Quadra Fire 810 02901 Users Manual 250 7251G Castile Pellet Insert 8 20 09.2

810-02901 Castile Insert

CASTINS-CSB to the manual aa98a5a8-5a91-4c16-a1bd-a1de559bd5c3

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CASTILE PELLET INSERT
Owner’s Manual

Tested and
Listed by

Installation and Operation

Portland
Oregon USA

O-T L
C

OMNI-Test Laboratories, Inc.

Models:
810-02901 (MBK)
810-03201 (PMH)
CASTINS-CSB
CASTINS-CWL

CAUTION
DO NOT DISCARD THIS MANUAL
• Important operating and • Read, understand and
follow these instrucmaintenance instructions for safe installations included.
tion and operation.

WARNING

• Leave this manual

with party responsible for use and
operation.

D
DI O N
SC O
AR T
D

WARNING

Please read this entire manual
before installation and use of this
pellet fuel-burning room heater.
Failure to follow these instructions
could result in property damage,
bodily injury or even death.

• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this
or any other appliance.
• Do not overfire - If any external part starts to
glow, you are overfiring. Reduce feed rate.
Overfiring will void your warranty.
• Comply with all minimum clearances to combustibles as specified. Failure to comply may
cause house fire.

HOT SURFACES!
Glass and other surfaces are
hot during operation AND
cool down.

Hot glass will cause burns.
• Do not touch glass until it is cooled
• NEVER allow children to touch glass
• Keep children away
• CAREFULLY SUPERVISE children in same room as
fireplace.
• Alert children and adults to hazards of high
temperatures.
High temperatures may ignite clothing or other
flammable materials.
• Keep clothing, furniture, draperies and other flammable
materials away.

CAUTION
CAUTION
Tested and approved for wood pellets and shelled
field corn fuel only. Burning of any other type of fuel
voids your warranty.
www.quadrafire.com

250-7251G

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.

August 20, 2009

Castile Pellet Insert

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.

SAMPLE OF CLEARANCE TO COMBUSTIBLES LABEL
LOCATION: On beaded chain behind right access
panel. Panel hinges open.

This commitment begins with our research of the
market, including ‘Voice of the Customer’ contacts,
ensuring we make products that will satisfy your
needs.

SAFETY LABEL
Tested and
Listed by

Manufactured by:

Portland
Oregon USA

O-T L

OMNI-Test Laboratories, Inc.

Castile Pellet Insert

Report No.
#061-S-42-2

1445 Highway North, Colville, WA 99114
www.quadrafire.com

Input Rating: 30,000 BTU/HR.
Electrical Rating: 115 VAC, 60 Hz, Start 4.1 Amps, Run 1.1 AMPS.

Our Research and Development facility then
employs the world’s most advanced technology
to achieve the optimum operation of our stoves,
inserts and fireplaces. And yet we are old-fashioned when it comes to craftsmanship. Each unit
is meticulously fabricated and are hand-finished for
lasting beauty and enjoyment.

Listed Solid Fuel Room Heater/Pellet Type Insert. Also suitable for Mobile Home Installation. This
appliance has been tested and listed for use in Manufactured Homes in accordance with OAR
814-23-9000 through 814-23-909.
Tested to: ASTM E-1509-95, ULC S628-93, ULC /ORD-C1482-M1990 Room Heating Pellet Burning Type,
(UM) 84-HUD FOR USE ONLY WITH PELLETIZED WOOD OR SHELLED FIELD CORN FUEL.
Route power cord away from unit. Do not route cord under or in front of appliance.

E
L
P

Our pledge to quality is completed as each model
undergoes a quality control inspection. From
design, to fabrication, to shipping: We wish you
and your family many years of enjoyment in the
warmth and comfort of your hearth appliance.

M
A

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS
AS A BUILT-IN UNIT

0 in. Clearance To Exposed Section and Face Trim

Thank you for choosing Quadra-Fire.

A Top of Hopper
B Side of Outside Skin
C Back of Hopper

Top/Rear Vent
Top/Rear Vent
Rear Vent
Top Vent
D Vent Pipe to Combustible Rear Vent
E From Panel Edge

0 in. (0mm)
0 in. (0mm)
0 in. (0mm)
2.5 in. (64mm)
3.0 in. (76mm)
0 in. (0mm)

Masonry or Zero Clearance
MANTEL

Face Trim

SIDE WALL

NOTE: Consult
insurance carrier, local
building inspector, fire
officials or authorities
having jurisdiction over
restrictions, installation
inspection and permits.

C
D

A
B
C
D
E
F

Insert side to combustible
Insert top to mantel
Insert top to face trim
Insert side face trim
Hearth extension from door opening
Hearth extension from side of door opening

DO NOT REMOVE THIS LABEL

0 in.
12 in.
0 in.
0 in.
6 in.
6 in.

0mm
305mm
0mm
0mm
152mm
152mm
7014-143

SAMPLE OF SERIAL NUMBER & DATE OF MANUFACTURE LABEL
LOCATION: Inside hopper on the top
HOT WHILE IN OPERATION DO NOT TOUCH, KEEP CHILDREN, CLOTHING AND FURNITURE AWAY. CONTACT MAY CAUSE SKIN

BURNS. SEE NAMEPLATE AND INSTRUCTIONS. Operate this unit with fuel hopper lid closed. Failure to do so may
CAUTION: result
in emissions products’ combustion from the hopper under certain conditions. Maintain hopper seal in

ATTENTION:
Tested and
Listed by

Portland
Oregon USA

O-T L
C

good condition. Do not overfill hopper.
CHAUD LORS DE L'OPÉRATION. NE PAS TOUCHER. GARDEZ LES ENFANTS ET LES VÊTEMENTS LOIN DE
L'ESPACE DÉSIGNÉ DE L'INSTALLATION. LE CONTACT PEUT CAUSER DES BRÛLURES À LA PEAU. VOIR
L'ÉTIQUETTE ET LES INSTRUCTIONS. Opérez cet appareil avec le couvercle de la trémie fermé. Le défautde ne pas suivre les instructions
peut résulter, sous certaines conditions, en une combustion des émissions des produits venant de la trémie. Ne pas remplir la trémie trop pleine.

Report / Rapport
#061-S-42-2

CASTILE PELLET INSERT

OMNI-Test Laboratories, Inc.

2009 2010 2011

JAN

DO NOT REMOVE THIS LABEL
NE PAS ENLEVER L'ÉTIQUETTE

Made in U.S.A.
Fait Aux États-Unis

SERIAL NO. / NUMÉRO DU SÉRIE

007

U.S. ENVIRONMENTAL
PROTECTION AGENCY

This model is exempt from EPA certification
under 40 CFR 60.531 by definition [Wood
Heater (A) "Air-to-Fuel Ratio"].

FEB MAR APR MAY JUNE JULY AUG SEPT OCT NOV DEC
250-7262F

Test Lab &
Rpt Nbr.

Page 2

Model
Name

Mfg Date

250-7251G

Serial No.

August 20, 2009

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.
B.
C.
D.
E.

Section 7: Appliance Set-Up

Appliance Certifications ......................4
Mobile Home Approved ......................4
Glass Specifications ............................4
Electrical Rating ..................................4
BTU & Efficiency Specifications ..........4

A. Reversible Top & Rear Flue Adapter ....18
B. Leveling System .................................18
C. Outside Air Kit .....................................19
D. Zero Clearance Trim Support .............19-20
E. Panel Set & Cast Trim ........................21
F. Panel & Trim Set Econo .....................21
G. Log Set Placement ..............................22
H. Thermostat Installation ........................23

Section 2: Getting Started
A. Design, Installation & Location
Considerations ....................................5
B. Locating Your Appliance & Chimney ..6
C. Draft ....................................................6
D. Negative Pressure ..............................6
E. Fire Safety ..........................................7
F. Tools & Supplies Needed ...................7
G. Inspect Appliance, Components
and Pre-Use Check List ......................7

Section 8: Operating Instructions
A.
B.
C.
D.
E.
F.
G.
H.

Section 3: Dimensions & Clearances
A. Appliance Dimensions ........................8
B. Clearances to Combustibles
As A Built-In, UL and ULC ..................9
C. Clearances to Combustibles,
Masonry & Zero Clearance .................10
D. Floor Protection ..................................10
E. Minimum Opening for FactoryBuilt Fireplace .....................................10
F. Removing Floor of Factory-Built
Fireplace .............................................11
G. Prefabricated Metal Chimney ..............12
H. Altering Factory-Built Fireplace ...........12

Fuel Size, Material & Storage .............24
General Operation Information ...........25
Before Your First Fire .........................25
Starting Your First Fire........................25
Fire Characteristics .............................25
Feed Rate Adjustment .......................26
Ignition Cycles ....................................26
Frequently Asked Questions...............27

Section 9: Troubleshooting ............................28-30
Section 10: Maintaining & Servicing Appliance
A.
B.
C.
D.
E.
F.
G.

Proper Shutdown Procedures .............31
Quick Reference Maintenance Chart ..31
General Maintenance & Cleaning .......32-35
High Ash Content Maintenance ..........35
Igniter Replacement ............................36
Glass Replacement .............................36
Baffle & Brick Removal .......................37-38

Section 12: Reference Material
Section 4: Vent Information

A.
B.
C.
D.
E.
F.
G.

Chimney & Exhaust Connections ........ 13
B. Venting Termination Requirements ....13
C. Equivalent Feet of Pipe.......................14
D. Pipe Selection Chart ...........................14
A.

Section 5: Venting Systems

Component Functions.........................39-40
Component Locations .........................41
Exploded Drawing...............................42
Service Parts & Accessories ...............43-47
Service & Maintenance Log ................48-49
Warranty Policy ...................................50-51
Contact Information .............................52

A. Full Reline with Outside Air-Horizontal 15
B. Full Reline with Outside Air-Vertical ....16

Section 6: Mobile Home ..................................17

August 20, 2009

250-7251G

Page 3

Castile Pellet Insert

Listing and Code Approvals
E. BTU & Efficiency Specifications

A. Appliance Certification
MODEL:

Castile Pellet Insert

LABORATORY:

OMNI Test Laboratories, Inc

Particulate Emissions Rating:

0.7 grams/hr

REPORT NO.

061-S-42-2

*BTU Output:

8,000 - 30,000 / hr

TYPE:

Solid Fuel Room Heater/Pellet Fuel
Burning Type Insert

Heating Capacity:

up to 1,500 sq. ft. depending
on climate zone

STANDARD:

ASTM E1509-95, ULC S628-93 and
ULC/ORD-C1482-M1990 Room
Heater Pellet Fuel Burning Type and
(UM) 84-HUD, Mobile Home Approved

Hopper Capacity:

45 lbs

Fuel:

Wood Pellets or Shelled Corn

Shipping Weight:

260 lbs

Colorado:

Approved 11-15-02
*BTU output will vary, depending on the brand of fuel you
use in your appliance. Consult your Quadra-Fire dealer
for best results.

B. Mobile Home Approved
This appliance is approved for mobile home installations
when not installed in a sleeping room and when an outside
combustion air inlet is used.
The structural integrity of the mobile home floor, ceiling, and
walls must be maintained.
The appliance must be properly grounded to the frame of
the mobile home and use only Listed pellet vent Class “L”
or “PL” connector pipe.
A Quadra-Fire Outside Air Kit must be installed in a mobile
home installation. You must order the Outside Air Kit separately.
Note: The appliance is also approved for installation
into a shop.

C. Glass Specifications

WARNING! Risk of Fire! Hearth & Home Technologies disclaims any responsibility for, and the warranty and agency
listing will be voided by the above actions.
DO NOT:
• Install or operate damaged appliance
• Modify appliance
• Install other than as instructed by Hearth & Home
Technologies
• Operate the appliance without fully assembling all
components
• Overfire
• Install any component not approved by Hearth &
Home Technologies
• Install parts or components not Listed or approved.
Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage.

This appliance is equipped with 5mm ceramic glass. Replace For assistance or additional information, consult a qualified
glass only with 5mm ceramic glass. Please contact your installer, service agency or your dealer.
dealer for replacement glass.

NOTE: This installation must conform with local codes.
In the absence of local codes you must comply with the
ASTM E1509-95, ULC S628-93, ULC/ORD-C-1482M1990 and (UM) 84-HUD

NOTE: Hearth & Home Technologies, manufacturer of
this appliance, reserves the right to alter its products,
their specifications and/or price without notice.

Quadra-Fire is a registered trademark
of Hearth & Home Technologies.

D. Electrical Rating
115 VAC, 60 Hz, Start 4.1 Amps, Run 1.1 Amps

Page 4

250-7251G

August 20, 2009

Castile Pellet Insert

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.
•

Consult insurance carrier, local building inspector, fire
officials or authorities having jurisdiction over restrictions,
installation inspection and permits.

It is a good idea to plan your installation on paper, using
exact measurements for clearances and floor protection,
before actually beginning the installation
Consideration must be given to:
• Safety, convenience, traffic flow
• Placement of the chimney and chimney connector.
• If you are not using an existing chimney, place the appliance where there will be a clear passage for a factorybuilt listed chimney through the ceiling and roof.
• Installing an optional outside air kit would affect the location of the vent termination.

Recommended Location:
• Above peak

• Air Intakes
• Air Conditioner
• Overhang, soffits, porch roofs, adjacent walls
• Landscaping, vegetation
When locating vent and venting termination, vent above
roof line when possible.
Warning! Risk of Fire Damaged parts could impair safe
operation. Do NOT install damaged, incomplete or substitute
components.
CAUTION! If burning shelled field corn, you must use approved venting specifically designed for corn to prevent corrosion or degradation. Follow the instructions from the venting
manufacturer.
NOTICE: Locating the appliance in a location of
considerable air movement can cause intermittent smoke
spillage from appliance. Do not locate appliance near:
•

Frequently open doors

•

Central heat outlets or returns

Recommended Location:
• Above peak
• Inside heated space

Marginal Location:
• Wind loading possible

Marginal Location:
• Below peak

Location NOT recommended:
• Not the highest point of the roof
• Wind loading possible

Recommended:
• Insulated exterior chase
in cooler climates

Location NOT recommended:
• Too close to tree
• Below adjacent structure
• Lower roof line
• Avoid outside wall

Windward
Leeward

Recommended:
Outside Air Intake
on windward side

Multi-level Roofs

NOT recommended:
Outside Air Intake
on leeward side

Figure 5.1
August 20, 2009

250-7251G

Page 5

Castile Pellet Insert
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.

•

Locate termination cap away from trees, adjacent
structures, uneven roof lines and other obstructions.

•

Minimize the use of chimney offsets.

•

Consider the appliance location relative to floor and ceiling
and attic joists.

CAUTION

Negative pressure results from the imbalance of air available for the appliance to operate properly. It can be strongest in lower levels of the house.
Causes include:
•

Exhaust fans (kitchen, bath, etc.)

•

Range hoods

•

Combustion air requirements for furnaces, water heaters
and other combustion appliances

•

Clothes dryers

•

Location of return-air vents to furnace or air conditioning

•

Imbalances of the HVAC air handling system

•

Upper level air leaks such as:

• DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE
SERVICING ANOTHER APPLIANCE.

- Recessed lighting
- Attic hatch

• DO NOT CONNECT TO ANY AIR DISTRIBUTON DUCT
OR SYSTEM.

- Duct leaks
To minimize the effects of negative air pressure:

C. Draft
Draft is the pressure difference needed to vent appliances
successfully. When an appliance is drafting successfully, all
combustion byproducts are exiting the home through the
chimney.

•

Install the outside air kit with the intake facing prevailing
winds during the heating season

•

Ensure adequate outdoor air for all combustion appliances
and exhaust equipment

•

Ensure furnace and air conditioning return vents are not
located in the immediate vicinity of the appliance

•

Avoid installing the appliance near doors, walkways or
small isolated spaces

•

Recessed lighting should be a “sealed can” design

•

Attic hatches weather stripped or sealed

•

Attic mounted duct work and air handler joints and seams
taped or sealed

Considerations for successful draft include:
•

Preventing negative pressure

•

Location of appliance and chimney

NOTICE: Hearth & Home Technologies assumes no
responsibility for the improper performance of the chimney
system caused by:
• Inadequate draft due to environmental conditions
•

Downdrafts

•

Tight sealing construction of the structure

•

Mechanical exhausting devices

Page 6

250-7251G

August 20, 2009

Castile Pellet Insert
E. Fire Safety

F. Tools And Supplies Needed

To provide reasonable fire safety, the following should be
given serious consideration:
• Install at least one smoke detector on each floor of your
home.
• Locate smoke detector away from the heating appliance
and close to the sleeping areas.
• Follow the smoke detector manufacturer’s placement and
installation instructions and maintain regularly.
• Conveniently locate a Class A fire extinguisher to contend
with small fires.
•

In the event of a hopper fire:

Tools and building supplies normally required
for installation, unless installing into an existing
masonry fireplace:
Reciprocating Saw
Hammer
Phillips Screw driver
Tape Measure
Plumb Line
Level
Framing Material
Hi-temp Caulking Material
Gloves

Safety Glasses
Framing Square
Electric Drill & Bits (1/4”)
1/4” Self-Tapping Screws
May also need:
Vent Support Straps
Venting Paint

• Evacute the house immediately.
• Notify fire department.

G. Inspect Appliance & Components and
Pre-Use Check List

WARNING
Inspect appliance and components for
damage. Damaged parts may impair safe
operation.
• Do NOT install damaged components.
• Do NOT install incomplete components.
• Do NOT install substitute components.

Place the appliance in a location near the
final installation area and follow the procedures below:

Open the appliance and remove all the parts
and articles packed inside the Component
Pack. Inspect all the parts and glass for shipping damage. Contact your dealer if any irregularities are noticed.

All safety warnings have been read and followed.

This Owner’s Manual has been read.

Floor protection requirements have been met.

Venting is properly installed.

The proper clearances from the appliance and
chimney to combustible materials have been
met.

The masonry chimney is inspected by a professional and is clean, or the factory built metal
chimney is installed according to the manufacturer’s instructions and clearances.

The chimney meets the required minimum
height.

10.

All labels have been removed from the glass
door.

11.

Plated surfaces have been wiped clean, if
applicable.

12.

Thermostat or remote has been installed.

13.

A power outlet is available nearby.

14.

A good quality surge protection is highly recommended to protect the electronics.

Report damaged parts to dealer.

WARNING
Fire Risk.
Hearth & Home Technologies disclaims any
responsibility for, and the warranty will be
voided by, the following actions:
• Installation and use of any damaged appliance.
• Modification of the appliance.
• Installation other than as instructed by Hearth & Home
Technologies.
• Installation and/or use of any component part not approved
by Hearth & Home Technologies.
• Operating appliance without fully assembling all
components.
• Do NOT Overfire.
Or any such action that may cause a fire hazard.

August 20, 2009

250-7251G

Page 7

Castile Pellet Insert

Dimensions and Clearances

A. Appliance Dimensions
28-1/16 in.

43-1/2 in.

(713mm)

(1105mm)

23-7/16 in.
(595mm)

42-1/2 in.
(1080mm)

8 in.
(203mm)

11-1/16 in.
(281mm)

30-3/8 in.
(772mm)

30 in.
(762mm)

32-5/16 in.
(821mm)

Figure 8.2- Front View

Figure 8.1 - Top View

Height
Panel Size

Width

inch

Small Cast

762

Large Cast

864

1219

Small Econo

762

1016

10-3/16 in.

13-1/16 in.

(259mm)

(332mm)

42-1/2 1078

24-3/16 in./
(614mm)

NOTE: All views are shown with Panel
& Cast Trim Set installed.

19.0 in.
(483mm)

24-3/4 in.
(629mm)

12-3/4 in.
(324mm)

9-3/16 in.
(234mm)

2.0 in. (51mm)
9-13/16 in.
(249mm)

Figure 8.3 -Side View

Page 8

250-7251G

August 20, 2009

Castile Pellet Insert
B. Clearance To Combustibles, UL and ULC
AS A BUILT-IN

D
B

0” (0mm) Clearance To Exposed Section And Face Trim
Figure 9.1
Inches

Millimeters

Top of Hopper

Top or Rear Vent

Side of Outside Skin

Top or Rear Vent

Back of Hopper

Top Vent

2.5

Rear Vent

Vent Pipe to Combustible

Top or Rear Vent

3.0

Front Panel Edge

Top or Rear Vent

INSTALLED AS A BUILT-IN UNIT
Shown Optional Outside Air

WARNING
Fire Risk.
Comply with all minimum clearances
to combustibles as specified.
Failure to comply may cause house
fire.

12 in
(305mm)

6 in
(153mm)

Outside
Air

NOTE:
• Illustrations reflect typical installations
and are FOR DESIGN PURPOSES
ONLY.
• Illustrations/diagrams are not drawn to
scale.
• Actual installation may vary due to
individual design preference.

Figure 9.2
August 20, 2009

250-7251G

Page 9

Castile Pellet Insert
C. Masonry and Zero Clearance Fireplaces

Inches Millimeters
MANTEL

SIDE WALL

B
C

A Insert side to combustible
side wall

B Insert top to mantel

305

C Insert top to face trim

D Insert side to face trim

Figure 10.1

D. Floor Protection
Inches

Millimeters

Floor protection hearth extension
from door opening

152

Floor protection to the side of door
opening

152

E. Minimum Opening for Masonry and Zero
Clearance Fireplaces

Location

Inches

Millimeters

Rear Width

23-7/16

595

Depth

18 for Zero Clearance
14 for Masonry

457
356

Height

19-1/4 if drop down
21-1/4 if flush or
hearth mount

489
540

Front Width

28-1/4

718

Figure 10.2

Page 10

250-7251G

August 20, 2009

Castile Pellet Insert
F. Removing Metal Floor of Factory-Built Firebox
•

•

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.

Use 2 x 4 from insert
packaging to support insert

The metal floor of the factory-built firebox may be removed
to facilitate the installation of the insert only when a 1/4
(6mm) inch airspace is provided between the insert and
the floor of outer wrap.
The following is only one example as there are many different models of factory-built fireplaces.

Figure 11.3. If the floor is made of thin metal,
we recommend using the 2 x 4 from the insert
packaging to support the insert. The 2 x 4
may need to be cut to the appropriate size.

Starter hole

Keep sharp edge of
metal floor away from
power cord

Mark area of
floor to cut

Figure 11.1. Measure and mark the metal
floor for cutting. With a drill, make a starter
hole in each corner.
Figure 11.4. Place the insert into the factory-built firebox. Ensure that the power
cord can not be damaged by the sharp metal
edge. You may need to cut out a notch to
accommodate the cord.

NOTE: Ensure that the leveling leg is positioned over the 2 x 4 before leveling the
insert. See page 18, for detailed instructions
on how to adjust the leveling legs.
Figure 11.2. Using a saws-all, cut out the
floor

August 20, 2009

250-7251G

Page 11

Castile Pellet Insert
G. Prefabricated Metal Chimney

H. Altering the Factory-Built Fireplace

The chimney can be new or existing, masonry or prefabricated
and must meet the following minimum requirements:

•

• Must be minimum 6 inch (152mm) inside diameter of
high temperature chimney listed to UL 103 HT (2100oF)
or ULC-S628.

The fireplace must not be altered, except for the
exceptions listed below. Do not removal the bricks and
mortar from the existing fireplace.

The following modifications are premissible:
•
•
•
•
•
•

• Must use components required by the manufacturer for
installation.
• Must maintain clearances required by the manufacturer
for installation.

Removal of damper or locked in open position
Removal of smoke shelf or baffle
Removal of ember catches
Removel of fire grate
Removal of view screen/curtain
Removal of doors

• Refer to manufacturers instructions for installation

•

•This insert is listed to UL 1482 Standard and is approved
for installation into listed factory-built zero clearance fireplaces listed to UL 127 conforming to the following specifications and instructions:

External trim pieces which do not affect the operation
of the fireplace may be removed providing they can be
stored on or within the fireplace for reassembly if the insert
is removed.

•

The permanent metal warning label provided must be
attached to the back of the fireplace, with screws or
nails, stating that the fireplace may have been altered to
accommodate the insert, and must be returned to original
condition for use as a conventional fireplace. Figure
11.1

•

If the hearth extension is lower than the fireplace opening,
the portion of the insert extending onto the hearth must
be supported.

•The liner must be securely attached to the insert flue collar
and the chimney top.

•

Manufacturer designed adjustable support kit can be
ordered from your dealer.

•The air flow of the factory-built zero-clearance fireplace
system must not be altered. The flue liner top support
attachment must not reduce the air flow for the existing
air-cooled chimney system.

•

Final approval of this installation type is contingent upon
the authority having jurisdiction.

•The original factory-built clearance fireplace chimney
cap must be re-installed after installing the approved
chimney liner meeting type UL 103 HT requirements
(2100°F) per UL 1777.
•If the chimney is not listed as meeting HT requirements,
or if the factory built fireplace was tested prior to 1998, a
full height listed chimney liner must be installed from the
appliance flue collar to the chimney top.

•No dilution air is allowed to enter the chimney.
1. Secure the fireplace damper in the open position. If
this cannot be accomplished, it will be necessary to
remove the damper
2. Seal damper area of chimney around chimney
connector with a high temperature sealant or seal
insert against the face of the fireplace.
3. Both methods must be removable and replaceable
for cleaning and re-installation.

NOTE: Refer to chimney liner manufacturer for recommendations on supporting the liner. Installation into
fireplaces without a permit will void the listing

WARNING! Risk of Fire!
Follow venting manufacturer’s clearances and instructions
when installing venting system.
NOTICE: In Canada when using a factory-built chimney it must be safety listed, Type UL103 HT (2100oF)
[1149oC] CLASS “A” or conforming to CAN/ULCS629M, STANDARD FOR 650oC FACTORY-BUILT
CHIMNEYS.

WARNING
THIS FIREPLACE MAY HAVE BEEN ALTERED
TO ACCOMMODATE AN INSERT. IT MUST BE
RETURNED TO ITS ORIGINAL CONDITION
BEFORE USE AS A SOLID FUEL BURNING
FIREPLACE.
250-2061
250-2061

Figure 121

Page 12

250-7251G

August 20, 2009

Castile Pellet Insert

Vent Information
B. Venting Termination Requirements

A. Chimney and Exhaust Connection

CAUTION

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. If using
the 3 inch (76mm) vertical Top Vent Adapter Kit or the 3
to 6 inch (76-152mm) Top Vent Offset Adapter, use Listed
double wall flue connector. A Quadra-Fire Outside Air Kit
must be used with manufactured home installations.

Do not terminate vent in any enclosed or semi-enclosed
area such as a carport, garage, attic, crawl space, under a
sun deck or porch, narrow walkway or closely fenced area,
or any location that can build up a concentration of fumes
such as a stairwell, covered breezeway, etc.
1. Termination must exhaust above air inlet elevation. It

is recommended that at least 60 inches (1.5m) of vertical pipe be installed when appliance is vented directly
through a wall. This will create a natural draft, which
will help prevent the possibility of smoke or odor venting
into the home during a power outage. It will also keep
exhaust from causing a nuisance or hazard by exposing
people or shrubs to high temperatures. The safest and
preferred venting method is to extend the vent vertically
through the roof.

3. Residential: The 3 inch (76mm) vertical Top Vent Adapter
Kit and the 3 to 6 inch (76-152mm) Top Vent Offset Adapter
are tested to use 24 gauge single wall flue connector or
Listed double wall flue connector to Class A Listed metal
chimneys, or masonry chimneys meeting International
Conference of Building Officials (ICBO) standards for solid
fuel appliances.
4. INSTALL VENT AT CLEARANCES SPECIFIED BY THE
VENT MANUFACTURER.
5. Secure exhaust venting system to the appliance with at

least 3 screws. Also secure all connector pipe joints with
at least 3 screws through each joint.
6. DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST
VENTING SYSTEM OF THIS UNIT.
7. DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE
SERVING ANOTHER APPLIANCE.
NOTE: All pipe must be welded seam pipe whenever possible. Seal pipe joints with high temperature silicone (500°F
[260°C] minimum rated only). Do not put silicone inside
of pipe.
NOTE: If burning shelled field corn, you must use approved
venting specifically designed for corn. Follow the instructions from the venting manufacturer.

WARNING
Fire Hazard.
• Only LISTED venting components may be
used.
• NO OTHER vent components may be used.
Substitute or damaged vent components may
impair safe operation.

WARNING
Vent surfaces get HOT, can cause burns if
touched. Noncombustible shielding or guards
may be required.

August 20, 2009

2. Distance from doors and opening windows, or gravity or
ventilation air inlets into building:
a. Not less than 48 inches (1.2m) below;
b. Not less than 48 inches (1.2m) horizontally from;
c. Not less than 12 inches (305mm) above.
3. Distance from permanently closed windows:
a. Not less than 12 inches (305mm) below, horizontally
from or above.
4. Distance between bottom of termination and grade
should be 12 inches (305mm) minimum. This is conditional upon plants in the area, and nature of grade
surface. The grade surface must be a non-combustible
material (i.e., rock, dirt). The grade surface must not be
lawn. Distance between bottom of termination and public
walkway should be 84 inches (2.13m) minimum.
5. Distance to combustible materials must be 24 inches
(610mm) minimum. This includes adjacent buildings,
fences, protruding parts of the structure, roof overhang,
plants and shrubs, etc.
6. Termination Cap Location (Home Electrical Service)
•

Side-to-side clearance is to be the same as minimum
clearance to vinyl inside corners.

•

Clearance of a termination cap below electrical service
shall be the same as minimum clearance to vinyl soffits.

•

Clearance of a termination cap above electrical service
will be 12 inches (305mm) minimum.

•

Location of the vent termination must not obstruct or
interfere with access to the electrical service.

250-7251G

Page 13

Castile Pellet Insert

WARNING

C. Equivalent Feet of Pipe
The table below can help you calculate the equivalent feet
of pipe which is a method used to determine pellet vent size.
Figure 14.1.

Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage. Refer
to the owner’s information manual provided with this appliance. For assistance or additional information consult a
qualified installer, service agency or your dealer.

Example of 3 Elbow-Rear Vent Termination Calculation

2 ft.

Pellet Venting
Component

# of
Elbows

90o Elbow or Tee

Feet of Multiplied
Pipe
By

45o Elbow

3 ft.

Equivalent
Feet

Equivalent Feet

Horizontal Pipe

Vertical Pipe

0.5

Components

7
1

Total Equivalent Feet

2 ft.

Note: This is a generic example and is not
intended to represent any specific fuel type.

2 ft.

Figure 14.1

D. Pipe Selection Chart
The chart will help you in determing proper venting size according to the equivalent feet of pipe
calcuated above and the altitude above sea level
of this installation. Figure 14.2.
Locate the calculated equivalent feet of pipe on
the vertical left side of the chart. Move to the
right horizontally on the chart until you reach your
altitude above sea level.

30
Example 1

Equivalent Pipe
Length In Feet
Example 2

If you fall below the diagonal line, 3 or 4 inch (76
to 102mm) pipe may be used. If it is anywhere
above the diagonal line, a 4 inch (102mm) diameter
pipe is required.
The chart reveals that a 90° elbow is 5 times as
restrictive to the flow of exhaust gases under positive pressure as 1 foot of horizontal pipe, and a
foot of horizontal pipe is twice as restrictive as a
foot of vertical pipe.

4 in. (102mm) Diameter Pipe Only

3 in. or 4 in. (76mm or 102mm) Diameter Pipe
0
1

ALTITUDE IN THOUSANDS OF FEET

Figure 14.2
Example 1: If the equivalent length of pipe is 23 feet with altitude of
8,000 feet you must use 4 inch (102mm) diameter type “L” or “PL”
vent.
Example 2: If the equivalent length of pipe is 12 feet with altitude of
6,000 feet you may use 3 or 4 inch (76 to 102mm) diameter type “L”
or “PL” vent

Page 14

250-7251G

August 20, 2009

Castile Pellet Insert

Venting Systems

A. Full Reline With Outside Air - Horizontal

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.

CAUTION
Never draw outside combustion air from:
• Wall, floor or ceiling cavity
• Enclosed space such as an attic or garage

NOTE; Use metal plate around
exhaust vent pipe and seal all
edges with non-flammable insulation such as fiberglass, mineral
wool or ceramic.
Do not use high temperature
caulking materials to seal any
edge to prevent furture serviceability.

Outside Air through Rear
Wall (Horizontal)

Figure 15.1
NOTE:
In Canada, where passage through a wall or partition of
combustible construction is desired, the installation shall
conform to CAN/CSA-B365.

August 20, 2009

NOTE:
• Illustrations reflect typical installations and are FOR
DESIGN PURPOSES ONLY.
• Illustrations/diagrams are not drawn to scale.
• Actual installation may vary due to individual design
preference.

250-7251G

Page 15

Castile Pellet Insert
B. Full Reline With Outside Air - Vertical
NOTE: Check clearances carefully for this type of installation to ensure adequate room for outside air venting.

NOTE: In Canada only a full reline is allowed per ULC
S628, ORD ULC C1482-M1990.

305mm min.
above
305mm min.
below

NOTE; Use metal plate around
exhaust vent pipe and seal all
edges with non-flammable insulation such as fiberglass, mineral
wool or ceramic.

Outside Air
Termination
at
Chimney Top
(Vertical)

Do not use high temperature caulking materials to seal any edge to
prevent furture serviceability.

Figure 16.1

NOTE: In Canada this fireplace insert must be installed
with a continous chimney liner a 6 inch (152mm) in diameter extending from the fireplace insert to the top of the
chimney. The chimney liner must conform to the Class
3 requirments of CAN/ULC-S635, Standard for Lining
Systems for Extising Masonry or Factory-Built Chimneys
and Vents, or CAN/ULC-S640, Standard for Lining Systems for New Masonry Chimneys.
Page 16

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.

250-7251G

August 20, 2009

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.

The combustion air duct system must be made of
metal. It must permit zero clearance to combustible
construction and prevent material from dropping into
the inlet or into the area beneath the dwelling and
contain a rodent screen.

CAUTION
THE STRUCTURAL INTEGRITY OF THE MOBILE HOME
FLOOR, WALL AND CEILING/ROOF MUST BE MAINTAINED
Do NOT cut through:
• Floor joist, wall, studs or ceiling trusses.
• Any supporting material that would affect the structural
integrity.

Spark Arrestor Cap

The appliance must be secured to the mobile home
structure by bolting it to the floor (using lag bolts). Use
the same holes that secured the appliance to the shipping pallet.

The appliance must be grounded with #8 solid copper
grounding wire or equivalent, terminated at each end
with an NEC approved grounding device.

Refer to clearances to combustibles and floor protection
requirements on pages 9 & 10 for listings to combustibles and appropriate chimney systems.

Use silicone to create an effective vapor barrier at
the location where the chimney or other component
penetrates to the the exterior of the structure.

Follow the chimney manufacturer’s instructions when
installing the vent system for use in a mobile home.

Installation shall be in accordance with the Manufacturers Home & Safety Standard (HUD) CFR 3280, Part
24.

Storm Collar
Roof Flashing

Joist Shield/Firestop

Approved Class “L”
or “PL” Pellet Vent

Figure 17.1

WARNING
Installation must comply with Manufactured Home and
Safety Standard (HUD), CFR 3280, Part 24.

WARNING
Asphyxiation Risk.
NEVER INSTALL IN A SLEEPING ROOM.
Consumes oxygen in the room.

August 20, 2009

250-7251G

Page 17

Castile Pellet Insert

Appliance Set-Up

A. Reversible Top or Rear Flue Adapter

B. Leveling System

Top Vent Installation

The back legs are adjustable to allow for customized fit
into zero clearance boxes.

1. Release ammo can latches on each side. Figure 18.1.
2. Place the reversible adapter in the correct position for your
installation.
3. Make sure BOTH latches are in position before securing
them.
Rear Vent Installation
1. Remove the 90o adapter and installation screws from the
packaging.

1. Loosen 2 top screws and remove 2 bottom screws.
2. Adjust leg to desired height. Leg can slide up (shorter)
or down (longer) to level the insert.
3. Tighten 2 top screws.
4. Drill 2 holes for the bottom 2 screws and re-install
screws. Figure 18.5.

2. Attach the 90o adapter onto the vent adapter, using the 3
screws provided. You will need to pre-drill the holes for screw
placement. Be sure to adjust the 90o adapter to the desired
position for venting before drilling.

Loosen top 2 screws and remove
bottom 2. Adjust leg to desired height.

3. Silicone the pipe joints according to the Note below.
NOTE: All pipe must be sealed using welded
seam pipe whenever possible. Seal pipe joints
with high temperature silicone, minimum rate of
5000F (2600C).

Ammo Can Latches

Figure 18.4

Drill 2 holes and
re-install bottom 2
screws

Figure 18.1 - Top Vent

Figure 18.5

screw

Figure 18.2 - Rear Vent
Page 18

Figure 18.3 - Rear Vent
250-7251G

August 20, 2009

Castile Pellet Insert
C. Outside Air Kit Instructions

D. Zero Clearance Trim Support Instructions

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 air intake channel, 1 trim ring, fasteners. NOTE:
Discard air intake channel, it is not used on this appliance.

NOTE: Only for use on small size panels.

Tools Needed: Phillips head screwdriver; wire cutters;
hole saw or jig saw.
1. Attach collar assembly to appliance. Figure 19.1.
Measure distance from floor to air vent opening in
appliance and mark location on wall.

Figure 19.2 - Assembled View

3. Use saw to cut opening in wall. Cut a 2-1/2 to 3 inch
(64-76mm) opening on inside wall and a 3 to 3-1/2
inch (76-89mm) opening on outside of house.

8
7

4. Use hose clamp to secure flex pipe to collar assembly.

5. Slide trim ring over flex pipe and run pipe through
pre-cut hole in back of appliance and through the
wall.
6. Attach hose to outside termination cap with second
hose clamp.

5
4

7. Secure termination cap to outside surface.
8. Secure trim ring to interior wall.
1
2

CAUTION
Never draw outside combustion air from:
• Wall, floor or ceiling cavity
• Enclosed space such as an attic or garage

Figure 19.3
Item

Description

Front, 3 inch

Front, 5 inch

Cast Ring, Top & Bottom, Interchangeable

Side, 5 inch

Side, 3 inch

Panel Extension, 5 inch

Panel Extension, 3 inch

Panel Extension, Base Plate Only

Air Intake Channel
(Discard)

Trim Ring
Hose Clamp
Collar
Assembly

Termination
Cap Assembly

Flex Hose
Hose Clamp

Figure 19.1
August 20, 2009

250-7251G

Page 19

Castile Pellet Insert
D. Zero Clearance Trim Support (Cont’d)

Cast Trim
Footer

1. Remove contents from box and lay on protective surface
to avoid scratching the paint.
2. Lay zero clearance front and sides face down. Bend the
tab down toward the inside.
3. The side pieces are shipped flat. It is much easier to
manually flex the sides into a bowed position before
installing.
4. Lay 1 cast ring face up, which will become the bottom ring
when installed. Attach the 2 sides FIRST and then the
front piece. Figure 20.1.
5. Now turn the cast ring right side up and attach the top cast
ring . Figure 20.2.
6. Attach the zero clearance panel extensions. Figure
20.3
7. Attach cast footers. Figure 20.4.
8. Place the assembled zero clearance trim support under
the insert. Figure 20.5.

Figure 20.4

Panel Leg

Figure 20.5

es
Sid
l
l
ta rst
Ins Fi
Install Front Last

Base Plate Only Installation

NOTE: Manually
pre-shape sides before
installing

Bend top and bottom tabs toward inside

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.

Figure 20.1

2. Place assembly under appliance.

Cast Trim Footer

Panel Leg

Turn right side up and attach top cast rin g
Figure 20.2
Zero Clearance
Panel Extension

Figure 20.6

Alignment
Hole

Zero Clearance Panel Extension

Figure 20.3
Page 20

250-7251G

August 20, 2009

Castile Pellet Insert

E. Panel Set And Cast Trim Set

F. Panel & Trim Set, Econo

Included in Panel Kit: (2) side panels, left and right; (1)
panel top; (1) fastener package.

Included in Panel & Trim Kit: (2) corner brackets and set
screws; (1) trim set, 3 piece; (2) side panels; (1) top panel;
(4) screws;

Included in Cast Trim Kit: (2) cast trim legs, left and right; (1)
cast trim header; (2) cast trim footers, left and right; (1) fastener
package.

Tools Needed: Powered Phillips head screw driver

1. Secure the top panel to the panel sides with the
screws provided. Figure 21.3.

1. Remove contents from box being careful not to scratch or
damage the cast trim pieces.

2. Assemble the gold trim with the (2) corner brackets
provided. Figure 21.4.

2. Lay the panel set face down on protective covering to prevent
scratching the painted surface.

3. Slide the assembled trim over the assembled panel
set.

3. Secure the panels legs to top panel with the screws provided.

4. Now bend the tabs down toward the backside of the panel set,
5 on top and 2 on each leg. Leave the panel set face down.

Slide panel and trim over the top of the insert into
place matching the mounting tabs on the panel with
the slots on the insert.

5. Place the corresponding cast trim pieces ( 2 cast trim legs and
1 cast trim header) underneath the panel set, also face down.
6. Place washer provided over tab and secure the trim and panel
together with screw. Continue for all tabs.

Back of Top Panel

7. Secure cast footers with screws.
Screws

8. Remove both left and right cast sides from insert, See Figures
32.1, 32.2 and 32.3 on page 32.
9. Slide panel and trim over the top of the insert into place matching
the mounting tabs on the panel with the slots on the insert.

CAUTION
• Do NOT pick up assembled unit by corners.
• It is too heavy and may damage the panels.
• Pick up from center.

Back of Side Panel

Figure 21.3

View of "L" Bracket
installed
2. Bend tabs down

1. Screw panels
together

2. Bend tabs
down

3. Install Cast Trim Header
Mounting tabs on each panel leg
to match up with slots on insert.

Figure 21.4

Figure 21.1

Figure 21.2 - Completed View
of Panel Set & Cast Trim Set

August 20, 2009

250-7251G

Page 21

Castile Pellet Insert
G. Optional Log Set Placement Instructions

CAUTION
Logs are FRAGILE. Use extreme care when handling or
cleaning logs.

Four Piece Log Set Installation
1. Open the hinged cast face and open the glass door
assembly.
2.

Positioning the logs.
Place the right rear log as shown. There is a notch in
the bottom of the log for clearance for the thermocouple and thermocouple cover (ceramic protection tube).
Figure 22.1

Figure 22.3

Continue placing the last 3 logs around the firepot as
show in Figures 22.2, 22.3 and 22.4. Be careful not to
block the drop tube in the back of the firebox where pellets feed into the firepot.

Notch

Figure 22.4
Thermocouple
Cover

Top Log Installation
Place the log over the firepot. The charred
area on the log is turned toward the back, not
the front.
The log will be about 2-1/2 inches (64mm)
above the firepot when in place. It must rest
on the 3 logs in a stable position to prevent it
from falling into the firepot. Figure 22.5.

Figure 22.1

Drop Tube

Figure 22.2
NOTE:
Due to the abrasive nature of a pellet appliance fire, the
logs are not covered under warranty. Any placement variation other than shown here can cause excessive heat and
shall void the appliance warranty.
Page 22

Figure 22.5

250-7251G

August 20, 2009

Castile Pellet Insert
H. 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.

CAUTION
Shock hazard.
• Do NOT remove grounding prong from plug.
• Plug directly into properly grounded 3 prong
receptacle.
• Route cord away from appliance.
• Do NOT route cord under or in front of appliance.

When mounting a thermostat on a wall, be sure to follow
your thermostat installation instructions carefully.
NOTE: Thermostat must be mounted level for accurate readings. The thermostat should be mounted
on an inside wall and not in direct line with the
appliance convection air. Remove any packaging
from inside the thermostat before using.
NOTE: If the thermostat is located too close to
the appliance, you may need to set the temperature setting slightly higher to maintain the desired
temperature in your home.

There is a 4 screw terminal block located on the junction box to the left of the power cord inlet. The center
2 screws are for the thermostat wires. The outer 2 are
the mounting screws for the terminal block. Figure
23.1.

Control Box

Red Call
Light
Fuse

Power Cord
Outlet
ue
Bl

t
gh
t

h
ig

rL
be
m
/A

Heat Output
Switch

Thermostat
Block

Reset Button
Junction Box

Figure 23.1

August 20, 2009

250-7251G

Page 23

Castile Pellet Insert

Operating Instructions

A. Fuel Size, Material and Storage
2. Shelled Field Corn (Cont’d)

1. Wood Pellets
Fuel pellets are made from sawdust or wood by-products. If the
source material is hardwood, they can have a higher mineral
content, creating more ash. Fuels containing bark will also
have higher ash content. Minerals and other noncombustible
materials such as sand will turn into a hard, glass-like substance
called a clinker when heated to the extreme temperatures our
firepot reaches. This is what forms clinkers in the bottom of the
firepot. Trees from different areas will vary in mineral content.
That is why some fuels produce more clinkers than others.
Pellets are manufactured in either 1/4 inch or 5/16 inch (6-8mm)
diameter and should be no more than 1-1/2 inches (38mm)
in length. Pellet lengths may even vary by lot from the same
manufacturer which is why the feed rate may need to be adjusted
occasionally. If you burn pellets longer than 1-1/2 inches
(38mm) you may have an inconsistent fuel feed rate and/or
missed ignitions.

When purchasing corn to burn in your appliance, read the
ingredient label very carefully. Do NOT purchase fuel
that contains any additives such as oils (i.e. soybean oil)
and meals as it will result in poor unit performance. If you
are buying corn the only ingredient that should be listed
is corn.
Shelled field corn must be 15% or less moisture content.
The corn must be clean and free from debris. Never burn
corn straight from the field. Stalk parts, excessive fines and
cob remnants, etc. will clog the auger mechanism. Corn
with excessive grain dust must be screened by sifting with
3/16 (4.76mm) inch mesh screening.

Pellet fuel quality can greatly fluctuate. We recommend using
premium grade fuel with ash content less than 1%. Even in some
fuel labeled “premium” ash content can vary from bag to bag
and possibly exceed 1%. High ash fuel, or lack of maintenance,
can cause the firepot to fill up and thus create a potential for
smoking, sooting and possible hopper fires.

Do not burn treated seed corn in your appliance. Seed corn
is treated with chemical pesticides that are harmful or fatal
if swallowed; therefore, seed corn is dangerous to have in
the house, expecially where children can reach it. Burning
treated seed corn in your appliane will void your warranty
and will destroy the exhaust system on the unit.

Always burn dry fuel. Burning fuel with high moisture content
takes heat from the fuel and tends to cool the appliance,
robbing heat from your home. Damp pellet fuel can clog the
feed system.

When changing to a different fuel, be sure to empty the
hopper of the previous fuel and vacuum the hopper before
you fill it with the new fuel.

corn used. In cases where it is acceptable for the appliance
to run full time, 100% corn will work after the fire has been
started using wood pellets.

We recommend that you buy fuel in multi-ton lots whenever
possible. Buying large quantities of fuel at once will greatly
reduce the number of times the feed adjustments will need to be
made. However, we do recommend trying various brands before
purchasing multi-ton lots to ensure your satisfaction.

WARNING
Risk of Chemical Poisoning.
• Do Not burn treated seed corn
• Chemical pesticides are harmful or fatal if
swallowed

WARNING

• Burning treated seed corn will void your
warranty

Fire Risk.
• High ash fuels, or lack of maintenance, can
cause the firepot to overfill. Follow proper
shutdown procedure if ash buildup exceeds
half way point in firepot.

3. Storage

• Failure to do so could result in smoking,
sooting and possible hopper fires.

Wood pellets should be left in their original sealed bag until
using. This will prevent moisture absorption.

2. Shelled Field Corn
Extensive factory and field testing has demonstrated shelled
field corn to be an efficient and very economical fuel. We
recommend the use of a 50-50 blend of corn and wood pellets.
The only change in operation is that the feed rate may require
a slight adjustment. The BTU output of the appliance varies
slightly compared to pellets, depending on the quality of the

Page 24

Shelled corn should be stored in a tight container where it
will not absorb moisture from damp or wet floors. This will
also prevent rodents from becoming a problem.
Do not store any pellet fuel within the clearance
requirements or in an area that would hinder routine cleaning
and maintenance.

250-7251G

August 20, 2009

Castile Pellet Insert
C. Before Your First Fire

B. General Operating Information
1. Thermostat Calls For Heat

1. First, make sure your appliance has been properly
installed and that all safety requirements have been met.
Pay particular attention to the fire protection, venting and
thermostat installation instructions.

The appliance is like most modern furnaces; when the thermostat
calls for heat, your appliance will automatically light and deliver
heat. When the room is up to temperature and the thermostat
is satisfied, the red call light will shut off and the appliance will
shut down. The red call light is located behind the left access
panel.

2. Double check that the ash pan and firebox are empty!

2. Heat Output Controls

4. Close the front door.

This appliance is equipped with a heat output control switch that
has three settings or burn rates; low, medium and high. The
appliance will turn on and off as the thermostat demands. When
the thermostat calls for heat, the appliance will always start up
on High. After burning approximately 4 minutes, the appliance
will then burn at the rate at which it was originally set. If the
appliance is set at one of the lower settings, it will run quieter
but takes longer to heat up an area than if it were set at a higher
burn rate. Regardless of the burn rate, when the area is warm
enough to satisfy the thermostat, the appliance will shut off.

3. Check the position of the thermocouple, located above
the firepot, and make sure that it protrudes approximately
3/4 inch (19mm) into the firepot.

CAUTION
Tip of thermocouple must be in contact with the inside
end of the thermocouple cover.
Missed ignitions can occur.

D. Starting Your First Fire
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.
2. The exhaust blower will stay on for approximately 18
minutes even though the thermostat is not calling for
heat. This is normal.

Heat Output
Switch

3. Locate the heat output control switch behind the right face
on the lower right side of the firebox. Set to the HIGH
setting and then adjust the thermostat to its highest setting.
The red call light will be on which is located on the top of
the junction box behind the right cast side. This indicates
the thermostat is calling for heat. Figure 25.1.

Right
Side
Ash Pan
Reset Button

4. The fuel feed system and the igniter should now be on.
Figure 25.1

WARNING
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.
• DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS
SUCH AS GASOLINE, NAPHTHA OR ENGINE OIL.
• DO NOT USE CHEMICALS OF FLUIDS TO START THE
FIRE.
• Keep all such liquids well away from the heater while it is in
use.
• Combustible materials may ignite.

August 20, 2009

5. For your first fire it will be necessary to press the reset
button once a minute until pellets start to drop into the
firepot, then press button 1 more time. This will fill the
feed system and allow the appliance to begin dropping
pellets. The appliance will continue to run as long as the
thermostat is calling for heat.
6. Once the appliance has ignited, let it burn for approximately
15 minutes, then set the thermostat to the desired room
temperature. Adjust the heat output control switch to the
desired setting.

E. Fire Characteristics
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). If the fire
has tall flames with black tails and seems somewhat lazy, the
feed rate will need to be reduced. If the fire is not 4 inches
(102mm) tall, increase the feed rate. A medium and low
setting will give a shorter flame. The flame will rise and fall
somewhat. This is normal.

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Castile Pellet Insert
F. Feed Rate Adjustment
The fuel adjustment control rod is factory set, and should be
adequate for most fuels.
Control Box

Red Call
Light

The set screw is located at the bottom of the hopper and
set loose at the factory so the fuel adjustment control rod
will slide by only loosening the wing nut. Do not re-tighten
bottom set screw.

Fuse
Power Cord
Outlet
t

gh
Li

u
Bl

However, if the flame height is too high or too low, you will
need to adjust the feed rate. Wait until the appliance has been
burning for 15 minutes before making your adjustments and
allow 15 minutes for feed adjustment to take effect. Make
adjustments in approximately 1/2 inch increments.

/
ed

en
re

Heat Output
Switch
Thermostat
Block

Reset Button

Loosen the wing nut. Figure 26.1.

Junction Box

2. Adjust the fuel adjustment control rod towards the
"+" symbol to increase the feed rate and flame height or
towards the "-" symbol, to decrease the feed rate and flame
height.

Figure 26.1

3. Re-tighten the wing nut.

WARNING
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.

Wing Nut

"-"

"+"
Figure 26.1

G. Iginition Cycles
1. During each ignition cycle, it is normal to see some smoke
in the firebox. The smoke will stop once the fire starts.
2. The convection blower will automatically turn on after your
appliance has reached the set temperature. This blower
transfers heat from your appliance into the room, and will
continue to run after the thermostat has stopped calling
for heat until the appliance has cooled down.
3. Occasionally the appliance may run out of fuel and shut
itself down. When this happens, the red call light will
be on. To restart it, fill the hopper and press the reset
button. Figure 26.2. When you press the reset button
the red call light will go out. Release the button and the
light will come back on. You should see a fire shortly.
If not, follow the instructions on page 25, “Starting Your
First Fire”.

Page 26

Back side of Firepot

Firepot floor left open

Figure 26.2 - DO NOT LEAVE FIREPOT FLOOR OPEN

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August 20, 2009

Castile Pellet Insert
H. Frequently Asked Questions
ISSUES

SOLUTIONS

1. Metallic noise.

1. Noise is caused by metal expanding and contracting as
it heats up and cools down, similar to the sound produced by a furnace or heating duct. This noise does not
affect the operation or longevity of your appliance.

Ash buildup on glass.

2. This is normal. Clean the glass.

Glass has turned dirty.

3. Excessive build up of ash. The lower burn settings will
produce more ash, the higher burn settings produce
less. The more it burns on low the more frequent cleaning of the glass is required.

Fire has tall flames with black tails and is lazy.

4. The feed rate needs to be reduced or the firepot needs
cleaning. Heat exchanger or exhaust blower needs
cleaning.

Smokey start-up or puffs of smoke from the airwash. 5. Either the firepot is dirty or there is too much fuel at
start-up and not enough air. Close down feed rate 1/4
(6mm) inch at a time until this no longer happens.

Large flame at start-up.

6. This is normal. Flame will settle down once the fire is
established.

CAUTION
Odors and vapors released during initial operation.
• Curing of high temperature paint.
• Open windows for air circulation.
Odors may be irritating to sensitive individuals.

August 20, 2009

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Castile Pellet Insert

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.

Troubleshooting

Possible Cause

Symptom
Plug in appliance - No
response.

Call light on. No fire.
No fuel in firepot.

Call light on. No fire.
Partially burned fuel in
firepot.

Corrective Action

No current to outlet.

Check circuit breaker at service panel.

.7 amp fuse defective.

Replace fuse.

#3 snap disc tripped or defective.

Reset or replace snap disc.

Control box defective.

Replace control box.

Out of fuel.

Check hopper. Fill with fuel.

#2 snap disc may be defective.

Replace snap disc.

Vacuum switch not closing, no vacuum.

Check exhaust blower is plugged in and
operating.
Check vacuum switch is plugged in.
Check vacuum hose is in good condition,
clear and connected at both ends.
Check thermocouple is in good condition
and plugged in properly.
Make sure venting system is clean.
Make sure front door is closed.

Control box defective.

Replace control box.

Firepot clean-out plate not closed.

Check that firepot clean-out plate is fully
closed.

Firepot is dirty (missed ignition).

Clean firepot. Make sure there is no clinker
in the firepot.
Clinkers may have to be broken up with
firepot scraper tool or other means.

Call light on. No fire.
Unburned pellets in
firepot.

Firepot clean-out plate not closed.

Check that firepot clean-out plate is fully
closed.

Firepot is dirty.

Clean firepot. Make sure there is not a
clinker in the firepot. Clinkers may have to
be pushed out of firepot with firepot scraper
tool or other means.

Ignition hole blocked.

Scrape with solid piece of wire.
Remove ash drawer to see if igniter is
glowing red on start-up.
Check igniter wires for good connection.
Replace igniter using 1/4 inch (6mm) male
/female spade connectors.

Igniter not working.

Slow or smoky start-up.

Page 28

Control box defective.

Replace control box.

Firepot clean-out plate not closed.

Check that firepot clean-out is fully closed.

Firepot is dirty.

Clean firepot. Make sure there is not a
clinker in the firepot. Clinkers may have to
pushed out of firepot with firepot scraper
tool or other means.

Excessive amount of fuel at start-up.

Reduce feed rate using feed rate adjustment control rod located inside hopper.

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August 20, 2009

Castile Pellet Insert

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. Firebox door must be
closed securely.

Vacuum switch not closing. No vacuum.

Feed system jammed or blocked.

Empty hopper of fuel. Use a wet/dry
vacuum cleaner to remove remaining fuel,
from hopper, including feed tube.
Check feed chute for obstructions.
Loosen 2 screws and jiggle feed assembly.

Feed spring not turning with feed motor.

Check that set screw is tight on feed
spring shaft at end of feed motor.

Feed motor defective or not plugged in.

Check connections on feed motor, replace
if defective.

Thermostat not set to a high enough temperature.

Adjust thermostat above room temperature.

Snap Disc #3 tripped.

Reset snap disc.

No power.

Connect to power.

Fuse blown.

Replace fuse.

No call light. Appliance
does not begin start
sequence.

Connections at thermostat and/or appliance not Check connections at thermostat and
making proper contact.
appliance.
Defective thermostat or thermostat wiring.

Replace thermostat or wiring.
NOTE: To test thermostat and wiring, use
a jumper wire at the thermostat block on
the appliance to by-pass thermostat and
wiring.

Control box defective.
Replace control box.
Appliance fails to shut
off.

August 20, 2009

Call light on.

Turn thermostat off.
If call light does not go out, disconnect
thermostat wires from appliance. If call
light does go out, thermostat or wires are
defective.

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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.

Possible Cause
No call light.

Defective control box.

#1 snap disc defective.

Replace snap disc.

Blower not plugged in.

Check that blower is plugged into wire harness.

Blower is defective.

Replace blower.

Control box is defective.

Replace control box.

Blower not plugged in.

Check that blower is plugged into wire harness.

Blower is clogged with ash.

Clean exhaust system.

Blower is defective.

Replace blower.

Control box is defective.

Replace control box.

Dirty appliance.
Poor fuel quality, high ash content.

Clean appliance, including firepot, heat
exchangers and venting system. Remove
stainless steel baffle from firebox to clean
ash from on top of baffle. Clean behind rear
brick panels. Change fuel brand to premium.

Firepot clean-out plate not completely
closed.

Nuisance shutdowns.

Appliance calls for heat.
Call light illuminates.
Exhaust blower starts.
No feed or igniter.

Page 30

Corrective Action

Check that firepot clean-out plate is fully
closed.

Excessive amount of fuel.

Reduce feed rate using feed rate adjustment
control rod located inside hopper.

Low flame.

Increase feed by opening feed rate adjustment control rod located inside hopper.

Sawdust buildup in hopper.

Clean hopper, see page 31.

Feed motor is reversing.

Check for good connections between feed
motor and wire harness.

Defective thermocouple.

Replace thermocouple.

Defective control box

Replace control box.

Firepot more than 1/2 full

See page 31 for detailed instructions for
“High Ash Fuel Content Maintenance”

Thermocouple is defective or not properly
plugged in.

Check connections on thermocouple or
replace if defective.
A flashing yellow light on the control box
indicates a problem with the thermocouple.

Defective control box

Replace control box.

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Castile Pellet Insert

Maintaining & Servicing Your Appliance
C. General Maintenance & Cleaning

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
Shock and Smoke Hazard
• Turn down thermostat, let appliance completely
cool and exhaust blower must be off. Now you
can unplug appliance before servicing.
• Smoke spillage into room can occur if appliance
is not cool before unplugging.
• Risk of shock if appliance not unplugged before
servicing appliance.

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.
Dirty fuel will cause clinkers to form in the firepot. A clinker
is formed when dirt, ash or a non-burnable substance is
heated to 2000°F (1093°C) and becomes glass-like. See
“D” page 35 in this section for more details on fuels with
high ash content.

Follow the detailed instructions found in this
section for each step listed as referenced in the
chart below.
Clinker

B. Quick Reference Maintenance Chart
Cleaning or Inspection

Figure 31.1 - Clinker
Frequency

Daily Weekly Monthly

Yearly

Ash Pan

Every 5 bags of fuel

Ash Removal from Firebox

More frequently depending on
the fuel type or ash build-up

Beneath Heat Exchanger

Every 1 ton of fuel

Blower, Combustion (Exhaust)

More frequently depending on
the fuel type

Blower, Convection

More frequently depending on
the fuel type

Door Latch Inspection

Prior to heating season

Exhaust Path

More frequently depending on
ash build-up

Firebox - Prepare for Non-Burn Season

At end of heating season

Firepot - Burning pellets - hardwood

Every 3 bags

Firepot - Burning pellets - softwood

Every 5 bags

Firepot - Burning Corn

Every 1 bag

Glass

When clear view of firepot
becomes obscure

Heat Exchanger & Drop Tube

Every 1 ton of fuel

Hopper

Every 1 ton of fuel or when
changing fuel types

Top Vent Adapter

More frequently depending on
the fuel type or ash build-up

Venting System

More frequently depending on
the fuel type

NOTICE: These are recommendations. Clean more frequently if you encounter heavy build-up of
ash at the recommended interval or you see soot coming from the vent. Not properly
cleaning your appliance on a regular basis will void your warranty.
August 20, 2009

250-7251G

Page 31

Castile Pellet Insert
3. Cleaning Firepot with Cleaning Rod & Firepot
Scraper

2. Remove Cast Sides for Cleaning & Maintenance
a. Loosen screw on top right corner directly under the cast
top, but do not remove. Figure 32.1.

•
•

b. With thumb, press upward on the frame to relieve the
pressure on the cast side. Figure 32.2.

Frequency: Daily or more often as needed
By: Homeowner
a. The appliance must be in complete shutdown and cool
and the exhaust blower off. If you are just cleaning the
firepot, there is no need to unplug the appliance.

c. Slide the cast side downward as shown in Figure 32.3.
(The top has been removed to show the details.

b. Pull firepot cleaning rod OUT a couple of times to help
shake debris loose. See Figure 33.1 on page 33. If rod
is hard to pull, it may be necessary to use your firepot
clean-out tool to chip away material that has built up
on the bottom plate of the firepot and to push out any
clinkers. Larger clinkers may have to be removed from
the top of the firepot. Corn clinkers can be especially
difficult to break up.

d. Lay sides on protective padding to avoid scratching the
paint or chipping the porcelain.
e. Repeat for the other side.

Top

c. The firepot floor plate must be fully closed when
finished. See Figure 26.2 on page 26.

WARNING

Front

Fire Risk

Right
Cast
Side

• NEVER pull firepot cleaning rod or cleaning
slide plates out when appliance is operating.
• The cleaning slide plates must be fully
CLOSED when appliance is operating.
•. Hot pellets may fall into ashpan and start a fire
or mis-starts due to lack of vacuum.

Figure 32.1

4. Ash Removal from Firebox
•
•
Flex frame upward with thumb
to relieve pressure on cast side.
CAST
SIDE

Figure 32.2

Frequency: Weekly or more frequently depending on
ash build-up.
By: Homeowner
a. There must not be any hot ashes in the firebox during
cleaning so allow the appliance to completely cool.
The firebox ash should be removed every time the
firepot is cleaned. Frequent cleaning of the ash in
the firebox will help slow down the build-up of ash in
the exhaust blower and vent system.
b. Plug in your appliance, if unplugged, and turn the
thermostat on and immediatley shut it off to start the
exhaust blower on its cycle time. It will pull fly ash
out the exhaust instead of into the room.
c. Open cast hinged face. Directly underneath the
firebox door and to the left and right of the firepot are
2 cleaning slide plates with finger holes. Pull both
slide plates out and then open the glass door. Sweep
the remaining ash from the firebox into the 2 open
holes. A paint brush works well for this. Close slide
plates.

Figure 32.3

Page 32

d. This ash is deposited in the same ash pan as the
firepot debris. The ash pan should be emptied every
time you clean the firebox. Remember to place
the ash and debris into a metal or noncombustible
container.
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August 20, 2009

Castile Pellet Insert
7. Disposal of Ashes

4. Ash Removal from Firebox (Cont’d)
e. The 2 cleaning slide plates must be fully closed when
cleaning is complete. See Disposal of Ashes.

•
•

Ashes should be placed in a metal container with a
tight-fitting lid. The closed container of ashes should
be placed on a non-combustible floor or on the ground,
well away from all combustible materials, pending final
disposal.

5. Cleaning Ash Pan
•
•

Frequency: As needed
By: Homeowner

Frequency: Weekly or every 5 bags of fuel
By: Homeowner

If the ashes are disposed of by burial in soil or otherwise
locally dispersed, they should be retained in the
closed container until all cinders have been thoroughly
cooled.

Locate the ash pan underneath the firepot. Open the
bottom ash door and slide the ash pan straight out.
Empty into a non-combustible container and re-install
ash pan. See Disposal of Ashes.
6. Cleaning Heat Exchanger Chambers & Drop Tube
•
•

10 Heat Exchanger Tubes

Frequency: Monthly or every 1 ton of fuel
By: Homeowner

WARNING

CLEANING RODS

Heat exchanger cleaning rods may be warm
to the touch. For safety purposes wear
gloves.
Do not pull heat exchanger cleaning rods
while appliance is operating.

Figure 33.1

Push cleaning rods IN when done, DO NOT
leave cleaning rods OUT. Injury can occur.

8. Cleaning Beneath Heat Exchanger
•
•

a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off

The amount of ash buildup in the firepot will be a good
guide to determine how often you should clean the heat
exchangers.

b. A more thorough cleaning is needed to remove the
excess ash that is left behind from the use of the
cleaning rods for the heat exchanger tubes.

a. Allow the appliance to completely cool down before
pulling the cleaning rods. Turn the thermostat on and
then immediately off to start the exhaust blower on its
cycle time. It will pull fly ash out the exhaust instead
of into the room. Open the cast front door to access
the 2 cleaning rods. Figure 33.1.
b. Locate the 2 rods directly underneath the heat
exchanger tubes. Rods are bent at a 90° angle for
easy handling.
c. To clean, pull the rods straight out until it stops,
approximately 10 inches (254mm). Slide the rods
OUT and IN a couple of times.

NOTE: There are heavy duty vacuum cleaners specifically
designed for solid fuel appliance cleaning.
9. Cleaning the Exhaust Path
•

Frequency: Yearly or more frequently depending on
ash build-up.
By: Homeowner
a. Appliance must be completely cool.

Disposal of Ashes
• Ashes should be placed in metal container
with tight fitting lid.
• Ashes should be retained in closed container
until all cinders have thoroughly cooled.

August 20, 2009

c. The ash will be resting on the back of the baffle.
This will require removing the cast baffle. Please
refer to page 33 for a detailed explanation of removing the baffle.

•

WARNING

Frequency: Monthly or after burning 1 ton of fuel
By: Homeowner

b. Open cast front door. Remove right brick and thoroughly
vacuum the area and continue throughout the rest of
the firebox. See Figure 37.3 on page 37.
c. Replace right brick and close cast front door.

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Page 33

Castile Pellet Insert
10. Cleaning the Hopper
•
•

CAUTION

Frequency: Monthly or after burning 1 ton of fuel
By: Homeowner

Handle glass assembly with care.

After burning approximately 1 ton of fuel you will need to
clean the hopper to prevent sawdust build-up.

When cleaning glass:
• Avoid striking, scratching or
slamming glass.
• Do NOT clean glass when hot.

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.

• Do NOT use abrasive cleaners.
• Use a hard water deposit glass cleaner on white film.
• Refer to maintenance instructions.

a. The appliance must be in complete shutdown. Allow
the appliance to completely cool down.
b. Empty the hopper of any remaining pellets.
c.

Vacuum the hopper and feed tube.

13. Cleaning Convection Blower - Requires No
Lubrication

11. Soot and Fly Ash: Formation & Need for Removal
in Exhaust Venting System.
•
•

•
•

Frequency: Yearly or more frequently depending on
ash build-up.
By: Qualified Service Technician/Homeowner

Frequency: Yearly or as needed
By: Qualified Service Technician
a. The appliance must be in complete shutdown and
completely cooled.
b. Remove both the left and right cast sides.

Be sure the appliance is allowed to cool, has been unplugged
and the exhaust blower is off.

c. Use either a can of compressed air or an air compressor.

The products of combustion will contain small particles of fly
ash. The fly ash will collect in the exhaust venting system
and restrict the flow of the flue gases.

d. Reach as far back as possible and spray compresssed air liberally from both sides at the blower.
This will remove any lint or dust build-up on the
impellers.

At start-up if there is incomplete combustion, or if there is a
shutdown or incorrect operation of the appliance it will lead
to some soot formation. This will collect in the exhaust vent- 14. Cleaning Exhaust Blower - Requires No
Lubrication
ing system.
The venting system may need to be cleaned at least once a • Frequency: Yearly or as needed
year or more often depending upon the quality of your fuel • By: Qualified Service Technician
or if there is a lot of horizontal pipe sections. Ash will build • Task: Contact your local dealer.
up more quickly in the horizontal sections.
15. Door Latch Inspection
12. Cleaning the Glass
•
•

Frequency: When clear view of the firepot becomes
obscure
By: Homeowner
a. Appliance must be completely cool before cleaning
glass.

•
•

Frequency: Prior to heating season
By: Homeowner

The door latch is non-adjustable but the gasketing between
the glass and firebox should be inspected periodically to
make sure there is a good seal.
NOTE: There is no gasket on the bottom of glass.

b. Use a damp paper towel or any non-abrasive glass
cleaner. Wipe off with dry towel.

WARNING
Handle glass with care.
• Inspect the gasket to ensure it is
undamaged.
• Do NOT strike, slam or scratch glass.
• Do NOT operate appliance with glass
assembly removed.
• Do NOT operate with glass cracked, broken or
scratched.

Page 34

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August 20, 2009

Castile Pellet Insert
16. Door Gasket Inspection

D. High Ash Fuel Content Maintenance

•
•

•

Frequency: Monthly or after burning 1 ton of fuel
By: Homeowner
To inspect the door rope (gasket), open the door and see
that the door rope extends approximately 1/8 to 3/16 inch
(3 to 9.5mm) from the door rope channel.
It should show signs of compaction all the way around the
door where the rope contacts the face of the insert.

17. Preparing Firebox for Non-Burn Season
•
•

Frequency: Yearly
By: Homeowner
a. Be sure the appliance is allowed to cool, has been
unplugged and the exhaust blower is off.
b. Remove all ash from the firebox and vacuum thoroughly.
c. Paint all exposed steel, including cast-iron.
•

Use the Touch-Up paint supplied with the appliance;
or;

•

Purchase paint from your local dealer.

•

Must use a high-temperature paint made specificially for heating appliances.

•

Frequency: When the ash build-up exceeds more
than half way up the firepot.
By: Homeowner

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 35.1 shows an example
where the firepot overfills, pellets back up into the feed tube
and ash has accumulated in the firebox.
An inefficient and non-economical method of burning of fuel
caused by poor quality pellet fuel is shown in Figure 35.2.
The correct flame size when good quality, premium pellet
fuel is burned is shown in Figure 35.3.
If the ash buildup exceeds the half way point in the firepot
IMMEDIATE ATTENTION AND CLEANING IS REQUIRED.

WARNING

Figure 35.1

Fire and Smoke Risk.

•

High ash fuels or lack of maintenance
can cause firepot to overfill. Follow
proper shutdown procedure if ash buildup
exceeds half way point in firepot.

•

Failure to do so could result in smoking,
sooting and possible hopper fires.

Incorrect

Tall, Lazy Flame, Orange in Color

Figure 35.2
Correct

Correct Flame Size, Yellow/White in Color

Figure 35.3
August 20, 2009

250-7251G

Page 35

Castile Pellet Insert

E. Igniter Replacement

F. 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

a. Open hinged cast face and lift door assembly off
from the insert and lay on a flat surface face down.

Igniter

Figure 36.1
a. Shut down the appliance by turning down the thermostat
and let the appliance completely cool down. After the
appliance has cooled down, unplug it and remove the
ash pan.
b. The wire leads to the igniter are connected to the wire
harness with 1/4 inch (6mm) male / female spade
connectors. These wires will pull forward approximately
4 to 5 inches (102 to 127mm). Disconnect the spade
connections and remove the igniter from the chamber.
Loosen the thumb screw and slide igniter out.

b. Using a screwdriver, tap the bottom of the rope
retainer rod to push it up out of the hole. The top
end of the rod will slide up. Swing the rod toward
you from the bottom and remove the rod. Repeat
for other side.
c. Remove old glass and replace with new glass.
d. Slide the retainer rod into the top hole first, and then
line up the bottom crimped end with the hole in the
door. The crimped end must be paralle with the glass
in order to insert it into place. Figure 36.2.

c. Install new igniter into the chamber and tighten the
thumb screw. Re-connect the wires to the 2 leads with
the spade connectors.
Rope Retainer
Rods

d. Remove the right cast side and pull the wire leads
back toward the rear of the appliance to take-up the 4
to 5 inches (102mm to 107mm) previously pulled out.
This will keep the wires out of the way of the ash pan.
Double check that the igniter wires are clear of any
movement, i.e. ash pan, firepot cleaning rod, cleaning
slide plates, etc.

Slide this
end in first

Glass
Crimped end
at the bottom

f. Re-install the ash pan and then re-install the cast side
panel and re-connect the power.

Crimped end must be
parallel with the glass

Figure 36.2

Page 36

250-7251G

August 20, 2009

Castile Pellet Insert

Re-installing Baffle & Brick Set

G. Baffle & Brick Set Removal
1. Follow proper shutdown procedures on Page 31.
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.
Remove the top baffle by first pulling the baffle forward
until back edge drops down. Then slide baffle back until
the front edge clears the shelf that it had been resting on.
Figure 37.1.
3. The top baffle must be removed before you can remove
the right and left brick. Remove the right brick by holding top lip of brick and lifting up, then push outside edge
back. Slide brick to the right until it is flush with the firebox.
Rotate the inside edge of the brick forward and remove
brick. Repeat for left brick. Figure 37.2.

1. Place right brick in behind the right bracket, and then
slide to the left so the tabs are behind the center brick.
Figure 37.4
2. The brick will be flush against the back wall and notches
exposed in the side bracket. Figure 37.5.
3. Lift slightly and pull the right edge of the brick forward until
it stops and then drops down into both top and bottom
notches of right bracket and locks into place. Figures
37.1 and 37.2.
4. Repeat for left brick.
5. Insert baffle into top front inside the firebox and pull forward. Then raise up the bottom end and insert baffle tab
into slot on the top of the right bracket to lock into place.
Figure 37.3. Place the left side hook at the bottom of
the baffle over the top edge of brick for stability. Figure
37.4.
6. The baffle does not completely cover the top of the firebox. There is an opening on the left as shown in Figure
37.5.

Hook on
left side

Tab on
right side

Tabs

Figure 37.1

Figure 37.4
Remove Right
& Left Brick

Brick is flush against back wall

Figure 37.2

Notches
exposed

Right Brick
Removed

Figure 37.5
Vacuum
Exhaust Area

Figure 37.3
August 20, 2009

250-7251G

Page 37

Castile Pellet Insert

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 38.4
Figure 38.1

Figure 38.5
Figure 38.2

Figure 38.3

Page 38

250-7251G

August 20, 2009

Castile Pellet Insert

Reference Materials

A. Component Function
1. Control Box

a. The control box is located on lower right side of
appliance, behind cast side on top of the junction
box.
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 200οF (93°C) in the firepot.
and will turn red when it reaches 600oF (315°C).
c. There is also an internal blue light located in the upper
left corner of the control box. When you plug in the
appliance the blue light will automatically start blinking
6 blinks every 10 seconds for 60 seconds and then will
stop.

When describing the location of a component
part it is always AS YOU FACE THE FRONT
OF THE APPLIANCE.

7. Heat Exchangers

The heat exchangers transfer heat from the exhaust system
into convection air. There are 2 clean out rods located under
the heat exchangers.
8. Heat Output Switch
The heat output switch is located on the lower right side of
firebox, behind the right face above the reset button. The
function of the heat output switch is to regulate the burn rates;
low, medium and high settings.
9.

Igniter

The igniter is mounted on the base of the firepot. Combustion
air travels over the red hot igniter creating super heated air
that ignites the pellets.

NOTE:

10. Junction Box And Wiring Harness

Do NOT open the control box. This will void the
warranty. If you need to plug in or remove the control
box you must first unplug the appliance.

The junction box is located behind right cast side of the
appliance. The junction box and wiring harness are replaced
as one component.
11. Power Supply

2. Convection Blower
The convection blower is mounted at the bottom rear of the
appliance. There are 2 impellers, one on each side of the
motor. The convection blower pushes heated air through the
heat exchange system into the room.
3. Exhaust Blower
The exhaust blower is mounted on the right side of the
appliance behind the right cast side. The exhaust blower is
designed to pull the exhaust from the appliance and push it
out through the venting system.
4. Feed System
The feed system is located on the right side and can be
removed as an entire assembly. The assembly includes
the feed motor, mounting bracket, bearing and feed spring
(auger). The hollow feed spring (auger) pulls pellets up the
feed tube from the hopper area and drops them down the
feed chute into the firepot.
5. Firepot

12. Red Call Light
The red call light is located behind the fuse behind the right
cast side. The function of the red call light is to indicate that
the thermostat is calling for heat.
13. Reset Button
The reset button is located on the lower right side of firebox
behind right face and below the heat output control switch. The
function of the switch is to momentarily open the thermostat
circuit, which restarts the system.
14. Thermocouple

The firepot is made of high quality ductile iron and has a
cleaning pull-out rod. The floor of the firepot opens for
cleaning when you pull out the rod. Be sure that the floor
returns to a completely closed position or your appliance will
not operate properly.
6. Fuse

The thermocouple is located on top of the firepot inside
the thermocouple cover (ceramic protection tube). The
thermocouple sends a millivolt signal to the control box
indicating the preset temperatures of the green and red lights
have been obtained.
15. Thermostat

The fuse is located on the right side behind the control box.
The fuse will blow should a short occur and shut off power
to the appliance.
August 20, 2009

The power outlet is located behind the right cast side of the
appliance behind the thermostat block on the junction box.
Check the wall receptacle for 120 volt, 60 Hz (standard
current). Make sure the outlet is grounded and has the correct
polarity. A good surge protector is recommended. When
operating with a generator you need at least 600 watts of
power, or with an inverter at least 800 watts of power available
for the appliance during the start cycle.

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.

250-7251G

Page 39

Castile Pellet Insert
16. Snap Disc #1 (Convection Blower) 110°F

19. Vacuum Switch

Snap disc #1 is located behind the right cast side of the firebox
above the red call light. There are 2 purple wires connected
to it. This snap disc turns the convection blower on and off as
needed. Power is always present at snap disc #1.

The vacuum switch is located at the back of the appliance.
This switch turns the feed system on when vacuum is present
in the firebox. The vacuum switch is a safety device to shut
off the feed motor if the exhaust or the heat exchanger
system is dirty or plugged or if the firebox door is open.

17. Snap Disc #2 (Fuel Delivery Interrupt) 250°F
Snap disc #2 is located on the back side of the feed drop
tube. There is 1 orange wire and 1 black wire connected to
it. This snap disc will turn off the feed system, which will turn
off the appliance if an overfire condition should occur or if the
convection blower should fail to operate. If this occurs the
snap disc with automatically reset itself.

20. Wiring Harness
See Figure 40.1 below

18. Snap Disc #3 (Burn Back Protector) 250°F
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 cast side. If the fire tries to burn back
into the feed system or push exhaust up the feed tube, this
snap disc will shut the entire system off. This disc must be
manually reset.

Female
Thermostat
Block

Male
Yellow
Blue
Gray
White

Burn
Selector

Yellow

Thermocouple

Vacuum
Switch

Yellow

Snap Capacitor
Disc #2

Red
Black
White
Red
Black
Black
White
Red
Purple
Gray
Blue
Black
Black

Feed
Motor

Snap Convection
Disc #1
Blower

Exhaust
Blower

Call
Light

Snap
Disc #3

Reset
Button

Fuse

Receptacle

Igniter

Figure 40.1

Page 40

250-7251G

August 20, 2009

Castile Pellet Insert
B. Component Locations

10 Heat Exchanger Tubes
Feed Motor

CLEANING RODS

Exhaust
Blower

Figure 41.2 - Cleaning Rods & Heat Exchanger Tubes

Convection Blower

Figure 41.1 - Blowers & Feed Motor

Control Box

Red Call
Light
Fuse

Power Cord
Outlet
t

e
lu

gh
Li

h
ig

Am
n/

Heat Output
Switch

e
re

Thermostat
Block

Reset Button
Junction Box
Figure 41.3

August 20, 2009

250-7251G

Page 41

Castile Pellet Insert
C. Exploded Drawing
33

29
28
27

26
25
4

24
23

6
21

7
8

9
18
17
16
15

12
Figure 42.2

Page 42

11
250-7251G

7025-006 3-24-09

August 20, 2009

Castile Pellet Insert
D. Service Parts and Accessories
HOW TO ORDER

IMPORTANT: THIS IS DATED INFORMATION

To order the entire assembly, order the top line part number only.
To order an individual part from an assembly, order the part(s)
listed in the indented portion.

When requesting service or replacement parts for your
appliance please provide model number and serial number.
All parts listed may be orderd from an authorized dealer.

Item
1

Description

Comments

Hopper Top Assembly

Part Number
SRV414-5830

Feed Adjustment Bracket
Assembly

SRV414-6230

Plate, Cover, Outer Can

480-1300

Leveling Leg

SRV414-0210

Bracket, Hinge

Baffle Assembly

Brick, Left / Right, Cast

Firepot Assembly

9
10
11

Attaches to Unit

SRV414-0610
UK-30KPEL

Interchangeable

414-0270
SRV414-5200

Bushing, Firepot

410-8320

Floor, Firepot

414-0290

Gasket, Firepot

240-0930

Nut, Lock 1/4-20

226-0090

Bolt, Firepot, 1-1/4” Long

225-0120

Pull Rod Assembly

229-0360

Spring, Firepot

200-2050
Matte Black

414-0060BK

Must Specify Porcelain Color

414-0060POR

Must Specify Powder Coat Color

414-0060PWD

Matte Black

414-0040BK

Must Specify Porcelain Color

414-0040POR

Must Specify Powder Coat Color

414-0040PWD

For Black Units

SRV414-0940

For Porcelain & Powder Coat Units

SRV414-0950

Quadra Fire 810 02901 Users Manual 250 7251G Castile Pellet Insert 8 20 09.2

810-02901 Castile Insert

CASTINS-CSB to the manual aa98a5a8-5a91-4c16-a1bd-a1de559bd5c3

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