Harman-Kardon PB 105 manual

R4 SAFETY NOTICE PLEASE READ THIS ENTIRE MANUAL BEFORE YOU INST ALL AND USE YOUR NEW BOILER. FAILURE T O FOL- LOW INSTRUCTIONS MA Y RESUL T IN PROPERTY DAMAGE, BODIL Y INJUR Y , OR EVEN DEA TH. FOR USE IN THE U.S. AND CANADA. SUIT ABLE FOR INST ALLA TION IN MOBILE HOMES IF THIS HARMAN PELLET BOILER IS NOT PROPERL Y INST ALLED, A HOUSE FIRE MA Y RES[...]

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4 Assembly 4 V enting 8 Installation 1 1 Operation 2 0 Maintenance 2 7 T roubleshooting 3 1 Feeder Parts 3 2 Specifications 3 3 Wiring Diagram 3 4 Parts List & Options 3 5 W arranty 3 6 T esting Label 3 7 Quick Reference S tar t-Up Back Cover Please read this entire manual before you install and use your new boiler . Failure to follow instructi[...]

5 Assembly T e m p e ra t u re / Press ure Ga uge Aq u a s ta t W e l l Pr es s u r e R e li e f V a lv e Bl a n k Co v er * H eat Ex c h a n ger Cl e a n o u t R o d H a n d l es A c c e s s C o ve r To S e c o nd a r y A s h C ha m b e r Re m o v e C o ve r to a c c e ss n u ts to f a s t e n F lu e T u n ne l W e ld m e nt t o t h e A s h C ha m[...]

6 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 V alve 1 - 1/2” Aquastat W ell 1 - 1/2” Dual T emperature/Pressure Gauge 1 - 100ft[...]

7 Design: The first thing that needs to be done is deciding where and how the boiler will be installed. Things that need to be taken into consideration are the intended use of the boiler for example, is the boiler going to be used as your primary heating system or is it going to be used as a secondary or backup heating system. If it is to be used i[...]

8 Assembly NOTE: All installation clearances and restrictions must be adhered to. INST ALLA TION IS T O BE PERFORMED BY A QUALIFIED INST ALLER. NOTE:Use only 4” diameter type “L” or “PL” venting system. Be sure to inspect and clean exhaust venting system frequently . When installing the PB105 in a mobile home several requirements must be [...]

9 Requir ements for T erminating the V enting W ARNING: V enting 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 combus- tible materials. NOTE: Always take into consideration the effect the prevailing wind direction or other wind currents will cause [...]

10 V enting Fig. 3[...]

11 The minimum vent configuration is a 90 o or T ee on a starter collar and a 24” length horizontal through an exterior wall. A cap or other bird screen on the end should direct the flue gasses down and away from the structure. See Fig. 5. The maximum horizontal length is 18 feet. The mini- mum termination height above the exterior grade is 18”[...]

12 Chimneys taller than 20’ above the connection will re- quire 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 T est procedure. Cr eosote - Formation and Need for Remo[...]

13 Outside Air 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. T o install outside air , use 2 3/4”" I.D.galvinized steel flex pipe, part # 2-00-08544 ( 12’ 6” length) or part # 2-00[...]

14 Main Wiring Inst allation T o install power to the boiler first remove the cover on the 4” X 4” junction box located on the back of the unit. There are se veral knockout holes provided for the incoming main power wires. Also, a knockout hole can be used for the auxiliary output overheat zone (if used). The minimum recommended circuit is 6 AM[...]

15 Installing Duct Inst allation[...]

16 Installing Duct/Air Conditioning Inst allation 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[...]

17 Inst allation[...]

18 Inst allation[...]

19 Inst allation[...]

20 Inst allation Draft T est Procedure After the venting is completed, the firebox low draft will need to be checked and possibly adjusted. After re- moving 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[...]

21 Power Light Indicates power to the control board. S t atus Light W ill be lit anytime ther e is a call for heat. Combustion Blower Light Indicates Power to combustion blower Feed Motor Light Indicates Power to the feed motor . Max T emp dial The “Max T emp Dial” is used to set the desired maximum operating temperatur e of the boiler . 7 Blin[...]

22 Setting The Boiler T emperature Without the Outdoor Air T emperature Sensor Installed T o set the maximum boiler water temperature, simply turn the Max. T emp. water temperature dial to the desired setting. The control and the boiler will then per- form to achieve and maintain the set temperature. The Min. T emp. Knob simply becomes the boiler m[...]

23 OAT 65 120 60 125 55 130 50 135 45 140 40 145 35 150 30 155 25 160 20 165 15 170 10 175 51 8 0 01 8 5 OAT 65 150 60 150 55 150 50 150 45 150 40 150 35 150 30 150 25 155 20 160 15 165 10 170 51 7 5 01 8 0 * No change in boil er tem perature af t er r eac hing m ini mum s et poi nt tem p E xamp l e # 2 Ma x se t @ 1 80 Pell et Bo i l er O utdoor A[...]

24 1. T urn Mode Selector to "OFF". This resets the control in addition to turning it off. S tar ting A Fire Automatically Operation 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, sc[...]

25 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. T urn Feed Adjuster to #4. If this is your first fire or you are trying di[...]

26 8. T urn 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 adjust[...]

27 Operation NOTE: S tirring the starting gel into the pellets usu- ally allows the fir e 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 lightin[...]

28 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 operat[...]

29 Maintenance Ash Removal It is recommended to remove the ashes when the boiler is not in operation. This lessens the chances of coming in contact with hot surfaces. Ashes can be removed while in operation but, extra care must be taken. Open Ash Door Lift the latch and open the door as shown in fig. 21. A s h D oor H andl e As h D o o r As h Pa n [...]

30 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 restartin[...]

31 Maintenance 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 ha[...]

32 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 closed doors , loose or missing gasket on doors or hopper lid, or a faulty pres- sure switch. 3. Feed motor will not run until ESP senses 170 deg. F . Maybe you did not put enough pellets in the bur[...]

33 Feeder Part s[...]

34 Specifications[...]

35 Wiring Diagram Wiring Diagram[...]

36 Parts List ITEM NUMBER DESCRIPTION 0-88-00248 RUBBER GROMMET (Hopper Lid - 7' Needed) 0-88-88100 1 " WHITE GASKET W/PSA SINGLE PL Y (Access Plate - 2' Needed) 1" WHITE GASKET W/PSA SINGLE PL Y (FDR Swing Plate - 5' Needed) 0-88-88250 1 " WHITE GASKET W/PSA DOUBLE PL Y (Firebox Door - 3.5' Needed) 1" WHITE [...]

37 W arranty 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. If defective in material or workm[...]

T esting Label 38[...]

NOTES 39[...]

1 T urn Mode Selector to OFF . 2 Use heat exchanger cleanout rods to clean the heat exchanger tubes.** 3 Scrape the air holes in the burnpot.** 4 Fill the hopper with pellets. 5 T urn Feed Adjuster to “T est”.* 6 Check the Combustion Blower and Feeder Motor for operation.* 7 T urn Feed Adjuster back to the #4 setting. 8 T urn the MAX TEMP dial [...]