) corner brackets and set
screws; (1) trim set, 3 piece; (2) side panels; (1) top panel;
(4) screws;
Included in Cast Trim Kit: (2) cast trim legs, left and right; (1)
cast trim header; (2) cast trim footers, left and right; (1) fastener
package.
Tools Needed: Powered Phillips head screw driver
1. Secure the top panel to the panel sides with the
Tools Needed: Powered Phillips head screw driver
screws provided. Figure 21.3.
2. Assemble the gold trim with the (2) corner brackets
1. Remove contents from box being careful not to scratch or
damage the cast trim pieces.
provided. Figure 21.4.
3. Slide the assembled trim over the assembled panel
set.
2. Lay the panel set face down on protective covering to prevent
scratching the painted surface.
3. Secure the panels legs to top panel with the screws provided.
4. Slide panel and trim over the top of the insert into
place matching the mounting tabs on the panel with
the slots on the insert.
4. Now bend the tabs down toward the backside of the panel set,
5 on top and 2 on each leg. Leave the panel set face down.
5. Place the corresponding cast trim pieces ( 2 cast trim legs and
1 cast trim header) underneath the panel set, also face down.
6. Place washer provided over tab and secure the trim and panel
together with screw. Continue for all tabs.
Back of Top Panel
7. Secure cast footers with screws.
Screws
8. Remove both left and right cast sides from insert, See Figures
32.1, 32.2 and 32.3 on page 32.
9. Slide panel and trim over the top of the insert into place matching
the mounting tabs on the panel with the slots on the insert.
CAUTION
• Do NOT pick up assembled unit by corners.
• It is too heavy and may damage the panels.
• Pick up from center.
Back of Side Panel
Figure 21.3
View of "L" Bracket
installed
1. Screw panels
2. Bend tabs down
together
1. Screw panels
together
2. Bend tabs
down
3. Install Cast Trim Header
Mounting tabs on each panel leg
to match up with slots on insert.
Figure 21.4
Figure 21.1
Figure 21.2 - Completed View
of Panel Set & Cast Trim Set
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G. Optional Log Set Placement Instructions
CAUTION
Logs are FRAGILE. Use extreme care when handling or
cleaning logs.
Four Piece Log Set Installation
1. Open the hinged cast face and open the glass door
assembly.
2. Positioning the logs.
Place the right rear log as shown. There is a notch in
the bottom of the log for clearance for the thermocou-
ple and thermocouple cover (ceramic protection tube).
Figure 22.1
Figure 22.3
Continue placing the last 3 logs around the firepot as
show in Figures 22.2, 22.3 and 22.4. Be careful not to
block the drop tube in the back of the firebox where pel-
lets feed into the firepot.
Notch
Figure 22.4
Thermocouple
Cover
Top Log Installation
Place the log over the firepot. The charred
area on the log is turned toward the back, not
the front.
The log will be about 2-1/2 inches (64mm)
above the firepot when in place. It must rest
on the 3 logs in a stable position to prevent it
from falling into the firepot. Figure 22.5.
Figure 22.1
Drop Tube
Figure 22.2
NOTE:
Due to the abrasive nature of a pellet appliance fire, the
logs are not covered under warranty. Any placement varia-
tion other than shown here can cause excessive heat and
shall void the appliance warranty.
Figure 22.5
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Castile Pellet Insert
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.
CAUTION
hock hazard.
Do NOT remove grounding prong from plug.
Plug directly into properly grounded 3 prong
receptacle.
Route cord away from appliance.
Do NOT route cord under or in front of appli-
ance.
•
•
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 tempera-
ture setting slightly higher to maintain the desired
temperature in your home.
3. There is a 4 screw terminal block located on the junc-
tion box to the left of the power cord inlet. The center
2 screws are for the thermostat wires. The outer 2 are
the mounting screws for the terminal block. Figure
23.1.
Control Box
Red Call
Light
Fuse
Power Cord
Outlet
Heat Output
Switch
Thermostat
Block
Reset Button
Junction Box
Figure 23.1
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Operating Instructions
8
A. Fuel Size, Material and Storage
1. Wood Pellets
2. Shelled Field Corn (Cont’d)
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
firepot reaches. This is what forms clinkers in the bottom of the
firepot. Trees from different areas will vary in mineral content.
That is why some fuels produce more clinkers than others.
Pellets are manufactured in either 1/4 inch or 5/16 inch (6-8mm)
diameter and should be no more than 1-1/2 inches (38mm)
in length. Pellet lengths may even vary by lot from the same
manufacturer which is why the feed rate may need to be adjusted
occasionally. If you burn pellets longer than 1-1/2 inches
(38mm) you may have an inconsistent fuel feed rate and/or
missed ignitions.
corn used. In cases where it is acceptable for the appliance
to run full time, 100% corn will work after the fire has been
started using wood pellets.
When purchasing corn to burn in your appliance, read the
ingredient label very carefully. Do NOT purchase fuel
that contains any additives such as oils (i.e. soybean oil)
and meals as it will result in poor unit performance. If you
are buying corn the only ingredient that should be listed
is corn.
Shelled field corn must be 15% or less moisture content.
The corn must be clean and free from debris. Never burn
corn straight from the field. Stalk parts, excessive fines and
cob remnants, etc. will clog the auger mechanism. Corn
with excessive grain dust must be screened by sifting with
3/16 (4.76mm) inch mesh screening.
Do not burn treated seed corn in your appliance. Seed corn
is treated with chemical pesticides that are harmful or fatal
if swallowed; therefore, seed corn is dangerous to have in
the house, expecially where children can reach it. Burning
treated seed corn in your appliane will void your warranty
and will destroy the exhaust system on the unit.
Pellet fuel quality can greatly fluctuate. We recommend using
premium grade fuel with ash content less than 1%. Even in some
fuel labeled “premium” ash content can vary from bag to bag
and possibly exceed 1%. High ash fuel, or lack of maintenance,
can cause the firepot to fill up and thus create a potential for
smoking, sooting and possible hopper fires.
When changing to a different fuel, be sure to empty the
hopper of the previous fuel and vacuum the hopper before
you fill it with the new fuel.
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.
WARNING
Risk of Chemical Poisoning.
•
Do Not burn treated seed corn
• Chemical pesticides are harmful or fatal if
swallowed
WARNING
• Burning treated seed corn will void your
warranty
Fire Risk.
•
•
High ash fuels, or lack of maintenance, can
cause the firepot to overfill. Follow proper
shutdown procedure if ash buildup exceeds
half way point in firepot.
3. Storage
Failure to do so could result in smoking,
sooting and possible hopper fires.
Wood pellets should be left in their original sealed bag until
using. This will prevent moisture absorption.
2. Shelled Field Corn
Shelled corn should be stored in a tight container where it
will not absorb moisture from damp or wet floors. This will
also prevent rodents from becoming a problem.
Extensive factory and field testing has demonstrated shelled
field corn to be an efficient and very economical fuel. We
recommend the use of a 50-50 blend of corn and wood pellets.
The only change in operation is that the feed rate may require
a slight adjustment. The BTU output of the appliance varies
slightly compared to pellets, depending on the quality of the
Do not store any pellet fuel within the clearance
requirements or in an area that would hinder routine cleaning
and maintenance.
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Castile Pellet Insert
C. Before Your First Fire
B. General Operating Information
1. First, make sure your appliance has been properly
installed and that all safety requirements have been met.
Pay particular attention to the fire protection, venting and
thermostat installation instructions.
1. Thermostat Calls For Heat
The appliance is like most modern furnaces; when the thermostat
calls for heat, your appliance will automatically light and deliver
heat. When the room is up to temperature and the thermostat
is satisfied, the red call light will shut off and the appliance will
shut down. The red call light is located behind the left access
panel.
2. Double check that the ash pan and firebox are empty!
3. Check the position of the thermocouple, located above
the firepot, and make sure that it protrudes approximately
3/4 inch (19mm) into the firepot.
2. Heat Output Controls
4. Close the front door.
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.
CAUTION
Tip of thermocouple must be in contact with the inside
end of the thermocouple cover.
Missed ignitions can occur.
D. Starting Your First Fire
1. A thermostat is required for proper operation of this
appliance, except for corn. At this time, fill the hopper
with pellets, set the thermostat to its lowest setting. Plug
the power cord into nearby outlet.
2. The exhaust blower will stay on for approximately 18
minutes even though the thermostat is not calling for
heat. This is normal.
Heat Output
Switch
3. Locate the heat output control switch behind the right face
on the lower right side of the firebox. Set to the HIGH
setting and then adjust the thermostat to its highest setting.
The red call light will be on which is located on the top of
the junction box behind the right cast side. This indicates
the thermostat is calling for heat. Figure 25.1.
Right
Side
Ash Pan
Reset Button
4. The fuel feed system and the igniter should now be on.
Figure 25.1
5. For your first fire it will be necessary to press the reset
button once a minute until pellets start to drop into the
firepot, then press button 1 more time. This will fill the
feed system and allow the appliance to begin dropping
pellets. The appliance will continue to run as long as the
thermostat is calling for heat.
WARNING
Fire Hazard.
Keep combustible materials, gasoline
and other flammable vapors and liquids
clear of appliance.
6. Oncetheappliancehasignited,letitburnforapproximately
15 minutes, then set the thermostat to the desired room
temperature. Adjust the heat output control switch to the
desired setting.
•
•
Do NOT store flammable materials in the appliance’s
vicinity.
DO NOT USE GASOLINE, LANTERN FUEL, KEROSENE,
CHARCOAL LIGHTER FLUID OR SIMILAR LIQUIDS TO
START OR “FRESHEN UP” A FIRE IN THIS HEATER.
E. Fire Characteristics
A properly adjusted fire with the heat output control switch
set on “HIGH” has a short active flame pattern that extends
out of the firepot approximately 4 inches (102mm). If the fire
has tall flames with black tails and seems somewhat lazy, the
feed rate will need to be reduced. If the fire is not 4 inches
(102mm) tall, increase the feed rate. A medium and low
setting will give a shorter flame. The flame will rise and fall
somewhat. This is normal.
•
•
DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS
SUCH AS GASOLINE, NAPHTHA OR ENGINE OIL.
DO NOT USE CHEMICALS OF FLUIDS TO START THE
FIRE.
•
•
Keep all such liquids well away from the heater while it is in
use.
Combustible materials may ignite.
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F. Feed Rate Adjustment
The fuel adjustment control rod is factory set, and should be
adequate for most fuels.
Control Box
Red Call
Light
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.
Fuse
Power Cord
Outlet
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
Heat Output
Switch
allow 15 minutes for feed adjustment to take effect. Make
adjustments in approximately 1/2 inch increments.
Thermostat
Block
Reset Button
1. Loosen the wing nut. Figure 26.1.
Junction Box
2. Adjust the fuel adjustment control rod towards the
"+" symbol to increase the feed rate and flame height or
towards the "-" symbol, to decrease the feed rate and flame
height.
Figure 26.1
3. Re-tighten the wing nut.
WARNING
Fire Risk
Do NOT operate appliance:
Wing Nut
•
•
•
With appliance door open.
Firepot floor 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 26.1
G. Iginition Cycles
1. During each ignition cycle, it is normal to see some smoke
in the firebox. The smoke will stop once the fire starts.
2. The convection blower will automatically turn on after your
appliance has reached the set temperature. This blower
transfers heat from your appliance into the room, and will
continue to run after the thermostat has stopped calling
for heat until the appliance has cooled down.
Back side of Firepot
Firepot floor left open
Figure 26.2 - DO NOT LEAVE FIREPOT FLOOR OPEN
3. Occasionally the appliance may run out of fuel and shut
itself down. When this happens, the red call light will
be on. To restart it, fill the hopper and press the reset
button. Figure 26.2. When you press the reset button
the red call light will go out. Release the button and the
light will come back on. You should see a fire shortly.
If not, follow the instructions on page 25, “Starting Your
First Fire”.
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H. Frequently Asked Questions
ISSUES
SOLUTIONS
1. Metallic noise.
1. Noise is caused by metal expanding and contracting as
it heats up and cools down, similar to the sound pro-
duced by a furnace or heating duct. This noise does not
affect the operation or longevity of your appliance.
2. Ash buildup on glass.
3. Glass has turned dirty.
2. This is normal. Clean the glass.
3. Excessive build up of ash. The lower burn settings will
produce more ash, the higher burn settings produce
less. The more it burns on low the more frequent clean-
ing of the glass is required.
4. Fire has tall flames with black tails and is lazy.
4. The feed rate needs to be reduced or the firepot needs
cleaning. Heat exchanger or exhaust blower needs
cleaning.
5. Smokey start-up or puffs of smoke from the airwash. 5. Either the firepot is dirty or there is too much fuel at
start-up and not enough air. Close down feed rate 1/4
(6mm) inch at a time until this no longer happens.
6. Large flame at start-up.
6. This is normal. Flame will settle down once the fire is
established.
CAUTION
Odors and vapors released during initial operation.
•
•
Curing of high temperature paint.
Open windows for air circulation.
Odors may be irritating to sensitive individuals.
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With proper installation, operation, and maintenance your appliance will provide years
of trouble-free service. If you do experience a problem, this troubleshooting guide
will assist a qualified service person in the diagnosis of a problem and the corrective
action to be taken. This troubleshooting guide can only be used by a qualified
service technician.
Troubleshooting
9
Possible Cause
Corrective Action
Check circuit breaker at service panel.
Replace fuse.
Symptom
Plug in appliance - No
response.
No current to outlet.
.7 amp fuse defective.
#3 snap disc tripped or defective.
Control box defective.
Reset or replace snap disc.
Replace control box.
Call light on. No fire.
No fuel in firepot.
Out of fuel.
Check hopper. Fill with fuel.
Replace snap disc.
#2 snap disc may be defective.
Vacuum switch not closing, no vacuum.
Check exhaust blower is plugged in and
operating.
Check vacuum switch is plugged in.
Check vacuum hose is in good condition,
clear and connected at both ends.
Check thermocouple is in good condition
and plugged in properly.
Make sure venting system is clean.
Make sure front door is closed.
Replace control box.
Control box defective.
Call light on. No fire.
Partially burned fuel in
firepot.
Firepot clean-out plate not closed.
Check that firepot clean-out plate is fully
closed.
Firepot is dirty (missed ignition).
Clean firepot. Make sure there is no clinker
in the firepot.
Clinkers may have to be broken up with
firepot scraper tool or other means.
Call light on. No fire.
Unburned pellets in
firepot.
Firepot clean-out plate not closed.
Firepot is dirty.
Check that firepot clean-out plate is fully
closed.
Clean firepot. Make sure there is not a
clinker in the firepot. Clinkers may have to
be pushed out of firepot with firepot scraper
tool or other means.
Scrape with solid piece of wire.
Ignition hole blocked.
Igniter not working.
Remove ash drawer to see if igniter is
glowing red on start-up.
Check igniter wires for good connection.
Replace igniter using 1/4 inch (6mm) male
/female spade connectors.
Replace control box.
Control box defective.
Slow or smoky start-up. Firepot clean-out plate not closed.
Firepot is dirty.
Check that firepot clean-out is fully closed.
Clean firepot. Make sure there is not a
clinker in the firepot. Clinkers may have to
pushed out of firepot with firepot scraper
tool or other means.
Reduce feed rate using feed rate adjust-
ment control rod located inside hopper.
Excessive amount of fuel at start-up.
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Symptom
Possible Cause
Corrective Action
Slow or smoky start-up Dirty exhaust and/or venting system.
(Cont’d)
Check for ash build up in appliance,
including behind rear panels, firebox, heat
exchanger, exhaust blower and venting.
Feed system fails to
start.
Out of fuel.
Check hopper, fill with fuel.
#2 snap disc may be defective.
Replace snap disc. Firebox door must be
closed securely.
Vacuum switch not closing. No vacuum.
Check exhaust blower is plugged in and
operating.
Check vacuum switch is plugged in.
Check vacuum hose is in good condition,
clear and connected at both ends.
Check thermocouple is in good condition
and plugged in properly.
Make sure venting system is clean.
NOTE: High winds blowing into the vent-
ing system can pressurize the firebox
causing loss of vacuum.
Feed system jammed or blocked.
Empty hopper of fuel. Use a wet/dry
vacuum cleaner to remove remaining fuel,
from hopper, including feed tube.
Check feed chute for obstructions.
Loosen 2 screws and jiggle feed assembly.
Feed spring not turning with feed motor.
Feed motor defective or not plugged in.
Check that set screw is tight on feed
spring shaft at end of feed motor.
Check connections on feed motor, replace
if defective.
No call light. Appliance Thermostat not set to a high enough tempera-
Adjust thermostat above room tempera-
ture.
does not begin start
sequence.
ture.
Snap Disc #3 tripped.
No power.
Reset snap disc.
Connect to power.
Replace fuse.
Fuse blown.
Connections at thermostat and/or appliance not Check connections at thermostat and
making proper contact.
appliance.
Defective thermostat or thermostat wiring.
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.
Call light on.
Replace control box.
Appliance fails to shut
off.
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.
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Symptom
Possible Cause
Corrective Action
Convection blower fails to No call light.
start.
Defective control box.
#1 snap disc defective.
Replace snap disc.
Blower not plugged in.
Blower is defective.
Check that blower is plugged into wire har-
ness.
Replace blower.
Control box is defective.
Blower not plugged in.
Replace control box.
Exhaust blower fails to
start or does not shut off.
Check that blower is plugged into wire har-
ness.
Blower is clogged with ash.
Blower is defective.
Clean exhaust system.
Replace blower.
Replace control box.
Control box is defective.
Large, lazy flame, orange Dirty appliance.
color. Black ash on glass. Poor fuel quality, high ash content.
Clean appliance, including firepot, heat
exchangers and venting system. Remove
stainless steel baffle from firebox to clean
ash from on top of baffle. Clean behind rear
brick panels. Change fuel brand to pre-
mium.
Firepot clean-out plate not completely
closed.
Check that firepot clean-out plate is fully
closed.
Excessive amount of fuel.
Reduce feed rate using feed rate adjustment
control rod located inside hopper.
Nuisance shutdowns.
Low flame.
Increase feed by opening feed rate adjust-
ment control rod located inside hopper.
Sawdust buildup in hopper.
Feed motor is reversing.
Clean hopper, see page 31.
Check for good connections between feed
motor and wire harness.
Defective thermocouple.
Replace thermocouple.
Replace control box.
Defective control box
Firepot more than 1/2 full
See page 31 for detailed instructions for
“High Ash Fuel Content Maintenance”
Appliance calls for heat.
Call light illuminates.
Exhaust blower starts.
No feed or igniter.
Thermocouple is defective or not properly
plugged in.
Check connections on thermocouple or
replace if defective.
A flashing yellow light on the control box
indicates a problem with the thermocouple.
Defective control box
Replace control box.
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Maintaining & Servicing Your Appliance
10
C. General Maintenance & Cleaning
A. Proper Shutdown Procedure
1. Types of Fuel
Depending on the type of fuel you are burning will dictate how
often you have to clean your firepot.
CAUTION
If the fuel you are burning has a high dirt or ash content or
you are burning shelled field corn, it may be necessary to
clean the firepot more than once a day.
hock and Smoke Hazard
Turn down thermostat, let appliance completely
cool and exhaust blower must be off. Now you
can unplug appliance before servicing.
Dirty fuel will cause clinkers to form in the firepot. A clinker
is formed when dirt, ash or a non-burnable substance is
heated to 2000°F (1093°C) and becomes glass-like. See
“D” page 35 in this section for more details on fuels with
high ash content.
• Smoke spillage into room can occur if appliance
is not cool before unplugging.
• Risk of shock if appliance not unplugged before
servicing appliance.
Follow the detailed instructions found in this
section for each step listed as referenced in the
chart below.
Clinker
Figure 31.1 - Clinker
B. Quick Reference Maintenance Chart
Cleaning or Inspection
Ash Pan
Frequency
Daily Weekly Monthly Yearly
Every 5 bags of fuel
OR
X
X
Ash Removal from Firebox
More frequently depending on OR
the fuel type or ash build-up
Beneath Heat Exchanger
Every 1 ton of fuel
OR
X
X
Blower, Combustion (Exhaust)
More frequently depending on OR
the fuel type
X
X
Blower, Convection
More frequently depending on OR
the fuel type
Door Latch Inspection
Exhaust Path
Prior to heating season
OR
More frequently depending on OR
ash build-up
X
X
Firebox - Prepare for Non-Burn Season At end of heating season
OR
OR
OR
OR
OR
Firepot - Burning pellets - hardwood
Firepot - Burning pellets - softwood
Firepot - Burning Corn
Every 3 bags
Every 5 bags
Every 1 bag
X
X
X
Glass
When clear view of firepot
becomes obscure
X
Heat Exchanger & Drop Tube
Hopper
Every 1 ton of fuel
OR
OR
X
X
Every 1 ton of fuel or when
changing fuel types
Top Vent Adapter
Venting System
More frequently depending on OR
the fuel type or ash build-up
X
X
More frequently depending on OR
the fuel type
NOTICE: These are recommendations. Clean more frequently if you encounter heavy build-up of
ash at the recommended interval or you see soot coming from the vent. Not properly
cleaning your appliance on a regular basis will void your warranty.
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3. Cleaning Firepot with Cleaning Rod & Firepot
Scraper
2. Remove Cast Sides for Cleaning & Maintenance
a. Loosen screw on top right corner directly under the cast
•
•
Frequency: Daily or more often as needed
By: Homeowner
top, but do not remove. Figure 32.1.
b. With thumb, press upward on the frame to relieve the
a. The appliance must be in complete shutdown and cool
and the exhaust blower off. If you are just cleaning the
firepot, there is no need to unplug the appliance.
pressure on the cast side. Figure 32.2.
c. Slide the cast side downward as shown in Figure 32.3.
(The top has been removed to show the details.
b. Pull firepot cleaning rod OUT a couple of times to help
shake debris loose. See Figure 33.1 on page 33. If rod
is hard to pull, it may be necessary to use your firepot
clean-out tool to chip away material that has built up
on the bottom plate of the firepot and to push out any
clinkers. Larger clinkers may have to be removed from
the top of the firepot. Corn clinkers can be especially
difficult to break up.
d. Lay sides on protective padding to avoid scratching the
paint or chipping the porcelain.
e. Repeat for the other side.
Top
c. The firepot floor plate must be fully closed when
finished. See Figure 26.2 on page 26.
WARNING
Front
Fire Risk
Right
Cast
Side
•
•
NEVER pull firepot cleaning rod or cleaning
slide plates out when appliance is operating.
The cleaning slide plates must be fully
CLOSED when appliance is operating.
Figure 32.1
•. Hot pellets may fall into ashpan and start a fire
or mis-starts due to lack of vacuum.
4. Ash Removal from Firebox
•
Frequency: Weekly or more frequently depending on
ash build-up.
•
By: Homeowner
a. There must not be any hot ashes in the firebox during
cleaning so allow the appliance to completely cool.
The firebox ash should be removed every time the
firepot is cleaned. Frequent cleaning of the ash in
the firebox will help slow down the build-up of ash in
the exhaust blower and vent system.
Flex frame upward with thumb
to relieve pressure on cast side.
CAST
SIDE
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 fly ash
out the exhaust instead of into the room.
Figure 32.2
c. Open cast hinged face. Directly underneath the
firebox door and to the left and right of the firepot are
2 cleaning slide plates with finger holes. Pull both
slide plates out and then open the glass door. Sweep
the remaining ash from the firebox into the 2 open
holes. A paint brush works well for this. Close slide
plates.
d. This ash is deposited in the same ash pan as the
firepot debris. The ash pan should be emptied every
time you clean the firebox. Remember to place
the ash and debris into a metal or noncombustible
container.
Figure 32.3
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7. Disposal of Ashes
4. Ash Removal from Firebox (Cont’d)
•
•
Frequency: As needed
By: Homeowner
e. The 2 cleaning slide plates must be fully closed when
cleaning is complete. See Disposal of Ashes.
Ashes should be placed in a metal container with a
tight-fitting lid. The closed container of ashes should
be placed on a non-combustible floor or on the ground,
well away from all combustible materials, pending final
disposal.
5. Cleaning Ash Pan
•
•
Frequency: Weekly or every 5 bags of fuel
By: Homeowner
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.
Locate the ash pan underneath the firepot. Open the
bottom ash door and slide the ash pan straight out.
Empty into a non-combustible container and re-install
ash pan. See Disposal of Ashes.
6. Cleaning Heat Exchanger Chambers & Drop Tube
10 Heat Exchanger Tubes
•
•
Frequency: Monthly or every 1 ton of fuel
By: Homeowner
WARNING
Heat exchanger cleaning rods may be warm
to the touch. For safety purposes wear
gloves.
Do not pull heat exchanger cleaning rods
while appliance is operating.
Figure 33.1
Push cleaning rods IN when done, DO NOT
leave cleaning rods OUT. Injury can occur.
8. Cleaning Beneath Heat Exchanger
•
•
Frequency: Monthly or after burning 1 ton of fuel
By: Homeowner
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off
The amount of ash buildup in the firepot will be a good
guide to determine how often you should clean the heat
exchangers.
b. A more thorough cleaning is needed to remove the
excess ash that is left behind from the use of the
cleaning rods for the heat exchanger tubes.
a. Allow the appliance to completely cool down before
pulling the cleaning rods. Turn the thermostat on and
then immediately off to start the exhaust blower on its
cycle time. It will pull fly ash out the exhaust instead
of into the room. Open the cast front door to access
the 2 cleaning rods. Figure 33.1.
c. The ash will be resting on the back of the baffle.
This will require removing the cast baffle. Please
refer to page 33 for a detailed explanation of remov-
ing the baffle.
b. Locate the 2 rods directly underneath the heat
exchanger tubes. Rods are bent at a 90° angle for
easy handling.
NOTE: There are heavy duty vacuum cleaners specifically
designed for solid fuel appliance cleaning.
c. To clean, pull the rods straight out until it stops,
approximately 10 inches (254mm). Slide the rods
OUT and IN a couple of times.
9. Cleaning the Exhaust Path
•
Frequency: Yearly or more frequently depending on
ash build-up.
•
By: Homeowner
WARNING
a. Appliance must be completely cool.
Disposal of Ashes
b. Open cast front door. Remove right brick and thoroughly
vacuum the area and continue throughout the rest of
the firebox. See Figure 37.3 on page 37.
•
•
Ashes should be placed in metal container
with tight fitting lid.
Ashes should be retained in closed container
until all cinders have thoroughly cooled.
c. Replace right brick and close cast front door.
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10. Cleaning the Hopper
CAUTION
•
•
Frequency: Monthly or after burning 1 ton of fuel
By: Homeowner
Handle glass assembly with care.
After burning approximately 1 ton of fuel you will need to
clean the hopper to prevent sawdust build-up.
When cleaning glass:
•
Avoid striking, scratching or
slamming glass.
A combination of sawdust and pellets on the auger
reduces the amount of fuel supply to the firepot. This
can result in nuisance shutdowns and mis-starts.
•
Do NOT clean glass when hot.
•
•
•
Do NOT use abrasive cleaners.
Use a hard water deposit glass cleaner on white film.
Refer to maintenance instructions.
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.
13. Cleaning Convection Blower - Requires No
Lubrication
11. Soot and Fly Ash: Formation & Need for Removal
in Exhaust Venting System.
•
•
Frequency: Yearly or as needed
By: Qualified Service Technician
•
Frequency: Yearly or more frequently depending on
ash build-up.
By: Qualified Service Technician/Homeowner
a. The appliance must be in complete shutdown and
completely cooled.
•
b. Remove both the left and right cast sides.
Be sure the appliance is allowed to cool, has been unplugged
and the exhaust blower is off.
c. Use either a can of compressed air or an air com-
pressor.
The products of combustion will contain small particles of fly
ash. The fly ash will collect in the exhaust venting system
and restrict the flow of the flue gases.
d. Reach as far back as possible and spray com-
presssed air liberally from both sides at the blower.
This will remove any lint or dust build-up on the
impellers.
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 vent-
ing system.
14. Cleaning Exhaust Blower - Requires No
Lubrication
•
•
•
Frequency: Yearly or as needed
By: Qualified Service Technician
Task: Contact your local dealer.
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.
15. Door Latch Inspection
12. Cleaning the Glass
•
•
Frequency: Prior to heating season
By: Homeowner
•
Frequency: When clear view of the firepot becomes
obscure
By: Homeowner
The door latch is non-adjustable but the gasketing between
the glass and firebox should be inspected periodically to
make sure there is a good seal.
•
a. Appliance must be completely cool before cleaning
glass.
NOTE: There is no gasket on the bottom of glass.
b. Use a damp paper towel or any non-abrasive glass
cleaner. Wipe off with dry towel.
WARNING
Handle glass with care.
•
Inspect the gasket to ensure it is
undamaged.
•
•
Do NOT strike, slam or scratch glass.
Do NOT operate appliance with glass
assembly removed.
•
Do NOT operate with glass cracked, broken or
scratched.
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D. High Ash Fuel Content Maintenance
16. Door Gasket Inspection
•
•
Frequency: Monthly or after burning 1 ton of fuel
By: Homeowner
•
Frequency: When the ash build-up exceeds more
than half way up the firepot.
•
By: Homeowner
To inspect the door rope (gasket), open the door and see
that the door rope extends approximately 1/8 to 3/16 inch
(3 to 9.5mm) from the door rope channel.
It should show signs of compaction all the way around the
door where the rope contacts the face of the insert.
Poor quality pellet fuel, or lack of maintenance, can create
conditions that make the firepot fill quickly with ashes and
clinkers.
This condition makes the appliance susceptible to overfilling
the firepot with pellets which may result in smoking, sooting
and possible hopper fires. Figure 35.1 shows an example
where the firepot overfills, pellets back up into the feed tube
and ash has accumulated in the firebox.
17. Preparing Firebox for Non-Burn Season
•
•
Frequency: Yearly
By: Homeowner
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off.
An inefficient and non-economical method of burning of fuel
caused by poor quality pellet fuel is shown in Figure 35.2.
b. Remove all ash from the firebox and vacuum thoroughly.
c. Paint all exposed steel, including cast-iron.
The correct flame size when good quality, premium pellet
fuel is burned is shown in Figure 35.3.
If the ash buildup exceeds the half way point in the firepot
IMMEDIATE ATTENTION AND CLEANING IS REQUIRED.
•
Use the Touch-Up paint supplied with the appliance;
or;
•
•
Purchase paint from your local dealer.
Must use a high-temperature paint made specifi-
cially for heating appliances.
WARNING
Figure 35.1
Fire and Smoke Risk.
Incorrect
• High ash fuels or lack of maintenance
can cause firepot to overfill. Follow
proper shutdown procedure if ash buildup
exceeds half way point in firepot.
• Failure to do so could result in smoking,
sooting and possible hopper fires.
Tall, Lazy Flame, Orange in Color
Figure 35.2
Correct
Correct Flame Size, Yellow/White in Color
Figure 35.3
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E. Igniter Replacement
F. Glass Replacement
WARNING
Glass is 5mm thick high temperature heat-
resistant ceramic glass.
DO NOT REPLACE with any other material.
Alternate material may shatter and cause
injury
Igniter Bracket
Thumb Screw
Figure 36.1
a. Open hinged cast face and lift door assembly off
from the insert and lay on a flat surface face down.
Igniter
b. Using a screwdriver, tap the bottom of the rope
retainer rod to push it up out of the hole. The top
end of the rod will slide up. Swing the rod toward
you from the bottom and remove the rod. Repeat
for other side.
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.
c. Remove old glass and replace with new glass.
d. Slide the retainer rod into the top hole first, and then
line up the bottom crimped end with the hole in the
door. The crimped end must be paralle with the glass
in order to insert it into place. Figure 36.2.
b. The wire leads to the igniter are connected to the wire
harness with 1/4 inch (6mm) male / female spade
connectors. These wires will pull forward approximately
4 to 5 inches (102 to 127mm). Disconnect the spade
connections and remove the igniter from the chamber.
Loosen the thumb screw and slide igniter out.
c. Install new igniter into the chamber and tighten the
thumb screw. Re-connect the wires to the 2 leads with
the spade connectors.
Rope Retainer
Rods
d. Remove the right cast side and pull the wire leads
back toward the rear of the appliance to take-up the 4
to 5 inches (102mm to 107mm) previously pulled out.
This will keep the wires out of the way of the ash pan.
Double check that the igniter wires are clear of any
movement, i.e. ash pan, firepot cleaning rod, cleaning
slide plates, etc.
Slide this
end in first
Glass
Crimped end
at the bottom
f. Re-install the ash pan and then re-install the cast side
panel and re-connect the power.
Crimped end must be
parallel with the glass
Figure 36.2
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Castile Pellet Insert
Re-installing Baffle & Brick Set
G. Baffle & Brick Set Removal
1. Place right brick in behind the right bracket, and then
slide to the left so the tabs are behind the center brick.
Figure 37.4
1. Follow proper shutdown procedures on Page 31.
The top baffle has a hook on the bottom left side that
rests on the top lip of the cast brick. There is a tab on
the bottom right side that hooks into the side bracket.
Remove the top baffle by first pulling the baffle forward
until back edge drops down. Then slide baffle back until
the front edge clears the shelf that it had been resting on.
Figure 37.1.
2. The brick will be flush against the back wall and notches
exposed in the side bracket. Figure 37.5.
3. Lift slightly and pull the right edge of the brick forward until
it stops and then drops down into both top and bottom
notches of right bracket and locks into place. Figures
37.1 and 37.2.
3
. The top baffle must be removed before you can remove
the right and left brick. Remove the right brick by hold-
ing top lip of brick and lifting up, then push outside edge
back. Slide brick to the right until it is flush with the firebox.
Rotate the inside edge of the brick forward and remove
brick. Repeat for left brick. Figure 37.2.
4. Repeat for left brick.
5. Insert baffle into top front inside the firebox and pull for-
ward. Then raise up the bottom end and insert baffle tab
into slot on the top of the right bracket to lock into place.
Figure 37.3. Place the left side hook at the bottom of
the baffle over the top edge of brick for stability. Figure
37.4.
6. The baffle does not completely cover the top of the fire-
box. There is an opening on the left as shown in Figure
37.5.
Hook on
left side
Tab on
right side
Tabs
Figure 37.1
Figure 37.4
Remove Right
& Left Brick
Brick is flush against back wall
Figure 37.2
Notches
exposed
Right Brick
Removed
Figure 37.5
Vacuum
Exhaust Area
Figure 37.3
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Castile Pellet Insert
Re-installing Baffle & Brick Set (Cont’d)
Lift brick, pull forward at an angle
and drop down into notches
Hook on
left side
Tab on
right side
Figure 38.4
Figure 38.1
Figure 38.5
Figure 38.2
Figure 38.3
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Castile Pellet Insert
Reference Materials
When describing the location of a component
part it is always AS YOU FACE THE FRONT
OF THE APPLIANCE.
11
A. Component Function
E
1. Control Box
7. Heat Exchangers
a. The control box is located on lower right side of
appliance, behind cast side on top of the junction
box.
The heat exchangers transfer heat from the exhaust system
into convection air. There are 2 clean out rods located under
the heat exchangers.
b. There is a light located inside of the control box. The
internal light will turn green when the appliance has
8. Heat Output Switch
ο
°
reached a temperature of 200 F (93 C) in the firepot.
and will turn red when it reaches 600 F (315 C).
The heat output switch is located on the lower right side of
firebox, behind the right face above the reset button. The
function of the heat output switch is to regulate the burn rates;
low, medium and high settings.
o
°
c. There is also an internal blue light located in the upper
left corner of the control box. When you plug in the
appliance the blue light will automatically start blinking
6 blinks every 10 seconds for 60 seconds and then will
stop.
9. Igniter
The igniter is mounted on the base of the firepot. Combustion
air travels over the red hot igniter creating super heated air
that ignites the pellets.
NOTE:
10. Junction Box And Wiring Harness
Do NOT open the control box. This will void the
warranty. If you need to plug in or remove the control
box you must first unplug the appliance.
The junction box is located behind right cast side of the
appliance. The junction box and wiring harness are replaced
as one component.
11. Power Supply
2. Convection Blower
The power outlet is located behind the right cast side of the
appliance behind the thermostat block on the junction box.
Check the wall receptacle for 120 volt, 60 Hz (standard
current). Make sure the outlet is grounded and has the correct
polarity. A good surge protector is recommended. When
operating with a generator you need at least 600 watts of
power, or with an inverter at least 800 watts of power available
for the appliance during the start cycle.
The convection blower is mounted at the bottom rear of the
appliance. There are 2 impellers, one on each side of the
motor. The convection blower pushes heated air through the
heat exchange system into the room.
3. Exhaust Blower
The exhaust blower is mounted on the right side of the
appliance behind the right cast side. The exhaust blower is
designed to pull the exhaust from the appliance and push it
out through the venting system.
12. Red Call Light
The red call light is located behind the fuse behind the right
cast side. The function of the red call light is to indicate that
the thermostat is calling for heat.
4. Feed System
The feed system is located on the right side and can be
removed as an entire assembly. The assembly includes
the feed motor, mounting bracket, bearing and feed spring
(auger). The hollow feed spring (auger) pulls pellets up the
feed tube from the hopper area and drops them down the
feed chute into the firepot.
13. Reset Button
The reset button is located on the lower right side of firebox
behind right face and below the heat output control switch. The
function of the switch is to momentarily open the thermostat
circuit, which restarts the system.
5. Firepot
14. Thermocouple
The firepot is made of high quality ductile iron and has a
cleaning pull-out rod. The floor of the firepot opens for
cleaning when you pull out the rod. Be sure that the floor
returns to a completely closed position or your appliance will
not operate properly.
The thermocouple is located on top of the firepot inside
the thermocouple cover (ceramic protection tube). The
thermocouple sends a millivolt signal to the control box
indicating the preset temperatures of the green and red lights
have been obtained.
6. Fuse
15. Thermostat
The fuse is located on the right side behind the control box.
The fuse will blow should a short occur and shut off power
to the appliance.
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.
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Castile Pellet Insert
16. Snap Disc #1 (Convection Blower) 110°F
19. Vacuum Switch
Snap disc #1 is located behind the right cast side of the firebox
above the red call light. There are 2 purple wires connected
to it. This snap disc turns the convection blower on and off as
needed. Power is always present at snap disc #1.
The vacuum switch is located at the back of the appliance.
This switch turns the feed system on when vacuum is present
in the firebox. The vacuum switch is a safety device to shut
off the feed motor if the exhaust or the heat exchanger
system is dirty or plugged or if the firebox door is open.
17. Snap Disc #2 (Fuel Delivery Interrupt) 250°F
20. Wiring Harness
Snap disc #2 is located on the back side of the feed drop
tube. There is 1 orange wire and 1 black wire connected to
it. This snap disc will turn off the feed system, which will turn
off the appliance if an overfire condition should occur or if the
convection blower should fail to operate. If this occurs the
snap disc with automatically reset itself.
See Figure 40.1 below
18. Snap Disc #3 (Burn Back Protector) 250°F
Snap disc #3 is mounted on the back of the auger tube in the
center of the appliance and has a reset button. To access
it remove the right cast side. If the fire tries to burn back
into the feed system or push exhaust up the feed tube, this
snap disc will shut the entire system off. This disc must be
manually reset.
Female
Male
Thermocouple
Thermostat
Burn
Block
Selector
Feed
Motor
Vacuum
Switch
Snap Capacitor
Disc #2
Yellow
Red
Black
White
Red
Black
Black
White
Red
Snap
Disc #1
Convection
Blower
Purple
Gray
Blue
Black
Black
Exhaust
Blower
Call
Light
Reset
Button
Snap
Disc #3
Fuse
Receptacle
Igniter
Figure 40.1
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B. Component Locations
10 Heat Exchanger Tubes
Feed Motor
Exhaust
Blower
Figure 41.2 - Cleaning Rods & Heat Exchanger Tubes
Convection Blower
Figure 41.1 - Blowers & Feed Motor
Control Box
Red Call
Light
Fuse
Power Cord
Outlet
Heat Output
Switch
Thermostat
Block
Reset Button
Junction Box
Figure 41.3
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C. Exploded Drawing
33
1
32
2
30
29
31
28
27
3
26
25
4
24
23
5
22
6
21
7
20
8
19
18
9
17
16
15
14
10
13
12
Figure 42.2
11
7025-006 3-24-09
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Castile Pellet Insert
D. Service Parts and Accessories
HOW TO ORDER
IMPORTANT: THIS IS DATED INFORMATION
To order the entire assembly, order the top line part number only.
To order an individual part from an assembly, order the part(s)
listed in the indented portion.
When requesting service or replacement parts for your
appliance please provide model number and serial number.
All parts listed may be orderd from an authorized dealer.
Stocked
at Depot
Item
Description
Comments
Part Number
1
Hopper Top Assembly
SRV414-5830
Feed Adjustment Bracket
Assembly
SRV414-6230
2
3
4
5
6
7
Plate, Cover, Outer Can
Leveling Leg
480-1300
SRV414-0210
SRV414-0610
UK-30KPEL
414-0270
Bracket, Hinge
Attaches to Unit
Baffle Assembly
Brick, Left / Right, Cast
Firepot Assembly
Bushing, Firepot
Floor, Firepot
Interchangeable
SRV414-5200
410-8320
Y
Y
414-0290
Gasket, Firepot
240-0930
Nut, Lock 1/4-20
Bolt, Firepot, 1-1/4” Long
Pull Rod Assembly
Clip, Hitch Pin, #25
Spring, Firepot
226-0090
225-0120
8
414-5270
229-0360
200-2050
Matte Black
414-0060BK
414-0060POR
414-0060PWD
414-5180
9
Top Cast
Must Specify Porcelain Color
Must Specify Powder Coat Color
10
11
Top Slide Assembly Left
Face
Matte Black
414-0040BK
414-0040POR
414-0040PWD
SRV414-0940
SRV414-0950
414-0280
Must Specify Porcelain Color
Must Specify Powder Coat Color
For Black Units
Face Hinge
For Porcelain & Powder Coat Units
Interchangeable
12
13
Backer, Side Window
Glass Assembly, Side, 1 Piece
Gasket, Channel 1/8X1-1/4
Speed Nut 5/16
5-7/8 in. W x 9 in. H, Interchangeable
Qty: 10 Ft., Field cut to size
Qty: 24
414-5380
Y
Y
Y
7000-377/10
7000-422/24
414-0050BK
414-0050POR
414-0050PWD
414-5170
Matte Black
14
15
Side
Must Specify Porcelain Color
Must Specify Powder Coat Color
Top Slide Assembly Right
SN # 0071389650 & Above, Bottom
Airwash
413-5110
16
Door Assembly
SN # 0071389649 & Below, Top Airwash 414-5190
Page 43
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Castile Pellet Insert
To order the entire assembly, order the top line part number only.
To order an individual part from an assembly, order the part(s)
listed in the indented portion.
HOW TO ORDER
Stocked
at Depot
Item
Description
Comments
Qty: 10 Ft., Field cut to size
17-1/in. W x 11-5/8 in. H
Part Number
842-5130
Gasket, Tadpole, 3/8
Glass Assembly
Y
Y
7001-038
Hinge, Female
450-2910
Retainer, Rope
7001-192
Tape, Door Corner
Door Latch Assembly
Qty: 1 Ft., Field cut to size
SRV7027-227
413-5200
17
18
Qty: 1
SRV7000-462
SRV7000-462/10
28758/24
Y
Y
Y
Y
Heating Element Assembly 18”
(Loop Igniter)
Qty: 10
Qty: 24
Qty: 24
Washer, 1/4 Sae
Wing Thumb Screw 8-32X1/2
Brick, Center, Cast
Ash Pan
7000-223/24
414-0260
19
20
21
414-0130
Wire Harness
SRV414-1040
230-2150
Y
Capacitor, Rep Jumper
Igniter Extension
7000-218
22
23
24
25
26
Control Board 3 Speed
Snap Disc, Manual Reset, # 3
Snap Disc, 110-20
Outer Skin
SRV7000-205
SRV230-1290
SRV230-1220
414-0500
Y
Y
Y
Blower, Exhaust Combustion
812-4400
Y
Y
Between Housing & Stove
240-0812
Gasket, Exhaust Combustion
Blower
Between Housing & Motor (round)
812-4710
27
28
29
30
Exhaust Transition Assembly
Latch, Draw
414-5100
229-0230
Exhaust Adapter Assembly
Gasket, Flue Adapter
Blower, Convection
Blower Magnet
414-5110
240-0850
812-4900
Y
7019-188
Feed Assembly
414-5400
Bearing, Feed System, Nylon
Collar, Set, 7/8
410-0552
229-0520
Feed Motor Bracket Assembly
Feed Motor
7001-039
812-4421
Y
Y
Feed Spring Assembly
Gasket, Feed Motor
Plate, Feed Motor Mount
SRV414-5540
240-0731
412-0240
SN # 0071389337 & Above (on drop
tube)
SRV7000-268
Y
31
Snap Disc, Manual Reset, # 3
SN # 0071389336 & Below
SRV230-1290
SRV7000-447
SRV414-0320
Y
Y
32
33
Vacuum Switch
Hopper Back
Page 44
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Castile Pellet Insert
To order the entire assembly, order the top line part number only.
To order an individual part from an assembly, order the part(s)
listed in the indented portion.
HOW TO ORDER
Item
Stocked
at Depot
Description
Comments
Part Number
Ash Catcher
414-0150
7001-186
414-0930
7005-253
Plate, Ash Cleanout
Bracket, Magnet
Bracket, Snap Disc
Call Light Bulb
Old Style Junction Box
Old Style Junction Box
SN # 1378393 & Above
Qty: 2
812-0760
Y
Y
Call Light Lens Cover
Call Light, Fluorescent
812-0750
SRV7000-122
812-0730
Y
Y
Ceramic Nuts, (Igniter)
Qty: 12
812-0730/12
414-5390
Matte Black
Component Pack Assembly
(Includes Firepot Cleanout Tool,
Touch-Up Paint, Power Cord,
Thermostat Wire Harness, Owners
Manual, Warranty Card, “How-To”
Dvd
Porcelain Mahogany
Powder Coat Sienna Bronze
414-5460
414-5510
Powder Coat Willow
414-5520
Cleanout Tool
414-1140
Dvd Original Energy Insert
7000-441
Matte Black
7000-304
Porcelain Mahogany
Powder Coat Sienna Bronze
Powder Coat Willow
855-1450
Paint Touch-Up
TOUCHUP-CSB
TOUCHUP-CWL
812-1180
Power Cord
Harness, Thermostat Wire
Deflector, Bottom Airwash
230-0810
413-0680
Qty: 1 Junction Box
Qty: 10 Junction Box
Qty: 1 Control Box
Qty: 10 Control Box
812-0380
Y
Y
Y
Y
Fuse, 7 Amp, Junction Box
Fuse, 8 Amp, Control Box
812-0380/10
812-3780
812-3780/10
450-2810
Hinge, Door, Male
Hook, Cast Mount
Hose, Vacuum, 5/32 Id
414-1010
QTY: 3 Ft, Field Cut to Size
Heat Output, Rocker Switch
SRV240-0450
Y
Y
Igniter Wire (5Ft) & (4) Ceramic
Nuts
812-4520
Magnet Round
SRV7000-140
812-3500
Y
Y
Y
Switch, 3-Position
Thermocouple
812-4470
Thermocouple Clamp
SRV7001-203
812-1322
Qty: 1
Y
Y
Thermocouple Cover
Qty: 10
812-4920
Thermocouple Grounding Kit
Wire Harness Snap Disk
812-4980
7001-224
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Castile Pellet Insert
To order the entire assembly, order the top line part number only.
To order an individual part from an assembly, order the part(s)
listed in the indented portion.
HOW TO ORDER
Stocked
at Depot
Item
Description
Comments
ACCESSORIES
Part Number
ADJSPT-12
PEL-DAMP3
PEL-DAMP4
811-0852
Adjustable Hearth Support
Damper, 3 Inch
12 in x 50 in, 2-10 in H
Tall Vertical Installs Only
Tall Vertical Installs Only
Qty: 4
Damper, 4 Inch
Log Set
Log Front, Left
7001-231
Log Front, Right
7001-230
Log Rear, Left
7001-233
Log Rear, Right
7001-232
Log Top, Twig, Center
Outside Air Kit, Rear
Channel, Air Intake
Cover, Outside Air Kit, Floor
Hose, Alum Flex, 2 Inch X 3 Ft
Outside Air Cap Assembly
Outside Air Collar Assembly
Trim Plate, Outside Air Kit
Panel & Trim Set, Basic, Standard
Bracket, -L-, Trim
To Cover Firepot
Qty: 3 Ft
811-0900
811-0872
413-7040
411-1071
200-0860
7001-044
7001-045
412-7100
With Gold Trim
811-0990
832-0840
Component Pack
413-5270
Trim, Panel Set, Std, Gold
Panel Set, Large
Gold Trim Set
811-0710
Use With Cast Trim
811-0920
Component Pack
Fasteners & Instructions For Cast Trim
Use With Cast Trim
413-5260
Panel Set, Standard
Component Pack
811-0910
Fasteners & Instructions For Cast Trim
413-5260
Thermostat, Mechanical
Thermostat, Programmable
812-3760
811-0520
Matte Black
811-0930
Porcelain Mahogany
Powder Coat Sienna Bronze
Powder Coat Willow
Matte Black
811-0960
Trim Cast
TR-CAST-CSB
TR-CAST-CWL
414-7090MBK
414-7090PMH
414-7090CSB
414-7090CWL
414-7100MBK
414-7100PMH
414-7100CSB
414-7100CWL
Porcelain Mahogany
Powder Coat Sienna Bronze
Powder Coat Willow
Matte Black
Footer, Left
Footer, Right
Porcelain Mahogany
Powder Coat Sienna Bronze
Powder Coat Willow
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Castile Pellet Insert
To order the entire assembly, order the top line part number only.
To order an individual part from an assembly, order the part(s)
listed in the indented portion.
HOW TO ORDER
Stocked
at Depot
Item
Description
Comments
Part Number
Matte Black
414-7110MBK
414-7110PMH
414-7110CSB
414-7110CWL
414-7120MBK
414-7120PMH
414-7120CSB
414-7120CWL
414-7130MBK
414-7130PMH
414-7130CSB
414-7130CWL
Porcelain Mahogany
Powder Coat Sienna Bronze
Powder Coat Willow
Matte Black
Header
Porcelain Mahogany
Powder Coat Sienna Bronze
Powder Coat Willow
Matte Black
Trim Leg, Left
Porcelain Mahogany
Powder Coat Sienna Bronze
Powder Coat Willow
Trim Leg, Right
Zero Clearance, Adjustable Trim
Support
For Standard Panel Surround Only
811-0980
FASTENERS
1/4-20 & 3/8-16 Rivnut Tools
Qty: 10
Avk Rivnut Repair Kit
Bolt, Hex Head, 1/4-20 X 1
Nut, Wing, 8-32
RIVNUT-REPAIR
25221A/10
Y
Y
Y
Qty: 24
226-0160/24
Screw, 1/4-20X3/8 Phillips Button
Head
Qty: 24
Qty: 24
7000-401/24
7000-130/24
225-0500/40
832-0860
Y
Y
Y
Screw Flat Head Screw 1/4-20
Screw, Pan Head Philips 8-32 X 3/8 Qty: 40
Screw, Flat Head Philips 8-32X1/2
Qty: 10
Qty: 24
Screw, Pan Head Philips, 10/32 X
1/4
229-1230/24
Y
Y
Screw, Sheet Metal #8 X 1/2 S-Grip Qty: 40
12460/40
Screw, Machine Screw 1/4-20X5/8
Speed Nut 5/16
Qty: 24
Qty: 24
Qty: 24
Qty: 24
220-0440/24
7000-422/24
28758/24
Y
Y
Y
Y
Washer, 1/4 Sae
Wing Thumb Screw 8-32X1/2
7000-223/24
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E. Service And Maintenance Log
Date of Service
Performed By
Description of Service
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Castile Pellet Insert
E. Service And Maintenance Log (Cont’d)
Date of Service
Performed By
Description of Service
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F. Warranty Policy
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CONTACT INFORMATION:
Hearth & Home Technologies
1445 North Highway
Colville, WA 99114
Division of HNI INDUSTRIES
Please contact your Quadra-Fire dealer with any questions or concerns.
For the number of your nearest Quadra-Fire dealer
please visit our web site at www.quadrafire.com
NOTICE
DO NOT DISCARD THIS MANUAL
• Read, understand and • Leave this manual with
• Important operating and
maintenance instruc-
tions included.
follow these instruc-
tions for safe installa-
tion and operation.
party responsible for use
and operation.
We recommend that you record the following pertinent
information for your CASTILE PELLET INSERT
Date purchased/installed:
Serial Number:
Location on appliance:
Dealer phone:
Dealership purchased from:
Notes:
This product may be covered by one or more of the following patents: (United States) 4593510, 4686807, 4766876, 4793322, 4811534,
5000162, 5016609, 5076254, 5113843, 5191877, 5218953, 5263471, 5328356, 5341794, 5347983, 5429495, 5452708, 5542407,
5601073, 5613487, 5647340, 5688568, 5762062, 5775408, 5890485, 5931661, 5941237, 5947112, 5996575, 6006743, 6019099,
6048195, 6053165, 6145502, 6170481, 6237588, 6296474, 6374822, 6413079, 6439226, 6484712, 6543698, 6550687, 6601579,
6672860, 6688302B2, 6715724B2, 6729551, 6736133, 6748940, 6748942, 6769426, 6774802, 6796302, 6840261, 6848441, 6863064,
6866205, 6869278, 6875012, 6880275, 6908039, 6919884, D320652, D445174, D462436; (Canada) 1297749, 2195264, 2225408,
2313972; (Australia) 780250, 780403, 1418504 or other U.S. and foreign patents pending.
250-7251G
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