Breckwell Classic Cast P4000 Configuration guide

PROFESSIONAL INSTALLATION IS HIGHLY RECOMMENDED
Manufactured by
Breckwell Hearth Products
Arlington, TX
Eugene, Oregon
www.breckwell.com
WARNING: If your appliance is not properly installed a house fire may result. For your safety,
follow the installation directions. Contact local building or fire officials about restrictions and
installation inspection requirements in your area.
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.
Save these instructions.
OWNER’S MANUAL
Classic Cast
P4000
BRECKWELL HEARTH PRODUCTS
02/09

FAILURE TO CLEAN AND MAINTAIN THIS UNIT AS INDICATED CAN
RESULT IN POOR PERFORMANCE AND SAFETY HAZARDS.
NEVER CLEAN WHEN HOT.
NOTE: Inspect burn pot periodically to see that holes have not become
plugged, if so, clean thoroughly.
ASH REMOVAL
Ashes should be placed in a metal container with a tight-fitting lid. The
closed container or ashes should be placed on a noncombustible
surface or on the ground, well away from all combustible materials
pending final disposal. If ashes are disposed of by soil burial or
otherwise locally dispersed, they should be retained in the closed
container until all cinders have thoroughly cooled.
ASH DISPOSAL
The P4000 has an ash bin located below the firebox. To remove ashes:
a. Make sure fire is out and firebox is cool.
b. With the door closed clean heat exchanger tubes.
(See “CLEANING” and Figure 15).
c. Open door and remove the optional imitation log set, if in use.
Remove the burnpot’s inner section by grasping it and pulling
straight up (see Figure 16).
d. Empty ashes from inner section into the ash bin through the
opening in the bottom of the firebox. Scrape inner section with
cleaning tool. Make sure holes are not plugged.
e. Scrape ash in firebox into the ash bin through the opening in the
bottom of the firebox or vacuum to remove ashes (see Figure 17).
WARNING: Make sure ashes are cool to the touch before
using a vacuum. See “VACUUM USE”.
f. Periodically remove and empty ash bin (see Figure 18) by
unscrewing the two knobs on the front of it and pulling it straight
out. Dispose of ashes properly.
(See “ASH REMOVAL” above)
g. Replace ash bin, making sure to tighten the knobs and maintaining
a good seal.
h. Replace inner section into burnpot; make sure it is level and
pushed all the way back down and that the igniter hole is to the
rear when it is reinstalled (see Figure 16).
i. Make the burnpot is level and pushed all the way back in when it is
reinstalled. If the collar on the burnpot attached to the fresh air
tube is not pushed back to meet the firebox wall, the Hot Rod will
not work properly.
VACUUM USE
If a vacuum is used to clean your unit, we suggest using a vacuum
designed for ashes.
(We recommend LoveLess Ash Vac, 1-800-568-3949 Ext. #27)
Some regular vacuums and shop vacs leak ash into the room. Your
vacuum or shop vac may have a special filter or bag available to
eliminate this leakage.
FIGURE 15
FIGURE 17
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FIGURE 16
Igniter Hole
FIGURE 18

CLEANING
a. Heat Exchange Tubes – Your Breckwell stove is designed
with a built-in heat exchange tube cleaner. This should be used
every two or three days to remove accumulated ash on the
tubes, which reduces heat transfer on the P4000. Insert the
handle end (with hole) of the cleaning tool onto the cleaning
rod (refer to figure 15). The cleaner rod is located in the grill
above the stove door. Move the cleaner rod back and forth
several times to clean the heat exchanger tubes. Be sure to
leave tube cleaner at the rear of the stove.
b. Interior Chambers – Four ash doors and two upper baffles in
the firebox in the P4000 can be removed for periodic cleaning
(Figure 19). These doors allow access to the chamber
surrounding the firebox.
NOTE: When removing the upper baffles do not remove the
screws; just loosen them enough to allow the baffles to be
removed.
Periodically, you must vacuum ashes from this chamber. In
some cases you will need to remove creosote, which can
accumulate rapidly under certain conditions. A small wire brush
can be used. It is important to remove this creosote because it
is highly combustible. INSPECT BEHIND THESE CLEANING
PLATES AT LEAST ONCE PER TON OF PELLETS BURNED
UNTIL YOU ARE FAMILIAR WITH HOW ASHES AND
CREOSOTE ACCUMULATE WITH YOUR OPERATING
PRACTICES. Use the small wire brush to also clean the inside
of the chamber walls, above the access doors.
BLOWERS
DANGER: RISK OF ELECTRIC SHOCK. DISCONNECT POWER
BEFORE SERVICING UNIT.
Cleaning – Over a period of time, ashes or dust may collect on the
blades of both the combustion blower and convection blower.
Periodically the blowers should be vacuumed clean as these ashes
can impede performance. Creosote can also accumulate in the
combustion blower. This needs to be brushed clean. The convection
blower is accessed by removing the stove’s left side panel. The
combustion blower can be accessed by removing the stove’s right
side panel. The convection blower is on the left (facing stove), and
the combustion blower is on the right.
NOTE: When cleaning, be careful not to dislodge balancing clip on
convection blower or to bend fan blades. Some stove owners lightly
spray an anti-creosote chemical on the fire to help reduce creosote
formation within the stove.
FIGURE 19
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FIGURE 20
Baffle Plates
FIGURE 21
Air Switch
Combustion
Blower
Auger Motor
High Temp
Thermodisc
Convection
Blower
Combustion
Blower
POF
Thermodisc
Auger Shaft
Ash Doors
Air Switch Tube

CHIMNEY CLEANING
a. Creosote Formation – When any wood is burned slowly, it produces tar and other organic vapors, which
combine with expelled moisture to form creosote. The creosote vapors condense in the relatively cool
chimney flue or a newly started fire or from a slow-burning fire. As a result, creosote residue accumulates on
the flue lining. When ignited, this creosote makes an extremely hot fire, which may damage the chimney or
even destroy the house. Despite their high efficiency, pellet stoves can accumulate creosote under certain
conditions.
b. Soot and Fly Ash: Formation and Need for Removal - 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. Incomplete combustion, such as occurs during startup, shutdown, or incorrect operation of the room
heater will lead to some soot formation which will collect in the exhaust venting system. The exhaust
venting system should be inspected at least once every year or ton of pellets burned to determine if cleaning
is necessary.
c. Inspection and Removal – The chimney connector and chimney should be inspected annually or per ton to
determine if a creosote or fly ash build-up has occurred. If creosote has accumulated, it should be removed
to reduce the risk of a chimney fire. Inspect the system at the stove connection and at the chimney top.
Cooler surfaces tend to build creosote deposits quicker, so it is important to check the chimney from the top
as well as from the bottom.
The creosote should be removed with a brush specifically designed for the type of chimney in use. A qualified
chimney sweep can perform this service. It is also recommended that before each heating season the entire
system be professionally inspected, cleaned and, if necessary, repaired.
To clean the chimney, detach the vent at the combustion blower transition where it is attached to the blower.
RECOMMENDED MAINTENANCE SCHEDULE
Use this as a guide under average-use conditions.
Daily Weekly Annually or per Ton
Burn Pot Stirred Emptied
Glass Wiped Cleaned
Combustion Chamber Brushed
Ashes Emptied
Interior Chambers Vacuumed
Heat Exchange Tubes Two passes
Combustion Blower Blades Vacuumed / Brushed
Convection Blower Impeller Vacuumed / Brushed
Vent System Cleaned
Gaskets Inspected
Hopper (end of season) Emptied and vacuumed
Gasket around door and door glass should be inspected and repaired or replaced when necessary.
(See “REPLACEMENT PARTS”)
REMOVAL AND REPLACEMENT OF BROKEN DOOR GLASS
While wearing leather gloves (or any other gloves suitable for handling broken glass), carefully remove any
loose pieces of glass from the doorframe. Dispose of all broken glass properly. Return the damaged door to
your Breckwell Dealer for repair or replacement.
Neither the appliance owner nor any other unauthorized person(s) should replace the door glass. An authorized
Breckwell dealer must perform all repairs involving door glass.
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