Installation & Operating Manual The Harman PB 105 Pellet Boiler “Ce manuel est disponible en Français sur demande” R11 SAFETY NOTICE Warning! Risk of fire or exploision! • Improper installation, operation or maintenance of this boiler can cause injury or death. • Follow all instructions contained in this manual BEfore installation and use of this boiler: • Please Read and understand this entire manual. Consult your local authorities having jurisdiction.
Access Cover To Secondary Ash Chamber Ash Door Firebox Door Viewing Glass Access Cover To Hopper / Swing Plate Knob Control Board Cover Control Board Hopper Hopper Lid Latches 1-1/4” FMPT Supply 1/2” FMPT Boiler Drain Combustion Blower Cover Combustion Blower Vent Pipe 1-1/4” FMPT Return (Removed w/ Domestic Hot Water Option) Blank Cover Pressure Relief Valve Aquastat Well Temperature / Pressure Gauge Parts Locations 3
Introduction Table Of Contents Warranty 5 Assembly 6 Venting 9 Installation 12 Fuel Specifications 22 Operation 23 Maintenance 30 Troubleshooting 34 Atmospheric Conversion 35 Service Parts 36 Specifications 41 Wiring Diagram 42 Testing Label 44 Appliance Certification. Model: Pellet Burning Boiler - PB105 Test Lab: Omni-Test Laboratories, Inc.
Warranty HARMAN™ CENTRAL HEATING PRODUCTS LIMITED WARRANTY Hearth & Home Technologies Inc., on behalf of its Harman™ brand (”HHT”), extends the following warranty for all Harman™ furnace and boiler products (“Products”) that are purchased from an HHT authorized dealer.
Assembly Boiler Kit Materials: (Refer to page 3) 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 42" CANADA 42" CANADA 18" CAN 16" USA 40" USA 40" USA Refer to the illustration on page 3 to identify the compoMINIMUM NON-COMBUSTIBLE FLOOR PROTECTION AREA nents listed below: 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 NON-COMBUSTIBLE ash door, firebox door and the heat exchanger cleanout rod FLOOR PROTECTOR handles.
Assembly 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. Be sure to inspect and clean exhaust venting system frequently.
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.
Venting Fig. 3 Avoiding Smoke and Odors - Negative Pressure, Shut-down and Electrical Power Failure. To reduce the probability of back-drafting or burn back in the pellet boiler during a power failure, it must be able to draft naturally without exhaust blower operation. Negative pressure in the house will resist this natural draft if not accounted for during installation. Heat rises in a house, and leaks out at upper levels.
Venting Venting Venting Use 4” pellet vent pipe only. 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 NOTE: Use only 4” diameter approved pellet venting system. Be sure to inspect and clean exhaust venting system frequently. INSTALLATION IS TO BE PERFORMED BY A QUALIFIED INSTALLER. DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST VENTING SYSTEM OF THIS UNIT. DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE. 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.
Installation Outside Air Inlet Cover part# 1-10-09542 Fig. 6 Outside Air Pipe Knockout Feeder Cover Fig. 7 Outside Air Inlet Pipe To install outside air, use 2 3/4” I.D.galvanized steel flex pipe, part # 2-00-08544 ( 12’ 6” length) or part # 2-00-08545 ( 25’ length) See Fig. 6. There is a breakaway hole on the rear panel which must be removed before connecting the flex pipe. See Fig. 7.
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. NOTE: If other sources of electrical power are to be used ( such as a generator ) for normal operation or emergency operation, this source should be checked before installation.
Installing Duct Installation NOTE: Cold return water temperature (Sustained temperatures below 140 degrees Fahrenheit) will lead to condensation in the firebox. This moisture can lead to creosote formation. To help minimize moisture and creosote, it is strongly recommended that some form of temperature balance is incorporated into the return water system. NOTICE: When installing with the atmospheric conversion: All of the pressurized system components shown are not necessary.
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 EXAMPLE OF TYPICAL TANKLESS DOMESTIC HOT WATER PIPING HIGH TEMPERATURE WATER (IF NEEDED) TEMPERED HOT WATER TO SHOWERS AND FAUCETS NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM. OPTIONAL DOMESTIC HOT WATER COIL INLET MIXING VALVE OUTLET MIXING VALVE SET TO DESIRED WATER TEMPERATURE. NORMALLY NOT MORE THAN 120 DEGREES.
Installation TYPICAL BOILER HOT WATER PIPING SHOWING AIR REMOVAL SYSTEM, PROVISIONS FOR THE EXPANSION OF WATER AND THE AUTOMATIC COLD WATER SUPPLY. ALSO SHOWN IS THE AUTOMATIC MIXING VALVE. THIS COULD ALSO BE DONE BY (2) CLOSELY SPACED TEE'S. THE PROPER PIPING FOR THE INTENDED USE WILL BE DETERMINED BY THE INSTALLING CERTIFIED PLUMBER OR HVAC CONTRACTOR.
Installation NOTE: Cold return water temperature (Sustained temperatures below 140 degrees Fahrenheit) will lead to condensation in the firebox. This moisture can lead to creosote formation. To help minimize moisture and creosote, it is strongly recommended that some form of temperature balance is incorporated into the return water system. NOTICE: When installing with the atmospheric conversion: All of the pressurized system components shown are not necessary.
Over Heat Safety Zone OverHeat Safety Zone (Dump Zone): STRONGLY RECOMMENDED in all installations. When the pellet boiler is operating at High burn, and all demand from the heating system stops, the control will reduce the feed rate and shut down completely as necessary. This may take several minutes, and the remaining heat may cause the water temperature to continue to rise.
Installation Firebox Door Draft Bolt Location Air Wash Slot Air wash Slot Viewing Window Fig. 9 “Test” 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 appliance doors and 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”.
Fuel Specifications Fuel and Fuel Storage Pellet fuel quality can fluctuate from manufacturer to manufacturer, and even from bag to bag. Hearth & Home Technologies recommends using only fuel that is certified by the Pellet Fuels Institute (PFI).
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. Afterward, combustion blower remains on low only. Overheat Safety Zone Light Indicates elevated boiler water temperature. Power flowing to Overheat circuit.
Operation Setting The Boiler Temperature WATER TEMPERATURE MAX. TEMP. Control Board Operation MIN. TEMP. Aquastat Sensor - This sensor is located in the aquastat well on the top of the water jacket. This sensor along with the outdoor air sensor is what the control board uses to regulate the feed rate based on these two observed conditions. (Boiler Temp. & Outdoor Air Temperature) Outdoor Air Temp.
OAT 65o 60o 55o 50o 45o 40o 35o 30o 25o 20o 15o 10o 5o 0o Example 2 Max set at 180o Min set at 150o Water Temp 150o 150o 150o 150o 155o 160o 165o 170o 175o 180o 180o 180o 180o 180o Water Temp 140o 145o 150o 155o 160o 165o 170o 175o 180o 185o 185o 185o 185o 185o Degree Change * * * -30o -25o -20o -15o -10o -5o 0o 0o 0o 0o 0o Degree Change -45° -40° -35° -30° -25o -20o -15o -10o -5o 0o 0o 0o 0° * No change in boiler temperature after reaching minimum setpoint 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. Scrape burnpot to remove any carbon build-up that may have occurred Scraping can be done while in operation 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.
Operation 4. If Starting After an Empty Hopper, Turn Feed Adjuster to “TEST” (for one 60 second cycle). This will feed 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 an average number for most pellets and may need to be adjusted for your particular fuel.
Operation 7. Open hopper swing plate as shown in Fig. 13 (See “NOTE” on page 26.) 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 approximately 5° F. less than the set temperature on the MAX TEMP. dial. This 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. Apply starting gel as shown in Fig.15 Fig. 15 NOTE: Stirring the starting gel into the pellets usually allows the fire to become established quicker. CAUTION: A vapor flash could occur if too much time is allowed to pass before lighting the starting gel. CAUTION: Care must be taken not to get starting gel on your hands or clothing. Serious burns could occur during the lighting process.
Maintenance 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 recommended the boiler be on minimum burn at the time of cleaning. Note: Scraping can be done while in operation if performed through the firebox door opening. See Fig.
Maintenance Ash Pan Handle Ash Door Ash Pan Ash Door Handle Fig. 21 Warning! Risk of Fire! Ash, soot or creosote build-up may cause overheating or fire. Routine cleaning of heat exchangers and venting is required. Disposal of Ashes Ashes should be placed in a steel container with a tight fitting lid. The closed container of ashes should be moved outdoors immediately and placed on a non-combustible • floor or on the ground, well away from all combustible materials, pending final disposal.
Maintenance Heat Exchanger Cleanout Rod Handles Firebox Door Heat Exchanger Tube Secondary Ash Chamber Access Plate Fines Cleanout Cover Firebox Wall 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.
Maintenance Heat Shield Latch Fig. 22 Exhaust Probe Combustion Blower Motor Thumb Screws (3 Total) Fig. 23 Sealing Overlap The boiler 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.
Troubleshooting FEEDER DOES NOT FEED 1. No pellets in hopper. 2. Firebox draft may be too low for low draft pressure switch in feeder circuit to operate. Check for improperly closed doors, loose or missing gasket on doors or hopper lid, or a faulty pressure switch. 3. Feed motor will not run until the ESP senses 170 deg. F. Maybe you did not put enough pellets in the burn pot before lighting the fire manually. 4. Something is restricting flow in the hopper or causing the slide plate to stick. 5.
Atmospheric Conversion Atmospheric Conversion: Item # 1-00-232200, provides automatic fill, and converts the heating system plumbing from pressurized to a zero pressure system. Allows for installation into more places where codes and standards restrict pressurized systems. Note that when using the atmospheric conversion, air bleeders and check valves may actually allow air into the lines. Another reason it is important to have a licensed Plumber involved in each phase of your installation.
pb105 Service parts beginning manufacturing date: N/A Ending manufacturing date: Active Central heat 1-90-07205 1 2 3 28 27 26 4 5 6 25 7 9 24 23 22 21 20 10 8 19 11 12 18 13 14 15 16 17 IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement parts for your appliance please provide model number and serial number. All parts listed in this manual may be ordered from an authorized dealer.
pb105 Service parts beginning manufacturing date: N/A Ending manufacturing date: Active #8 Ash base Assembly 8.4 8.3 8.2 8.1 8.20 8.5 8.19 8.18 8.6 8.17 8.7 8.16 8.10 8.8 8.9 8.11 8.12 8.13 8.14 8.15 IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement parts for your appliance please provide model number and serial number. All parts listed in this manual may be ordered from an authorized dealer. ITEm dESCrIpTION COmmENTS Ash Base Gasket 8.
pb105 Service parts beginning manufacturing date: N/A Ending manufacturing date: Active IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement parts for your appliance please provide model number and serial number. All parts listed in this manual may be ordered from an authorized dealer.
pb105 Service parts beginning manufacturing date: N/A Ending manufacturing date: Active #28 Feeder Assembly 28.1 28.15 28.16 28.12 28.14 28.2 28.13 28.11 28.3 28.10 28.9 28.4 28.5 28.7 28.8 28.6 IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement parts for your appliance please provide model number and serial number. All parts listed in this manual may be ordered from an authorized dealer. ITEm 28.
pb105 Service parts beginning manufacturing date: N/A Ending manufacturing date: Active IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement parts for your appliance please provide model number and serial number. All parts listed in this manual may be ordered from an authorized dealer. ITEm dESCrIpTION COmmENTS #30 Waterplate kit #29 boiler kit 30.1 29.1 Stocked at depot pArT NumbEr #31 handle kit 31.1 30.2 30.3 29.2 29.3 29.
1.4 AMP .7 AMP 3.6 AMP .05 AMP .2 KWH Auger motor Igniter element Control board Approximate operating wattage 120 VAC 60 Hz Combustion blower Electrical * 8500 BTU per pound figures Max. Burn = 13.4 pounds per hour Min. Burn = 1.1 pound per hour 0 BTU if system is satisfied.
GREEN WHITE DARK BLUE RED 4" SQUARE JUNCTION BOX PVC CORD MOTOR LEAD AUX. OUTPUT (OVERHEAT ZONE) RED WHITE BROWN WHITE BLACK GREEN/YELLOW 120 VOLTS A.C. 60 HZ. 5.3 AMPS ( ignition mode ) 635 WATTS200 WATTS1.7 AMPS ( normal operation ) COMBUSTION MOTOR WHITE 3/8"FLEX CONDUIT RED WHITE MOTOR WIRE MALE/FEMALE CONNECTION FEEDER MOTOR N.O.
to combustion motor 3/8"FLEX CONDUIT RED WHITE GREEN/YELLOW WHITE WHITE BLACK 120 VAC power (by installer) WHITE WHITE GREEN WHITE BROWN DARK BLUE WHITE GR Relay enclosure box GRAINGER # 1EGH7 GREEN RED RED RED BLACK D RE D RE 8 5 1 2 3 6 4 7 GREEN BLACK WHITE WHITE BLACK GREEN FEMALE POWER TO THE UPS / Plug UPS into here. When current is present, will keep UPS in Ready mode. CORD CONNECTOR 16-3 AWG PVC CORD MALE POWER FROM THE UPS / This plugs into the UPS.
Testing Label O L Wood E E B A L Y L N MPL A S WARNING: Risk of fire - Do not operate with the flue draft exceeding -.9 in Water Column / -224Pa. ATTENTION: Risque de feu - Ne fonctionnez pas avec l'ébauche deconduite de cheminée excédant -.9 " colonne de l'eau / -224Pa. Hearth & Home Technologies, Inc.
Service Record / Notes 45
Service Record / Notes 46
Proudly Printed On 100% Recycled Paper 47
**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.
