Quadra-Fire Classic Bay 1200 Service Manual

Quadra-Fire Classic Bay 1200 Service Manual

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CB1200 INSERT PELLET STOVE
1445 N. Highway
Colville, Wa 99114
SERVICE MANUAL
#250-7700
February 12, 2003
www.quadrafire.com
www.quaddealer.com
R

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Summary of Contents for Quadra-Fire Classic Bay 1200

  • Page 1 CB1200 INSERT PELLET STOVE SERVICE MANUAL 1445 N. Highway www.quadrafire.com #250-7700 February 12, 2003 Colville, Wa 99114 www.quaddealer.com...
  • Page 2: Table Of Contents

    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 10-11 CONVECTION BLOWER TROUBLE-SHOOTING 12-13 POWER SUPPLY TROUBLE-SHOOTING 14-15 THERMOSTAT TROUBLESHOOTING 16-17 THERMOCOUPLE TESTING FIREPOT & EXHAUST SYSTEM TROUBLE-SHOOTING 19-21 EXPLODED VIEW 22-23 WIRE DIAGRAM...
  • Page 3: Trouble-Shooting Symptoms

    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.
  • Page 4 CB1200-I PELLET STOVE SERVICE MANUAL TROUBLE SHOOTING & REPAIR 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 F.
  • Page 5 CB1200-I PELLET STOVE SERVICE MANUAL TROUBLE SHOOTING & REPAIR I. UNIT FAILS TO SHUT OFF 1) CHECK THERMOSTAT AND THERMOSTAT WIRE 2) CHECK THE JUNCTION BOX & WIRE HARNESS 3) CHECK THE CONTROL BOX 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...
  • Page 6: Feed Motor Trouble-Shooting

    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.
  • Page 7 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) 3) TURN ON THE THERMOSTAT (THE THERMOSTAT INDICATOR LIGHT SHOULD COME ON) 4) TURN ON THE FEED MOTOR SWITCH.
  • Page 8: Igniter Trouble-Shooting

    CB1200-I PELLET STOVE SERVICE MANUAL IGNITER TROUBLE-SHOOTING 1) TURN ON THE THERMOSTAT CIRCUIT AND MAKE SURE THE CALL LIGHT IS ON. 2) CHECK FOR POWER AT THE IGNITER: A. IF NO POWER------CHECK THE WIRE HARNESS OR REPLACE THE CONTROL BOX B.
  • Page 9 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.
  • Page 10: Exhaust Blower Trouble-Shooting

    CB1200-I PELLET STOVE SERVICE MANUAL EXHAUST BLOWER TROUBLE-SHOOTING 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. OPEN CIRCUIT VOLTAGE AT THE MOLEX CONNECTOR WILL BE 115 V ON HIGH, MEDIUM, & LOW CLOSED CIRCUIT VOLTAGE WILL BE: 115 V (HIGH) 85 V (MEDIUM) 75 V (LOW) A.
  • Page 11 CB1200-I PELLET STOVE SERVICE MANUAL EXHAUST BLOWER 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 EXHAUST BLOWER SWITCH ON.
  • Page 12: Convection Blower Trouble-Shooting

    CB1200-I PELLET STOVE SERVICE MANUAL CONVECTION BLOWER TROUBLE-SHOOTING 1) CHECK FOR POWER AT THE PURPLE WIRE FROM THE #11 PIN AT THE SNAP DISC. OPEN CIRCUIT VOLTAGE TO ONE SIDE OF SNAP DISC WILL BE 115 V FOR HIGH, MEDIUM, & LOW. CLOSED CIRCUIT VOLTAGE WILL BE: 115 V (HIGH) 101 V (MEDIUM) 82 V (LOW) A.
  • Page 13 CB1200-I PELLET STOVE SERVICE MANUAL CONVECTION BLOWER TESTING USING THE TEST BOX: 1) UNPLUG THE STOVE, REMOVE THE CONTROL BOX AND INSTALL THE TEST BOX. 2) INSTALL A JUMPER WIRE ON THE #1 SNAP DISC (PURPLE WIRES) AND THEN PLUG THE STOVE IN. 3) TURN ON THE CONVECTION BLOWER SWITCH.
  • Page 14: Power Supply Trouble-Shooting

    CB1200-I PELLET STOVE SERVICE MANUAL POWER SUPPLY TROUBLE-SHOOTING 1) CHECK FOR POWER AT THE BLACK WIRE FROM THE POWER CORD. (SEE FIG. 1) A. IF NO POWER------CHECK OUTLET OR REPLACE POWER CORD B. IF POWER IS PRESENT, CONTINUE TO STEP 2 2) CHECK FOR POWER AT THE GREY WIRE ON THE 7 AMP FUSE HOLDER.
  • Page 15 CB1200-I PELLET STOVE SERVICE MANUAL POWER SUPPLY TESTING THERMOSTAT FIGURE 1 FIGURE 2 BLOCK BLACK WIRE POWER CORD WHITE GREY WIRE BLACK FIGURE 3 7 AMP FUSE HOLDER CHECK FOR POWER ON BOTH SIDES. TO CHECK FOR CONTINUITY: 1) PUT A JUMPER WIRE ON THE END OF THE POWER #3 SNAP DISC CORD.
  • Page 16: Thermostat Troubleshooting

    CB1200-I PELLET STOVE SERVICE MANUAL THERMOSTAT CIRCUIT TROUBLE-SHOOTING 1) UNPLUG THE STOVE & REMOVE THE CONTROL BOX. 2) TURN ON THE THERMOSTAT & MAKE SURE THE ACCESSORY JUMPER IS IN PLACE. 3) CHECK FOR CONTINUITY AT PIN 7 & PIN 9 ON THE JUNCTION BOX. IF THE CIRCUIT HAS CONTINUITY: REPLACE THE CONTROL BOX IF NO CONTINUITY, CONTINUE TO THE NEXT STEP 4) INSTALL A JUMPER WIRE ON THE THERMOSTAT &...
  • Page 17 CB1200-I PELLET STOVE SERVICE MANUAL THERMOSTAT CIRCUIT TESTING USING THE TEST BOX: 1) UNPLUG STOVE, REMOVE CONTROL BOX, INSTALL TEST BOX & PLUG STOVE BACK IN. 2) TURN ON THE THERMOSTAT. IF THE THERMOSTAT LIGHT COMES ON: REPLACE THE CONTROL BOX IF NO THERMOSTAT LIGHT: REFER TO THERMOSTAT CIRCUIT TROUBLE-SHOOTING THERMOSTAT INDICATOR LIGHT...
  • Page 18: Thermocouple Testing

    CB1200-I PELLET STOVE SERVICE MANUAL THERMOCOUPLE TESTING THE THERMOCOUPLE IS MADE UP OF TWO DISSIMILAR METALS THAT WHEN JOINED TOGETHER PRODUCE A SMALL AMOUNT OF ELECTRICITY WHEN HEAT IS APPLIED. THE HOTTER THE FIRE THE HIGHER THE VOLTAGE THAT IS PRODUCED. THIS THERMOCOUPLE WILL TOP OUT AT AROUND 30 MILLIVOLTS (DC) WHILE THE STOVE IS BURNING ON HIGH.
  • Page 19: Firepot & Exhaust System Trouble-Shooting

    CB1200-I PELLET STOVE SERVICE MANUAL FIREPOT AND EXHAUST SYSTEM TROUBLE-SHOOTING THE FIREPOT IS MADE OF CAST STEEL AND IS DESIGNED WITH AIR INTAKE HOLES THAT SWIRL THE FIRE AND HELP TO REMOVE THE ASH CREATED FROM THE BURNING OF THE PELLET FUEL. THERE IS ALSO A SLOT OR AIR PASSAGE IN THE BOTTOM SIDE OF THE FIREPOT THAT ALLOWS HOT AIR FROM THE IGNITER TO LIGHT THE PELLET FUEL.
  • Page 20 CB1200-I PELLET STOVE SERVICE MANUAL FIREPOT AND EXHAUST SYSTEM TROUBLE-SHOOTING FIG. 1 FIG. 2 EXAMPLE OF A LARGE CLINKER COMBUSTION AIR INTAKE HEAT EXCHANGER TUBES AIR INTAKE FIREPOT FIREPOT FIG. 4 FIG. 3 FIREBOX AREA w/ BAFFLE PLATES REMOVED AIR INTAKE IN THE COMBUSTION CHAMBER 7-31-2002 PAGE 20 250-7700...
  • Page 21 CB1200-I PELLET STOVE SERVICE MANUAL FIREPOT AND EXHAUST SYSTEM TROUBLE-SHOOTING FIG. 5 EXHAUST BLOWER CLEAN OUT DOOR HEAT EXCHANGER CLEAN OUT PLATE REMOVED VENT PIPE ADAPTER FIG. 6 EXHAUST BLOWER CLEAN OUT DOOR 7-31-2002 PAGE 21 250-7700...
  • Page 22 CB1200-I PELLET STOVE SERVICE MANUAL 1200-I EXPLODED VIEW LEGEND 1) GLASS (CENTER)....812-3510 13) HOPPER TOP.....410-7730 2) GLASS (SIDE).......812-3520 14) HOPPER LID.......410-7960 3) DOOR ASSY (GOLD)....812-3491 15) FEED MOTOR COVER..410-7920 4) FRONT GRILL.......410-8370 16) FEED MOTOR.....812-4420 5) IGNITER........812-3811 17) EXHAUST ADPTR......N/A 6) ASHPAN DOOR....410-7900 18) EXHAUST BLOWER...812-3381 7) ASHPAN........812-4130...
  • Page 23: Exploded View

    CB1200-I PELLET STOVE SERVICE MANUAL 1200-I EXPLODED VIEW 7-31-2002 PAGE 23 250-7700...
  • Page 24: Wire Diagram

    CB1200-I PELLET STOVE SERVICE MANUAL COMPLETE WIRE DIAGRAM ACCY JUMPER T-STAT CONN (YEL) T-STAT CONN BURN RATE SNAP DISC #2 (YEL) (GRAY) BLUE SNAP DISC #2 (YEL) PURPLE SNAP DISC #3 (GREY) P.B. ORANGE LIGHT SNAP DISC #1 (PUR) (PUR) SNAP DISC #1 POWER IN (BLK) GREY...
  • Page 25: Dimensions & Specs

    CB1200-I PELLET STOVE SERVICE MANUAL DIMENSIONS AND SPECS 40" 29 1/4" 12" 22" 40" 8 3/4" 13" 10 3/4" 30" 28 1/2" 11" WATTS: 621w TOTAL //// 110w EXHAUST //// 127w CONVECTION //// 380w IGNITER //// 4w FEED MOTOR AMPS: 5.38A TOTAL //// .95A EXHAUST //// 1.1A CONVECTION //// 3.3A IGNITER //// .03A FEED MOTOR VOLTS: 115V VOLTS ON THE MEDIUM FEED SETTING: 85 V ( + 1 V ) EXHAUST ////// 101 V ( + 1 V ) CONVECTION VOLTS ON THE LOW FEED SETTING: 75 V ( + 1 V ) EXHAUST /////// 82 V ( + 1 V ) CONVECTION...
  • Page 26: Check-Off Sheet

    CB1200-I PELLET STOVE SERVICE MANUAL TECH CHECK SHEET PELLET STOVES PLEASE ANSWER ALL OF THE QUESTIONS BELOW IF YOU NEED TO CONTACT THE TECHNICAL SERVICES DEPARTMENT. THIS WILL HELP US TO IDENTIFY THE PROBLEM FASTER AND WILL SAVE YOU TIME. WHAT IS WRONG WITH THE STOVE?____________________________________________ ____________________________________________________________________________ MODEL_____________________________SERIAL NUMBER__________________________...
  • Page 27: Cleaning & Maintenance Tips

    CB1200-I PELLET STOVE SERVICE MANUAL CLEANING & MAINTENANCE TIPS CAUTION: REMEMBER TO UNPLUG THE STOVE BEFORE PERFORMING ANY CLEANING OR MAINTENANCE ON THE STOVE. CLEANING OR DAILY WEEKLY MONTHLY YEARLY INSPECTION FIREPOT USING WOOD PELLETS: EVERY 3 BAGS OR FIREPOT USING SHELLED CORN: EVERY BAG OR FIREBOX ASH...
  • Page 28 CB1200-I PELLET STOVE SERVICE MANUAL CLEANING & MAINTENANCE TIPS FIREPOT: THE FIREPOT NEEDS TO BE CLEANED AS NEEDED. THE BUILD-UP OF CLINKER MATERIAL WILL DEPEND ON THE QUALITY OF THE FUEL BEING USED. IN SOME CASES, IT MAY BE NECESSARY TO CLEAN THE FIREPOT ON A DAILY BASIS. FIREPOT CLEANING INVOLVES SIMPLY PULLING THE CLEANOUT ROD ON THE FRONT OF THE STOVE.
  • Page 29: Service Tools

    CB1200-I PELLET STOVE SERVICE MANUAL RECOMMENDED SERVICE TOOLS 1) DIGITAL VOLTMETER------FOR CHECKING VOLTS AND CONTINUITY OF CIRCUITS 2) DIGITAL MANOMETER-----FOR CHECKING VACUUM IN THE FIREBOX 3) TEST CORD-----FOR CHECKING INDIVIDUAL COMPONENTS 4) TEST BOX------FOR CHECKING THE WIRE HARNESS & COMPONENTS DIGITAL MANOMETER DIGITAL VOLTMETER TEST CORD...
  • Page 30 CB1200-I PELLET STOVE SERVICE MANUAL...

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