Quadra-Fire CLASSIC BAY 1200 Service Manual Download

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1445 N. Highway

Colville, Wa 99114

www.quadrafire.com

www.quaddealer.com

#250-7700 February 12, 2003

CB1200 INSERT PELLET STOVE

SERVICE MANUAL

Summary of Contents for CLASSIC BAY 1200

Page 1: ...1445 N Highway Colville Wa 99114 www quadrafire com www quaddealer com 250 7700 February 12 2003 CB1200 INSERT PELLET STOVE SERVICE MANUAL R ...

Page 2: ...TROUBLE SHOOTING CONVECTION BLOWER TROUBLE SHOOTING POWER SUPPLY TROUBLE SHOOTING THERMOSTAT TROUBLESHOOTING THERMOCOUPLE TESTING FIREPOT EXHAUST SYSTEM TROUBLE SHOOTING EXPLODED VIEW WIRE DIAGRAM DIMENSIONS SPECS CHECK OFF SHEET CLEANING MAINTENANCE TIPS SERVICE TOOLS 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 7 31 2002 PAGE 2 250 7700 ...

Page 3: ...TTON ADJUST FEED ADJUSTMENT PLATE 3 CHECK THERMOCOUPLE 4 CHECK VENTING SYSTEM FOR OBSTRUCTIONS 5 CHECK VACUUM SWITCH AND VACUUM HOSE 6 CHECK FEED MOTOR 7 CHECK EXHAUST BLOWER C CALL LIGHT ON NO FIRE PARTIALLY BURNED FUEL IN POT 1 CHECK FIREPOT AND CLEAN 2 CHECK THERMOCOUPLE GREEN LIGHT 2 5 mV 5mV RED LIGHT 12 1 mV 1mV 3 CHECK INITIAL FEED TIME 1 MINUTE 35 SECONDS D CALL LIGHT ON NO FIRE FUEL IN FI...

Page 4: ... SWITCH 5 CHECK EXHAUST SYSTEM FOR OBSTRUCTIONS H THERMOSTAT WILL NOT START UNIT 1 CHECK THERMOSTAT WIRES FOR CONTINUITY 2 CHECK THE ACCESSORY JUMPER WIRE ON THE J BOX 3 CHECK 2 SNAP DISC 4 CHECK THE RESET BUTTON 5 CHECK FOR POWER TO THE STOVE 6 CHECK CONTROL BOX F STOVE RUNS FOR 10 MINUTES THEN STOPS FEEDING FUEL 1 CHECK THERMOCOUPLE GREEN LIGHT 2 5 mVDC 5mV RED LIGHT 12 1 mVDC 1mV 2 ADJUST FEED ...

Page 5: ...SNAP DISC COOLS DOWN IT WILL TURN THE THERMOSTAT BACK ON CALL LIGHT 3 CHECK WIRING FOR LOOSE CONNECTIONS L LARGE FIRE ASH BUILD UP DIRTY GLASS 1 CHECK FIREPOT MAY NEED TO BE CLEANED 2 CLEAN EXHAUST AND HEAT EXCHANGER SYSTEM 3 ADJUST FEED ADJUSTMENT PLATE IN THE HOPPER 4 CHECK CONTROL BOX FEED TIMES HIGH 7 5 SECOND ON TIME MEDIUM 6 SECOND ON TIME LOW 4 7 SECOND ON TIME M STOVE IGNITES GOES OUT CALL...

Page 6: ... WIRE HARNESS OR CONNECTOR PIN B IF POWER IS PRESENT REPLACE FEED MOTOR OR CHECK CONNECTOR PIN NOTE REMEMBER THAT THE FEED CIRCUIT INITIAL FEED TIME IS 1 35 PUSH THE RESET BUTTON BEFORE EACH TEST 2 12 2003 PAGE 6 250 7700 FEED MOTOR VACUUM SWITCH JUNCTION BOX FEED MOTOR CIRCUIT CAPACITOR WHITE RED WHITE RED NOTE CAPACITOR IS LOCATED IN THE JUNCTION BOX ACCY JUMPER 1 3 4 5 6 2 WHITE WHITE BLACK RED...

Page 7: ...COMES ON REPLACE CONTROL BOX USING THE COMPONENT TEST CORD 1 UNPLUG THE FEED MOTOR FROM THE WIRE HARNESS 2 INSTALL THE FEED MOTOR ADAPTER ON THE TEST CORD NOTE THE NEW STYLE FEED MOTOR WILL NEED THE CAPACITOR JUMPER ADDED TO THE ADAPTER 3 PLUG IN THE TEST CORD TO THE FEED MOTOR AND TURN ON THE SWITCH TEST BOX AS IT IS INSTALLED IN THE STOVE 3 TURN ON THE THERMOSTAT THE THERMOSTAT INDICATOR LIGHT S...

Page 8: ...GNITER CIRCUIT TAN HT TAN HT ACCY JUMPER 1 3 4 5 6 2 1 TURN ON THE THERMOSTAT CIRCUIT AND MAKE SURE THE CALL LIGHT IS ON B IF POWER IS PRESENT REPLACE THE IGNITER A IF NO POWER CHECK THE WIRE HARNESS OR REPLACE THE CONTROL BOX 2 CHECK FOR POWER AT THE IGNITER 7 31 2002 PAGE 8 250 7700 ...

Page 9: ... REPLACE THE CONTROL BOX IF THE IGNITER DOESN T COME ON REPLACE THE IGNITER OR CHECK THE WIRE HARNESS USING THE COMPONENT TEST CORD 1 UNPLUG THE STOVE AND DISCONNECT THE IGNITER FROM THE WIRE HARNESS 2 INSTALL THE ALLIGATOR CLIPS ONTO THE TEST CORD 3 CLIP THE TEST CORD TO THE WIRES ON THE IGNITER AND TURN THE SWITCH ON TEST BOX AS IT IS INSTALLED IN THE STOVE TEST CORD w CLIPS ATTACHED CLIPS HOOKE...

Page 10: ...AND MAKE SURE THE CALL LIGHT IS ON 2 CHECK FOR POWER AT THE BLUE WIRE ON THE MOLEX CONNECTOR A IF POWER IS PRESENT REPLACE THE EXHAUST BLOWER B IF NO POWER CHECK THE WIRE HARNESS OR REPLACE THE CONTROL BOX NOTE OPEN CIRCUIT VOLTAGE IS MEASURED WITH THE BLOWER DISCONNECTED FROM THE WIRE HARNESS CLOSED CIRCUIT VOLTAGE IS MEASURED WITH THE BLOWER HOOKED UP TO THE HARNESS CLOSED CIRCUIT VOLTAGE WILL B...

Page 11: ...ERMOSTAT THE THERMOSTAT INDICATOR LIGHT SHOULD COME ON 3 TURN THE EXHAUST BLOWER SWITCH ON A IF THE BLOWER COMES ON REPLACE THE CONTROL BOX B IF THE BLOWER DOESN T COME ON CHECK THE WIRE HARNESS OR REPLACE THE BLOWER 1 UNPLUG THE BLOWER FROM THE WIRE HARNESS 2 INSTALL THE EXHAUST BLOWER ADAPTER TO THE TEST CORD 3 PLUG IN THE TEST CORD TO THE EXHAUST BLOWER AND TURN THE SWITCH ON TEST CORD w ADAPTE...

Page 12: ...HE SNAP DISC C IF NO POWER IS PRESENT CHECK THE FUSES WIRE HARNESS OR REPLACE CONTROL BOX OPEN CIRCUIT VOLTAGE TO ONE SIDE OF SNAP DISC WILL BE 115 V FOR HIGH MEDIUM LOW CLOSED CIRCUIT VOLTAGE WILL BE 115 V HIGH 101 V MEDIUM 82 V LOW NOTE THE VOLT METER MUST HAVE ONE LEAD CONNECTED TO THE WHITE NEUTRAL WIRE FROM THE POWER SUPPLY TO BE ABLE TO READ THE CORRECT VOLTAGE AT THE SNAP DISC 7 AMP FUSE JU...

Page 13: ...HE STOVE IN 3 TURN ON THE CONVECTION BLOWER SWITCH A IF BLOWER COMES ON REPLACE 1 SNAP DISC OR THE CONTROL BOX B IF BLOWER DOESN T COME ON CHECK WIRE HARNESS OR REPLACE BLOWER 1 UNPLUG THE CONVECTION BLOWER FROM THE WIRE HARNESS 2 INSTALL THE FEED MOTOR ADAPTER WIRE TO THE TEST CORD 3 PLUG IN THE TEST CORD TO THE CONVECTION BLOWER AND TURN THE SWITCH ON NOTE THIS WILL ONLY TEST THE HIGH SPEED CIRC...

Page 14: ...FIG 1 A IF NO POWER CHECK OUTLET OR REPLACE POWER CORD B IF POWER IS PRESENT CONTINUE TO STEP 2 2 CHECK FOR POWER AT THE GREY WIRE ON THE 7 AMP FUSE HOLDER SEE FIG 2 A IF NO POWER REPLACE THE FUSE OR THE FUSE HOLDER B IF POWER IS PRESENT CONTINUE TO STEP 3 3 CHECK FOR POWER AT THE GREY WIRES ON SNAP DISC 3 SEE FIG 3 A IF NO POWER RESET THE SNAP DISC OR REPLACE IT B IF POWER IS PRESENT CHECK FOR CO...

Page 15: ... JUMPER WIRE ON THE END OF THE POWER CORD SEE FIGURE 5 2 SET THE VOLT METER TO OHMS AND PUT THE PROBES ON PIN 5 PIN 12 SEE FIGURE 4 IF THE CIRCUIT IS COMPLETE THE READING SHOULD BE 0 JUMPER WIRE FIGURE 5 FIGURE 4 FIGURE 3 FIGURE 2 FIGURE 1 BLACK WIRE GREY WIRE THERMOSTAT BLOCK WHITE BLACK POWER CORD 7 AMP FUSE HOLDER CHECK FOR POWER ON BOTH SIDES ...

Page 16: ...EP 4 INSTALL A JUMPER WIRE ON THE THERMOSTAT CHECK FOR CONTINUITY AT PIN 7 PIN 9 IF THE CIRCUIT HAS CONTINUITY REPLACE THE THERMOSTAT IF NO CONTINUITY CONTINUE TO THE NEXT STEP 5 REMOVE THE THERMOSTAT WIRES FROM THE THERMOSTAT BLOCK INSTALL A JUMPER WIRE IF THE CIRCUIT HAS CONTINUITY REPLACE THE THERMOSTAT WIRE IF NO CONTINIUTY CONTINUE TO THE NEXT STEP 6 INSTALL A JUMPER WIRE ON THE T STAT BLOCK ...

Page 17: ...OVE BACK IN 2 TURN ON THE THERMOSTAT IF THE THERMOSTAT LIGHT COMES ON REPLACE THE CONTROL BOX IF NO THERMOSTAT LIGHT REFER TO THERMOSTAT CIRCUIT TROUBLE SHOOTING 9 7 THERMOSTAT INDICATOR LIGHT TESTING FOR CONTINUITY ON PIN 7 PIN 9 IN THE JUNCTION BOX THERMOSTAT BLOCK WITH A JUMPER WIRE ATTACHED ACCESSORY JUMPER PLUG ON THE JUNCTION BOX 2 SNAP DISC WITH A JUMPER WIRE ATTACHED ACCESSORY JUMPER PLUG ...

Page 18: ...ERATURE IN THE FIREPOT IF THE THERMOCOUPLE IS FRACTURED IT WILL NOT PRODUCE VOLTAGE NOTE BE SURE TO SET THE METER TO MILLIVOLTS DC 1 ATTACH A DIGITAL VOLT METER TO THE TWO THERMOCOUPLE WIRES ON THE JUNCTION BOX 2 APPLY HEAT TO THE THERMOCOUPLE TIP IN THE FIREPOT IF THE THERMOCOUPLE STARTS PRODUCING VOLTAGE CHECK TERMINAL CONNECTIONS ON THE JUNCTION BOX OR REPLACE THE CONTROL BOX IF NO VOLTAGE FROM...

Page 19: ...LOWS INTO A ROUND OPENING LOCATED ON THE RIGHT SIDE OF THE UNIT SEE FIGURE 2 THIS AIR TRAVELS TO A ROUND OPENING LOCATED JUST BEHIND THE BOTTOM RIGHT SIDE OF THE FIREPOT SEE FIGURE 3 COMBUSTION AIR WILL FLOW THROUGH THE AIR OPENINGS IN THE FIREPOT AND IS THEN TRANSFORMED INTO EXHAUST GASES THE EXHAUST GASES WILL FLOW FROM THE FIREPOT TO THE BAFFLE PLATES AND HEAT EXCHANGER TUBES SEE FIGURE 4 THE E...

Page 20: ...XHAUST SYSTEM TROUBLE SHOOTING 7 31 2002 PAGE 20 250 7700 FIG 1 FIG 2 EXAMPLE OF A LARGE CLINKER COMBUSTION AIR INTAKE FIG 3 FIG 4 FIREPOT AIR INTAKE IN THE COMBUSTION CHAMBER HEAT EXCHANGER TUBES FIREBOX AREA w BAFFLE PLATES REMOVED FIREPOT AIR INTAKE ...

Page 21: ...TOVE SERVICE MANUAL FIREPOT AND EXHAUST SYSTEM TROUBLE SHOOTING 7 31 2002 PAGE 21 250 7700 FIG 5 FIG 6 HEAT EXCHANGER CLEAN OUT PLATE REMOVED CLEAN OUT DOOR EXHAUST BLOWER VENT PIPE ADAPTER EXHAUST BLOWER CLEAN OUT DOOR ...

Page 22: ...410 7900 7 ASHPAN 812 4130 8 SIDE CURTAIN RT 812 4320 9 DRAW LATCH 812 3530 10 CONVECTION FAN 812 4280 11 J BOX HARNESS 812 4160 12 CONTROL BOX 812 4940 13 HOPPER TOP 410 7730 14 HOPPER LID 410 7960 15 FEED MOTOR COVER 410 7920 16 FEED MOTOR 812 4420 17 EXHAUST ADPTR N A 18 EXHAUST BLOWER 812 3381 19 HINGE MOUNT 410 7290 20 SIDE CURTAIN LEFT 812 4310 21 PULL ROD 410 7350 22 FIREPOT 812 3351 23 T C...

Page 23: ...CB1200 I PELLET STOVE SERVICE MANUAL 7 31 2002 PAGE 23 250 7700 2 12 3 4 5 6 7 8 9 1 14 16 18 20 22 11 13 15 17 19 21 10 23 1200 I EXPLODED VIEW ...

Page 24: ... PUR PUR VAC SWITCH YEL T C RED GRAY BLACK ACCY JUMPER 1 3 4 5 6 2 AUG CAP ORANGE CONV BLOWER BLK BLK BLK WHITE WHITE BLK POWER IN BLK B L K R E D YELLOW YELLOW YELLOW YELLOW PURPLE PURPLE ORANGE RED RED BLUE BLUE GREY WHITE BLACK HI TEMP HI TEMP T C FUSE YELLOW 3 4 AMP FUSE FEED START HIGH FEED MEDIUM FEED LOW FEED RED GRN CONTROL BOX TOP VIEW MEDIUM CONV LOW CONV MEDIUM EXH LOW EXHAUST RED GRN 4...

Page 25: ...UNDS PER HOUR BURN RATE 2 5 lbs LOW 3 75 lbs MEDIUM 5 0 lbs HIGH FEED MOTOR RPM 2 EXHAUST BLOWER CFM 80 CONVECTION BLOWER CFM 160 HOPPER CAPACITY 65 lbs VOLTS ON THE MEDIUM FEED SETTING 85 V 1 V EXHAUST 101 V 1 V CONVECTION VOLTS ON THE LOW FEED SETTING 75 V 1 V EXHAUST 82 V 1 V CONVECTION NOTE OPEN CIRCUIT VOLTAGE WILL BE 115 V ON HIGH MEDIUM LOW THERMOSTAT CIRCUIT VOLTS 24 VAC 5 V 7 31 2002 PAGE...

Page 26: ...______ IS THE FEED SYSTEM OPERATING _____________________________________________ IS THERE POWER TO THE STOVE ______________________________________________ IS THERE FUEL IN THE HOPPER ________________________________________________ WILL THE THERMOSTAT CALL LIGHT COME ON ___________________________________ IS THE IGNITER WORKING ________IS THE EXHAUST BLOWER WORKING ___________ ARE YOU REACHING T...

Page 27: ...OVE CLEANING OR DAILY WEEKLY MONTHLY YEARLY INSPECTION FIREPOT USING WOOD PELLETS EVERY 3 BAGS OR FIREPOT USING SHELLED CORN EVERY BAG OR FIREBOX ASH REMOVAL AS NEEDED OR HEAT EXCHANGER CLEANING AS NEEDED OR VENT CHIMNEY SYSTEM EVERY 2 TONS OF FUEL OR CONVECTION BLOWER EVERY 3 TONS OF FUEL OR EXHAUST BLOWER EVERY 2 TONS OF FUEL OR GLASS DOOR EVERY 5 BAGS OF FUEL OR X X X X X X X X ...

Page 28: ...LL BE NEEDED AT LEAST ONCE A MONTH THIS WILL INCLUDE REMOVING THE BAFFLE PLATES IN THE FIREBOX AND ACCESSING THE CLEAN OUT PLATE ON THE RIGHT HAND SIDE OF THE STOVE THIS IS NECESSARY TO REMOVE THE EXCESS ASH THAT IS LEFT BEHIND FROM THE USE OF THE PULL RODS FOR THE HEAT EXCHANGER TUBES VENT CHIMNEY SYSTEM THIS NEEDS TO BE CLEANED AND INSPECTED AT LEAST ONCE A YEAR IT MAY BE NECESSARY TO PERFORM MO...

Page 29: ...250 7700 1 DIGITAL VOLTMETER FOR CHECKING VOLTS AND CONTINUITY OF CIRCUITS 2 DIGITAL MANOMETER FOR CHECKING VACUUM IN THE FIREBOX 3 TEST CORD FOR CHECKING INDIVIDUAL COMPONENTS 4 TEST BOX FOR CHECKING THE WIRE HARNESS COMPONENTS DIGITAL VOLTMETER DIGITAL MANOMETER TEST CORD TEST BOX ...

Page 30: ...CB1200 I PELLET STOVE SERVICE MANUAL ...

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