Installation & Operating Manual The Harman PB 105 Pellet Boiler “Ce manuel est disponible en Français sur demande” R1 SAFETY NOTICE PLEASE READ THIS ENTIRE MANUAL BEFORE YOU INSTALL AND USE YOUR NEW BOILER. FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR EVEN DEATH. FOR USE IN THE U.S. AND CANADA. SUITABLE FOR INSTALLATION IN MOBILE HOMES IF THIS HARMAN PELLET BOILER IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT. FOR YOUR SAFETY, FOLLOW INSTALLATION DIRECTIONS.
Table of Contents Assembly 4 Venting 8 Installation 11 Operation 20 Maintenance 27 Troubleshooting 31 Feeder Parts 32 Specifications 33 Wiring Diagram 34 Parts List & Options 35 Warranty 36 Testing Label 37 Quick Reference Start-Up Back Cover Please read this entire manual before you install and use your new boiler. Failure to follow instructions may result in property damage, bodily injury, or even death.
½”MPT Boiler Drain (Not Shown) Remove Cover to access nuts to fasten Flue Tunnel Weldment to the Ash Chamber.
Assembly Boiler Kit Materials: (Refer to pages 4 & 5) List of items contained within the boiler kit shipped with the unit. 1 - Control board cover 1 - Access cover (Hopper Swing Plate Knob) 5 - Spring Handles 1 - 1/2” Boiler Drain 1 - 3/4” Safety Relief Valve 1 - 1/2” Aquastat Well 1 - 1/2” Dual Temperature/Pressure Gauge 1 - 100ft. Sensor Cable (Outdoor Air Sensor) 1 - Outdoor Air Sensor 1 - Flue Tunnel Weldment 1 - Combustion Blower Assembly 1 - Heat Shield (Comb.
Assembly After assembly of the flue tunnel weldment, combustion blower assembly with wiring and heat shield, the boiler can now be installed. 1. Install the control board cover as well as the access cover located on the feeder cover. 2. Install the spring handles provided with the unit on the ash door, firebox door and the heat exchanger cleanout rod handles. (Fasten handles by turning them counterclockwise and pushing inward simultaneously). 3. Install 1/2” MPT boiler drain in the fitting as shown.
Assembly When installing the PB105 in a mobile home several requirements must be followed: 1. The unit must be bolted to the floor. 2. The unit must be connected to outside air. 3. Floor protection and clearances must be followed. 4. Unit must be grounded to the metal frame of the mobile home. INSTALLATION IS TO BE PERFORMED BY A QUALIFIED INSTALLER. NOTE: All installation clearances and restrictions must be adhered to. NOTE:Use only 4” diameter type “L” or “PL” venting system.
Venting Requirements for Terminating the Venting WARNING: Venting terminals must not be recessed into a wall or siding. NOTE: Only PL vent pipe wall pass-throughs and fire stops should be used when venting through combustible materials. NOTE: Always take into consideration the effect the prevailing wind direction or other wind currents will cause with flyash and /or smoke when placing the termination. In addition, the following must be observed: A. The clearance above grade must be a minimum of 18".1 B.
Fig.
Venting Venting Venting Use 4” pellet vent pipe to vent your PB105. A combustion blower is used to extract the combustion gases from the firebox. This creates a negative pressure in the firebox and a positive pressure in the venting system as shown in Fig. 4. The longer the vent pipe and more elbows used in the system, the greater the flow resistance. Because of these facts we recommend using as few elbows as possible and 30 feet or less of vent pipe. The maximum horizontal run should not exceed 18 feet.
Venting Installation Chimneys taller than 20’ above the connection will require a draft test to determine if the draft is too high. Note: The High Burn Draft should not exceed .85 IWC. Some form of a restrictor plate may be required at the top of high chimneys to reduce the draft. See page 19 for the Draft Test procedure. The PB105 Boiler may be used and installed into an existing masonary or Class A metal chimney. Certain Canadian and Local Codes may require that the chimney be fully relined.
Installation Outside Air Inlet Cover part# 1-10-09542 Fig. 6 Outside Air Pipe Knockout Feeder Cover Fig. 7 Outside air is optional, although it may be required by some building codes. The benefit of outside air is higher efficiency and reduced venting restrictions mainly noticed in small and very tight houses. To install outside air, use 2 3/4”" I.D.galvinized steel flex pipe, part # 2-00-08544 ( 12’ 6” length) or part # 2-00-08545 ( 25’ length) See Fig. 6.
This boiler should never be powered by the use of an extension cord. The recommended high and low voltages are, 130 V.A.C. 60 Hz maximum high voltage, and 113 V.A.C. 60 Hz minimum low voltage.The furnace will continue to operate at voltages as low as 105 V.A.C. , although it can not be guaranteed that automatic ignition will occur.
Installing Duct Installation 15
Installing Duct/Air Conditioning Installation Boilers intended to be connected to an existing boiler or boiler system shall: 1. Be capable of being installed without interfering with the normal delivery of heated water from the original boiler to the radiation system. 2. Be capable of being installed to operate as intended without affecting the operation of the electrical and mechanical safety controls of the original boiler. 3.
Installation 17
Installation 18
Installation 19
Installation Draft Bolt Location Air wash Slot Viewing Window Fig. 9 Draft Test Procedure After the venting is completed, the firebox low draft will need to be checked and possibly adjusted. After removing the 3/8” bolt from the draft hole shown in Fig. 9, insert the draft meter tube. The hopper lid must be latched during this test. (It is recommended that the draft meter have a scale of 0 to 1” WC.) Turn the feed adjuster to “Test”.
Operation Power Light Indicates power to the control board. Feed adjuster Sets the maximum feed rate Status Light Will be lit anytime there is a call for heat. Test Combustion blower, feed motor and safety dump zone are fully energized for the first minute. Combustion blower alternates from high to low every minute. Overheat Saftey Zone Light Indicates that the boiler water temperature has reached 205 Degree F.
Operation Setting The Boiler Temperature Without the Outdoor Air Temperature Sensor Installed To set the maximum boiler water temperature, simply turn the Max. Temp. water temperature dial to the desired setting. The control and the boiler will then perform to achieve and maintain the set temperature. The Min. Temp. Knob simply becomes the boiler mode switch, on or off.
Water Temp 65 60 55 50 45 40 35 30 25 20 15 10 5 0 OAT 65 60 55 50 45 40 35 30 25 20 15 10 5 0 Max set @ 185 Min set @ 120 Example # 2 Max set @ 180 Min set @ 150 Degree Degree * No change in boiler temperature after reaching minimum setpoint temp 150 150 150 150 150 150 150 150 155 160 165 170 175 180 120 125 130 135 140 145 150 155 160 165 170 175 180 185 OAT Example # 1 Water Temp When the outdoor air sensor is installed, at zero degrees OAT (Outdoor Air Temp) operate at the temperature
Operation Starting A Fire Automatically 1. Turn Mode Selector to "OFF". This resets the control in addition to turning it off. 2. Clean burnpot with scraper, if necessary. This is usually a weekly maintenance procedure. Cleaning the burn pot with the scraper with a small amount of new fuel in the bottom is not a problem. First, scrape the ashes on the front of the burn pot into the ash pan. Then scrape the hole grid surface downward into the burn pot.
Operation 4. If starting after an empty hopper, turn Feed Adjuster to "TEST" (for one 60 second cycle). This will purge pellets into the auger tube and also allow you to check the motors for operation. NOTE: The auger motor will not operate with any of the doors open. 5. Turn Feed Adjuster to #4. If this is your first fire or you are trying different pellets, set the feed adjuster to #4, This is a conservative number and will probably need to be increased if maximum BTU output is desired.
Operation Fig. 12 7. Open hopper swing plate as shown in Fig. 13 (See “NOTE” on page 23.) 8. Turn the MIN. TEMP. Dial on the control board to the desired Minimum temperature. This will start the lighting process if the temperature at the aquastat sensor is less than the set temperature on the MAX TEMP. dial. The PB105 is more than just an automatic ignition pellet boiler. The automatic system will allow the fire size to be adjusted to match the heating needs and even put the fire out if necessary.
Operation 11. Turn Mode Selector to desired MIN TEMP setting. This will start the combustion blower and allow the ESP to control the fire in relation to the MAX TEMP Dial setting. (The MAX TEMP dial setting must always be set above the MIN TEMP setting) Once the fire is well established the MAX TEMP dial can remain on any temperature setting desired. Fig. 15 NOTE: When the Switch is set to Manual igniter position the boiler will function as in auto igniter except the fire will not be allowed to go out.
Burnpot cleaning: The burnpot should be cleaned no less than once a week. For best operation the burnpot should be cleaned every time the hopper is filled with pellets. The fire does not have to be out to scrape the burnpot although it is recomended the boiler be on minimum burn at the time of cleaning. Note: Scraping can be done while in operation if performed throug the firebox door opening. See Fig. 17 Use the flat end of the scraper provided to scrape down over the holed surface of the burnpot grate.
Maintenance Ash Pan Handle Ash Door Ash Door Handle Ash Removal Ash Pan Secondary Ash Chamber Access Cover Fig. 21 Disposal of Ashes Ashes should be placed in a metal container with a It is recommended to remove the ashes when the boiler is not in operation. This lessens the chances of coming in tight fitting lid. The closed container of ashes should be placed contact with hot surfaces.
Maintenance Cleaning This cleaning should be done after each ton of pellets used. The frequency of this cleaning will be directly related to the quality and the ash content of the pellets being used. Keep in mind that the cleaner the heat exchanger surface is kept, the higher the heat transfer efficiency will be. Due to it’s ease of restarting it is recommended that the boiler be OFF and COOL before cleaning.
Maintenance Heat Shield Latch (2) Fig. 22 The furnace MUST be OFF and COOL before you should attempt to clean the combustion blower. The wire to the combustion blower doesn’t need to be disconnected during the cleaning process. Loosen the three (3) thumb screws about 4 turns each. See Fig. 23. Hold the motor head with one hand and the blower plate handle with the other hand. Pull outward on the plate handle until the complete unit comes loose. Now rotate the plate counter-clockwise about 1/8 turn.
FEEDER DOES NOT FEED 1. No pellets in hopper. SMOKE IS VISIBLE COMING OUT OF VENT 2. Firebox draft may be too low for low draft 1. Air-fuel ratio is too rich. pressure switch in feeder circuit to operate. A. Feed rate too high. Check for closed doors, loose or missing B. Draft too low caused by a gasket leak. gasket on doors or hopper lid, or a faulty pressure switch. LOW HEAT OUTPUT 3. Feed motor will not run until ESP 1. Feed rate too low senses 170 deg. F. Maybe you did not put 2.
Feeder Parts 33
Specifications 34
Wiring Diagram Diagram 35
Parts List ITEM NUMBER 0-88-00248 0-88-88100 1-10-00330 1-10-07210 1-10-09330 1-10-72129 1-10-73416 2-00-73362 3-00-08534 3-00-677154 3-10-05060 3-10-77382 3-10-78422 3-10-935111 3-20-00607 3-20-00744 3-20-02583 3-20-05630 3-20-09302 3-20-09302B 3-20-3433 3-20-49447 3-20-502221 3-20-72180 3-20-72181 3-20-72195 3-21-08639 3-31-015 3-31-199110 3-31-3014 3-31-605 3-31-72196 3-40-00086-3 3-44-00409 3-44-375501 3-44-53500 3-50-00565 DESCRIPTION RUBBER GROMMET (Hopper Lid - 7' Needed) 1" WHITE GASKET W/PSA SING
Warranty HARMAN GOLD WARRANTY 6 YEAR TRANSFERABLE LIMITED WARRANTY (Residential) 1 YEAR LIMITED WARRANTY (Commercial) Harman Stove Company warrants its products to be free from defects in material or workmanship, in normal use and service, for a period of 6 years from the date of sales invoice and for mechanical and electrical failures, in normal use and service, for a period of 3 years from the date of sales invoice.
Testing Label 38
NOTES 39
**See the section on Maintenance for more details about cleaning. *See the section on Operation for information about Manual Lighting and Emergency Power. The boiler will ignite if the temperature of the boiler water is less than the temperature set on MAX TEMP dial.. 10 Flip the igniter switch to Auto.* 9 Turn MIN TEMP dial to the desired settings.* 8 Turn the MAX TEMP dial to the desired temperature. 7 Turn Feed Adjuster back to the #4 setting.
