Harman Stove Company PB 105 Installation instructions

R4
SAFETY NOTICE
PLEASE READ THIS ENTIRE MANUAL BEFOREYOU INSTALLAND USEYOUR NEW BOILER. FAILURE TO FOL-
LOW INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR EVEN DEATH.
FOR USE IN THE U.S.AND CANADA. SUITABLE FOR INSTALLATION IN MOBILE HOMES
IF THIS HARMAN PELLET BOILER IS NOT PROPERLY INSTALLED,AHOUSEFIREMAYRESULT. FORYOURSAFETY,
FOLLOW INSTALLATION DIRECTIONS.
CONTACT LOCAL BUILDING OR FIRE OFFICIALSABOUT RESTRICTIONSAND INSTALLATION INSPECTION
REQUIREMENTSINYOURAREA.
CONTACT YOUR LOCALAUTHORITY (SUCHAS MUNICIPAL BUILDING DEPARTMENT, FIRE DEPARTMENT, FIRE
PREVENTIONBUREAU, ETC.) TODETERMINE THE NEEDFORAPERMIT.
CETTEGUIDED'UTILISATIONESTDISPONIBLEENFRANCAIS.CHEZVOTRECONCESSIONNAIREDEHARMANSTOVE
COMPANY.
SAVETHESEINSTRUCTIONS
The Harman PB 105 Pellet Boiler
Installation & Operating Manual
“Ce manuel est disponible en Français sur demande” R1
Tested by
OMNI-Test Labortories

3
Hopper Lid Latches
Hopper Control Board Cover
Control Board
C
ombu
stio
C
ombustion
Bl
Temperature / Pressure Gauge
Pressure Relief Valve
Aquastat Well
1-1/4”FMPT Supply
1-
1
/4” FMPT Re
turn
Ash Door
Firebox Door
Access Cover To
Hopper / Swing Plate Knob
Access Cover To Secondary Ash Chamber
H
eat Exchanger Cle
an
Blank Cover
(
Removed w
/ D
H
ot Water O
pt
Vent Pipe
1
/2” FMPT (Boiler
Dr
not shown)
Viewing Glass
PB-105 Parts
PB105 Parts

4
Assembly 4
Venting 8
Installation 11
Operation 20
Maintenance 27
Troubleshooting 31
Feeder Parts 32
Specifications 33
Wiring Diagram 34
Parts List & Options 35
Warranty 36
Testing Label 37
Quick Reference Start-Up Back Cover
Please read this entire manual before you install and use your new
boiler. Failure to follow instructions may result in
property damage, bodily injury, or even death.
SAVE THESE INSTRUCTIONS
HarmanStoveCompany
352Mountain House Road
Halifax,PA17032
Table of Contents

5
Assembly
Temperature / Pressure Gauge
Aquastat Well
Pressure Relief Valve
Blank Cover*
Heat Exchanger Cleanout Rod Handles
Access Cover To Secondary Ash Chamber Remove Cover to access nuts to fasten Flue Tunnel Weldment to the Ash Chamber.
F
lue Tunnel Weldme
nt
ESP Probe
C
ombustio
n B
He
Thumb Screws (3)
Firebox & Ash Door Handles
QTY (5)
*Removed w/ Domestic Hot
W
aterCoilOptionShownH
ere
½”MPT Boiler Drain (Not Shown)
Temperature / Pressure Gauge
Aquastat Well
Pressure Relief Valve
Blank Cover*
Heat Exchanger Cleanout Rod Handles
Access Cover To Secondary Ash Chamber Remove Cover to access nuts to fasten Flue Tunnel Weldment to the Ash Chamber.
F
lue Tunnel Weldme
nt
ESP Probe
C
ombustio
n B
He
Thumb Screws (3)
Firebox & Ash Door Handles
QTY (5)
*Removed w/ Domestic Hot
W
aterCoilOptionShownH
ere
½”MPT Boiler Drain (Not Shown)
OutdoorAirTemperatureSensorWiring:

6
Assembly
Boiler Kit Materials: (Refer to pages 4 & 5)
List of items contained within the boiler kit shipped with the
unit. 1 - Control board cover
1 - Access cover (Hopper Swing Plate Knob)
5 - Spring Handles
1 - 1/2” Boiler Drain
1 - 3/4” Safety Relief Valve
1 - 1/2” Aquastat Well
1 - 1/2” Dual Temperature/Pressure Gauge
1 - 100ft. Sensor Cable (Outdoor Air Sensor)
1 - Outdoor Air Sensor
1 - Flue Tunnel Weldment
1 - Combustion BlowerAssembly
1 - Heat Shield (Comb. Blower)
2 - UY Connectors
2 - Terminals 1/4 Female
1 - #8 X 1/2” TEK
3 - 1/4-20 X 5/8” Wing Screw
4 - 1/4” Lock Washer
4 - 1/4-20 Nuts
Installation of the Flue Tunnel Weldment,
Combustion Blower and Wiring, ESP and Heat
Shield:
Step 1: First install the flue tunnel weldment by aligning
the (4) studs up with the (4) holes in the ash
chamber base.Fasten the (4) nuts and lock washers
provided, to the studs by removing the access cover on
the secondary ash chamber.
Step 2: Place the combustion motor onto the flue tunnel
weldment and tighten the (3) wing screws provided.
Step 3: Insert the Exhaust Sensing Probe (ESP) into
the 1/8" hole provided on the flue pipe stub. Fasten
with the (1) #8x1/2" TEK screw also provided. ESP
will be taped to the sheet metal jacket for shipping
purposes.
Step 4: Connect the flex conduit 90 degree elbow(Not
Shown) to the heat shield in the hole provided. Then
connect the (3) wires from the combustion blower with
the (3) wires in the flex conduit by using the push-on
connectors and matching the wire colors as follows:
Red to Black, White to White and Green to Green.
Step 5: Place Heat Shield over combustion blower and
align the swell latches with the holes in the sheet metal
and tighten.
NOTE: Refer to Fig’s 22, 23 and 24 located in the
maintenance section of this manual.

7
Design:
Thefirst thingthatneeds tobedone isdecidingwhere and
howtheboilerwillbeinstalled.
Thingsthat needtobe taken intoconsiderationare the
intendeduse ofthe boilerfor example,isthe boilergoing to
beused asyourprimary heating systemoris itgoingto be
usedasasecondaryor backup heating system. If it is to be
usedinconjunctionwithanexistingoilorgasboilersystem
willit bepipedin parallelorin series?Theanswers tothese
andother questionscanbe determinedbytalking toyour
certifieddealerora qualifiedHVAC orplumbing contrac-
tor.Thiswillinsurethattheboilerisinstalledandpipedto
accommodateyour needsandexpectations.
Considerationmustbegiventotheventingaswellas
electricalandclearancerequirements. (Clearancesmust be
maintainedtocombustiblesandalso forservice)
Afterthe boiler isset into placetheventing can bedone.
1. Install the control board cover as well as the access
cover located on the feeder cover.
2. Install the spring handles provided with the unit on
the ash door, firebox door and the heat exchanger cleanout
rod handles. (Fasten handles by turning them counterclock-
wise and pushing inward simultaneously).
3. Install 1/2” MPT boiler drain in the fitting as
shown.
Note: Use teflon pipe thread sealant or teflon
tape on ALL threads before connections are made.
4. Install 3/4” MPT pressure relief valve as shown.
5. Install the 1/2” MPT aquastat well in fitting as
shown, then place aquastat in the well and fasten with a zip
tie. 6. Install the 1/2” MPT temperature/pressure gauge in
fitting as shown.
7. Locate and install outside air temperature sensor.
Location of this sensor should be on the north side of the
home or building and out of direct sunlight. Use the cat
cable supplied with the boiler to attach sensor to the
terminals located on the hopper. (Place at the back side just
above and to the right of the main power connection box)
The wires can be connected to the sensor with the connec-
tors supplied. Wire nut or butt splice connectors could also
be used. The connections at the boiler can be done with the
two 1/4” female push on connectors supplied.
8.Fasten conduit to the ash basewiththe clamps
provided.
Assembly
FloorProtection:
Thestripedareaindicatestheminimumrequiredfloor
protectionareaifthe PB105 is going to be placed on a
combustiblefloor. Itrequires30” X55”of non combus-
tiblefloor protectionasshown below. 6”ofthe floor
protectionmust be infrontof the boilerasshown. Floor-
ingmustbe aminimum of26gaugesheetmetal.Floor
protectionmustalsobeprovidedunderanyhorizontal run
ofvent pipeequal totheoutsidediameterof theventing
plus2”to each side.
Example:4”type “L” or“PL”vent pipe hasanoutside
diameterof4-1/2” + 2” on each side equals a protected
floorarea of8-1/2” wideunderneaththehorizontalrun.
After assembly of the flue tunnel weldment, combustion
blower assembly with wiring and heat shield, the boiler can
now be installed.
Non-Combustible
FloorProtector
MINIMUMNON-COMBUSTIBLEFLOORPROTECTIONAREA
Makesure fans are notusedin the fuel storagearea,unless
theyare installed so asnotto create a negativepressuresin
theroomwherethesolid fuelburning applianceis located

8
Assembly
NOTE: All installation clearances and restrictions
must be adhered to.
INSTALLATION IS TO BE PERFORMED BY A
QUALIFIEDINSTALLER.
NOTE:Useonly 4”diameter type “L” or “PL” venting
system. Be sure to inspect and clean exhaust venting
system frequently.
WheninstallingthePB105inamobilehomeseveral
requirementsmustbefollowed:
1.Theunitmust be boltedtothefloor.
2.Theunit must be connectedtooutside air.
3.Floor protection andclearancesmust be followed.
4.Unit mustbegrounded tothe metalframeof themobile
home.

9
Requirements forTerminatingtheVenting
WARNING:Ventingterminalsmustnotberecessed
intoawallorsiding.
NOTE:OnlyPL ventpipewallpass-throughsand
firestopsshouldbeusedwhenventingthroughcombus-
tiblematerials.
NOTE:Alwaystake intoconsiderationtheeffect
theprevailingwinddirectionorotherwindcurrentswill
causewithflyashand/orsmokewhenplacingthetermi-
nation.
Inaddition,thefollowingmustbeobserved:
A.Theclearanceabovegrade mustbeaminimum
of18".1
B.Theclearancetoa window or door that may
beopened must beaminimum of 48"tothe side, 48"
belowthe window/door,and12" above thewindow/
door.1
( withoutsideairinstalled, 18” )
C.A12" clearance to a permanently closed win-
dow is recommendedtopreventcondensation on the
window.
D.The vertical clearance toaventilatedsoffit lo-
catedabovetheterminalwithin ahorizontal distanceof
2feet(60cm)from thecenter-line ofthe terminal must
beaminimumof18".
E.Theclearancetoanunventilatedsoffit mustbe
aminimumof12".
F.The clearance to an outside corner is 11"from
centerof pipe.
G.The clearancetoan inside corner is12".
H. Aventmust not be installed within 3 feet (90
cm) abovea gasmeter/regulatorassembly whenmea-
suredfromthehorizontalcenter-lineoftheregulator.1
I. The clearance to service regulator vent outlet
mustbeaminimumof 6feet.1
J. The clearance to a non-mechanical air supply
inletto the building or the combustion air inlet to any
otherappliancemustbea minimumof 48”.1
K.The clearance to amechanicalair supply inlet
mustbeaminimumof10feet.1
(withoutside air installed, 6feet)
L. The clearance above a paved sidewalk or a
paveddriveway located on public property must be a
minimumof 7feet.1,2
M. The clearance under a veranda, porch, deck
orbalconymustbeaminimum of12 inches.1,3
NOTE: The clearance to vegetation and other
exteriorcombustiblessuchasmulchis36”asmeasured
from the center of the outlet or cap. This 36” radius
continues to grade or a minimum of 7 feet below the
outlet.
1CertainCanadian and or Local codesorregula-
tionsmayrequiredifferentclearances.
2Avent shall not terminate directlyabovea side-
walkor paveddrivewaywhich is locatedbetween two
single familydwellingsandservesbothdwellings.
3Only permitted if veranda, porch, deck, or bal-
conyisfullyopenona minimumof 2sidesbeneaththe
floor.
VA
= Vent terminal = Air supply inlet
Fixed
Closed
Openable
Openable Fixed
Closed
Inside
Corner
Detail
= Area where terminal is not permitted Fig.2
NOTE:Wherepassagethroughawall,orpartition
of combustible construction is desired, the
installation shall conform to CAN/CSA-B365. (if
in Canada)
Venting

10
Venting
Fig.3

11
The minimumvent configurationis a90oorTee on a
startercollaranda24”lengthhorizontalthroughanexterior
wall. Acap or other bird screen on the end should direct
theflue gassesdown andaway fromthestructure.SeeFig.
5. Themaximumhorizontal lengthis18feet.The mini-
mumterminationheightabovetheexteriorgradeis18”.The
maximumtotallengthofanyconfigurationis30feet*.
*(see venting graph on page 9 for exceptions)
NOTE: Cleanout Tee’s should always be used on the
transitions to horizontal pipe to allow easy access for
cleaning.
Theventing graphallowsfor (one)90 deg.orTeefit-
tinginanyconfiguration.
If more 90’s, T’s, or 45’s are needed the total length
mustbe adjusted toallowforthe added restriction.
Up to four (4) additional 90’s, Tee’s, or equivalent
45’scanbe added as long astheoverall length is adjusted
inaccordancewiththevalueslisted below.
(Seethe venting graph on page 9.)
Each Vertical ---- 90 deg. or Tsubtract 2.5 feet
Each Vertical ---- 45 deg. subtract 1.5 feet
EachHorizontal-90deg. or T subtract 5.0 feet
Each Horizontal - 45 deg. subtract 2.5 feet
Any exterior venting (vent pipe exposed to out-
sideambianttemperatures)should be kept to amini-
mum,due to potentialcondensationproblems.
This is especially important in high humidity cold
weatherclimates, suchasmaritime areas, lakeshores, and
lowrivervalleys.
Venting
Venting
4” Type “L” or
“PL” Vent pipe
Thisistheminimumventingconfiguration. Fig.5
Venting
Use4” pellet vent pipeto vent your PB105.
Acombustion blower isused toextract the combustion
gases from the firebox. This creates a negative pressure in
the firebox and a positive pressure in the venting system as
shown in Fig. 4. The longer the vent pipe and more elbows
used in the system, the greater the flow resistance. Because
of these facts we recommend using as few elbows as pos-
sibleand 30 feetor lessof vent pipe.The maximumhorizon-
talrun should not exceed18 feet.
Be sure to use wall and ceiling pass through fit-
tings (which are approved for pellet vent pipe ) when
going through combustible materials. Be sure to use a
startingcollar to attachthe venting system to the stove. The
starting collar must be sealed to the stove flue collar
withhigh tempsiliconecaulking oraluminumtape, and
screwed into the stove flue collar at least three (3)
places.
-
Fig.4
+
Vent Pipe
4”pelletventpipe(alsoknownasPLvent)isconstructed
oftwolayerswith airspacebetweenthelayers. Thisairspace
actsas aninsulator andreduces theoutside surface tempera-
turetoallow aminimumclearanceto combustiblesof1 inch.
InCanadatheminimumclearancetocombustiblesis3inches.
The sections of pipe lock together to form an air tight
seal in most cases; however, in some cases a perfect seal is
not achieved. For this reason and the fact that the PB105
operates with a positive vent pressure, we specify that all
joints within the structure should also be sealed with
clear silicone.
NOTE:Useonly 4” diametertype “L” or“PL” venting
system. Be sure to inspect and clean exhaust venting
system frequently.

12
Chimneystallerthan20’abovetheconnection willre-
quirea drafttestto determine ifthe draft istoohigh.
Note: The High Burn Draft should not exceed .85
IWC.Someform ofa restrictorplatemayberequiredatthe
top of high chimneys to reduce the draft. See page 19 for
theDraftTest procedure.
Creosote - Formation and Need for Removal - When 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
of a slow-burning fire. As a result, creosote residue accumulates on the flue lining. When ignited, this creosote makes an
extremely hot fire. The pellet vent pipe should be inspected at least twice monthly during the heating season to determine
if a creosote buildup has occurred. If creosote has accumulated it should be removed to reduce the risk of a chimney fire.
Guidance on minimizing creosote formation and the need for periodic creosote removal: The chimney should be
inspected during the heating season to determine if a creosote build-up has occurred. If a significant layer of creosote has
accumulated (3mm or more) it should be removed to reduce the risk of a chimney fire.
The PB105 Boiler may be used and installed into an
existingmasonaryorClassAmetalchimney.
CertainCanadian and LocalCodes may requirethat
thechimneybefullyrelined.
ItCan Not be installed inachimney serving another
appliance.
Thechimneyshouldbecleaned and or inspected be-
foreinstallation.
Venting Installation
NOTE:All installation clearances and restrictions
must be adhered to.
NOTE: Read and follow all of the vent pipe
manufacturers’ instructions on the proper
installation and support of the vent pipe. Adhere
to all clearances.
DO NOT INSTALLA FLUE DAMPER IN THE
EXHAUSTVENTINGSYSTEMOFTHISUNIT.
DO NOT CONNECT THIS UNIT TO A
CHIMNEY FLUE SERVING ANOTHER
APPLIANCE.
INSTALLVENT WALLPASS-THROUGHSAT
CLEARANCES SPECIFIED BY THE VENT
MANUFACTURER
INSTALLATION IS TO BE PERFORMED BY A
QUALIFIEDINSTALLER.
NOTE: Use only 4” diameter type “L” or “PL”
venting system. Be sure to inspect and clean
exhaust venting system frequently.
Keepcombustiblematerialssuchasgrass,leaves,etc.
atleast 3feetaway fromthepoint directlyunderthe
venttermination.(betweentheventandtheground)
WARNING
KEEP COMBUSTIBLES AWAY
FROM FLUE OUTLET.
CAUTION
DONOTINSTALLIN SLEEPINGROOM
WARNING
Otherexamplesofpossibleinstallationsoftheventing.

13
Outside Air
Outsideairisoptional,althoughitmayberequired
by some building codes. The benefit of outside air is
higherefficiency andreducedventingrestrictionsmainly
noticedinsmallandverytighthouses.
Toinstalloutsideair,use23/4”"I.D.galvinizedsteel
flexpipe,part # 2-00-08544 ( 12’ 6” length) or part #
2-00-08545(25’ length) See Fig. 6. There is a break-
away hole on the rear panel which must be removed
before connecting the flex pipe. See Fig. 7. The pipe
shouldbe runoutsideand terminate3feet or more be-
lowor 1footor moreto thesideof theventpipe outlet.
Neverterminatetheoutsideairabovetheventpipe out-
let. The maximum length of this pipe is 20 feet. Inlet
coverpart number 1-10-09542 shouldbeused to keep
birds,rodents etc.out of the inletpipe.SeeFig.6.
NOTE:If outside air is installed, the inlet cover
should not be placed in an area where drifting of
snow or ice will build up, blocking the intake air
supply.
The OutsideAirknockout is located on the face
of the Feeder Cover. It is pre-cut except for several
small tabs. There is also a filler plate screwed to the
insideto cover the topofthe hole aftertheOutsideAir
Pipehas been installed. Thiswillallow for removalof
theFeederCoverwithoutdisconnectingtheOutsideAir
Pipe. See Fig. 7.
Only metal Intake Flex should be used for the
OutsideAirSupply connection.
Onlyascreened or rodent protected OutsideAir
Intakecovershouldbeusedasanoutsideweathercover.
TheOutsideAirIntakePipeis inside the Feeder
Coverand to the right of the feeder motor.The 2 3/4”
steelflexpipeismadetoslideovertheoutsideoftheAir
IntakePipe.SeeFig.8.It shouldbeheld intoplacewith
somesilicone, foiltape,or ahoseclamp.
(notsupplied)
Heat Reclaiming Ventilation System
(HRV)
WheninstallinginahousewithaHeatReclaiming
Ventilation System (HRV) be sure the system is bal-
ancedandisnotcreatinganegativepressureinthehouse.
Inlet Cover part#
1-10-09542
NOTE: If the boiler is installed with the out-
side air system no adjustments to the HRV should be
necessary.
Installation
Outside Air Inlet Pipe
Hopper/FeederSwing
Plate Knob
Outside Air Inlet Pipe
Hopper/FeederSwing
Plate Knob
Outside Air Pipe
Knockout
FeederCover
Outside Air Pipe
Knockout
FeederCover
Fig.6
Fig.7
Fig.8

14
Main Wiring Installation
To install powertothe boiler first removethecoveron the 4” X4”junction box located ontheback of the unit.Thereareseveralknockout holes providedfor theincomingmain powerwires.Also,a knockoutholecan beused fortheauxiliary outputoverheatzone (ifused). Theminimum recommended circuit is6AMP- 120VAC - 60HZ.Thisboiler should be theonlyappliance on thecircuit.If a 15AMPcircuitbreaker isused at thedistributionbox, the boiler mustbeprotected with anin-linefuse rated at6AMP. This boiler should never be powered by the use of an extension cord. The recommended high and low voltages are, 130 V.A.C. 60 Hz maximum high voltage, and 113 V.A.C. 60 Hz minimum low voltage.The furnace will continue to operate at voltages as low as 105 V.A.C. , although it can not be guaranteed that automatic ignition will occur.
NOTE: If other sources of electrical power are to be used ( such as a generator ) for normal operation or emergency operation, this
source should be checked before installation. Many generators and inverters may not supply 120V.A.C. 60Hz. power stable enough to operate the control board properly. (Control board damage could occur).

15
Installing Duct
Installation

16
Installing Duct/Air Conditioning
Installation
Boilers intended to be connected to an existing boiler or boiler system shall:
1. Be capable of being installed without interfering with the normal delivery of heated water from the original boiler to the radiation
system.
2. Be capable of being installed to operate as intended without affecting the operation of the electrical and mechanical safety controls
of the original boiler.
3. Provide, upon completion of the installation, for a change over from one fuel to the other without requiring the manual adjustment of
any controls or components other than the thermostats.
4. Be compatible with the operation of a service water-heating coil within the original boiler without bypassing the operation of the
solid-fuelboiler.
5. Have provision for preventing, or adequate water capacity within the boiler to prevent, damage to the boiler from loss of circulation
due to electrical power failure.
6. Be capable of being installed without changing the function of the control or rewiring of the original boiler. Awiring interconnection
is permitted. The electrical system of both boilers shall be powered from a single branch circuit without exception.
(CAN/CSA-B366.1-M91)

17
Installation

18
Installation

19
Installation

20
Installation
DraftTest Procedure
Afterthe ventingiscompleted, thefirebox lowdraft
willneed to be checked and possibly adjusted. After re-
movingthe3/8” bolt from the draft hole showninFig.9,
insertthedraftmeter tube.The hopperlid mustbelatched
during this test. (It is recommended that the draft meter
have a scale of 0 to 1” WC.)
Turnthefeedadjusterto“Test”.thiswillstartthecom-
bustionblowerandallowyoutocheckandrecordtheHigh
Draft ______ -IWCdate_______ (Thereisnoadjust-
mentfortheHigh Draft)
Afterthefirst 60seconds the“Test”modelowersthe
combustionblowervoltagetotheLowBurnvoltage.(The
“Test”modecycles thevoltage fromhightolowevery 60
seconds).DuringthisloweredvoltagecycletheLowBurn
Draft must be checked and adjusted if necessary. The
recommendedlowdraftsetting shouldbe between-.25 &
-.35IWC.Dependingontheamountofverticalrise,itmay
notbepossible to get a low draft reading in this range.In
thiscase, a maximumlowdraft of -.55isacceptable.
Theadjustmentscrewisthroughthesmallholetothe
rightoftheIgniterLight.SeeFig.10.Adjusted LowDraft
is __________ -IWC.
Don’t forget to turn the feed adjuster back to #4.
Draft Bolt Location
Viewing Window
Air washSlot
Fig.9
“Test”
Low Draft
Adjustment Pot
Fig.10
The Control
The PB105 has the option to have the control panel
coveredor un-covered See Fig.11.There is apairof slots
providedforeach position. Simply move the cover to the
desired position by placing the tabs on the cover in the
properslots.
WARNING: Do not operate with fire
chamber or ash removal doors open.
WARNING: Do not store fuel or other
combustible material within installation
clearance area.
CAUTION: Hot while in operation. Do not
touch.Keepchildren,clothing, furniture,and
other combustible material out of the
installation clearance area.
Fig.11
Covered Un-Covered
Air Wash Slot