Quadra-Fire CLASSIC BAY 1200 Bedienungsanleitung

1445 N. Highway

Colville, Wa 99114

www.quadrare.com

www.quaddealer.com

#250-7700 February 12, 2003

CB1200 INSERT PELLET STOVE

SERVICE MANUAL

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL

TABLE OF CONTENTS

SECTION PAGE

TROUBLE-SHOOTING SYMPTOMS

FEED MOTOR TROUBLE-SHOOTING

IGNITER TROUBLE-SHOOTING

EXHAUST BLOWER TROUBLE-SHOOTING

CONVECTION BLOWER TROUBLE-SHOOTING

POWER SUPPLY TROUBLE-SHOOTING

THERMOSTAT TROUBLESHOOTING

THERMOCOUPLE TESTING

FIREPOT & EXHAUST SYSTEM TROUBLE-SHOOTING

EXPLODED VIEW

WIRE DIAGRAM

DIMENSIONS & SPECS

CHECK-OFF SHEET

CLEANING & MAINTENANCE TIPS

SERVICE TOOLS

3-5

6-7

8-9

10-11

12-13

14-15

16-17

19-21

22-23

27-28

7-31-2002 PAGE 2 250-7700

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL

TROUBLE SHOOTING & REPAIR

A. PLUG IN STOVE -- NO RESPONSE

1) CHECK THE POWER SUPPLY FOR 115 VOLTS

2) CHECK THE FUSE IN THE JUNCTION BOX (7 AMP)

3) CHECK SNAP DISC #3 FOR POWER

4) CHECK CONTROL BOX

B. CALL LIGHT ON -- NO FIRE -- NO FUEL IN FIREPOT

1) CHECK HOPPER FOR BRIDGING OF PELLETS

2) PUSH RESET BUTTON & ADJUST FEED ADJUSTMENT PLATE

3) CHECK THERMOCOUPLE

4) CHECK VENTING SYSTEM FOR OBSTRUCTIONS

5) CHECK VACUUM SWITCH AND VACUUM HOSE

6) CHECK FEED MOTOR

7) CHECK EXHAUST BLOWER

C. CALL LIGHT ON -- NO FIRE -- PARTIALLY BURNED FUEL IN POT

1) CHECK FIREPOT AND CLEAN

2) CHECK THERMOCOUPLE

*GREEN LIGHT-----2.5 mV (+.5mV)

*RED LIGHT---------12.1 mV (+ 1mV)

3) CHECK INITIAL FEED TIME (1 MINUTE 35 SECONDS)

D. CALL LIGHT ON -- NO FIRE -- FUEL IN FIREPOT

1) CHECK FIREPOT FOR “CLINKER” MATERIAL

2) CLEAN FIREPOT

3) CHECK IGNITER

4) CHECK CONTROL BOX

7-31-2002 PAGE 3 250-7700

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL

E. SLOW OR SMOKEY START UP

1) CLEAN FIREPOT

2) FEED ADJUSTMENT PLATE MAY BE SET TOO HIGH

3) CHECK EXHAUST BLOWER AND HEAT EXCHANGER

4) MAKE SURE TRAP DOOR UNDER FIREPOT IS CLOSED

TROUBLE SHOOTING & REPAIR

G. FEED SYSTEM FAILS TO START

1) CHECK FRONT DOOR AND MAKE SURE IT IS CLOSED

2) CHECK TO SEE IF CALL LIGHT IS ON

3) CHECK THERMOSTAT

4) CHECK FEED MOTOR AND VACUUM SWITCH

5) CHECK EXHAUST SYSTEM FOR OBSTRUCTIONS

H. THERMOSTAT WILL NOT START UNIT

1) CHECK THERMOSTAT WIRES FOR CONTINUITY

2) CHECK THE “ACCESSORY JUMPER WIRE” ON THE J-BOX

3) CHECK #2 SNAP DISC

4) CHECK THE RESET BUTTON

5) CHECK FOR POWER TO THE STOVE

6) CHECK CONTROL BOX

F. STOVE RUNS FOR 10 MINUTES -- THEN STOPS FEEDING FUEL

1) CHECK THERMOCOUPLE

*GREEN LIGHT-------2.5 mVDC ( +.5mV)

*RED LIGHT-----------12.1 mVDC (+ 1mV)

2) ADJUST FEED ADJUSTMENT PLATE FOR LARGER FIRE

3) CHECK THERMOCOUPLE COVER

*COVER NEEDS TO TOUCH THE END OF THE T-COUPLE WIRE

*COVER SHOULD EXTEND 1 3/4” INTO FIREPOT

4) CHECK CONTROL BOX

7-31-2002 PAGE 4 250-7700

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL

I. UNIT FAILS TO SHUT OFF

1) CHECK THERMOSTAT AND THERMOSTAT WIRE

2) CHECK THE JUNCTION BOX & WIRE HARNESS

3) CHECK THE CONTROL BOX

TROUBLE SHOOTING & REPAIR

J. CONVECTION BLOWER KEEPS RUNNING OR FAILS TO START

1) CHECK #1 SNAP DISC

2) CHECK CONVECTION BLOWER

3) CHECK FOR VOLTAGE TO THE #1 SNAP DISC

K. STOVE CYCLES ON AND OFF -- THERMOSTAT ALWAYS ON

1) CHECK #1 SNAP DISC (CONVECTION BLOWER)

2) IF #1 SNAP DISC FAILS THEN #2 SNAP DISC WILL TRIP

*AFTER THE #2 SNAP DISC COOLS DOWN IT WILL TURN THE

THERMOSTAT BACK ON (CALL LIGHT)

3) CHECK WIRING FOR LOOSE CONNECTIONS

L. LARGE FIRE, ASH BUILD UP & DIRTY GLASS

1) CHECK FIREPOT, MAY NEED TO BE CLEANED

2) CLEAN EXHAUST AND HEAT EXCHANGER SYSTEM

3) ADJUST FEED ADJUSTMENT PLATE IN THE HOPPER

4) CHECK CONTROL BOX FEED TIMES

*HIGH ------- (7.5 SECOND ON TIME)

*MEDIUM -- (6 SECOND ON TIME)

*LOW --------(4.7 SECOND ON TIME)

M. STOVE IGNITES -- GOES OUT -- CALL LIGHT STILL ON

“ STOVE IS INCONSISTANT IN OPERATION “

1) INSPECT THERMOCOUPLE AND ITS POSITION OVER THE POT

2) CHECK THE FEED MOTOR

3) ADJUST FEED ADJUSTMENT PLATE FOR A LARGER FIRE

4) CHECK THE EXHAUST AND HEAT EXCHANGER SYSTEM

5) CHECK THE VACUUM SWITCH

7-31-2002 PAGE 5 250-7700

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL

FEED MOTOR TROUBLE-SHOOTING

1) TURN ON THERMOSTAT CIRCUIT AND MAKE SURE THAT THE CALL LIGHT IS ON.

2) CHECK FOR POWER AT THE VACUUM SWITCH:

A. IF NO POWER FROM RED WIRE-----CHECK CONTROL BOX OR WIRE HARNESS

B. POWER ON RED BUT NO POWER ON ORANGE-----CHECK VACUUM SWITCH OR VENT SYSTEM

3) CHECK FOR POWER AT THE RED WIRE FROM THE CAPACITOR:

A. IF NO POWER FROM RED WIRE----CHECK WIRE HARNESS OR CONNECTOR PIN

B. IF POWER IS PRESENT-----REPLACE FEED MOTOR OR CHECK CONNECTOR PIN

NOTE: REMEMBER THAT THE FEED CIRCUIT INITIAL FEED TIME IS 1:35. PUSH THE RESET

BUTTON BEFORE EACH TEST.

2-12-2003 PAGE 6 250-7700

FEED MOTOR

VACUUM

SWITCH

JUNCTION BOX

FEED MOTOR CIRCUIT

CAPACITOR WHITE

RED/WHITE

RED

NOTE: CAPACITOR IS LOCATED IN THE JUNCTION BOX

ACCY

JUMPER

WHITE WHITE

BLACK

RED

WHITE

ORANGE

RED

CAPACITOR JUMPER

WIRE. PART# 230-2150

JUMPER IS NEEDED IF

CAPACITOR IN J-BOX

IS BAD OR IF THE

MOTOR NEEDS TO BE

TESTED WITH A TEST

CORD.

*Color will be black for SN 505324 & above.

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL

FEED MOTOR TESTING

USING THE TEST BOX:

1) UNPLUG THE STOVE, REMOVE THE CONTROL BOX, INSTALL TEST BOX & PLUG IN STOVE

2) TURN ON THE EXHAUST BLOWER SWITCH. (THIS WILL PULL THE VACUUM SWITCH IN)

4) TURN ON THE FEED MOTOR SWITCH.

IF THE FEED DOESN’T COME ON: BAD FEED MOTOR, VACUUM SWITCH, OR WIRE HARNESS

IF THE FEED COMES ON: REPLACE CONTROL BOX

USING THE COMPONENT TEST CORD:

1) UNPLUG THE FEED MOTOR FROM THE WIRE HARNESS

2) INSTALL THE FEED MOTOR ADAPTER ON THE TEST CORD.

NOTE: THE NEW STYLE FEED MOTOR WILL NEED THE CAPACITOR JUMPER ADDED TO THE ADAPTER.

3) PLUG IN THE TEST CORD TO THE FEED MOTOR AND TURN ON THE SWITCH.

TEST BOX (AS IT IS INSTALLED IN THE STOVE)

3) TURN ON THE THERMOSTAT (THE THERMOSTAT INDICATOR LIGHT SHOULD COME ON)

THERMOSTAT LIGHT

FEED MOTOR SWITCH

EXHAUST BLOWER SWITCH

TEST CORD w/ ADAPTERS CAPACITOR JUMPER WIRE

7-31-2002 PAGE 7 250-7700

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL

IGNITER TROUBLE-SHOOTING

IGNITER

JUNCTION BOX

IGNITER CIRCUIT

TAN (HT)

ACCY

JUMPER

1) TURN ON THE THERMOSTAT CIRCUIT AND MAKE SURE THE CALL LIGHT IS ON.

B. IF POWER IS PRESENT-----REPLACE THE IGNITER

A. IF NO POWER------CHECK THE WIRE HARNESS OR REPLACE THE CONTROL BOX

2) CHECK FOR POWER AT THE IGNITER:

7-31-2002 PAGE 8 250-7700

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL

IGNITER TESTING

USING THE TEST BOX:

1) UNPLUG THE STOVE, REMOVE THE CONTROL BOX, INSTALL THE TEST BOX & PLUG IN THE STOVE.

2) TURN ON THE THERMOSTAT. (THE THERMOSTAT INDICATOR LIGHT SHOULD COME ON)

3) TURN THE IGNITER SWITCH ON.

IF THE IGNITER COMES ON--------REPLACE THE CONTROL BOX

IF THE IGNITER DOESN’T COME ON--------REPLACE THE IGNITER OR CHECK THE WIRE HARNESS

USING THE COMPONENT TEST CORD:

1) UNPLUG THE STOVE AND DISCONNECT THE IGNITER FROM THE WIRE HARNESS.

2) INSTALL THE ALLIGATOR CLIPS ONTO THE TEST CORD.

3) CLIP THE TEST CORD TO THE WIRES ON THE IGNITER AND TURN THE SWITCH ON.

TEST BOX (AS IT IS INSTALLED IN THE STOVE)

TEST CORD w/ CLIPS ATTACHED CLIPS HOOKED UP TO THE IGNITER

IGNITER SWITCH

THERMOSTAT LIGHT

7-31-2002 PAGE 9 250-7700

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL

EXHAUST BLOWER TROUBLE-SHOOTING

EXHAUST

BLOWER

EXHAUST BLOWER CIRCUIT

GREEN

BLACK

NOTE: THE ACCESSORY JUMPER IS LOCATED ON THE JUNCTION BOX HOUSING

JUNCTION BOX

ACCY

JUMPER

BLACK

WHITE

BLUE

WHITE

BLUE

7-31-2002 PAGE 10 250-7700

1) TURN ON THE THERMOSTAT CIRCUIT AND MAKE SURE THE CALL LIGHT IS ON.

2) CHECK FOR POWER AT THE BLUE WIRE ON THE MOLEX CONNECTOR.

A. IF POWER IS PRESENT------REPLACE THE EXHAUST BLOWER

B. IF NO POWER------CHECK THE WIRE HARNESS OR REPLACE THE CONTROL BOX

NOTE: OPEN CIRCUIT VOLTAGE IS MEASURED WITH THE BLOWER DISCONNECTED FROM THE WIRE

HARNESS. CLOSED CIRCUIT VOLTAGE IS MEASURED WITH THE BLOWER HOOKED UP TO THE

HARNESS.

CLOSED CIRCUIT VOLTAGE WILL BE: 115 V (HIGH) 85 V (MEDIUM) 75 V (LOW)

OPEN CIRCUIT VOLTAGE AT THE MOLEX CONNECTOR WILL BE 115 V ON HIGH, MEDIUM, & LOW

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