Quadra-Fire CASTILEI-MBK User manual

1 7022-515B May 5, 2015
NOTICE: DO NOT DISCARD THIS MANUAL
CASTILE PELLET INSERT STOVE
Model(s):
CASTILEI-MBK
CASTILEI-PMH
CASTILEI-CSB
CASTILEI-CWL
O-T L
Tested and
Listed by Portland
Oregon USA
OMNI-Test Laboratories, Inc.
CUS
Owner’s Manual
Operation & Care
INSTALLER: Leave this manual with party responsible for use and operation.
OWNER: Retain this manual for future reference.
Contact your dealer with questions on installation, operation, or service.
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.
WARNING
If the information in these instruc-
tions is not followed exactly, a
fire could result causing property
damage, personal injury, or death.
• Do not store or use gasoline or other flam-
mable vapors and liquids in the vicinity of
this or any other appliance.
• Do not overfire - If heater or chimney con-
nector glows, you are overfiring. Overfiring
will void your warranty.
• Comply with all minimum clearances to
combustibles as specified. Failure to
comply may cause house fire.
WARNING
CAUTION
Tested and approved for wood pellets and corn pellets.
Burning of any other type of fuel voids your warranty.
NOTE
To obtain a French translation of this manual, please contact
your dealer or visit www.quadrafire.com
Pour obtenir une traduction française de ce manuel, s’il vous
plaît contacter votre revendeur ou visitez www.quadrafire.com
CAUTION
Check building codes prior to installation.
• Installation MUST comply with local, regional, state and na-
tional codes and regulations.
• Consult local building, fire officials or authorities having juris-
diction about restrictions, installation inspection, and permits.

2 7022-515B May 5, 2015
CASTILE INSERT
B. Sample of Serial Number / Safety Label
LOCATION: Riveted to appliance behind left side panel. Remove cast side and swing label forward
A
B
C
FE
Insert
Maximum Mantel Depth - 10 inches
Fascia or Trim
D
Masonry or Zero Clearance
A
B
C
D
E
F
Dégagement de la maçonnerie ou Dégagement zéro
16 in. 406mm
12 in. 305mm
4.75 in. 121mm
10 in. 254mm
6 in. 152mm
6 in. 152mm
MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS
AS A BUILT-IN UNIT
ESPACES LIBRES MINIMUM DES MATÉRIAUX COMBUSTIBLES:
G 2 in. (51mm)*
2.5 in. (64mm)**
H2 in. (51mm)
I4 in. (102mm)
J 3 in. (76mm)
COMME APPAREIL INSÉRÉ
0 in. Clearance To Exposed Section and Face Trim / Espace libre
de 0 mm de la section expos
é e et de la garniture du devant.
*Top Vent /
Des Conduits Du Haut
**Rear Vent /Des Conduits Arrières
Side Wall / Mur De Côté
Back Wall to Insert / Mur Arrière du
Insére
Back Wall to Flue Pipe / Mur ArrièreTuyau Rigide
NE PAS ENLEVER L'ÉTIQUETTE
DO NOT REMOVE THIS LABEL
Listed Solid Fuel Room Heater/Pellet Type Insert. “For Use with Solid Wood Fuel and Shelled
Field Corn Only”.
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.
PREVENT HOUSE FIRES
Install and use only in accordance with manufacturer's installation and operating instructions.
CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND
INSTALLATION INSPECTIONS IN YOUR AREA.
WARNING: FOR MOBILE HOMES: Do not install appliance in a sleeping room. An outside
combustion air inlet must be provided. The structural integrity of the mobile home floor, ceiling
and walls must be maintained.
Refer to manufacturer's instructions and local codes for precautions required for passing chimney
through a combustible wall or ceiling. Inspect and clean vent system frequently in accordance
with manufacturer's instructions.
DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING ANOTHER APPLIANCE.
Use a 3 or 4 inch (76-102mm) diameter type "L" or "PL" venting system.
Tested to: ASTM E1509-04, ULC S628-93, ULC/ORD-C1482-M1990 Room Heating Pellet
Burning Type, (UM) 84-HUD FOR USE
ONLY WITH PELLETIZED WOOD. DO NOT USEANY OTHER
TYPE OF FUEL.
OMNI-Test Laboratories, Inc. has determined that this appliance complies with
Canadian Standards Association (CSA) B415.1 and Title 40 of the U.S. Code of Federal
Regulations, Part 60, SubPart AAA.OMNI-Test Laboratories Accrediations: The Standards
Council of Canada, the American National Standards Institute, and the U.S. Environmental
ProtectionAgency.
Input Rating: 38,700 BTU/HR.
Electrical Rating:
115 VAC, 60 Hz, Start 4.1 Amps, Run 1.1Amps.
Route power cord away from unit. Do not route cord under or in front of appliance.
DANGER:
Risk of electrical shock. Disconnect power supply before servicing.
Replace glass only with 5mm ceramic available from your dealer.
To start, set thermostat above room temperature, the stove will light automatically. To shutdown,
set thermostat to below room temperature. For further instruction refer to owner's manual.
KEEP VIEWINGANDASH REMOVAL DOORS TIGHTLY CLOSED DURING OPERATION.
PRÉVENTION DES FEUX DE MAISON
I nstallez et utilisez en accord avec les instructions d'installation et d'opération du fabricant. CONTACT
BÂTIMENT LOCAL OU POUR CONNAÎTRE LES RESTRICTIONS ET INSPECTIONS INSTALLATION DANS
VOTRE RÉGION.
A VIS - Pour Les Maisons Mobiles: Ne pas installer dans une chambre à coucher. Un tuyau extérieur de
combustion d'air doit être installé et ne doit pas être obstrué lorsque l'appareil est en usage. La structure
intégrale du plancher, du plafond et des murs de la maison mobile doit être maintenue intacte.
Référez vous aux instructions du fabricant et des codes locaux pour les précautions requises pour passer une
cheminée à travers un mur ou un plafond combustibles, et les compensations maximums.
Inspectez et nettoyez la cheminée fréquemment.
Ne pas connecter cet appareil à une cheminée servant un autre appareil.
Utilitsez le syst
è me de ventilation de 3 or 4 inch (76-102mm) de diametre de type “L” ou “PL”.
Testé à: ASTM #1509-04, ULC S628-93, ULC/ORD-C1482-M1990 Room Heating. Pellet Burning Type, (UM)
84-HUD POUR USAGE AVEC LES BOULETTES DE BOIS.
OMNI-Test Laboratories, Inc. a déterminé que cet
appareil se conforme avec la norme de l’Association Canadienne de normalisation (CSA) B415.1 ainsi que le Titre 40 du
Code Fédéral de Régulations des États-Unis, partie 60, sous-partie AAA. Accréditations OMNI-Test Laboratories : Le
Conseil Canadien des Normes (CCN/SCC), l’Institue des Standards Nationaux Américain (ANSI) et l’Agence de Protection
Environnemental (EPA).
Puissance de Rendement: 38,700 BTU/HR
Puissance Électrique: 115 VAC, 60 Hz, Début 4.1Amps, Courir 1.1 Amps,
Éloignez le fil électrique de l'appareil. Ne pas faire passer le fil électrique au dessus ou en dessous de l'appareil.
DANGER: Il y a risque de décharge électrique. Déconnectez le fil électrique de la prise de contact avant le service.
Remplacez la vitre seulement avec une vitre céramique de 5 mm disponible chez votre fournisseur.
Pour allumer, monter la température du thermostat au dessus de la température de la pièce, le poêle s'allumera
automatiquement. Pour éteindre, descendre la température du thermostat en dessous de la température de la pièce.
Pour des instructions supplémentaires, référez vous au manuel du propriétaire. Gardez la porte d'ouverture et la porte
des cendres fermées hermétiquement durant l'opération.
Appareil de chauffage inséré de combustible solide/de type de boulettes. “Pour Usage Avec Bois Solide et
Champ de Maïs égrené Seulement”. Accepté dans l'installation dans les maisons mobiles. Cet appareil a
été testé et enregistré pour l
'usage dans les Maisons Mobiles en accord avec OAR 814-23-9000 jusqu'à
814-23-909.
7022-121E
Garniture
de façade
Mantel/Manteau
Sidewall / Mur Latéral
Insére
Profondeur Maximale Mantel - 254mm
*When constructing floor protection for your pellet appliance, any parts or
materials used, must be non-combustible.
* Lors de la construction de protection de sol pour votre appareil à
granules, toute pièces ou matériaux utilisés, doivent être incombustibles.
H
J
I
G
H
K
I
BARCODE LABEL
2015 2016 2017
JAN FEB MAR
APR MAY JUN
JUL AUG SEP
OCT NOV DEC
®
Castile Pellet Insert-B
SERIAL NO. / NUMÉRO DU S É RIE
007023
Made in U.S.A. of US and
imported parts.
Fabriqué par :
Manufactured by:
1445 North Highway, Colville, WA 99114
www.quadrafire.com
États-Unis-d’Amérique par des
pièces d’origine américaine et
pièces importées.
Report / Rapport
#061-S-77d-6.2
SAFETY LABEL / ÉTIQUETTE DE SÉCURITÉ
U.S. ENVIRONMENTAL PROTECTION AGENCY OMNI Test Laboratories, Inc., Portland, OR Report/Rapport 061-S-77d-6.2
U.S. ENVIRONMENTAL PROTECTIONAGENCY CERTIFIEDTO COMPLY WITH 2015 PARTICULATE EMISSIONS STANDARDS AT 1.8 G/HR EPAMETHOD 28AND 5G. NOT APPROVED FOR SALEAFTER MAY 15, 2020
THIS WOOD HEATER NEEDS PERIODIC INSPECTIONAND REPAIR FOR PROPER OPERATION. CONSULTTHE OWNER’S MANUAL FOR FURTHER INFORMATION. IT IS AGAINST FEDERALREGULATIONS TO OPERATE
THIS WOOD HEATER INA MANNER INCONSISTENT WITHTHE OPERATING INSTRUCTIONS IN THE OWNER’S MANUAL
Serial Number
Model
Test Lab &
Report No.
Mfg By Mfg Date
A. Congratulations
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.
This commitment begins with our research of the market,
including ‘Voice of the Customer’ contacts, ensuring we
make products that will satisfy your needs. Our Research
and Development facility then employs the world’s most
advanced technology to achieve the optimum opera-
tion of our stoves, inserts and fireplaces. And yet we are
old-fashioned when it comes to craftsmanship. Each unit
is meticulously fabricated and gold and nickel surfaces are
hand-finished for lasting beauty and enjoyment. Our pledge
to quality is completed as each model undergoes a quality
control inspection.
We wish you and your family many years of enjoyment in
the warmth and comfort of your hearth appliance. Thank
you for choosing Quadra-Fire.
NOTE: Clearances may only be reduced by means
approved by the regulatory authority having jurisdiction
and Welcome to the Quadra-Fire Family!

May 5, 2015 7022-515B 3
CASTILE INSERT
TABLE OF CONTENTS
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.
A. Congratulations..................................................................2
B. Sample of Serial Number / Safety Label............................2
C. Warranty Policy .................................................................4
1 Listing and Code Approvals ............. 6
A. Appliance Certification......................................................6
B. BTU & Efficiency Specifications........................................6
C. Glass Specifications.........................................................6
D. Electrical Rating................................................................6
E. Mobile Home Approved .................................................... 6
2 Operating Instructions ...................... 7
A. Fire Safety .........................................................................7
B. Non-Combustible Materials ...............................................7
C. Combustible Materials.......................................................7
D. Fuel Material and Fuel Storage........................................7
E. General Operating Information.........................................8
F. Before Your First Fire........................................................8
G. Clear Space......................................................................8
H. Starting Your First Fire .....................................................8
I. Fire Characteristics............................................................9
J. Feed Rate Adjustment Instructions ...................................9
K. Ignition Cycles ..................................................................9
L. Insert Removal..................................................................9
M. Ignition Cycles..................................................................9
N. Frequently Asked Questions.............................................10
3 Maintenance and Service.................11
A. Quick Reference Maintenance Chart................................11
B. General Maintenance and Cleaning.................................12
4 Troubleshooting Guide.................... 15
5 Service Parts Replacement............. 18
A. Blower Replacement..........................................................18
B. Baffle & Brick Replacement...............................................19
C. Re-installing Baffle & Brick Set..........................................19
D. Igniter Replacement ..........................................................21
E. Glass Replacement ...........................................................21
6 Reference Materials......................... 22
A. Component Functions .......................................................22
B. Component Locations........................................................24
C. Exploded Drawings............................................................25
D. Service Parts List...............................................................26

4 7022-515B May 5, 2015
CASTILE INSERT
Hearth & Home Technologies Inc.
LIMITED LIFETIME WARRANTY
H
earth & Home Technologies Inc., on behalf of its hearth brands (”HHT”), extends the following warranty for
H
HT gas, wood, pellet, coal and electric hearth appliances that are purchased from an HHT authorized dealer.
W
ARRANTY COVERAGE:
H
HT warrants to the original owner of the HHT appliance at the site of installation, and to any transferee taking ownership
o
f the appliance at the site of installation within two years following the date of original purchase, that the HHT appliance
w
ill be free from defects in materials and workmanship at the time of manufacture. After installation, if covered compo-
n
ents manufactured by HHT are found to be defective in materials or workmanship during the applicable warranty period,
H
HT will, at its option, repair or replace the covered components. HHT, at its own discretion, may fully discharge all of its
o
bligations under such warranties by replacing the product itself or refunding the verified purchase price of the product
i
tself. The maximum amount recoverable under this warranty is limited to the purchase price of the product. This warranty
i
s subject to conditions, exclusions and limitations as described below.
W
ARRANTY PERIOD:
W
arranty coverage begins on the date of original purchase. In the case of new home construction, warranty coverage
begins on the date of first occupancy of the dwelling or six months after the sale of the product by an independent,
a
uthorized HHT dealer/ distributor, whichever occurs earlier. The warranty shall commence no later than 24 months
f
ollowing the date of product shipment from HHT, regardless of the installation or occupancy date. The warranty period fo
r
parts and labor for covered components is produced in the following table.
T
he term “Limited Lifetime” in the table below is defined as: 20 years from the beginning date of warranty coverage for
g
as appliances, and 10 years from the beginning date of warranty coverage for wood, pellet, and coal appliances. These
t
ime periods reflect the minimum expected useful lives of the designated components under normal operating conditions.
See conditions, exclusions, and limitations on next page.
Parts Labor Gas Wood Pellet EPA
Wood Coal Electric Venting
XXXXXXX
All parts and material except as
covered by Conditions,
Exclusions, and Limitations
listed
XXX Igniters, electronic components,
and
g
lass
XXXXX Factor
y
-installed blowers
X Molded refractor
yp
anels
XFire
p
ots and burn
p
ots
5
y
ears 1
y
ear X X Castin
g
s and baffles
7 years 3 years X X X Manifold tubes,
HHT chimne
y
and termination
10
y
ears 1 year X Burners, logs and refractory
Limited
Lifetime 3yearsXXXXX Fireboxandheatexchanger
XXXXXXX All replacement parts
be
y
ond warrant
yp
eriod
Warranty Period HHT Manufactured Appliances and Venting
1 Year
Components Covered
3 years
2 years
90 Days
C. Warranty Policy

May 5, 2015 7022-515B 5
CASTILE INSERT
WARRANTY CONDITIONS:
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This warranty is void if:
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$#!!!!!
"
 %
 !
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!
LIMITATIONS OF LIABILITY:
 '*'!!*
!!!!!!
+8
*+!

;!<=<>$
<<=<?>@$KN<NOQRU!Z[<8?$<=>@<88U@@?<8$<@?<U@@?Q
8><\<N<@<?<N]@$?$\?QZ>R<NU@@?Q8RZ<N$N]@$?$\<
<=>@<88<NU@@?Q8><\<NO$K<
WARRANTY EXCLUSIONS:
^
 !
*
 N!!!!!!!
*
 @%
^!!"!"!!!!-

 Z*!!-

 N^_`q!!
!!;_{q
;_|q;_}q-
!!!!!!~
;_q!+!!
!"#!*
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6 7022-515B May 5, 2015
CASTILE INSERT
Model Castile Pellet Insert-B
Laboratory OMNI Test Laboratories, Inc.
Report No. 061-S-77d-6.2
Type Solid Fuel Room Heater/Pellet Fuel
Burning Type Insert
Standard ASTM E1509-2004, ULC S628-93 and
ULC/ORD-C1482-M1990 Room Heater
Pellet Fuel Burning Type and (UM) 84-
HUD, Mobile Home Approved
FCC Complies with Part 15 of FCC Rules.
Operation is subject to the following
two conditions: (1) this device may not
cause harmful interference, and (2) this
device must accept any interference
received, including interference that may
cause undesired operation.
1 Listing and Code Approvals
A. Appliance Certification
NOTE: Hearth & Home Technologies, manufacturer of
this appliance, reserves the right to alter its products, their
specifications and/or price without notice.
NOTE: This installation must conform with local codes. In
the absence of local codes you must comply with the ASTM
E1509-2004, ULC S628-93, ULC/ORD-C-1482-M1990,
(UM) 84-HUD
Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage.
For assistance or additional information, consult a qualified
installer, service agency or your dealer.
Quadra-Fire is a registered trademark of Hearth & Home
Technologies.
• 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.
• Operatingappliancewithout legs attached (ifsupplied with unit).
• Do NOT Overfire - If appliance or chimney connector glows,
you are overfiring.
Any such action that may cause a fire hazard.
WARNING
Fire Risk.
Hearth & Home Technologies disclaims any
responsibility for, and the warranty will be voided
by, the following actions:
B. BTU & Efficiency Specifications
C. Glass Specifications
This stove is equipped with 5mm ceramic glass. Replace
glass only with 5mm ceramic glass. Please contact your
dealer for replacement glass.
D. Electrical Rating
115 VAC, 60 Hz, Start 4.1Amps, Run 1.1 Amps
E. Mobile Home Approved
• This appliance is approved for mobile home installa-
tions when not installed in a sleeping room and when
an outside combustion air inlet is provided.
• The structural integrity of the mobile home floor, ceil-
ing, 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.
• Outside Air Kit, part OAK-ACC must be installed in a
mobile home installation.
TheQuadra-FireCastilePelletInsertmeetstheU.S.Environ-
mentalProtectionAgency’semission limits for pellet heaters
sold after May 15, 2015.
This pellet insert needs periodic inspection and repair for
proper operation. It is against federal regulations to operate
this pellet insert in a manner inconsistent with operating
instructions in this manual.
EPA Certification #: 940-14
EPA Certified Emissions: 1.8 grams per hour
*LHV Tested Efficiency: N/A
**HHV Tested Efficiency: N/A
***EPA BTU Output: 8,500 to 28,200 / hr.
****BTU Input: 11,600 to 38,700 / hr.
Vent Size: 3 or 4 inches, “L” or “PL”
Hopper Capacity: 45 lbs.
Fuel Wood Pellets
* Weighted average LHV efficiency using data collected during
EPA emissions test.
**Weighted average HHV efficiency using data collected during
EPA emissions test.
***A range of BTU outputs based on EPA Default Efficiency and
the burn rates from the low and high EPA tests.
****Based on the maximum feed rate per hour multiplied by
approximately 8600 BTU’s which is the average BTU’s from a
pound of pellets.

May 5, 2015 7022-515B 7
CASTILE INSERT
User Guide
2 Operating Instructions
A. Fire Safety
To provide reasonable fire safety, the following should be
given serious consideration:
• Installatleast one smoke detector andCOmonitoron each
floor of your home.
• Locatedetectors away from theheatingapplianceandclose
to the sleeping areas.
• Follow the detector’s 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:
• Evacuate the house immediately.
• Notify fire department.
B. Non-Combustible Materials
Material which will not ignite and burn, composed of any
combination of the following:
- Steel - Plaster - Glass - Tile
- Brick - Iron - Slate - Concrete
Materials reported as passing ASTM E 136, Standard
Test Method for Behavior of Metals, in a Vertical Tube
Furnace of 750° C.
C. Combustible Materials
Material made of/or surfaced with any of the following
materials:
- Compressed Paper - Wood - Plywood/OSB
- Sheet Rock (drywall) - Plastic - Plant Fibers
Any material that can ignite and burn: flame proofed or not,
plastered or un-plastered.
D. Fuel Material and Fuel Storage
Pellet fuel quality can greatly fluctuate. This appliance has
been designed to burn a wide variety of fuels, giving you the
choice to use the fuel that is most economical in your region.
Hearth& HomeTechnologiesstronglyrecommendsonly using
Pellet Fuel Institute (PFI) certified fuel.
Fuel Material
• Made from sawdust or wood by-products
• Shelled field corn & other biomass fuels
• Depending on the source material it may have a high or
low ash content.
Higher Ash Content Material
• Hardwoods with a high mineral content
• Fuel that contains bark
• Standard grade pellets, high ash pellets, corn and other
biomass fuels
Lower Ash Content Material
• Softwoods
• Fuels with low mineral content
• Premium grade pellets
Shelled Field Corn
• Must be 15% or less moisture content.
• Must be clean and free from debris
• Never burn corn straight from the field
• Stalkparts,excessivefinesandcob remnants, etc. will clog
the auger mechanism
• Cornwith excessive graindust must bescreenedby sifting
with 3/16 inch (4.7mm) mesh screening
WARNING
Fire Risk.
• Do not operate appliance before reading and
understanding operating instructions.
• Failure to operate appliance properly may cause a
house fire.
Clinkers
Minerals and other non-combustible materials such as sand
willturnintoahard,glass-likesubstancecalleda clinker when
heated in the firepot.
Trees from different areas will vary in mineral content. That
is why some fuels produce more clinkers than others.
Moisture
Alwaysburn dry fuel. Burningfuel with highmoisture 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.
CAUTION
Do not burn fuel that contains an additive; (such as
soybean oil).
• May cause hopper fires
• Damage to product may result
Read the ingredients list on the package. If you are buying
corn the only ingredient that should be listed is corn.
WARNING
Risk of Chemical Poisoning!
Do NOT burn treated seed corn
• Chemical pesticides are harmful or fatal if swallowed
• Burning treated seed corn will void your warranty

8 7022-515B May 5, 2015
CASTILE INSERT
High
Med
Low
Reset
Button
E. General Operating Information
1. Thermostat Calls For Heat
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 right
access panel.
2. Heat Output Controls
This appliance is equipped with a heat output control switch
that has three settings or burn rates; low, medium and high.
Figure 8.1.
Theappliancewillturn on and off as the thermostatdemands.
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.
Figure 8.1
G. Clear Space
Mantel: Avoid placing candles and other heat-sensitive objects
on mantel or hearth. Heat may damage these objects.
NOTICE: Clearances may only be reduced by means approved
by the regulatory authority having jurisdiction.
CAUTION
Tip of thermocouple must be in contact with the inside
end of the thermocouple cover.
Missed ignitions can occur.
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.
• NEVER USE GASOLINE, GASOLINE-TYPE LANTERN
FUEL, KEROSENE, CHARCOAL LIGHTER FLUID, OR
SIMILAR LIQUIDS TO START OR “FRESHEN UP” A FIRE
IN THIS HEATER. KEEPALL SUCH LIQUIDS WELLAWAY
FROM THE HEATER WHILE IT IS IN USE.
• DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS
SUCH AS GASOLINE, NAPHTHA OR ENGINE OIL.
• DO NOT USE CHEMICALS OF FLUIDS TO START THE
FIRE.
• Combustible materials may ignite.
H. 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
minuteseventhoughthethermostatisnotcallingforheat.
This is normal.
3. Locate the heat output control switch on the lower right
sideofthefireboxbehinddecorativefront door. Set tothe
HIGHsettingand then adjust the thermostattoitshighest
setting. The red call light will be on which is located on
the top of the junction box behind the right access panel.
This indicates the thermostat is calling for heat. Figure
24.3.
4. The fuel feed system and the igniter should now be on.
5. For your first fire it will be necessary to press the reset
button once per 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
F. Before Your First Fire
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.
2. Double check that the ash drawer and firebox are empty!
3. Close the front door.

May 5, 2015 7022-515B 9
CASTILE INSERT
WARNING
Fire Risk.
• High ask fuels, or lack of maintenance, can
cause the firepot to fill with ash and clinker. If the
firepot fills to the top, immediately shut down the
appliance and clean.
• Failure to do so could result in smoking, sooting
and possible hoper fires.
I. Fire Characteristics
A properly adjusted fire with the heat output control button
set on “HIGH” has a short active flame pattern that extends
out of the firepot approximately 4 inches (102mm). If the fire
hastall flames with blacktails and seems somewhatlazy,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.
J. Feed Rate Adjustment Instructions
The feed adjustment control rod is factory set, and should be
adequate for most fuels. T he control rod will slide by only
loosening the wing screw.
However, if the flame height is too high or too low, you will
needto adjust the feedrate. Waituntil the appliancehasbeen
burning for 15 minutes before making your adjustments and
a llow 15 minutes for feed adjustment to take effect. Make
adjustments in approximately 1/2 inch increments.
1. Loosen the wing screw.
2. Adjustthe fuel adjustment controlrodtowards to the right
and up to increase the feed rate and flame height or to
the left and down to decrease the feed rate and flame
height.
3. Re-tighten the wing screw.
K. Ignition Cycles
1. Duringeachignition cycle, it is normal toseesomesmoke
in the firebox. The smoke will stop once the fire starts.
2. Theconvectionblower 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. Torestartit,fillthehopper and press the reset button.
When you press the reset button the red call light will go
out. Release the button and the light will come back on.
Youshouldseeafireshortly. Ifnot,followtheinstructions
on page 8, “Starting Your First Fire”.
L. Insert Removal
In the case that service or inspection is required the unit may
need to be removed from the wall.
1. Unit must be unplugged before removal of unit is possible.
Unplug the unit from its power source.
2. Remove insert surround from unit, to ease the process of
removal.
3. Unclip the exhaust transition from the exhaust outlet in the
back of the unit. This is what connects the venting to the unit.
Removal of the clips will allow you to remove the unit from the
wall without damaging or adjusting the venting.
4. Slideunit from thewall and rotateeither directionasneeded.
M. Ignition Cycles
1. At the beginning of each ignition cycle, it is normal to see
some smoke in the firebox. The smoke will stop once
the fire starts.
2. Theconvectionblower 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. See Figure 24.3 on page 24.
To restart it, fill the hopper and press the reset button.
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 18, “Starting Your
First Fire”.
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.
pellets. The appliance will continue to run as long as the
thermostat is calling for heat.
6. Oncetheappliancehasignited,letitburn forapproximately
15 minutes, then set the thermostat to the desired room
temperature. Adjust the heat output control switch to the
desired setting.
NOTE: 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. If the appliance is
running all of the time, 100% corn will work after the fire has
been started using wood pellets.

10 7022-515B May 5, 2015
CASTILE INSERT
Odors and vapors released during initial operation.
• Curing of high temperature paint.
• Open windows for air circulation.
Odors may be irritating to sensitive individuals.
CAUTION
N. 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 pro-
duced by a furnace or heating duct. This noise does not
affect the operation or longevity of your appliance.
2. Ash build-up on glass 2. This is normal. Clean the glass.
3. 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 clean-
ing of the glass is required.
4. Fire has tall flames with black tails and is lazy 4. The flame height adjustment needs to be reduced or
the firepot needs cleaning. Heat exchanger or exhaust
blower needs cleaning.
5. Excessive smoky start-up 5. Either the firepot is dirty or there is too much fuel at
start-up and not enough air.
6. Large flame at start-up 6. This is normal. Flame will settle down once the fire is
established. Some smoke is normal.
7. Mechanical Noise 7. The floor of the firepot in the auto-clean system may
make some noise as it scrapes the ash into the ash
pan.
CONTACT YOUR DEALER for additional information regarding operation and troubleshooting.
Visit www.quadrafire.com to find a dealer.

May 5, 2015 7022-515B 11
CASTILE INSERT
This pellet insert has a manufacturer-set minimum low burn
rate that must not be altered. It is against federal regulations
toalter this settingor otherwise operatethis pellet heater ina
mannerinconsistent with operatinginstructionsinthis manual.
3 Maintenance and Service
When properly maintained, your fireplace will give you
many years of trouble-free service. Contact your dealer to
answer question regarding proper operation, troubleshoot-
ing and service for your appliance. Visit www.quadrafire.
com to find a dealer. We recommend annual service by a
qualified service technician.
A. Quick Reference Maintenance Chart
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.
Cleaning or Inspection Frequency Daily Weekly Every 2
Weeks Monthly Yearly
Ash Pan - Burning Wood Pellets Every 5 bags of fuel OR X
Ash Pan - Burning Alternate Fuels Every 1 bag of fuel OR X
Ash Removal from Firebox More frequently depending on the
fuel type or ash build-up OR X
Auto-Clean Inspection More frequently depending on the
fuel type OR X
Blower, Combustion (Exhaust) More frequently depending on the
fuel type OR X
Blower, Convection More frequently depending on the
operating environment OR X
Door Latch Inspection Prior to heating season OR X
Firebox - Prepare for Non-Burn Season At end of heating season OR X
Firepot - Burning Softwood Pellets Every 5 bags OR X
Firepot - Burning Hardwood Pellets Every 3 bags OR X
Firepot - Burning Alternate Fuels Every 1 bag OR X
Glass When clear view of firepot
becomes obscured OR X
Heat Exchanger & Drop Tube Every 1 ton of fuel OR X
Hopper Every 1 ton of fuel or when chang-
ing fuel types OR X
Venting System More frequently depending on the
fuel type OR X
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.
CAUTION

12 7022-515B May 5, 2015
CASTILE INSERT
Clinker
Figure 12.1
3. Ash Removal from Firebox
• 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.
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 immediately 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.
B. General Maintenance and Cleaning
1. Types of Fuel
Dependingon the type of fuelyouare burning will dictatehow
often you have to clean your firepot.
Ifthefuel you are burning hasahighdirt or ash content oryou
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. Aclinker is
formed when dirt, ash or a non-burnable substance is heated
to 2000F (1093C) and becomes glass-like. See page 14 in
this section for more details on fuels with high ash content.
2. Cleaning Firepot with Cleaning Rod & Firepot
Clean-Out Tool
• Frequency: Daily or more often as needed
• By: Homeowner
a. The appliance must be in complete shutdown and
cool and the exhaust blower off. NOTE: If you are
just cleaning the firepot, there is no need to unplug the
insert.
b. Pull firepot cleaning rod OUT and IN a couple of times
to help shake debris loose. See page 23.
If rod is hard to pull, it may be necessary to use your
firepotclean-out tool to chipaway material that hasbuilt
uponthebottomplateof the firepot and to push out any
clinkers. Largerclinkers may have tobe removed from
the top of the firepot. Corn clinkers can be especially
difficult to break up.
c. The firepot floor plate must be fully closed when
finished.
WARNING
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.
WARNING
Fire Risk
NEVER pull firepot cleaning rods or cleaning slide
plates when appliance is operating. Hot pellets may
fall into ashpan and may start a fire or have mis-starts
due to lack of vacuum.
WARNING
Fire Risk.
The cleaning slide plates must be fully CLOSED when
appliance is operating. Hot pellets may fall into ash
pan and start a fire.
c. Open door. There are 2 cleaning slide plates to the
left and right of the firepot with finger holes. Pull both
slide plates out and sweep the remaining ash from the
firebox into the 2 open holes. A paint brush works well
for this. Close slide plates.
d. This ash is deposited in the same ash drawer as the
firepotdebris.Theashdrawershouldbeemptiedevery
timeyoucleanthefirebox. Remembertoplacethe ash
and debris into a metal or non-combustible container.
e. The 2 cleaning slide plates must be fully closed when
cleaning is complete.
4. Cleaning Ash Drawer
• Frequency: Weekly or every 5 bags of fuel
• By: Homeowner
Locate the ash drawer underneath the firepot and
slide the ash drawer straight out. Empty into a non-
combustible container and re-install ash drawer.
5. Disposal of Ashes
• Frequency: As needed
• By: Homeowner
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.
Ifthe ashes aredisposed of by burialin soil or otherwise
locally dispersed, they should be retained in the
closed container until all cinders have been thoroughly
cooled.

May 5, 2015 7022-515B 13
CASTILE INSERT
Figure 13.1
WARNING
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.
Push cleaning rods IN when done, DO NOT
leave cleaning rods OUT. Injury can occur.
Cleaning Rods
10 Heat Exchanger Tubes
6. Cleaning Heat Exchanger Chambers
• Frequency: Weekly or every 1 ton of fuel
• By: Homeowner
T he amount of ash buildup in the firebox will be a good guide
to determine how often you should clean the heat exchang-
ers.
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.
b. Locatethe2exposedrodsdirectly underneath the heat
exchanger tubes. Figure 13.1.
c. To clean, pull the rods straight out until it stops,
approximately 8 inches (203mm). Slide the rods OUT
and IN a couple of times.
7. Cleaning Beneath Heat Exchanger
• Frequency: Monthly or every 1 ton of fuel
• By: Homeowner
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. The ash will be resting on the
back of the baffle.
This will require removing the baffle and cast brick set.
Please refer to pages 19 for a detailed explanation of remov-
ing the baffle and brick set.
NOTE:There are heavyduty vacuum cleanersspecifically
designed for solid fuel appliance cleaning.
8. Cleaning the Glass
• Frequency: When clear view of the firepot is obscure
• By: Homeowner
a. Appliance must be completely cool before cleaning
glass.
b. Use a damp paper towel or any non-abrasive glass
cleaner. Wipe off with dry towel.
9. Door Latch Inspection
• Frequency: Prior to heating season
• By: Homeowner
The door latch is non-adjustable but the gasketing between
theglassand fireboxshouldbeinspectedperiodicallytomake
sure there is a good seal.
NOTE: There is no gasket on the bottom of glass.
10. Cleaning the Hopper
• Frequency: Monthly or every 1 ton of fuel
• By: Homeowner
After burning approximately 1 ton of fuel you will need to
clean the hopper to prevent sawdust build-up. A combina-
tion of sawdust and pellets on the auger reduces the amount
of fuel supply to the firepot. This can result in nuisance shut-
downs and mis-starts.
1. The appliance must be in complete shutdown. Allow the
appliance to completely cool down.
2 Empty the hopper of any remaining pellets.
3. Vacuum the hopper and feed tube.
Handle glass assembly with care.
When cleaning glass:
• Avoid striking, scratching or slamming glass.
• Do NOT clean glass when hot.
• Do NOT use abrasive cleaners.
CAUTION
• Use a hard water deposit glass cleaner on white film.
• Refer to maintenance instructions.
Glass
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.
WARNING
• Do NOT operate with glass cracked, broken or scratched.
Glass

14 7022-515B May 5, 2015
CASTILE INSERT
11. Cleaning Exhaust Blower - Requires No Lubrication
• Frequency: Yearly or as needed
• By: Quality Service Technician/Homeowner
a. Remove left & right brick. The exhaust blower path is
behind the right brick. Vacuum this area thoroughly.
See page 19 for removing bricks. Re-install bricks
when done.
12. Cleaning Convection Blower - Requires No
Lubrication
• Frequency: Yearly or as needed
• By: Qualified Service Technician
• Task: Contact your local dealer.
13. 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
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 combus-
tion, 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
to determine if cleaning is necessary.
The venting system may need to be cleaned at least once a
year or more often depending upon the quality of your fuel or
if there is a lot of horizontal pipe sections. Ash will build up
more quickly in the horizontal sections.
14. Preparing Firebox for Non-Burn Season
• Frequency: At the end of the heating season
• 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.
• UsetheTouch-Uppaintsuppliedwiththeappliance;
or,
• Purchase paint from your local dealer.
• Must use a high-temperature paint made specifi-
cally for heating appliances.
C. High Ash Fuel Content Maintenance
• 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 14.1 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 14.2.
The correct flame size when good quality, premium pellet
fuel is burned is shown in Figure 14.3.
If the ash buildup exceeds the half way point in the firepot
IMMEDIATE ATTENTION AND CLEANING IS REQUIRED.
Ash Build Up in Firebox
Pellets Back Up
In Feed Tube
Firepot Overfills
Tall, Lazy Flame, Orange in Color
Incorrect
Correct Flame Size, Yellow/White in Color
Correct
Figure 14.1
Figure 14.2
Figure 14.3
WARNING
- High ash fuels, or lack of maintenance, can
cause the firepot to overfill. Follow proper shutdown
procedure if ash build up exceeds half way point.
- Failure to do so could result in smoking, sooting and
possible hopper fires.
Fire Risk.

May 5, 2015 7022-515B 15
CASTILE INSERT
With proper installation, operation, and maintenance your appliance will provide years of trouble-free service. If you do experience a prob-
lem, 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.
4 Troubleshooting Guide
Symptom Possible Cause Corrective Action
Plug in appliance - No
response. No current to outlet.
7 amp fuse defective.
#3 snap disc tripped or defective.
Control box defective.
Check circuit breaker at service panel.
Replace fuse.
Reset or replace snap disc.
Replace control box.
Call light on. No fire.
No fuel in firepot. Out of fuel.
#2 snap disc may be defective.
Vacuum switch not closing, no vacuum.
Control box defective.
Check hopper. Fill with fuel.
Replace snap disc.
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.
Replace control box.
Call light on. No fire.
Partially burned fuel in
firepot.
Firepot clean-out plate not closed.
Firepot is dirty (missed ignition).
Check that firepot clean-out plate is fully
closed.
Clean firepot. Make sure there is no clinker
in the firepot. See page 12.
Clinkers may have to be broken up with
firepot clean-out tool or other means.
Call light on. No fire.
Unburned pellets in
firepot.
Firepot clean-out plate not closed.
Firepot is dirty.
The ignition hole between the igniter bracket
and firepot is blocked.
Igniter not working.
Control box defective.
Check that firepot clean-out plate is fully
closed.
Clean firepot. Make sure there is not a
clinker in the firepot. Clinkers may have to
be pushed out of firepot with firepot clean-
out tool or other means.
Scrape with solid piece of wire or firepot
tool.
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.
Replace control box.
Slow or smoky start-up. Firepot clean-out plate not closed.
Firepot is dirty.
Excessive amount of fuel at start-up.
Check that firepot clean-out is fully closed.
Clean firepot. Make sure there is not a
clinker in the firepot. Clinkers may have to
pushed out of firepot with firepot clean-out
tool or other means.
Reduce feed rate using feed rate adjust-
ment control rod located inside hopper.

16 7022-515B May 5, 2015
CASTILE 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.
#2 snap disc may be defective.
Vacuum switch not closing. No vacuum.
Feed system jammed or blocked.
Feed spring not turning with feed motor.
Feed motor defective or not plugged in.
Check hopper, fill with fuel.
Replace snap disc.
Firebox door must be closed securely.
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.
NOTE: High winds blowing into the
venting system can pressurize the firebox
causing loss of vacuum.
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.
Check that set screw is tight on feed
spring shaft at end of feed motor.
Check connections on feed motor, replace
if defective.
No call light. Appliance
does not begin start
sequence.
Thermostat not set to a high enough tempera-
ture.
Snap Disc #3 tripped.
No power.
Fuse blown.
Connections at thermostat and/or appliance not
making proper contact.
Defective thermostat or thermostat wiring.
Control box defective.
Adjust thermostat above room tempera-
ture.
Reset snap disc.
Connect to power.
Replace fuse.
Check connections at thermostat and
appliance.
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.
Replace control box.
Appliance fails to shut
off. 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.

May 5, 2015 7022-515B 17
CASTILE INSERT
Symptom Possible Cause Corrective Action
Convection blower fails to
start. #1 snap disc defective.
Blower not plugged in.
Blower is defective.
Control box is defective.
Replace snap disc.
Check that blower is plugged into wire har-
ness.
Replace blower.
Replace control box.
Exhaust blower fails to
start or does not shut off. Blower not plugged in.
Blower is clogged with ash.
Blower is defective.
Control box is defective.
Check that blower is plugged into wire har-
ness.
Clean exhaust system.
Replace blower.
Replace control box.
Large, lazy flame, orange
color. Black ash on glass. Dirty appliance. Poor fuel quality, high ash content.
Firepot clean-out plate not completely
closed.
Excessive amount of fuel.
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 pre-
mium.
Check that firepot clean-out plate is fully
closed.
Reduce feed rate using feed rate adjustment
control rod located inside hopper.
Nuisance shutdowns. Low flame.
Sawdust buildup in hopper.
Feed motor is reversing.
Defective thermocouple.
Defective control box
Firepot more than 1/2 full
Increase feed by opening feed rate adjust-
ment control rod located inside hopper.
Clean hopper, see page 13.
Check for good connections between feed
motor and wire harness.
Replace thermocouple.
Replace control box.
See page 14 for detailed instructions for
“High Ash Fuel Content Maintenance”
Appliance calls for heat.
Call light illuminates.
Exhaust blower starts.
No feed or igniter.
Thermocouple is defective or not properly
plugged in.
Defective control box
Check connections on thermocouple or
replace if defective.
A flashing yellow light on the control box
indicates a problem with the thermocouple.
Replace control box.
Hopper lid not closed all
the way Switch or magnet is out of adjustment (auger will not function) Close the lid. If that doesn’t work, adjust or replace the switch or magnet

18 7022-515B May 5, 2015
CASTILE INSERT
5 Service Parts Replacement
2. Convection Blower Replacement
a. The blower is located at the bottom rear of the insert.
If an outside air kit is also installed, you will first need
to remove the outside air flange by removing the 2
screws using a Phillips head screwdriver. You do not
need to remove the flex pipe from the flange.
b. If you have adequate clearance you will not have to
remove the panel set and disconnect flue, if not then
you will have to remove the panel set and disconnect
the flue.
c. Pull appliance out onto the hearth.
d. Remove left cast side.
e. Disconnect the wires from the blower. The wires
comingfrom the wiring harnessarepurple & whiteand
the wires from the blower are black.
f. The blower is held in place with a wing screw.
g. Re-install in reverse order.
A. Blower Replacement
1. Combustion (Exhaust) Blower Replacement
a. If you have adequate clearance you will not have to
remove the panel set and disconnect flue, if not then
you will have to remove the panel set and disconnect
the flue.
b. Pull appliance out onto the hearth.
c. Remove right cast side.
d. Disconnect the white and blue wires from the blower.
e. Remove blower mounting screws (not housing bolts),
Figure 18.1, from blower housing and remove blower.
The replacement blower is shipped with a housing. If
youdo not need thehousing, discard it. If youdo need
tothereplace the housing youwillalsoneed to replace
thegasket. SeeServiceParts List for the part number.
f. Re-install in reverse order.
Figure 18.1
Housing Bolts
(Do Not Remove)
Blower
Screws

May 5, 2015 7022-515B 19
CASTILE INSERT
Brick is flush against back wall
Notches
exposed
C. Re-installing Baffle & Brick Set
1. Place right brick in behind the right bracket, and then
slide to the left so the tabs are behind the center brick.
Figure 19.4.
2.
The brick will be flush against the back wall and notches
exposed in the side bracket. Figure 19.5.
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
19.1 and 19.2.
4. Repeat for left brick.
5. Insert baffle into top front inside the firebox and pull for-
ward. Then raise up the bottom end and insert baffle tab
into slot on the top of the right bracket to lock into place.
Figure 19.3. Place the left side hook at the bottom of the
baffle over the top edge of brick for stability. Figure 19.4.
6. The baffle does not completely cover the top of the firebox.
There is an opening on the left as shown in Figure 19.5.
Tabs
Figure 19.4
Figure 19.5
B. Baffle & Brick Replacement
1. Follow proper shutdown procedures in Section 10.
2. 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 19.1.
3 . The top baffle must be removed before you can remove
the right and left brick. Remove the right brick by hold-
ing 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 19.2.
Remove Right
& Left Brick
Hookon
left side Tab on
right side
Vacuum
Exhaust Area
Right Brick
Removed
Figure 19.1
Figure 19.2
Figure 19.3

20 7022-515B May 5, 2015
CASTILE INSERT
Figure 20.2
Figure 20.3
Figure 20.4
Lift brick, pull forward at an angle
and drop down into notches
Figure 20.1
Re-installing Baffle & Brick Set (Cont’d)