Quadra-Fire CLASSIC BAY 1200 User manual

1445 N. Highway
Colville, Wa 99114
www.quadrare.com
www.quaddealer.com
#250-7700 February 12, 2003
CB1200 INSERT PELLET STOVE
SERVICE MANUAL
R

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
TABLE OF CONTENTS
SECTION PAGE
TROUBLE-SHOOTING SYMPTOMS
FEED MOTOR TROUBLE-SHOOTING
IGNITER TROUBLE-SHOOTING
EXHAUST BLOWER TROUBLE-SHOOTING
CONVECTION BLOWER TROUBLE-SHOOTING
POWER SUPPLY TROUBLE-SHOOTING
THERMOSTAT TROUBLESHOOTING
THERMOCOUPLE TESTING
FIREPOT & EXHAUST SYSTEM TROUBLE-SHOOTING
EXPLODED VIEW
WIRE DIAGRAM
DIMENSIONS & SPECS
CHECK-OFF SHEET
CLEANING & MAINTENANCE TIPS
SERVICE TOOLS
3-5
6-7
8-9
10-11
12-13
14-15
16-17
18
19-21
22-23
24
25
26
27-28
29
7-31-2002 PAGE 2 250-7700

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
TROUBLE SHOOTING & REPAIR
A. PLUG IN STOVE -- NO RESPONSE
1) CHECK THE POWER SUPPLY FOR 115 VOLTS
2) CHECK THE FUSE IN THE JUNCTION BOX (7 AMP)
3) CHECK SNAP DISC #3 FOR POWER
4) CHECK CONTROL BOX
B. CALL LIGHT ON -- NO FIRE -- NO FUEL IN FIREPOT
1) CHECK HOPPER FOR BRIDGING OF PELLETS
2) PUSH RESET BUTTON & ADJUST FEED ADJUSTMENT PLATE
3) CHECK THERMOCOUPLE
4) CHECK VENTING SYSTEM FOR OBSTRUCTIONS
5) CHECK VACUUM SWITCH AND VACUUM HOSE
6) CHECK FEED MOTOR
7) CHECK EXHAUST BLOWER
C. CALL LIGHT ON -- NO FIRE -- PARTIALLY BURNED FUEL IN POT
1) CHECK FIREPOT AND CLEAN
2) CHECK THERMOCOUPLE
*GREEN LIGHT-----2.5 mV (+.5mV)
*RED LIGHT---------12.1 mV (+ 1mV)
3) CHECK INITIAL FEED TIME (1 MINUTE 35 SECONDS)
D. CALL LIGHT ON -- NO FIRE -- FUEL IN FIREPOT
1) CHECK FIREPOT FOR “CLINKER” MATERIAL
2) CLEAN FIREPOT
3) CHECK IGNITER
4) CHECK CONTROL BOX
7-31-2002 PAGE 3 250-7700

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
E. SLOW OR SMOKEY START UP
1) CLEAN FIREPOT
2) FEED ADJUSTMENT PLATE MAY BE SET TOO HIGH
3) CHECK EXHAUST BLOWER AND HEAT EXCHANGER
4) MAKE SURE TRAP DOOR UNDER FIREPOT IS CLOSED
TROUBLE SHOOTING & REPAIR
G. FEED SYSTEM FAILS TO START
1) CHECK FRONT DOOR AND MAKE SURE IT IS CLOSED
2) CHECK TO SEE IF CALL LIGHT IS ON
3) CHECK THERMOSTAT
4) CHECK FEED MOTOR AND VACUUM SWITCH
5) CHECK EXHAUST SYSTEM FOR OBSTRUCTIONS
H. THERMOSTAT WILL NOT START UNIT
1) CHECK THERMOSTAT WIRES FOR CONTINUITY
2) CHECK THE “ACCESSORY JUMPER WIRE” ON THE J-BOX
3) CHECK #2 SNAP DISC
4) CHECK THE RESET BUTTON
5) CHECK FOR POWER TO THE STOVE
6) CHECK CONTROL BOX
F. STOVE RUNS FOR 10 MINUTES -- THEN STOPS FEEDING FUEL
1) CHECK THERMOCOUPLE
*GREEN LIGHT-------2.5 mVDC ( +.5mV)
*RED LIGHT-----------12.1 mVDC (+ 1mV)
2) ADJUST FEED ADJUSTMENT PLATE FOR LARGER FIRE
3) CHECK THERMOCOUPLE COVER
*COVER NEEDS TO TOUCH THE END OF THE T-COUPLE WIRE
*COVER SHOULD EXTEND 1 3/4” INTO FIREPOT
4) CHECK CONTROL BOX
7-31-2002 PAGE 4 250-7700

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
I. UNIT FAILS TO SHUT OFF
1) CHECK THERMOSTAT AND THERMOSTAT WIRE
2) CHECK THE JUNCTION BOX & WIRE HARNESS
3) CHECK THE CONTROL BOX
TROUBLE SHOOTING & REPAIR
J. CONVECTION BLOWER KEEPS RUNNING OR FAILS TO START
1) CHECK #1 SNAP DISC
2) CHECK CONVECTION BLOWER
3) CHECK FOR VOLTAGE TO THE #1 SNAP DISC
K. STOVE CYCLES ON AND OFF -- THERMOSTAT ALWAYS ON
1) CHECK #1 SNAP DISC (CONVECTION BLOWER)
2) IF #1 SNAP DISC FAILS THEN #2 SNAP DISC WILL TRIP
*AFTER THE #2 SNAP DISC COOLS DOWN IT WILL TURN THE
THERMOSTAT BACK ON (CALL LIGHT)
3) CHECK WIRING FOR LOOSE CONNECTIONS
L. LARGE FIRE, ASH BUILD UP & DIRTY GLASS
1) CHECK FIREPOT, MAY NEED TO BE CLEANED
2) CLEAN EXHAUST AND HEAT EXCHANGER SYSTEM
3) ADJUST FEED ADJUSTMENT PLATE IN THE HOPPER
4) CHECK CONTROL BOX FEED TIMES
*HIGH ------- (7.5 SECOND ON TIME)
*MEDIUM -- (6 SECOND ON TIME)
*LOW --------(4.7 SECOND ON TIME)
M. STOVE IGNITES -- GOES OUT -- CALL LIGHT STILL ON
“ STOVE IS INCONSISTANT IN OPERATION “
1) INSPECT THERMOCOUPLE AND ITS POSITION OVER THE POT
2) CHECK THE FEED MOTOR
3) ADJUST FEED ADJUSTMENT PLATE FOR A LARGER FIRE
4) CHECK THE EXHAUST AND HEAT EXCHANGER SYSTEM
5) CHECK THE VACUUM SWITCH
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CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
FEED MOTOR TROUBLE-SHOOTING
1) TURN ON THERMOSTAT CIRCUIT AND MAKE SURE THAT THE CALL LIGHT IS ON.
2) CHECK FOR POWER AT THE VACUUM SWITCH:
A. IF NO POWER FROM RED WIRE-----CHECK CONTROL BOX OR WIRE HARNESS
B. POWER ON RED BUT NO POWER ON ORANGE-----CHECK VACUUM SWITCH OR VENT SYSTEM
3) CHECK FOR POWER AT THE RED WIRE FROM THE CAPACITOR:
A. IF NO POWER FROM RED WIRE----CHECK WIRE HARNESS OR CONNECTOR PIN
B. IF POWER IS PRESENT-----REPLACE FEED MOTOR OR CHECK CONNECTOR PIN
NOTE: REMEMBER THAT THE FEED CIRCUIT INITIAL FEED TIME IS 1:35. PUSH THE RESET
BUTTON BEFORE EACH TEST.
2-12-2003 PAGE 6 250-7700
FEED MOTOR
VACUUM
SWITCH
JUNCTION BOX
FEED MOTOR CIRCUIT
CAPACITOR WHITE
RED/WHITE
RED
NOTE: CAPACITOR IS LOCATED IN THE JUNCTION BOX
ACCY
JUMPER
1
3
4
5
6
2
WHITE WHITE
BLACK
RED
RED
WHITE
ORANGE
RED
CAPACITOR JUMPER
WIRE. PART# 230-2150
JUMPER IS NEEDED IF
CAPACITOR IN J-BOX
IS BAD OR IF THE
MOTOR NEEDS TO BE
TESTED WITH A TEST
CORD.
*
*Color will be black for SN 505324 & above.

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
FEED MOTOR TESTING
USING THE TEST BOX:
1) UNPLUG THE STOVE, REMOVE THE CONTROL BOX, INSTALL TEST BOX & PLUG IN STOVE
2) TURN ON THE EXHAUST BLOWER SWITCH. (THIS WILL PULL THE VACUUM SWITCH IN)
4) TURN ON THE FEED MOTOR SWITCH.
IF THE FEED DOESN’T COME ON: BAD FEED MOTOR, VACUUM SWITCH, OR WIRE HARNESS
IF THE FEED COMES ON: REPLACE CONTROL BOX
USING THE COMPONENT TEST CORD:
1) UNPLUG THE FEED MOTOR FROM THE WIRE HARNESS
2) INSTALL THE FEED MOTOR ADAPTER ON THE TEST CORD.
NOTE: THE NEW STYLE FEED MOTOR WILL NEED THE CAPACITOR JUMPER ADDED TO THE ADAPTER.
3) PLUG IN THE TEST CORD TO THE FEED MOTOR AND TURN ON THE SWITCH.
TEST BOX (AS IT IS INSTALLED IN THE STOVE)
3) TURN ON THE THERMOSTAT (THE THERMOSTAT INDICATOR LIGHT SHOULD COME ON)
THERMOSTAT LIGHT
FEED MOTOR SWITCH
EXHAUST BLOWER SWITCH
TEST CORD w/ ADAPTERS CAPACITOR JUMPER WIRE
7-31-2002 PAGE 7 250-7700

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
IGNITER TROUBLE-SHOOTING
IGNITER
JUNCTION BOX
IGNITER CIRCUIT
TAN (HT)
TAN (HT)
ACCY
JUMPER
1
3
4
5
6
2
1) TURN ON THE THERMOSTAT CIRCUIT AND MAKE SURE THE CALL LIGHT IS ON.
B. IF POWER IS PRESENT-----REPLACE THE IGNITER
A. IF NO POWER------CHECK THE WIRE HARNESS OR REPLACE THE CONTROL BOX
2) CHECK FOR POWER AT THE IGNITER:
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CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
IGNITER TESTING
USING THE TEST BOX:
1) UNPLUG THE STOVE, REMOVE THE CONTROL BOX, INSTALL THE TEST BOX & PLUG IN THE STOVE.
2) TURN ON THE THERMOSTAT. (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 DOESN’T COME ON--------REPLACE THE IGNITER OR CHECK THE WIRE HARNESS
USING THE COMPONENT TEST CORD:
1) UNPLUG THE STOVE AND DISCONNECT THE IGNITER FROM THE WIRE HARNESS.
2) INSTALL THE ALLIGATOR CLIPS ONTO THE TEST CORD.
3) CLIP THE TEST CORD TO THE WIRES ON THE IGNITER AND TURN THE SWITCH ON.
TEST BOX (AS IT IS INSTALLED IN THE STOVE)
TEST CORD w/ CLIPS ATTACHED CLIPS HOOKED UP TO THE IGNITER
IGNITER SWITCH
THERMOSTAT LIGHT
7-31-2002 PAGE 9 250-7700

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
EXHAUST BLOWER TROUBLE-SHOOTING
EXHAUST
BLOWER
EXHAUST BLOWER CIRCUIT
GREEN
BLACK
NOTE: THE ACCESSORY JUMPER IS LOCATED ON THE JUNCTION BOX HOUSING
JUNCTION BOX
ACCY
JUMPER
1
3
4
5
6
2
BLACK
WHITE
BLUE
WHITE
BLUE
7-31-2002 PAGE 10 250-7700
1) TURN ON THE THERMOSTAT CIRCUIT AND MAKE SURE THE CALL LIGHT IS ON.
2) CHECK FOR POWER AT THE BLUE WIRE ON THE MOLEX CONNECTOR.
A. IF POWER IS PRESENT------REPLACE THE EXHAUST BLOWER
B. IF NO POWER------CHECK THE WIRE HARNESS OR REPLACE THE CONTROL BOX
NOTE: OPEN CIRCUIT VOLTAGE IS MEASURED WITH THE BLOWER DISCONNECTED FROM THE WIRE
HARNESS. CLOSED CIRCUIT VOLTAGE IS MEASURED WITH THE BLOWER HOOKED UP TO THE
HARNESS.
CLOSED CIRCUIT VOLTAGE WILL BE: 115 V (HIGH) 85 V (MEDIUM) 75 V (LOW)
OPEN CIRCUIT VOLTAGE AT THE MOLEX CONNECTOR WILL BE 115 V ON HIGH, MEDIUM, & LOW

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
EXHAUST BLOWER TESTING
7-31-2002 PAGE 11 250-7700
USING THE TEST BOX:
USING THE COMPONENT TEST CORD:
TEST BOX (AS IT IS INSTALLED IN THE STOVE)
1) UNPLUG THE STOVE, REMOVE THE CONTROL BOX, INSTALL THE TEST BOX & PLUG IN THE STOVE
2) TURN ON THE THERMOSTAT (THE THERMOSTAT INDICATOR LIGHT SHOULD COME ON)
3) TURN THE EXHAUST BLOWER SWITCH ON.
A. IF THE BLOWER COMES ON: REPLACE THE CONTROL BOX
B. IF THE BLOWER DOESN’T COME ON: CHECK THE WIRE HARNESS OR REPLACE THE BLOWER
1) UNPLUG THE BLOWER FROM THE WIRE HARNESS.
2) INSTALL THE EXHAUST BLOWER ADAPTER TO THE TEST CORD.
3) PLUG IN THE TEST CORD TO THE EXHAUST BLOWER AND TURN THE SWITCH ON.
TEST CORD w/ ADAPTER ATTACHED
EXHAUST BLOWER w/ TEST CORD
THERMOSTAT LIGHT
EXHAUST BLOWER SWITCH

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
CONVECTION BLOWER TROUBLE-SHOOTING
7-31-2002 PAGE 12 250-7700
1) CHECK FOR POWER AT THE PURPLE WIRE FROM THE #11 PIN AT THE SNAP DISC.
A. IF POWER IS PRESENT ON BOTH SIDES OF THE DISC: CHECK THE WIRE HARNESS OR REPLACE
THE CONVECTION BLOWER.
B. IF POWER IS PRESENT ON JUST ONE SIDE: REPLACE THE SNAP DISC
C. IF NO POWER IS PRESENT: CHECK THE FUSES & WIRE HARNESS OR REPLACE CONTROL BOX
OPEN CIRCUIT VOLTAGE TO ONE SIDE OF SNAP DISC WILL BE 115 V FOR HIGH, MEDIUM, & LOW.
CLOSED CIRCUIT VOLTAGE WILL BE: 115 V (HIGH) 101 V (MEDIUM) 82 V (LOW)
NOTE: THE VOLT METER MUST HAVE ONE LEAD CONNECTED TO THE WHITE NEUTRAL WIRE FROM
THE POWER SUPPLY TO BE ABLE TO READ THE CORRECT VOLTAGE AT THE SNAP DISC.
7 AMP FUSE
JUNCTION BOX
#1 SNAP DISC
CONVECTION BLOWER CIRCUIT
ACCY
JUMPER
1
3
4
5
6
2
WHITE
CONVECTION
BLOWER
PURPLE
PURPLE
BLACK BLACK

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
CONVECTION BLOWER TESTING
7-31-2002 PAGE 13 250-7700
USING THE TEST BOX:
USING THE COMPONENT TEST CORD:
TEST BOX (AS IT IS INSTALLED IN THE STOVE)
1) UNPLUG THE STOVE, REMOVE THE CONTROL BOX AND INSTALL THE TEST BOX.
2) INSTALL A JUMPER WIRE ON THE #1 SNAP DISC (PURPLE WIRES) AND THEN PLUG THE STOVE IN.
3) TURN ON THE CONVECTION BLOWER SWITCH.
A. IF BLOWER COMES ON: REPLACE #1 SNAP DISC OR THE CONTROL BOX
B. IF BLOWER DOESN’T COME ON: CHECK WIRE HARNESS OR REPLACE BLOWER
1) UNPLUG THE CONVECTION BLOWER FROM THE WIRE HARNESS.
2) INSTALL THE FEED MOTOR ADAPTER WIRE TO THE TEST CORD.
3) PLUG IN THE TEST CORD TO THE CONVECTION BLOWER AND TURN THE SWITCH ON.
NOTE: THIS WILL ONLY TEST THE HIGH SPEED CIRCUIT OF THE BLOWER.
CONVECTION BLOWER
SWITCH
SNAP DISC #1
JUMPER WIRE
TEST CORD w/ ADAPTER
TEST CORD CONNECTED TO THE BLOWER

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
POWER SUPPLY TROUBLE-SHOOTING
POWER IN
7 AMP FUSE
JUNCTION BOX
#3 SNAP DISC
POWER SUPPLY
BLACK
GREY
WHITE
GREEN
ACCY
JUMPER
1
3
4
5
6
2
WHITE
GREY
GREY
7-31-2002 PAGE 14 250-7700
1) CHECK FOR POWER AT THE BLACK WIRE FROM THE POWER CORD. (SEE FIG. 1)
A. IF NO POWER------CHECK OUTLET OR REPLACE POWER CORD
B. IF POWER IS PRESENT, CONTINUE TO STEP 2
2) CHECK FOR POWER AT THE GREY WIRE ON THE 7 AMP FUSE HOLDER. (SEE FIG. 2)
A. IF NO POWER------REPLACE THE FUSE OR THE FUSE HOLDER
B. IF POWER IS PRESENT, CONTINUE TO STEP 3
3) CHECK FOR POWER AT THE GREY WIRES ON SNAP DISC #3. (SEE FIG. 3)
A. IF NO POWER------RESET THE SNAP DISC OR REPLACE IT.
B. IF POWER IS PRESENT---CHECK FOR CONTINUITY AT PIN 5 (WHITE WIRE) TO POWER CORD
(FIG.4 & 5) OR REPLACE THE CONTROL BOX.

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
POWER SUPPLY TESTING
7-31-2002 PAGE 15 250-7700
#3 SNAP DISC
5
12
JUNCTION BOX
TO CHECK FOR CONTINUITY:
1) PUT A JUMPER WIRE ON THE END OF THE POWER
CORD. (SEE FIGURE 5)
2) SET THE VOLT METER TO OHMS AND PUT THE
PROBES ON PIN 5 & PIN 12. (SEE FIGURE 4)
IF THE CIRCUIT IS COMPLETE, THE READING
SHOULD BE “0”.
JUMPER WIRE
FIGURE 5
FIGURE 4
FIGURE 3
FIGURE 2
FIGURE 1
BLACK WIRE
GREY WIRE
THERMOSTAT
BLOCK
WHITE
BLACK
POWER
CORD
7 AMP FUSE HOLDER
CHECK FOR POWER ON BOTH SIDES.

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
THERMOSTAT CIRCUIT TROUBLE-SHOOTING
JUNCTION BOX
THERMOSTAT CIRCUIT
YELLOW
ACCY
JUMPER
1
3
4
5
6
2
RESET BUTTON
CALL LIGHT
THERMOSTAT BLOCK
#2 SNAP DISC
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
7-31-2002 PAGE 16 250-7700
1) UNPLUG THE STOVE & REMOVE THE CONTROL BOX.
2) TURN ON THE THERMOSTAT & MAKE SURE THE ACCESSORY JUMPER IS IN PLACE.
3) CHECK FOR CONTINUITY AT PIN 7 & PIN 9 ON THE JUNCTION BOX.
IF THE CIRCUIT HAS CONTINUITY: REPLACE THE CONTROL BOX
IF NO CONTINUITY, CONTINUE TO THE NEXT STEP
4) INSTALL A JUMPER WIRE ON THE THERMOSTAT & CHECK FOR CONTINUITY AT PIN 7 & PIN 9
IF THE CIRCUIT HAS CONTINUITY: REPLACE THE THERMOSTAT
IF NO CONTINUITY, CONTINUE TO THE NEXT STEP
5) REMOVE THE THERMOSTAT WIRES FROM THE THERMOSTAT BLOCK & INSTALL A JUMPER WIRE.
IF THE CIRCUIT HAS CONTINUITY: REPLACE THE THERMOSTAT WIRE
IF NO CONTINIUTY, CONTINUE TO THE NEXT STEP
6) INSTALL A JUMPER WIRE ON THE T-STAT BLOCK & #2 SNAP DISC. CHECK CONTINUITY AT PIN 7&9.
IF THE CIRCUIT HAS CONTINUITY: REPLACE THE #2 SNAP DISC
IF NO CONTINUITY, CONTINUE TO THE NEXT STEP
7) INSTALL A JUMPER WIRE ON THE T-STAT BLOCK & THE RESET BUTTON. CHECK CONTINUITY. (7&9)
IF THE CIRCUIT HAS CONTINUITY: REPLACE THE RESET BUTTON
IF NO CONTINUITY: REPLACE THE JUNCTION BOX

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
THERMOSTAT CIRCUIT TESTING
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USING THE TEST BOX:
TEST BOX (AS IT IS INSTALLED IN THE STOVE)
1) UNPLUG STOVE, REMOVE CONTROL BOX, INSTALL TEST BOX & PLUG STOVE BACK IN.
2) TURN ON THE THERMOSTAT.
IF THE THERMOSTAT LIGHT COMES ON: REPLACE THE CONTROL BOX
IF NO THERMOSTAT LIGHT: REFER TO THERMOSTAT CIRCUIT TROUBLE-SHOOTING
9
7
THERMOSTAT
INDICATOR LIGHT
TESTING FOR CONTINUITY ON PIN 7 &
PIN 9 IN THE JUNCTION BOX.
THERMOSTAT BLOCK WITH A
JUMPER WIRE ATTACHED.
ACCESSORY JUMPER PLUG ON
THE JUNCTION BOX.
#2 SNAP DISC WITH A JUMPER
WIRE ATTACHED.
ACCESSORY
JUMPER PLUG
JUMPER WIRE

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
7-31-2002 PAGE 18 250-7700
THERMOCOUPLE TESTING
THE THERMOCOUPLE IS MADE UP OF TWO DISSIMILAR METALS THAT WHEN JOINED TOGETHER PRODUCE A
SMALL AMOUNT OF ELECTRICITY WHEN HEAT IS APPLIED. THE HOTTER THE FIRE THE HIGHER THE VOLTAGE
THAT IS PRODUCED. THIS THERMOCOUPLE WILL TOP OUT AT AROUND 30 MILLIVOLTS (DC) WHILE THE STOVE IS
BURNING ON HIGH. THE FUNCTION OF THE THERMOCOUPLE IS TO SENSE THE TEMPERATURE IN THE FIREPOT. IF
THE THERMOCOUPLE IS FRACTURED, IT WILL NOT PRODUCE VOLTAGE.
NOTE: BE SURE TO SET THE METER TO MILLIVOLTS (DC)
1) ATTACH A DIGITAL VOLT METER TO THE TWO THERMOCOUPLE WIRES ON THE JUNCTION BOX.
2) APPLY HEAT TO THE THERMOCOUPLE TIP IN THE FIREPOT.
IF THE THERMOCOUPLE STARTS PRODUCING VOLTAGE: CHECK TERMINAL CONNECTIONS ON THE JUNCTION
BOX OR REPLACE THE CONTROL BOX.
IF NO VOLTAGE FROM THE THERMOCOUPLE: REPLACE THE THERMOCOUPLE
CONTROL BOX IN HOPPER
GREEN THERMOCOUPLE
LIGHT
RED THERMOCOUPLE
LIGHT
THERMOCOUPLE
TERMINALS
THERMOCOUPLE TIP
THERMOCOUPLE TIP WITH PROTECTIVE COVER
THERMOCOUPLE
WIRE
YELLOW
RED
TEST PROBE

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
7-31-2002 PAGE 19 250-7700
FIREPOT AND EXHAUST SYSTEM TROUBLE-SHOOTING
THE FIREPOT IS MADE OF CAST STEEL AND IS DESIGNED WITH AIR INTAKE HOLES THAT SWIRL THE
FIRE AND HELP TO REMOVE THE ASH CREATED FROM THE BURNING OF THE PELLET FUEL. THERE IS
ALSO A SLOT OR AIR PASSAGE IN THE BOTTOM SIDE OF THE FIREPOT THAT ALLOWS HOT AIR FROM
THE IGNITER TO LIGHT THE PELLET FUEL. DURING THE BURN CYCLE PROCESS IN THE FIREPOT,
“CLINKER” MATERIAL WILL START TO BUILD-UP. (SEE *FIGURE 1) THE RATE OF THIS BUILD-UP WILL
DEPEND ON THE QUALITY OF THE PELLET FUEL BEING USED. OVER TIME THIS BUILD-UP OF CLINKER
MATERIAL CAN OBSTRUCT THE AIR PASSAGES AND CAN CAUSE PROBLEMS WITH THE OPERATION OF
THE FIREPOT. THIS CAN ALSO CAUSE THE FIREPOT CLEAN OUT DOOR TO BECOME HARD TO PULL IF
THE FIREPOT IS NOT CLEANED ON A REGULAR BASIS.
* FIGURE EXAMPLES ARE LOCATED ON THE NEXT PAGE.
THE FIREPOT IS JUST ONE COMPONENT OF THE TOTAL COMBUSTION SYSTEM. COMBUSTION AIR
FLOWS INTO A ROUND OPENING LOCATED ON THE RIGHT SIDE OF THE UNIT. (SEE *FIGURE 2) THIS
AIR TRAVELS TO A ROUND OPENING LOCATED JUST BEHIND THE BOTTOM RIGHT SIDE OF THE FIREPOT.
(SEE *FIGURE 3) COMBUSTION AIR WILL FLOW THROUGH THE AIR OPENINGS IN THE FIREPOT AND IS
THEN TRANSFORMED INTO EXHAUST GASES. THE EXHAUST GASES WILL FLOW FROM THE FIREPOT
TO THE BAFFLE PLATES AND HEAT EXCHANGER TUBES. (SEE *FIGURE 4) THE EXHAUST WILL FLOW
FROM THE HEAT EXCHANGER TUBES TO THE EXHAUST BLOWER HOUSING. (SEE *FIGURE 5) THIS
COMPLETES THE NEGATIVE PRESSURE OR VACUUM PORTION OF THE COMBUSTION SYSTEM. AFTER
THE EXHAUST ENTERS THE EXHAUST BLOWER HOUSING IT IS THEN PUSHED OUT INTO THE VENT PIPE
OR CHIMNEY PORTION OF THE EXHAUST SYSTEM. (SEE *FIGURE 6)
IF ANY PART OF THE EXHAUST SYSTEM IS RESTRICTED, THE STOVE WILL BURN DIRTY WITH TALL
LAZY FLAMES. THE STOVE MAY ALSO EXPERIENCE PROBLEMS WITH LIGHTING THE PELLET FUEL DUE
TO THE REDUCED AIR FLOW THROUGH THE FIREPOT.
IF ANY PART OF THE EXHAUST SYSTEM IS BLOCKED, THE STOVE WILL NOT FEED BECAUSE THE
VACUUM SWITCH WILL NOT ENGAGE. NORMALLY THE STOVE WILL HAVE BETWEEN .20 TO .30 INCHES
OF WATER COLUMN IN THE FIREBOX WITH STOVE SET ON THE HIGH FEED RATE.

CB1200-I PELLET STOVE SERVICE MANUAL CB1200-I PELLET STOVE SERVICE MANUAL
FIREPOT AND EXHAUST SYSTEM TROUBLE-SHOOTING
7-31-2002 PAGE 20 250-7700
FIG. 1
FIG. 2
EXAMPLE OF A LARGE CLINKER COMBUSTION AIR INTAKE
FIG. 3 FIG. 4
FIREPOT
AIR INTAKE IN THE COMBUSTION CHAMBER
HEAT EXCHANGER TUBES
FIREBOX AREA w/ BAFFLE PLATES REMOVED
FIREPOT
AIR INTAKE