Quadra-Fire Castile Insert - Burn Pot Overfill

[sesro1978]

Hi-

I have a 4-year (or so) old Quadra-Fire Castile pellet insert that up until very recently has been running like a champ. Now about 3-weeks ago I noticed that the Combustion Blower was making a weird noise. Also, from time-to-time I have to manually get the black wheel spinning for it to work - not ideal.

My father-in-law and I pulled the stove out and checked it out and from what we could tell, the combustion blower needs to be replaced as the black wheel that is attached to it seems to have a faulty bearing and is a bit wobbly when spinning (and it makes a bit of a grinding noise). Thinking I could limp the stove through the holidays - I did just that.

So I get home last night and fire the stove up and proceed to snow blow my driveway. When I came back in about an hour later the burn pot was filled with pellets, on fire.

My question is this; could the failing Combustion Blower cause the auger to continue to drop pellets into a burning pile of pellets (in the burn pot)? Possibly due to reduced air flow in the burn chamber so that the signal to 'stop dropping' never gets sent to the computer/auger?

Thanks for any insight!

 

[B-Mod]

Yes it will continue to drop pellets until the thermocouple sees a low enough temp to shut off the flow of pellets, or the temp in the shoot gets to high, in the case of pellets burning up the shoot.

 

[SwineFlue]

Possibly due to reduced air flow in the burn chamber so that the signal to 'stop dropping' never gets sent to the computer/auger?

Test your stove's vacuum switch: open the door an inch or so while the stove is running. The flame should become lazy and pellets should stop dropping. Close the door, and the flame should immediately become lively and pellets should begin dropping again. If pellets continue dropping while the door is open, you should replace the vacuum switch ASAP.

 

[tjnamtiw]

The first question that should be asked/suggested is 'Have you cleaned the stove?'. Especially, have you cleaned behind the right hand metal access plate and into the area where the combustion blower fan is located? You can use a small tube attached to your vacuum hose. Next would be to pull the exhaust blower out, which is a fairly easy thing to do except that it's an insert like mine! The black wheel (fan) does indeed wobble on both my stoves. The resistance you feel could either be a bad bearing or more likely a build up of soot in the exhaust area around the fan. Since the exhaust pipe goes straight up into the chimney, if you haven't cleaned the pipe, soot can fall right back down off of the pipe and into the fan. Look in that area before doing anything else.

If it is indeed bad, then this has worked for some Quad owners > http://www.amazon.com/dp/B000W3Q4QO...UTF8&colid=8CS88Z6P63FF&coliid=I3JYPX6JPITCRH

 

[sesro1978]

I clean the burn chamber daily (I'm obsessed with keeping that clean) and the stove has a major cleaning done annually by our local dealer. Outside of that, I have vacuumed around the combustion blower (located on the right-hand side of the stove) but I have not yet (I don't think) vacuumed behind any access panels. Can you post a picture of this?

Also, is the motor you posted part of this assembly > http://www.amazon.com/Quadrafire-Pellet-Exhaust-Combustion-812-4400/dp/B005DSB0NK

I've been under the impression (perhaps due to lack of info/experience) that I need to replace the entire assembly, but if it's just the motor, that would be quite a bit less.

Finally, is the exhaust blower located on the back of the stove or is the exhaust blower the same as the combustion blower (sorry, I'm a bit of a noob about this)? Oh, and if I do pull it off, should I be prepared to replace the gasket(s)?

Thanks for all the help!!

 

[tjnamtiw]

You don't need the whole assembly. You only need the motor. The impeller (fan) is attached to it. You will probably need a gasket too, which can be bought from your dealer or online. My posting was for an alternate aftermarket fan/motor combination that was suggested by others.
Sorry I used 'exhaust' blower and 'combustion' blower in same post. It's the same thing on the right hand side. By access panels, I mean the two metal panels that are on either side of the drop chute. You do take them out to clean the stove, I hope, along with the top, sloped plate? Behind the right panel is a small opening where you can feel the combustion fan. That can very easily get clogged with ash.

 

[sesro1978]

Oh yes, I do take those panels out once a week to clean out the ash that collects behind the panels and on the heat exchange tubes.

 

[tjnamtiw]

OK, do you also have a small tube that you can attach to your vacuum and feed back into the small hole on the right side of the opening behind the right plate? Something like this > http://www.homedepot.com/p/VaccuFlex-Vacuum-Accessory-Kit-VF7/203362171#
That will allow you to push the little tube into the area around the combustion blower and vacuum out the ash which is GUARANTEED to be there. When I do it, I also take a rubber mallet and gently tap the flex pipe coming off of the blower outlet and a LARGE amount of additional ash falls down.
If you have never had the combustion blower out of the machine in 4 years, it is DEFINITELY time to pull it out. Many times there is also build up behind the impeller wheel that restricts the spinning of the impeller. Unplug the stove. Unplug the motor. Remove the 6 small bolts that are in a circle around the round plate and pull the motor assembly out. Don't take off the bolts holding the motor to the round plate. Not necessary. Now see how much ash is in there plus look for buildup behind the fan/impeller. Once clean, you can assess whether the motor is shot or not. Spin it and see if it turns freely. You can also make up a test cord and plug the motor directly into an outlet to see if it spins OK. BE VERY CAREFUL WITH THIS STEP. NO ELECTROCUTIONS AND NOT IMPACT WITH THE SPINNING BLADES!

 

[sesro1978]

Sorry for the delayed response - in laws in town this weekend.

I don't have an attachment like that, but could probably get one...actually, I could use my Dust-buster, which has a hose attachment like that.

I'll pull the stove out tonight and let you know what I find.

Out of curiosity, how loud should a Castile insert be? Are these stove inserts expected to be loud (i.e. on high setting, I can't really watch TV in the same room without really turning up the TV)?

Thanks!

 

[tjnamtiw]

The dust buster will probably blow ash all over the room followed shortly thereafter by a frying pan flying back at your head! I'd advise you to go get something similar at HomeDepot or Lowes for your ash vacuum. Even if it's some tubing that they sell and a roll of duct tape.
My inserts are pretty loud but because I'm partially deaf, my wife and I both wear wireless headphones when we're watching TV so it doesn't bother us. The Castile has the cast iron door which blocks the flow and contributes to the noise so I leave it open when burning. Doesn't look pretty but it's in MY ROOM.

 

[RockyMtnHigh]

Don't forget to check the flue also. These stoves have all kinds of little nooks and crannies where ash can hide and cause issues. There should be a little trap door held closed with a buckle arrangement where the exhaust attaches to the stove. It may be pretty well plugged up back there. Also don't forget to check and make sure there isn't a bunch of gunk in the way of the air inlet (usually behind the ash pan).

 

[tjnamtiw]

Don't forget to check the flue also. These stoves have all kinds of little nooks and crannies where ash can hide and cause issues. There should be a little trap door held closed with a buckle arrangement where the exhaust attaches to the stove. It may be pretty well plugged up back there. Also don't forget to check and make sure there isn't a bunch of gunk in the way of the air inlet (usually behind the ash pan).

The Castile insert doesn't have that trap door, RMH. REGRETTABLY.... There's no easy way to get back there except with the little tubing. At least I haven't found a way short of pulling it out and unsnapping the flex liner.

 

[RockyMtnHigh]

That's true TJ, I should have remembered that too because I cut the crap out of my hand doing that exact job about a month ago. Those things can be a bugger to get back together when you have no room!

 

[tjnamtiw]

That's true TJ, I should have remembered that too because I cut the crap out of my hand doing that exact job about a month ago. Those things can be a bugger to get back together when you have no room!

TELL ME ABOUT IT

 

[sesro1978]

I wanted to follow-up on this post...

I pulled out my Castile this weekend and as suggested, inspected and cleaned the combustion/exhaust blower. Based on this, I ended up purchasing a new unit at the local dealer - got it for a steal after some whining on my part, but still expensive. At any rate, I successfully swapped out the motor and replaced the housing gasket. While I had the thing out I also took the time to do some cleaning and inspection, something I have never done. I'm glad I did as I discovered about 4-cups of ash being held in the cup (not exactly sure what this is called, but on my stove it's a detachable 'cup' that sits at the base of the flex-liner and the exhaust blower intersection) at the base of the flex-liner. Now I thought the good folks who service my stove annually would clean this out, but apparently not...unless this ash build-up is from 2-months of running the stove (service tech. was in 2-months ago to clean the stove)?

I also took the time to put small pieces of Velcro between the parts of the stove where metal meets metal - thinking here is that this will cut down on the vibration noises I hear when the stove is running...I think I read something on here about doing that and thought I'd give it a try. So far, so good. Next I vacuumed out the convection blower located on the back of the insert - it looked pretty clean but I figured it couldn't hurt. I also checked and tightened every single screw I could find - actually found a few loose ones which seems to have helped with the noise. At the very least, it makes me feel better knowing all screws are tight.

Sort of related to all this, I noticed my insert was set to 4 in the control box and I read somewhere the correct setting for the Castile insert is 6. Anyone know which setting is correct and does it make any difference?

Finally, I think I may have to pull the damn thing out again as I'm noticing a bit of smoke leakage when the insert starts up. It's coming somewhere from the back - my guess is either at the connection between the flex-liner and the exhaust blower or that the exhaust blower gasket didn't seal all the way. It's not enough smoke that I'm real concerned, but I feel that I should investigate in the near future...which means pulling the beast out again.

 

[SwineFlue]

I noticed my insert was set to 4 in the control box and I read somewhere the correct setting for the Castile insert is 6. Anyone know which setting is correct and does it make any difference?

What does your manual say? The component description section should tell you the number of blue blinks on the control box. This number will match the switch setting.

I have seen both 4 and 6 specified for the Insert, so I'd go with what's in your manual.

 

[sesro1978]

Thanks. I did look in the manual this weekend but couldn't find the setting. I'll take a closer look this evening!

 

[SwineFlue]

Thanks. I did look in the manual this weekend but couldn't find the setting. I'll take a closer look this evening!

It's at the very beginning of the "Reference Materials" section: "Component Functions".

 

[tjnamtiw]

It's at the very beginning of the "Reference Materials" section: "Component Functions".

He's right! About page 36 under Control Box. Mine says 6. He's a good man, that Swine Flue chap.

 

[SwineFlue]

He's right! About page 36 under Control Box. Mine says 6. He's a good man, that Swine Flue chap.

Well, except for the fact that the Castile Insert manual I downloaded today from the Quad web site says it should be '4' Did they change something, or is it a typo?

 

[tjnamtiw]

Well, except for the fact that the Castile Insert manual I downloaded today from the Quad web site says it should be '4' Did they change something, or is it a typo?

Mine's an 07 and says 6. What does yours say as an 02?

They must have changed something or the translation from Chinenglish got screwed up....

UPDATE: I was answering the question from a manual that I downloaded from their website 3 years ago and it says 6 blinks. I just pulled out the manual for my Castile (07). The manual is copyrighted 2003! It speaks of the green and red lights on top of the control box and says nothing about a blue Light! The manual I have for my Sante Fe is copyrighted 2006 and says 6 blinks for it.

 

[SwineFlue]

Mine's an 07 and says 6. What does yours say as an 02?

They must have changed something or the translation from Chinenglish got screwed up....

UPDATE: I was answering the question from a manual that I downloaded from their website 3 years ago and it says 6 blinks. I just pulled out the manual for my Castile (07). The manual is copyrighted 2003! It speaks of the green and red lights on top of the control box and says nothing about a blue Light! The manual I have for my Sante Fe is copyrighted 2006 and says 6 blinks for it.

My 2002 has the old box with separate red & green lights. There is no blue light, no amber light either. It has a jumper that I assume serves the same function as the switch to configure the box.

By the way, StoveGuy13 pointed out here https://www.hearth.com/talk/threads/newbie-to-pellet-stoves-quadra-fire.118862/#post-1591363 that there is a new control box. I re-downloaded the Castile Freestanding manual: it is now dated 2013 and includes the new box part number. The number of blue blinks changed from the 2011 copy, so I assumed that the settings on the control box replacement instruction sheet don't apply to this new box. Anyway, that's why I gave the 'read the manual' response here.

(The Castile Insert manual is still dated 2011 by the way)

 

[sesro1978]

Mine is an '08 and my manual says 6 blinks.

 

[tjnamtiw]

I just downloaded the 2013 manual for the free standing Castile and it says 6 blinks.!

I did notice that the green light comes on now at 175 versus 200 degrees. BUT for the insert version, it is still 200 degrees and, yes, 4 blinks! I am so confused..... Where's my Valium?

 

[sesro1978]

Yea, my manual is at 6 blinks but the green light comes on at 200 (or so it says). I guess I'll leave it at 6 blinks like the manual says, but very confusing. What does changing this setting actually do to the stove?