Hearth & Home QUADRA-FIRE Castile Insert Programming manual

February 15, 2019250-7690B1
Castile Insert
Troubleshooting Manual
(THIS MANUAL IS INTENDED FOR TRAINED & QUALIFIED DEALERS &
TECHNICIANS USE ONLY)

February 15, 2019250-7690B2
CASTILE INS
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 appliance or to property.
TABLE OF CONTENTS
1 Normal Operation Sequence .......................................3
2 Basic Troubleshooting & Repair ....................................5
3 Feed System ....................................................6
4 Igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Exhaust Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Convection Blower ..............................................12
7 Power Supply...................................................14
8 Thermostat.....................................................16
9 Thermocouple ..................................................18
10 Firebox Vacuum & Vacuum Switch ................................20
11 Complete Wiring Diagram........................................ 22
12 General Specications ..........................................23
13 Exploded View & Service Parts ................................... 24
13 Tech Check Sheet ..............................................31
14 Cleaning & Maintenance Tips..................................... 32
15 Service Repair Tools ............................................33
16 Notes.........................................................34

February 15, 2019 250-7690B 3
CASTILE INS
1 Normal Operation Sequence
1. Turn on thermostat a red call light will illuminates on
the stove.
2. The exhaust blower will turn on.
3. The igniter turns on.
4. The vacuum switch closes.
5. The feed motor turns on. The initial feed of the feed
motor will last approximately 64 seconds and then
stop.
6. Pellets will ignite in the repot.
7. Heat from re turns on the green thermocouple light
in the control box (2.5 - 3mVDC); 200°F.
8. Feed motor starts its cycle mode:
SETTING SECONDS
LOW 0.9
MEDIUM 1.6
HIGH 2.2

February 15, 2019250-7690B4
CASTILE INS
9. Heat from the re turns on the red thermocouple light
in the control box (12.0 - 13.0mVDC); 600°F.
10. The igniter turns o󰀨
11. Heat from the re closes the #1 snap disc.
12. The convection blower will turn on.
13. Room reaches temperature
14. Thermostat will turn o󰀨.
15. The red call light will turn o󰀨.
16. Feed motor will turn o󰀨.
17. The exhaust blower will start a 18 minute countdown.
18. The #1 snap disc cools o󰀨
19. The convection blower shuts o󰀨
20. The end of the cycle; the appliance is now ready for
another call for heat.

February 15, 2019 250-7690B 5
CASTILE INS
A. Plug in stove with no response
1. Check the power supply for 115 volts
2. Check the fuse in the junction box (7amps)
3. Check snap disc #3 for power
4. Check control box
B. Call light on with no r and no fuel in re
pot
1. Check hopper for bridging of pellets
2. Push reset button and 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 with no re and partially
burned fuel in re pot
1. Check repot and clean
2. Check thermocouple
-Green light - 2.5 - 3.0mV
-Red light - 12.0 - 13.0mV
3. Check initial feed time (60 seconds)
D. Call light is on with no re and fuel in the
re pot
1. Check repot for “clinker” material
2. Clean repot
3. Check igniter
4. Check control box
E. Slow or smoky start-up
1. Clean repot
2. Feed adjustment plate may be set too high
3. Check exhaust blower and heat exchanger
4. Make sure trap door is under the repot in the closed
position
G. Feed system fails to start
1. Check front door and make sure it is closed
2. Check to see if the call light is on
3. Check the thermostat and #2 snap disc
4. Check feed motor and vacuum switch
5. Check exhaust system for obstructions
H. Thermostat will not start appliance
1. Check the thermostat wires for continuity
2. Check the “accessory jumper wire” on the junction
box
3. Check the reset button
4. Check the power to the stove
5. Check the control box
F. Stove Runs for 18 minutes then stops
feeding fuel
1. Check thermocouple
-Green light - 2.5 - 3.0mVDC
-Red light - 12.0 - 13.0mVDC
2. Adjust feed adjustment plate for larger re
3. Check thermocouple cover
- Cover needs to touch the end of the
thermocouple wire
- Cover should extend 1-3/4 inches into the repot
4. Check the control box
2 Basic Troubleshooting & Repair
I. Appliance fails to shut o󰀨
1. Check the thermostat and thermostat wire
2. Check the junction box and wire harness
3. Check the control box
J. Convection blower keep running or fails
to start
1. Check the #1 snap disc
2. Check convection blower
3. Check for voltage to the #1 snap disc
K. Appliance cycles on and o󰀨 with the
thermostat is always on
1. Check the control box
2. Check vacuum switch
3. Check wiring for loose connections
L. Large re, ash build up and dirty glass
1. Check repot, 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 - 2.2 seconds on time
-MEDIUM - 1.6 seconds on time
-LOW - 0.9 seconds on time
M. Appliance ignites then goes out but call
light is still on
“ STOVE IS INCONSISTENT IN OPERATION“
1. Inspect thermocouple and its position over the pot
2. Check the feed motor
3. Adjust feed adjustment plate for a larger re
4. Check the exhaust and heat exchanger system
5. Check the vacuum switch

February 15, 2019250-7690B6
CASTILE INS
NOTE: Remember that
the feed circuits
initial feed time
is 60 seconds.
Push the reset
button before
each test.
3 Feed System
TECH TIP:
MAKE SURE THE
FEED SYSTEM IS
CLEAN AND FREE
OF OBSTRUCTIONS
BEFORE
TROUBLESHOOTING
TURN ON THE
T-STAT & APPLIANCE
SYSTEM IS
REPAIRED
AFTER 2 MIN,
IS THE AUGER
TURNING?
YES
NO
CHECK FEED
MOTOR. IS THERE
115VAC AT FEED
MOTOR?
REPLACE THE FEED
MOTOR
REPLACE THE
VACUUM SWITCH
REPLACE #2 SNAP
DISC
REPLACE RESET
BUTTON
REPLACE THE WIRE
HARNESS
REPLACE THE
CONTROL BOX
CHECK VACUUM
SWITCH
BAD
GOOD
CHECK #2 SNAP
DISC
CHECK RESET
BUTTON
CHECK THE
WIRE HARNESS &
CONNECTIONS
BAD
BAD
BAD
GOOD
GOOD
GOOD
YES
NO

February 15, 2019 250-7690B 7
CASTILE INS
FEED MOTOR
VACUUM
SWITCH
COMBUTION
BLOWER
RECEPTACLE
CONVECTION
BLOWER
JUNCTION BOX
FEED MOTOR CIRCUIT
WHITE
WHITE
BLACK
WHITE
BLACK
BLACK
RED
RED RED
WHITE
BLACK ORANGE
RED
FUSE
T.C.
CAPACITOR
A / 1
B / 2
C / 3
D / 4
E / 5
F / 6
H / 7
J / 8
K / 9
L / 10
M / 11
N / 12
P / 13
R / 14
S / 15
#2 SNAP DISC
N
FEED MOTOR TESTING WITH TEST BOX
(IN CONJUNCTURE TO THIS SERVICE MANUAL USE THE INSTRUCTION SHEET FOR THE TEST BOX
KIT)
1. Unplug the appliance, remove the control box, install the test box, and plug the appliance back in.
2. Turn on the exhaust blower switch; this will active the vacuum switch to close.
3. Turn on the thermostat - the thermostat indicator light should come on.
4. Turn on the feed motor switch.
- If the feed system does come on:
– Replace the control box
- If the feed system does not come on:
– Check the feed motor
– Check the vacuum switch
– Check the wire harness
– Replace #2 snap disc

February 15, 2019250-7690B8
CASTILE INS
4 Igniter
TECH TIP:
MAKE SURE THE
FIREPOT AND
SURROUNDING
AREA IS CLEAN
BEFORE
TROUBLESHOOTING
IS VOLTAGE PRESENT?
IS THERE CONTINUITY
PRESENT?
CONNECT A MULTIMETER
TO THE IGNITER WIRE
HARNESS
CONNECT A MULTIMETER
TO THE IGNITER
IS THERE POWER TO THE
APPLIANCE?
IS THE IGNITER
GETTING HOT
AFTER 60
SECONDS?
IS THE GREEN
CALL LIGHT
ILLUMINATED ON
THE CONTROL
BOX?
NO
NO
REPLACE THE
CONTROL BOX
YES
YES
YES
YES
NO
CHECK THE IGNITER WIRE
HARNESS
IS THE WIRING BROKEN?
REPAIR OR
REPLACE THE
WIRE HARNESS
REPLACE THE
IGNITER
CHECK POWER
NO
NO
NO
SYSTEM IS
REPAIRED
YES
YES
SAFETY
NOTE: DO NOT touch
igniter for it will be
hot and burn you.
TURN ON
THE T-STAT &
APPLIANCE

February 15, 2019 250-7690B 9
CASTILE INS
JUNCTION BOX
IGNITER CIRCUIT
FUSE
T.C.
IGNITER
HIGH-TEMP
HIGH-TEMP
A / 1
B / 2
C / 3
D / 4
E / 5
F / 6
H / 7
J / 8
K / 9
L / 10
M / 11
N / 12
P / 13
R / 14
S / 15
FEED MOTOR TESTING WITH TEST BOX
(IN CONJUNCTURE TO THIS SERVICE MANUAL USE THE INSTRUCTION SHEET FOR THE TEST BOX
KIT)
1. Unplug the appliance, remove the control box, install the test box, and plug the appliance back in.
2. Turn on the thermostat switch (the thermostat indicator light should come on).
3. Turn the igniter switch on.
- If the igniter comes on:
– Replace the control box.
- If the igniter does not come on:
– Check the wire harness
– Replace the igniter

February 15, 2019250-7690B10
CASTILE INS
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. THE MEDIUM AND LOW VOLTAGES WILL BE 115 FOR THE FIRST 4:15 IF THE UNIT HAS
THE NEW CONTROL BOX. (PART # 230-2070).
5 Exhaust Blower
PLUG STOVE IN
IS THE BLOWER
RUNNING? YES
NO
IS THERE 75 VAC
OR HIGHER GOING
TO THE BLOWER?
BAD
GOOD
CHECK WIRE
CONNECTIONS
BETWEEN THE
BLOWER AND THE
JUNCTION BOX
REPAIR OR
REPLACE THE WIRE
HARNESS
CHECK FOR
AIR PATH
RESTRICTIONS.
IS THE BLOWER &
EXHAUST SYSTEM
CLEAN?
SYSTEM IS
REPAIRED
YES
NO REPLACE THE
EXHAUST BLOWER
CLEAN THE
BLOWER AND
EXHAUST PATHS
REPLACE THE
CONTROL BOX
YESNO
TECH TIP:
MAKE SURE THE AIR
PATH IS FREE FROM
RESTRICTIONS
AND THE EXHAUST
SYSTEM IS
CLEAN BEFORE
TROUBLESHOOTING

February 15, 2019 250-7690B 11
CASTILE INS
FUSE T.C.
EXHAUST BLOWER CIRCUIT
EXHAUST
BLOWER
CONVECTION
BLOWER
JUNCTION BOX
BLUE
BLUE
WHITE
A / 1
B / 2
C / 3
D / 4
E / 5
F / 6
H / 7
J / 8
K / 9
L / 10
M / 11
N / 12
P / 13
R / 14
S / 15
FEED MOTOR TESTING WITH TEST BOX
(IN CONJUNCTURE TO THIS SERVICE MANUAL USE THE INSTRUCTION SHEET FOR THE TEST BOX
KIT)
1. Unplug the appliance, remove the control box, install the test box, and plug the appliance back in.
2. Turn on the thermostat switch (the thermostat indicator light should come on).
3. Turn the exhaust blower switch on.
- If the blower comes on:
– Replace the control box
- If the blower does not come on:
– Check the wire harness
– Replace the blower

February 15, 2019250-7690B12
CASTILE INS
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.
6 Convection Blower
ARE FUSES
GOOD?
ARE THE WIRE
CONNECTIONS
GOOD?
PLUG IN STOVE
IS THEIR
POWER PRESENT
ON BOTH SIDES?
IS THE BLOWER
RUNNING? YES
NO SYSTEM IS
REPAIRED
CHECK VOLTS
TO BLOWER. IS
THERE 95 VAC
OR HIGHER?
REPLACE THE WIRE
HARNESS
REPLACE THE
CONVECTION
BLOWER
YES
YES
YES
YES
NO
NO
NO
NO
REPLACE THE FUSES
REPLACE THE
CONTROL BOX
TECH TIP
INSTALLING A JUMPER
WIRE ON THE #1 SNAP
DISC PURPLE WIRES AND
THEN PLUGGING IN THE
APPLIANCE WILL TURN
ON THE BLOWER

February 15, 2019 250-7690B 13
CASTILE INS
7 AMP FUSE
JUNCTION BOX
HI / LOW SWITCH
FUSE
T.C.
PURPLE
PURPLE
WHITE
WHITE
#1 SNAP DISC
BLACK BLACK
A / 1
B / 2
C / 3
D / 4
E / 5
F / 6
H / 7
J / 8
K / 9
L / 10
M / 11
N / 12
P / 13
R / 14
S / 15
CONVECTION
BLOWER
RECEPTACLE
CONVECTION BLOWER CIRCUIT
CONVECTION BLOWER TESTING WITH TEST BOX
(IN CONJUNCTURE TO THIS SERVICE MANUAL USE THE INSTRUCTION SHEET FOR THE TEST BOX KIT)
1. Unplug the appliance, remove the control box, install the test box, and plug the appliance back in.
2. Install a jumper wire onto the #1 snap disc purple wires and then plug in the appliance.
3. Turn on the convection blower switch.
- If the blower comes on:
– Replace #1 snap disc, or
– Replace the control box
- If the blower does not come on:
– Check the wire harness
– Replace the blower

February 15, 2019250-7690B14
CASTILE INS
7 Power Supply
TECH TIP:
VERIFY OUTLET
FOR CONTINUITY
RESET #3 SNAP
DISC
CONSULT
A LICENSED
ELECTRICIAN
PLUG IN STOVE
IS THERE
POWER PRESENT
AT THE BLACK
WIRE FROM THE
POWER CORD?
IS THERE
POWER
PRESENT AT THE
GRAY WIRE ON
THE 7 AMP FUSE
HOLDER?
IS THERE
POWER
PRESENT AT THE
GRAY WIRES ON
THE #3 SNAP
DISC?
REPLACE POWER
CORD
REPLACE THE FUSE
HOLDER
REPLACE CONTROL
BOX
REPLACE THE #3
SNAP DISC
REPLACE THE WIRE
HARNESS
IS THERE
CONTINUITY AT
PIN 5 (WHITE
WIRE TO THE
POWER CORD?
YES
NO SYSTEM IS
REPAIRED
IS THE #3 SNAP
DISC TRIPPED?
YES
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
IS THE CALL LIGHT
ILLUMINATED ON THE
CONTROL BOX?

February 15, 2019 250-7690B 15
CASTILE INS
7 AMP FUSE
JUNCTION BOX
FUSE
T.C.
POWER SUPPLY CIRCUIT
POWER IN
WHITE
GREY
GREY
GREY
GREY
BLACK
GREEN
WHITE
GREEN
GREEN
#3 SNAP DISC
CONVECTION
BLOWER
A / 1
B / 2
C / 3
D / 4
E / 5
F / 6
H / 7
J / 8
K / 9
L / 10
M / 11
N / 12
P / 13
R / 14
S / 15
TEST POWER SUPPLY FOR CONTINUITY
1. Add a jumper wire on the end of the power cord.
2. Set the volt meter to OHMs and put the probes on pin 5 and pin 12 of the junction box.
- If the circuit is complete, the reading should be “0”

February 15, 2019250-7690B16
CASTILE INS
8 Thermostat
TECH TIP:
SUGGEST USING A JUMPER
WIRE TO CLOSE CIRCUITS WITH
THE TESTS POINTS (JUNCTION
BOX, THERMOSTAT BLOCK,
#2 SNAP DISC, AND RESET
BUTTON).
UNPLUG APPLIANCE, REMOVE CONTROL BOX, TURN ON
THERMOSTAT, AND INSTALL JUMPER WIRE AT THERMOSTAT
IS THE THERMOSTAT
TURNING ON & OFF
THE APPLIANCE? YES
NO
IS THERE
CONTINUITY AT
PINS 7 & 9 ON
THE JUNCTION
BOX?
SYSTEM IS
REPAIRED
REMOVE
THERMOSTAT
WIRES FROM
THERMOSTAT
BLOCK & INSTALL
JUMPER WIRE.
INSTALL
A JUMPER
WIRE ON THE
THERMOSTAT
BLOCK.
INSTALL
A JUMPER
WIRE ON THE
THERMOSTAT
BLOCK & RESET
BUTTON (7 & 9).
IS THERE
CONTINUITY?
IS THERE
CONTINUITY AT
PINS 7 & 9 ON
THE JUNCTION
BOX?
IS THERE
CONTINUITY AT
PINS 7 & 9 ON
THE JUNCTION
BOX?
YES
YES
YES
YES
NO
NO
NO
NO
REPLACE THE
CONTROL BOX
REPLACE THE
THERMOSTAT
REPLACE THE
THERMOSTAT WIRES
REPLACE THE RESET
BUTTON
REPLACE THE
JUNCTION BOX

February 15, 2019 250-7690B 17
CASTILE INS
FUSE
T.C.
THERMOSTAT
BLOCK
JUNCTION BOX
THERMOSTAT CIRCUIT
RESET BUTTON
YELLOW
YELLOW
YELLOW YELLOW
BLUE BLUE
BLUE
ORANGE
BLACK BLACK
BLACK
ORANGE
ORANGE
YELLOW
YELLOW YELLOW
YELLOW
WR
WR
THERMOSTAT
BLOCK
A / 1
B / 2
C / 3
D / 4
E / 5
F / 6
H / 7
J / 8
K / 9
L / 10
M / 11
N / 12
P / 13
R / 14
S / 15
3 POSITION
ROCKER
SWITCH
TEST POWER SUPPLY FOR CONTINUITY
1. Unplug stove, remove control box, install test box & plug appliance back into power source.
2. Turn on the thermostat.
- If the thermostat light comes on; replace the control box
- If the thermostat light does no come on; refer to thermostat circuit troubleshooting on page 16.

February 15, 2019250-7690B18
CASTILE INS
9 Thermocouple
TECH TIP:
SET VOLT METER TO
MILLIVOLTS (DC)
PLUG IN STOVE
YES
NO
IS THE GREEN CALL
LIGHT ILLUMINATED
ON THE CONTROL
BOX?
IS THERE A
FIRE IN THE FIRE
POT?
IS THERE
3mVDC AT THE
THERMOCOUPLE
WIRE
CONNECTION
POINTS AT THE
JUNCTION BOX?
YES
YES
NO
NO
ARE THE
TERMINAL
CONNECTIONS
ON THE
JUNCTION BOX
LOOSE?
SECURE
THERMOCOUPLE
WIRE ENDS
PROPERLY.
REPLACE THE
THERMOCOUPLE
REPLACE THE
CONTROL BOX
NOTE: The thermocouple is made up of two dissimilar metals that when joined together will produce a small
amount of electricity when heat is applied. The hotter the re the higher the voltage produced; topping out
at 30 millivolts (DC) while the stove is burning on high. The function of the thermocouple is to sense the
temperature in the re pot; if the thermocouple is fractured, it will not produce voltage.

February 15, 2019 250-7690B 19
CASTILE INS
FUSE
T.C.
JUNCTION BOX
THERMOCOUPLE CIRCUIT
THERMOCOUPLE
BLOCK
THERMOCOUPLE
YELLOW
YELLOW
YELLOW
YELLOW
RED
RED
RED
RED
A / 1
B / 2
C / 3
D / 4
E / 5
F / 6
H / 7
J / 8
K / 9
L / 10
M / 11
N / 12
P / 13
R / 14
S / 15

February 15, 2019250-7690B20
CASTILE INS
10 Firebox Vacuum & Vacuum Switch
TECH TIP:
Low vacuum can be the result of a leaking
door gasket, re pot not closing all of the way,
dirty heat exchanger, or plugged vent system.
Always make sure the unit is clean before
making any repairs.
TURN ON THE
EXHAUST BLOWER
SYSTEM IS
REPAIRED
DOES THE VACUUM
SWITCH TOGGLE
FROM OPEN TO
CLOSED?
BAD GOOD
CHECK WIRE
CONNECTIONS &
VACUUM HOSE.
NO
DID THE
FIREBOX
VACUUM REACH
.2 INCHES OF
WATER COLUMN
OR HIGHER?
YES
NO
YES
CHECK DOOR
GASKETS, CLEAN
HEAT EXCHANGER &
COMPLETE EXHAUST
SYSTEM.
REPAIR WIRES OR
REPLACE THE WIRE
HARNESS
REPLACE THE
VACUUM SWITCH