R CASTILE PELLET INSERT Owner’s Manual Tested and Listed by Installation and Operation O-T L C Portland Oregon USA US OMNI-Test Laboratories, Inc. Model: CASTILEI-MBK CASTILEI-PMH CASTILEI-CSB CASTILEI-CWL NOTICE • Important operating and • Read, understand and • Leave this manual with follow these instrucparty responsible for use maintenance instructions for safe installaand operation. tions included. tion and operation.
Castile Pellet Insert R and Welcome to the Quadra-Fire Family! Hearth & Home Technologies welcomes you to our tradition of excellence! In choosing a Quadra-Fire appliance, you have our assurance of commitment to quality, durability, and performance. This commitment begins with our research of the market, including ‘Voice of the Customer’ contacts, ensuring we make products that will satisfy your needs.
R 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.
Castile Pellet Insert 1 R Listing and Code Approvals A. Appliance Certification E. BTU & Efficiency Specifications MODEL: Castile Pellet Insert-B LABORATORY: OMNI Test Laboratories, Inc REPORT NO. 061-S-77d-6.2 TYPE: Solid Fuel Room Heater/Pellet Fuel Burning Type Insert STANDARD: ASTM E1509-2004, ULC S628-93 and ULC/ORD-C1482-M1990 Room Heater Pellet Fuel Burning Type and (UM) 84HUD, Mobile Home Approved NOTE: This installation must conform with local codes.
R Castile Pellet Insert 2 Getting Started A. Design, Installation & Location Considerations Since pellet exhaust can contain ash, soot or sparks, you must consider the location of: 1. Appliance Location • Windows NOTICE: Check building codes prior to installation. • Installation MUST comply with local, regional, state and national codes and regulations.
Castile Pellet Insert R 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. • Penetrate the highest part of the roof. This minimizes the effects of wind loading.
R Castile Pellet Insert E. Avoiding Smoke and Odors Vent Configurations Negative Pressure, Shut-Down and Electrical Power Failure To reduce the probability of back-drafting or burn-back in the pellet appliance during power failure or shut down conditions, 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 in the pellet appliance installation. Heat rises in the house and leaks out at upper levels.
Castile Pellet Insert R F. Fire Safety H. Inspect Appliance & Components To provide reasonable fire safety, the following should be given serious consideration: • Remove appliance and components from packaging and inspect for damage. • Install at least one smoke detector on each floor of your home. • Report to your dealer any parts damaged in shipment. • Locate smoke detector away from the heating appliance and close to the sleeping areas.
R 3 Castile Pellet Insert Dimensions and Clearances A. Appliance Dimensions 27-7/8 in. (707mm) 23-3/8 in. (594mm) 8 in. (203mm) 24-3/4 in. (629mm) 19 in. (483mm) 9-3/4 in. (249mm) 13 in. (330mm) 2 in. (51mm) 32-1/4 in. (819mm) Figure 9.1 - Top View Figure 9.2 -Side View A B Figure 9.3- Front View Overall Size January 19, 2011 A B Metal Surround w/Cast Trim, STD 42-1/2 in. (1080mm) 30 in. (762mm) Metal Surround w/Cast Trim, LRG 48 in. (1219mm) 34 in.
Castile Pellet Insert R NOTE: All Clearances are Minimum Clearances B. Clearance To Combustibles, UL and ULC AS A BUILT-IN A C D B C B 0 in. Clearance To Exposed Section And Face Trim Figure 10.1 A Must be installed in a non-tapered enclosure. Top of Hopper Inches Millimeters Top Vent 2.0 51 Rear Vent 2.5 64 Top or Rear Vent 2.0 51 B Side of Hopper C Back of Hopper Top or Rear Vent 4.0 102 D Vent Pipe to Combustible Top or Rear Vent 3.
R Castile Pellet Insert C. Masonry and Factory-Built Fireplaces E. Floor Protection Maximum Mantel Depth: 12 inches (305mm) Face Trim Mantel B Millimeters E Floor protection hearth extension from door opening 6 152 F Floor protection to the side of door opening 6 152 C Side Wall Inches F.
Castile Pellet Insert R G. Removing Metal Floor of Factory-Built Fireplace • 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 requirements. • Any smoke shelves, shields and baffles may be removed from a factory-built firebox if attached with mechanical fasteners.
R 4 Castile Pellet Insert Vent Information B. Venting Termination Requirements A. Chimney and Exhaust Connection 1. Chimney & Connector: Use 3 or 4 inch (76-102mm) diameter type "L" or "PL" venting system. It can be vented vertically or horizontally. 2. Mobile Home: Approved for all Listed pellet vent. Use Listed double wall flue connector. A Quadra-Fire outside air kit must be used with manufactured home installations. 3.
Castile Pellet Insert R C. Pellet Venting Charts WARNING The maximum horizontal venting allowed with no vertical venting attached is 48 inches (1219mm) including one 90° elbow or two 45° elbows. This is our recommended horizontal venting installation. Addition of any horizontal venting beyond 48 inches (1219mm) Hearth & Home Technologies strongly recommends a minimum of 60 inches (1524mm) of additional vertical vent. Horizontal sections of vent pipe should have a 1/4 inch (6.35mm) rise per foot.
R 5 Castile Pellet Insert Venting Systems A. Full Reline With Horizontal Outside Air WARNING Fire Risk. Inspection of Chimney: • Masonry chimney must be in good condition. • Meets minimum standard of NFPA 211 • Factory-built chimney must be a minimum 6 inch (152mm) UL103 HT.
Castile Pellet Insert R C. Full Reline With Vertical Outside Air NOTE: Check clearances carefully for this type of installation to ensure adequate room for outside air venting. 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. 12” (305mm) min. above 12” (305mm) min.
R 6 Castile Pellet Insert Mobile Home A. Mobile Home Installation You must use a Quadra-Fire Outside Air Kit for installation in a mobile home. 1. An outside air inlet must be provided for the combustion air and must remain clear of leaves, debris, ice and/or snow. It must be unrestricted while the appliance is in use to prevent room air starvation which causes smoke spillage. Smoke spillage can also set off smoke alarms. 2. The combustion air duct system must be made of metal.
7 Castile Pellet Insert R Appliance Set-Up B. Outside Air Kit Instructions A. Leveling System The leveling bolts are located at the rear of the appliance. To access the bolts, remove the side access panels. Reach in and turn the bolt to the desired height to level the appliance. Shown in Figures 18.1 and 18.2. Parts Included in Kit: 1 piece of 2 inch x 3 ft. flex hose, 2 hose clamps, 1 collar assembly, 1 termination cap assembly, 1 trim ring, fasteners and air intake channel (discard).
R Castile Pellet Insert C. Door Handle Removal fastener for the type of wall material, i.e., brick, sheetrock, etc. 1. Open the outer door. 2. Unlatch and open the firebox door. 3. Continue to turn handle until it is free from the firebox door. NOTE: 3/8 inch (9.5mm) thick tile or like material can be cut to size and fit under lip of top trim edge for a decorative touch. Figure 20.3. D. Door Removal EXPLODED VIEW OF SCISSORS 1. Open the outer door. 2. Unlatch and open the firebox door.
Castile Pellet Insert R F. Hearth Support For Standard Surround Only es id ll Sst a t r Ins Fi Install Front Last Figure 20.1 - Assembled View Bend top and bottom tabs toward inside 8 NOTE: Manually pre-shape sides before installing Figure 20.3 7 6 5 4 Turn right side up and attach top cast ring 1 2 Figure 20.4 3 Figure 20.
R Castile Pellet Insert F. Hearth Support (Cont’d) Base Plate Only Installation Parts Needed: (1) cast ring (2) base zero clearance panel extensions. Discard balance of parts. Tools Needed: Phillips head screwdriver 1. Attach base zero clearance panel extensions to cast ring. 2. Place assembly under appliance. 8. If power enters appliance on the left side: The cord will have to be routed through the back of the insert.
Castile Pellet Insert R G. Surround & Trim Set, Econo (Cont’d) 4. Assemble Cast Trim and attach to surround: a) Place corresponding cast trim pieces (2 cast trim sides and 1 cast trim header) underneath the surround set, also face down. Align the holes in the metal pieces with the 5 bosses on the top cast piece and 2 bosses on each side piece. Figure. 22.1. View of "L" Bracket installed b) Attach the magnets to the magnet brackets with one countersink screw each.
R Castile Pellet Insert H. Surround and Cast Trim Set (Cont’d) I. Optional Log Set Placement Instructions CAUTION (4) Felt Vibration Insulation Pads Logs are FRAGILE. Use extreme care when handling or cleaning logs. Secure Surrounds to Cast Trim Kit Two Piece Log Set Installation Attach Magnet before installing Cast Footers 1. Open door to expose the firebox. 2. Install the left log first and then the right log. Figure 23.1 3. Lean the logs against the cast iron brick in the back of the firebox.
Castile Pellet Insert R J. Thermostat Installation 1. A 12 volt AC thermostat is required to operate this pellet appliance. You may use the included wall mount thermostat or purchase an optional programmable thermostat or remote control. The included thermostat is equipped with an adjustable heat anticipator. The current rating is .05 amps. The anticipator needs to be adjusted to the lowest setting available. 2.
R 8 Castile Pellet Insert Operating Instructions Clinkers A. Combustible/Non-Combustible Materials • Combustible Material Material made of or surfaced with wood, compressed paper, plant fibers, plastics, or any material capable of igniting and burning, whether flame-proofed or not, plastered or unplastered. • Non-combustible Material Material which will not ignite and burn. Such materials are those consisting entirely of steel, iron, brick, tile, slate, glass or plasters, or any combination thereof.
Castile Pellet Insert R C. General Operating Information WARNING 1. Thermostat Calls For Heat Fire Hazard. Keep combustible materials, gasoline and other flammable vapors and liquids clear of appliance. • 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.
R Castile Pellet Insert F. Starting Your First Fire G. Fire Characteristics 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. 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).
Castile Pellet Insert R I. Ignition Cycles WARNING 1. At the beginning of each ignition cycle, it is normal to see some smoke in the firebox. The smoke will stop once the fire starts. Fire Risk Do NOT operate appliance: • With appliance door open. • Firepot floor open. • Cleaning slide plates open. Do NOT store fuel: • Closer than required clearances to combustibles to appliance • Within space required for loading or ash removal. 2.
R 9 Castile Pellet Insert Troubleshooting 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. Turn down thermostat and let the appliance completely cool. Exhaust blower must be off.
Castile Pellet Insert R Symptom Possible Cause Corrective Action Slow or smoky start-up (Cont’d) Dirty exhaust and/or venting system. 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. Vacuum switch not closing. No vacuum. Firebox door must be closed securely. Check exhaust blower is plugged in and operating.
R Castile Pellet Insert Symptom Convection blower fails to start. Exhaust blower fails to start or does not shut off. Large, lazy flame, orange color. Black ash on glass. Nuisance shutdowns. Appliance calls for heat. Call light illuminates. Exhaust blower starts. No feed or igniter. Hopper lid not closed all the way January 19, 2011 Possible Cause Corrective Action #1 snap disc defective. Replace snap disc. Blower not plugged in. Check that blower is plugged into wire harness.
Castile Pellet Insert 10 R Maintaining & Servicing Your Appliance C. General Maintenance 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.
R Castile Pellet Insert 4. Cleaning Ash Drawer 2. Cleaning Firepot with Cleaning Rod & Firepot Clean-Out Tool • • • Frequency: Daily or more often as needed By: Homeowner • Frequency: Weekly or every 5 bags or more frequently depending on ash build By: Homeowner Locate the ash drawer underneath the firepot and a. The appliance must be in complete shutdown and slide the ash drawer straight out. Empty into a noncool and the exhaust blower off.
Castile Pellet Insert R 8. Cleaning the Glass 6. Cleaning Heat Exchanger Tubes • • • • Frequency: Weekly or every 5 bags of fuel By: Homeowner Frequency: When clear view of the firepot is obscure By: Homeowner a. Appliance must be completely cool before cleaning glass. The amount of ash buildup in the firebox will be a good guide to determine how often you should clean the heat exchangers. b. Vacuum fly ash from the glass and door rope. a.
R Castile Pellet Insert 10. Cleaning the Hopper • • 14. Preparing Firebox for Non-Burn Season Frequency: Monthly or every 50 bags of fuel By: Homeowner • • After burning approximately 1 ton of fuel you will need to clean the hopper to prevent sawdust build-up. A combination of sawdust and pellets on the auger reduces the amount of fuel supply to the firepot. This can result in nuisance shutdowns and mis-starts. Frequency: At the end of the heating season By: Homeowner a.
Castile Pellet Insert R D. High Ash Fuel Maintenance • • Frequency: When the ash build-up exceeds more than half way up the firepot. By: Homeowner Pellets Back Up In Feed Tube Firepot Overfills 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 36.
R Castile Pellet Insert F. Convection Blower Replacement E. Combustion Blower Replacement 1. If you have adequate clearance you will not have to remove the panel set and disconnect flue, if not then you will have to remove the panel set and disconnect the flue. 2. Pull appliance out onto the hearth. 3. Remove right cast side. 4. Disconnect the white and blue wires from the blower. 5. Remove blower mounting screws (not housing bolts), Figure 37.1, from blower housing and remove blower.
Castile Pellet Insert R G. Igniter Replacement H. Glass Replacement WARNING • Glass is 5mm thick high temperature heatresistant ceramic glass. • DO NOT REPLACE with any other material. • Alternate material may shatter and cause injury Igniter Bracket Thumb Screw 1. Open the face and remove door from the appliance by lifting door off of hinge pin and and lay on a flat surface face down. Igniter Figure 38.1 1.
R Castile Pellet Insert I. Baffle & Brick Set Removal Re-installing Baffle & Brick Set 1. Follow proper shutdown procedures in Section 10. 1. Place right brick in behind the right bracket, and then slide to the left so the tabs are behind the center brick. Figure 39.4. 2. 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.
Castile Pellet Insert R 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 40.4 Figure 40.1 Figure 40.5 Figure 40.2 Figure 40.
R 11 Castile Pellet Insert Reference Materials A. Component Function 1. Control Box a. The control box is located on lower right side of appliance, on top of the junction box. When describing the location of a component part it is always AS YOU FACE THE FRONT OF THE APPLIANCE. shut off power to the appliance. 7. Heat Exchangers b. There is a light located inside of the control box. The internal light will turn green when the appliance has reached a temperature of 200F (93C) in the firepot.
Castile Pellet Insert R have been obtained. snap disc with automatically reset itself. 16. Thermostat 19. Snap Disc #3 (Burn Back Protector) 250°F 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. 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 side panel.
R Castile Pellet Insert B. Component Locations 10 Heat Exchanger Tubes Cleaning Rods Figure 43.1 - Cleaning Rods & Heat Exchanger Tubes RIGHT SIDE Feed Motor Combustion Blower Vacuum Switch Leveling Bolt Convection Blower Figure 43.2 Fuse Control Box Red Call Light ue Bl Power Cord Outlet t gh Li Heat Output Switch Firepot Cleaning Rod en re /G ed R ht ig rL be m /A Reset Button Junction Box Thermostat Block Figure 43.
R Castile Insert Service Parts Beginning Manufacturing Date: Jan 2011 Ending Manufacturing Date: Active Castile Pellet Insert CASTILEI-MBK, CASTILEI-PMH, CASTILEI-CSB CASTILEIW-CWL 1 2 3 5 4 6 7 36 8 35 34 32 9 31 30 37 29 28 10 25 27 11 12 13 26 14 16 15 17 24 18 19 21 20 23 22 Part number list on following pages. Figure 44.
R Castile Insert Service Parts Beginning Manufacturing Date: Jan 2011 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.
R Castile Insert Service Parts Beginning Manufacturing Date: Jan 2011 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 Stocked at Depot PART NUMBER 23.4 #23 Door Assembly 23.5 23.3 23.6 23.2 23.1 23 Door Assembly SRV7021-007 23.
R Castile Insert Service Parts Beginning Manufacturing Date: Jan 2011 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 29 DESCRIPTION COMMENTS PART NUMBER 812-4400 Y ...Housing & Stove 240-0812 Y ...
R Castile Insert Service Parts Beginning Manufacturing Date: Jan 2011 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.
R Castile Insert Service Parts Beginning Manufacturing Date: Jan 2006 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.
R Castile Insert Service Parts Beginning Manufacturing Date: Jan 2006 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.
R Castile Pellet Insert E.
Castile Pellet Insert R E.
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Castile Pellet Insert R Hearth & Home Technologies Inc. LIMITED LIFETIME WARRANTY Hearth & Home Technologies Inc., on behalf of its hearth brands (”HHT”), extends the following warranty for HHT gas, wood, pellet, coal and electric hearth appliances that are purchased from an HHT authorized dealer.
R Castile Pellet Insert WARRANTY CONDITIONS: 7KLV ZDUUDQW\ RQO\ FRYHUV ++7 DSSOLDQFHV WKDW DUH SXUFKDVHG WKURXJK DQ ++7 DXWKRUL]HG GHDOHU RU GLVWULEXWRU $ OLVW RI ++7 DXWKRUL]HG GHDOHUV LV DYDLODEOH RQ WKH ++7 EUDQGHG ZHEVLWHV 7KLV ZDUUDQW\ LV RQO\ YDOLG ZKLOH WKH ++7 DSSOLDQFH UHPDLQV DW WKH VLWH RI RULJLQDO LQVWDOODWLRQ &RQWDFW \RXU LQVWDOOLQJ GHDOHU IRU ZDUUDQW\ VHUYLFH ,I WKH LQVWDOOLQJ GHDOHU LV XQDEOH WR SURYLGH QHFHVVDU\ SDUWV FRQWDFW WKH QHDUHVW ++7 DXWKRUL]HG GHDOHU RU VXSSOLHU
R CONTACT INFORMATION: Hearth & Home Technologies 1445 North Highway Colville, WA 99114 Division of HNI INDUSTRIES www.quadrafire.com Please contact your Quadra-Fire dealer with any questions or concerns. For the number of your nearest Quadra-Fire dealer visit our website at www.quadrafire.com NOTICE • Leave this manual with party responsible for use and operation.