Hearth & Home QUADRA-FIRE Castile Insert Manual de programación

February 15, 2019250-7690B1

Castile Insert

Troubleshooting Manual

(THIS MANUAL IS INTENDED FOR TRAINED & QUALIFIED DEALERS &

TECHNICIANS USE ONLY)

February 15, 2019250-7690B2

CASTILE INS

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 appliance or to property.

TABLE OF CONTENTS

1 Normal Operation Sequence .......................................3

2 Basic Troubleshooting & Repair ....................................5

3 Feed System ....................................................6

4 Igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 Exhaust Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6 Convection Blower ..............................................12

7 Power Supply...................................................14

8 Thermostat.....................................................16

9 Thermocouple ..................................................18

10 Firebox Vacuum & Vacuum Switch ................................20

11 Complete Wiring Diagram........................................ 22

12 General Specications ..........................................23

13 Exploded View & Service Parts ................................... 24

13 Tech Check Sheet ..............................................31

14 Cleaning & Maintenance Tips..................................... 32

15 Service Repair Tools ............................................33

16 Notes.........................................................34

February 15, 2019 250-7690B 3

CASTILE INS

1 Normal Operation Sequence

1. Turn on thermostat a red call light will illuminates on

the stove.

2. The exhaust blower will turn on.

3. The igniter turns on.

4. The vacuum switch closes.

5. The feed motor turns on. The initial feed of the feed

motor will last approximately 64 seconds and then

stop.

6. Pellets will ignite in the repot.

7. Heat from re turns on the green thermocouple light

in the control box (2.5 - 3mVDC); 200°F.

8. Feed motor starts its cycle mode:

SETTING SECONDS

LOW 0.9

MEDIUM 1.6

HIGH 2.2

February 15, 2019250-7690B4

CASTILE INS

9. Heat from the re turns on the red thermocouple light

in the control box (12.0 - 13.0mVDC); 600°F.

10. The igniter turns o󰀨

11. Heat from the re closes the #1 snap disc.

12. The convection blower will turn on.

13. Room reaches temperature

14. Thermostat will turn o󰀨.

15. The red call light will turn o󰀨.

16. Feed motor will turn o󰀨.

17. The exhaust blower will start a 18 minute countdown.

18. The #1 snap disc cools o󰀨

19. The convection blower shuts o󰀨

20. The end of the cycle; the appliance is now ready for

another call for heat.

February 15, 2019 250-7690B 5

CASTILE INS

A. Plug in stove with no response

1. Check the power supply for 115 volts

2. Check the fuse in the junction box (7amps)

3. Check snap disc #3 for power

4. Check control box

B. Call light on with no r and no fuel in re

pot

1. Check hopper for bridging of pellets

2. Push reset button and 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 with no re and partially

burned fuel in re pot

1. Check repot and clean

2. Check thermocouple

-Green light - 2.5 - 3.0mV

-Red light - 12.0 - 13.0mV

3. Check initial feed time (60 seconds)

D. Call light is on with no re and fuel in the

re pot

1. Check repot for “clinker” material

2. Clean repot

3. Check igniter

4. Check control box

E. Slow or smoky start-up

1. Clean repot

2. Feed adjustment plate may be set too high

3. Check exhaust blower and heat exchanger

4. Make sure trap door is under the repot in the closed

position

G. Feed system fails to start

1. Check front door and make sure it is closed

2. Check to see if the call light is on

3. Check the thermostat and #2 snap disc

4. Check feed motor and vacuum switch

5. Check exhaust system for obstructions

H. Thermostat will not start appliance

1. Check the thermostat wires for continuity

2. Check the “accessory jumper wire” on the junction

box

3. Check the reset button

4. Check the power to the stove

5. Check the control box

F. Stove Runs for 18 minutes then stops

feeding fuel

1. Check thermocouple

-Green light - 2.5 - 3.0mVDC

-Red light - 12.0 - 13.0mVDC

2. Adjust feed adjustment plate for larger re

3. Check thermocouple cover

- Cover needs to touch the end of the

thermocouple wire

- Cover should extend 1-3/4 inches into the repot

4. Check the control box

2 Basic Troubleshooting & Repair

I. Appliance fails to shut o󰀨

1. Check the thermostat and thermostat wire

2. Check the junction box and wire harness

3. Check the control box

J. Convection blower keep running or fails

to start

1. Check the #1 snap disc

2. Check convection blower

3. Check for voltage to the #1 snap disc

K. Appliance cycles on and o󰀨 with the

thermostat is always on

1. Check the control box

2. Check vacuum switch

3. Check wiring for loose connections

L. Large re, ash build up and dirty glass

1. Check repot, 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 - 2.2 seconds on time

-MEDIUM - 1.6 seconds on time

-LOW - 0.9 seconds on time

M. Appliance ignites then goes out but call

light is still on

“ STOVE IS INCONSISTENT IN OPERATION“

1. Inspect thermocouple and its position over the pot

2. Check the feed motor

3. Adjust feed adjustment plate for a larger re

4. Check the exhaust and heat exchanger system

5. Check the vacuum switch

February 15, 2019250-7690B6

CASTILE INS

NOTE: Remember that

the feed circuits

initial feed time

is 60 seconds.

Push the reset

button before

each test.

3 Feed System

TECH TIP:

MAKE SURE THE

FEED SYSTEM IS

CLEAN AND FREE

OF OBSTRUCTIONS

BEFORE

TROUBLESHOOTING

TURN ON THE

T-STAT & APPLIANCE

SYSTEM IS

REPAIRED

AFTER 2 MIN,

IS THE AUGER

TURNING?

YES

CHECK FEED

MOTOR. IS THERE

115VAC AT FEED

MOTOR?

REPLACE THE FEED

MOTOR

REPLACE THE

VACUUM SWITCH

REPLACE #2 SNAP

DISC

REPLACE RESET

BUTTON

REPLACE THE WIRE

HARNESS

REPLACE THE

CONTROL BOX

CHECK VACUUM

SWITCH

BAD

GOOD

CHECK #2 SNAP

DISC

CHECK RESET

BUTTON

CHECK THE

WIRE HARNESS &

CONNECTIONS

BAD

GOOD

YES

February 15, 2019 250-7690B 7

CASTILE INS

FEED MOTOR

VACUUM

SWITCH

COMBUTION

BLOWER

RECEPTACLE

CONVECTION

BLOWER

JUNCTION BOX

FEED MOTOR CIRCUIT

WHITE

BLACK

WHITE

BLACK

RED

RED RED

WHITE

BLACK ORANGE

RED

FUSE

T.C.

CAPACITOR

A / 1

B / 2

C / 3

D / 4

E / 5

F / 6

H / 7

J / 8

K / 9

L / 10

M / 11

N / 12

P / 13

R / 14

S / 15

#2 SNAP DISC

FEED MOTOR TESTING WITH TEST BOX

(IN CONJUNCTURE TO THIS SERVICE MANUAL USE THE INSTRUCTION SHEET FOR THE TEST BOX

KIT)

1. Unplug the appliance, remove the control box, install the test box, and plug the appliance back in.

2. Turn on the exhaust blower switch; this will active the vacuum switch to close.

3. Turn on the thermostat - the thermostat indicator light should come on.

4. Turn on the feed motor switch.

- If the feed system does come on:

– Replace the control box

- If the feed system does not come on:

– Check the feed motor

– Check the vacuum switch

– Check the wire harness

– Replace #2 snap disc

February 15, 2019250-7690B8

CASTILE INS

4 Igniter

TECH TIP:

MAKE SURE THE

FIREPOT AND

SURROUNDING

AREA IS CLEAN

BEFORE

TROUBLESHOOTING

IS VOLTAGE PRESENT?

IS THERE CONTINUITY

PRESENT?

CONNECT A MULTIMETER

TO THE IGNITER WIRE

HARNESS

CONNECT A MULTIMETER

TO THE IGNITER

IS THERE POWER TO THE

APPLIANCE?

IS THE IGNITER

GETTING HOT

AFTER 60

SECONDS?

IS THE GREEN

CALL LIGHT

ILLUMINATED ON

THE CONTROL

BOX?

REPLACE THE

CONTROL BOX

YES

CHECK THE IGNITER WIRE

HARNESS

IS THE WIRING BROKEN?

REPAIR OR

REPLACE THE

WIRE HARNESS

REPLACE THE

IGNITER

CHECK POWER

SYSTEM IS

REPAIRED

YES

SAFETY

NOTE: DO NOT touch

igniter for it will be

hot and burn you.

TURN ON

THE T-STAT &

APPLIANCE

February 15, 2019 250-7690B 9

CASTILE INS

JUNCTION BOX

IGNITER CIRCUIT

FUSE

T.C.

IGNITER

HIGH-TEMP

A / 1

B / 2

C / 3

D / 4

E / 5

F / 6

H / 7

J / 8

K / 9

L / 10

M / 11

N / 12

P / 13

R / 14

S / 15

FEED MOTOR TESTING WITH TEST BOX

(IN CONJUNCTURE TO THIS SERVICE MANUAL USE THE INSTRUCTION SHEET FOR THE TEST BOX

KIT)

1. Unplug the appliance, remove the control box, install the test box, and plug the appliance back in.

2. Turn on the thermostat switch (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 does not come on:

– Check the wire harness

– Replace the igniter

February 15, 2019250-7690B10

CASTILE INS

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. THE MEDIUM AND LOW VOLTAGES WILL BE 115 FOR THE FIRST 4:15 IF THE UNIT HAS

THE NEW CONTROL BOX. (PART # 230-2070).

5 Exhaust Blower

PLUG STOVE IN

IS THE BLOWER

RUNNING? YES

IS THERE 75 VAC

OR HIGHER GOING

TO THE BLOWER?

BAD

GOOD

CHECK WIRE

CONNECTIONS

BETWEEN THE

BLOWER AND THE

JUNCTION BOX

REPAIR OR

REPLACE THE WIRE

HARNESS

CHECK FOR

AIR PATH

RESTRICTIONS.

IS THE BLOWER &

EXHAUST SYSTEM

CLEAN?

SYSTEM IS

REPAIRED

YES

NO REPLACE THE

EXHAUST BLOWER

CLEAN THE

BLOWER AND

EXHAUST PATHS

REPLACE THE

CONTROL BOX

YESNO

TECH TIP:

MAKE SURE THE AIR

PATH IS FREE FROM

RESTRICTIONS

AND THE EXHAUST

SYSTEM IS

CLEAN BEFORE

TROUBLESHOOTING

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