PF100 and PB105 Burn Pot Issues

[Ejectr]

How difficult is it to change the burn pot on a PF100? I don't know if I have a hard carbon build up on the right side ramp of the burn pot going down to the auger or a bubble. I'll have to get a mirror and flashlight in there to see. Furnace is under warrantee but my dealer is out of business. I may have an avenue to get a burn pot under warrantee, but I'd have to put it in myself.

 

[Skippydo]

Know what you mean by a carbon buildup on the right (and left) side of the burnpot.
It is not the easiest to remove.
The easiest way is when the pellets are hot, use a leather glove and a sharp ended
screwdriver and scrape at a angle
or
after the fire is out, but still warm, also use a sharp screwdriver at an angle and scrape. Usually comes
off in a big hunk.
I then use my hands to feel the whole burn pot......when it is cool, naturally.
Make sure when you clean out under the burn pot that you tap the top of the burn pot,
a heck of a lot of debris will fall.
Never removed my burnpot yet!! knock on wood!!

 

[exoilburner]

How difficult is it to change the burn pot on a PF100? I don't know if I have a hard carbon build up on the right side ramp of the burn pot going down to the auger or a bubble. I'll have to get a mirror and flashlight in there to see. Furnace is under warrantee but my dealer is out of business. I may have an avenue to get a burn pot under warrantee, but I'd have to put it in myself.

Not difficult for someone with some home mech. repair experience.

Shut power off to the furnace.

Either disconnect the igniter wires (you can see the igniter wires in the picture) or unbolt the igniter and feed it thru the burnpot hole. The igniter wire connectors are located behind the lower cover under the pellet hopper.

Remove the Fire Brick and it's mounting bracket.

Remove the 4 nuts holding the burn-pot to the fire box. It's gasket is very fragile and should probably be replaced before reinstalling (it looks like fiberglass matting). The 4 studs that the burnpot is fastened with are anchored in the thin firebox metal so be careful to not over torque the nuts. The back 2 nuts are a bit difficult to get to and blind so you may need a socket with an extension and a u-joint or just a combination wrench.

 

[Ejectr]

Thanks. I'm going to get a better scraping tool and hopefully it is carbon. If not, your directions are very helpful.

 

[Skippydo]

If it is not carbon, I owe you a beer!

 

[Ejectr]

If it is not carbon, I owe you a beer!

I owe you a beer. Used a sharp screw driver and it was carbon build up. Burn pot is fine.

 

[Skippydo]

I feel bad winning a sure thing!
But thanks for the beer...

 

[wil lanfear]

These photos are of the new and improved (maybe)burnpot that was installed in my PB105 boiler today. It appears that the burning surface is still stainless with cross bracing welded to the bottom.

UPDATE: It has been nearly 3 months since the new designed burnpot was installed in my boiler. To date, this burnpot looks the same as when it was installed, no bubble issue at all. Prior to this burnpot, any that were replaced,after 2 weeks a small bubble could be seen forming. If you have a pb105 or a pf100 with the burnpot bubble issue, if you have the pressure ignition, talk to you're dealer about this burnpot. If you have the finned ignition, talk to you're dealer, telling them about the fix for the bubble issue, maybe changing to the pressure ignition with this burnpot, do it now before the warranty expires.

 

[Ar-ef-bee]

UPDATE: It has been nearly 3 months since the new designed burnpot was installed in my boiler. To date, this burnpot looks the same as when it was installed, no bubble issue at all. Prior to this burnpot, any that were replaced,after 2 weeks a small bubble could be seen forming. If you have a pb105 or a pf100 with the burnpot bubble issue, if you have the pressure ignition, talk to you're dealer about this burnpot. If you have the finned ignition, talk to you're dealer, telling them about the fix for the bubble issue, maybe changing to the pressure ignition with this burnpot, do it now before the warranty expires.

Hi Wil,
How has the PB been treating you? Is that burnpot still holding up?
I burned far more than usual last year; the pot is holding up but I have had regular ignition issues. I believe the current cold snap is pushing the manufacturers to ship inferior pellets that are either too moist or too high temp to ignite easily.
Last question - did they need to replace your control board for the new burnpot and igniter to work?
RichB

 

[wil lanfear]

Hi Wil,
How has the PB been treating you? Is that burnpot still holding up?
I burned far more than usual last year; the pot is holding up but I have had regular ignition issues. I believe the current cold snap is pushing the manufacturers to ship inferior pellets that are either too moist or too high temp to ignite easily.
Last question - did they need to replace your control board for the new burnpot and igniter to work?
RichB

I'M HAPPY, I now have the newest model burnpot which has outlasted any other burnpot that was replaced. I can't remember when this burnpot was installed, I think it's been over a year now and it looks as good as when it was installed. IMHO, I believe the burnpot bubble issue has been resolved. My control board was replaced when the pressure ignition was installed, some time ago in an effort to fix the burnpot bubble issue. If you are having ignition problems, meaning long ignition times, make sure the quanity of pellets in the burnpot at ignition is not excessive. The least amount of pellets in the burnpot the better for quick ignition. The link below is to the newest designed burnpot kit including the part number. post # 39

https://www.hearth.com/talk/threads/pb-105-burnpot-revisited.115489/page-2

 

[d-dayman]

I'M HAPPY, I now have the newest model burnpot which has outlasted any other burnpot that was replaced. I can't remember when this burnpot was installed, I think it's been over a year now and it looks as good as when it was installed. IMHO, I believe the burnpot bubble issue has been resolved. My control board was replaced when the pressure ignition was installed, some time ago in an effort to fix the burnpot bubble issue. If you are having ignition problems, meaning long ignition times, make sure the quanity of pellets in the burnpot at ignition is not excessive. The least amount of pellets in the burnpot the better for quick ignition. The link below is to the newest designed burnpot kit including the part number. post # 39

https://www.hearth.com/talk/threads/pb-105-burnpot-revisited.115489/page-2

Hey Wil,

Did they ever get the burnpot issues resolved. Is it just the ignition process not being set right, or do you have to have the new 309 stainless steel burnpot? I Just picked up a used Pf100 that's in great condition for $1000. Burnout is fine right now, but does have a slight hump where the usual problem occurs. I would like to get this resolved before the burning season arrives.

 

[Duffman]

Hey there, sorry to resurrect an old thread, but I picked up a pf100 for my shop/garage and am absolutely in love

Attached are my pictures of the repair of the burn pot, I'll let you know how it goes.

Figure I'll run it the rest of the season on this repair and maybe grab a new one in the summer

TIG
150amps
309 filler
Brushed and ground through
Drilled both ends to prevent more cracking
Hammered back to flat(ish)

Sent from my SM-G955U using Tapatalk

 

[Mr._Graybeard]

Nice, neat repair. You might find it interesting that the improved "lifetime" burnpot has slots cut in the perforated area -- in effect, built-in "cracks."

 

[Former Farmer]

Nice, neat repair. You might find it interesting that the improved "lifetime" burnpot has slots cut in the perforated area -- in effect, built-in "cracks."

New style burnpot also has holes drilled in the sides.

 

[Duffman]

Nice, neat repair. You might find it interesting that the improved "lifetime" burnpot has slots cut in the perforated area -- in effect, built-in "cracks."

I did see that, I figured I'd see how this does for the remainder of the season and maybe cut those in if I can get a slitting saw in there.

The thought of just fabricating a new one from 309l isn't out of the question.


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[Mr._Graybeard]

New style burnpot also has holes drilled in the sides.

Yep, that may decentralize the draft and keep it from getting too hot front and center.

 

[Mr._Graybeard]

I did see that, I figured I'd see how this does for the remainder of the season and maybe cut those in if I can get a slitting saw in there.

The thought of just fabricating a new one from 309l isn't out of the question.


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You may be aware of this, but EarthSense has made its own version of the improved burnpot. Still not cheap at over $400, but more reasonable than the factory model.

I had the burnpot on my boiler replaced three times under warranty. Third time, with the final redesign, was the charm. I'm thinking it all came down to the type of steel Harman used.

 

[Duffman]

You may be aware of this, but EarthSense has made its own version of the improved burnpot. Still not cheap at over $400, but more reasonable than the factory model.

I had the burnpot on my boiler replaced three times under warranty. Third time, with the final redesign, was the charm. I'm thinking it all came down to the type of steel Harman used.

I think so too, afaik they just used a medium carbon steel, maybe even just regular low carbon stuff.

I was aware they did make a new weldment but it isn't as much fun as building your own!

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[d-dayman]

I think so too, afaik they just used a medium carbon steel, maybe even just regular low carbon stuff.

I was aware they did make a new weldment but it isn't as much fun as building your own!

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Duffman, What did you end up doing with your burnpot? Did you but a new one or fab one youself?

I took mine to a local guy here who said he could cut out the flat section of the burn surface and weld in a new piece of stainless for $150.00. I explained to him how the new burnpot is designed, with the slits cut in, and the side vents. He said he would cut in the slits too. Figured it might be worth trying.

 

[Mr._Graybeard]

Well, well. Scraping the burnpot in my boiler the other day I noticed a small crack extending from a hole that is at the end of one of the expansion slots in the burnpot floor. It's 3/16 of an inch at most, and I don't see any warpage associated with it ... so I'll just keep and eye on it for now.

 

[Former Farmer]

Well, well. Scraping the burnpot in my boiler the other day I noticed a small crack extending from a hole that is at the end of one of the expansion slots in the burnpot floor. It's 3/16 of an inch at most, and I don't see any warpage associated with it ... so I'll just keep and eye on it for now.

How long has your burnpot been installed? Is it a Harman burnpot?

I haven't been using my PB105 the last few years with propane prices being lower. This year, propane was just a little cheaper than what pellets are.

 

[Mr._Graybeard]

The pot was installed under warranty, I think, at the end of the 2013-14 season by my Harman dealer. I've been getting lots of pellets on sale from Menards, mostly in the $180/ton range. So pellet heat is pretty competitive to oil in that range. ... plus, the pellet boiler is more efficient then my cast-iron oil dragon.

It's a small crack, way toward the front of the pot in the second rank of holes, IIRC -- I suspect it's the result of expansion and contraction in that area rather than direct heat damage