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Earth Klear Sky 400 Owner's Manual - Pcd Mounting Location

Manual is about: Outdoor Wood Furnace

Summary of Klear Sky 400

  • Page 1

    Klear sky 400 p.O. Box 310 mountain grove, mo 65711 417-746-0043 www.Earthoutdoor.Com.

  • Page 2

    L etter from e arth o utdoor thank you for purchasing an earth outdoor wood furnace! We know how exciting this moment is. You may have looked forward to having an outdoor furnace for days, weeks or years. Our staff has worked hard to provide you with a quality product that you should enjoy for many ...

  • Page 3: Warning!

    F urnace s pecifications make sure you read this manual and follow the recommendations contained in it to have the joy of operating your furnace for years to come. Warranties. Always follow requirements. Please seek the help of qualified craftsmen when installing the furnace or systems associated wi...

  • Page 4

    4 always latch the doors securely. If the fire box door is open for any extended amount of time past the normal loading period, it will cause over-firing of the unit and result in the overheating of the unit. This will cause damage to the electrical equipment and will result in causing the unit to b...

  • Page 5

    5 remember to give the furnace a “once over” regularly. O “once” a day check the water level o “once” a week clean the ashes out (or often if needed) o “once” a month clean the chimney specifications for the klear sky model epa phase ii qualified manufacturer: earth manufacturing, llc model #klear s...

  • Page 6

    6 g etting to k now y our f urnace c ommon q uestions i s it safe ? Having the furnace outside eliminates the possibility of causing a fire in your home. The furnace is a non-pressurized system which eliminates any chance of explosion associated with pressurized furnaces. Also the oversize door make...

  • Page 7

    7 3. Maybe a friend or family member could help and feed the unit while you’re away. 4. You could look into special anti freeze. Keep in mind most anti freeze is terrible to our environment and costly. 5. You can let the fire die down and drain the furnace. It only takes about 10-20 minutes to drain...

  • Page 8

    F urnace o verview – f 1. The overflow port is where you will see water water expands when heated, when firing it up. 2. The manual fill valve: a quarter turn valve used to fill the water tank of the furnace. 3. The light switch and light are all pre that can be used in all weather conditions. The l...

  • Page 9

    9 h ow does it work ? The fire chamber is completely immersed in a jacket of water (except for the front of the furnace at the fill door). When a fire is built it heats the water and a pump takes the hot water to the house. Inside the house you have some kind of heat transfer appliance; this can be ...

  • Page 10

    10 s tarting up the f urnace make sure all the valves on the back of the furnace are closed and that the power is off. Begin filling the furnace with water. Turn the manual fill valve on the front of the furnace to allow water to flow into the furnace tank. You can work on other things while it is f...

  • Page 11

    11 m aintenance the front wood door has two “u” bolts that are adjustable. If you feel the door is not closing tightly or may be too tight, loosen the bolts with the door open and tighten or loosen the bolts as necessary. It is important that the water is checked daily, especially after the first st...

  • Page 12

    12 t rouble s hooting s quealing p ump on initial start up if the pump is not primed with water it may squeal and can burn your pump out. Make sure the ball valve to the pump is open and the water tank is full. On occasion the pump may get a piece of debris in the impellers from the installation pro...

  • Page 13

    13 l ines not getting hot but water is hot the water is not moving to the house or through the house. Make sure the return ball valve is open at the furnace and that all valves are open through the house. If you have a multi-speed pump try increasing the speed. It could be that you have an air bubbl...

  • Page 14

    14 earth outdoor wood furnaces ™ w arranty i nformation 1. “earth” furnaces have a 10 year limited warranty. 2. This warranty is on, and covers the furnace only, not fans , thermostats , pump , etc . Or any product or work your installer does or supplies . 3. The electrical components like the therm...

  • Page 15

    15 12. This warranty will be voided by operating this residential wood furnace/hydronic heater in a manner inconsistent with this owner’s manual. Earth outdoor wood furnaces ™ w arranty e xclusions 1) burning any material of any kind other than regular non-treated wood. 2) any modifications or chang...

  • Page 16

    16 4) faulty installation or connection. 5) not testing and treating your water for recommended chemical treatment, & rust inhibitor. 6) disasters, such as wind storms, fires, etc. 7) failure to properly power ground furnace. 8) insufficient and/or excessive draft 9) consumption that exceeds use lim...

  • Page 17: Epa

    17 h elpful t ips and l inks via epa how to use a moisture meter video- http://www.Youtube.Com/watch?V=jm2wggrcnm0 epa offers tips on how to properly use a moisture meter to test firewood before using in a wood- burning stove or fireplace. Wet wood can create excessive smoke which is wasted fuel. Sp...

  • Page 18

    W arranty fill in the following information and mail a owner name: ______________________________ address: __________________________ ________________________ phone number: _______________ e-mail: ___________________________________ earth model: ______________________ serial number: _______________ ...

  • Page 19: Model 150 Series

    Model 150 series catalytic gasification control systems for installation & user guide patents pending updated 4 december 2013.

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    1.

  • Page 21: Clearstak Model 150

    2 clearstak model 150 user guide introduction thank you for choosing an earth outdoor klear sky 400, complete with clearstak. You have joined a growing group of customers that are leading the industry in improved efficiency and clean burning. Intended use earth outdoor the earth outdoor model 150 is...

  • Page 22

    3 is able to turn off the heater when the catalyst reaches the activation temperature, or when the furnace is not calling for heat. The ibc also provides diagnostics to assist the professional during installation and troubleshooting. The ibc is intended to be mounted on the exterior surface of the e...

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    4.

  • Page 24: Table Of Contents

    5 table of contents introduction 2 i ntended u se 2 c atalytic g asification c ontrol s ystem (cgcs) 2 m odel 150 i ntelligent b iomass c ontroller 2 t he c atalyst and c atalyst p re -­‐ heater 3 pollution control device installation 8 pcd a ssembly 8 pcd m ounting l ocation 9 pcd m ounting r equir...

  • Page 25

    6 led d igital d isplay 14 o ptional led d igital and a nalog d isplay 14 m odel 150 i ntelligent b io -­‐ fuel c ontroller 14 ibc-­‐3.1 overview and technical specification 16 ibc-­‐3.1 o verview 16 ibc-­‐3.1 c omponents 17 ibc-­‐3.1 l ow v oltage p ower and i nput c ircuit s ection 17 ibc-­‐3.1 m ...

  • Page 26

    7.

  • Page 27: Pcd Assembly

    8 pollution control device installation pcd assembly the pcd located inside of the exhaust chamber of this earth outdoor unit. Before opening any panel or cover of the pcd, disconnect the power to the furnace. When opening the panel on the back of the furnace, please examine the pcd to make sure all...

  • Page 28: Pcd Mounting Location

    9 pcd mounting location for the best operating performance, the ibc is mounted close to the firebox of the earth outdoor furnace and before the heat exchanger. This provides the best performance by using the heat from the firebox to reduce the need for the catalyst pre-heater and allows the earth ou...

  • Page 29: Pcd Wiring Requirements

    10 pcd wiring requirements two cables connect the pcd to the ibc. The heater cable is a 14/3 gauge sjo cable, high temperature rated. In colder climates, an arctic ul approved 14/3 sjtw cable may be used. The yellow jacketed thermocouple cable is a 22 gauge shielded wire that is designed for low vol...

  • Page 30: Controller Installation

    11 correct operation of the pcd. Please have an electrician check to ensure the heater has 120 vac and the ability to safely draw up to 20 amps of current. Model 150 intelligent bio-fuel controller installation ibc-3.1 installation ibc-3.1 assembly when viewing the ibc-3.1 please examine the labeled...

  • Page 31: Connections

    12 a protective earth, known as an equipment-grounding conductor in the us national electrical code, avoids an electrical hazard by keeping the exposed conductive surfaces of the earth outdoor furnace and the ibc-3.1 at earth potential. To avoid a possible voltage drop, no current is allowed to flow...

  • Page 32: Switches And Breakers

    13 implements a common neutral and a common ground. Before powering the model 150, use a test plug or multimeter to ensure that the existing wiring of the plugs inside the earth outdoor furnace is correct. A continuity tester should also be used to ensure that no wires are reversed between the power...

  • Page 33: Displays

    14 and that the outlet has the ability to safely source 20 amps of current. Displays clearstak offers a variety of displays to show the user and/or installer important information of their furnace during operation. The klear sky utilizes an led digital display led digital display the led digital dis...

  • Page 34

    15 the vfds are preprogrammed at the factory. When a vfd is replaced please see the following programming instructions for the combustion fan only. 1. Power-up the vfd without the serial cable attached. 2. Press the ‘m’ button one time. The number displayed on the right side of the vfd display will ...

  • Page 35: Specification

    16 13. Press the ‘m’ key three times. Either ‘rd’ or ‘ih’ will be displayed on the left side of the vfd display. You are now done after not adjusting the vfd address. Variable frequency drive operation please ensure that electronics connected to a frequency drive are running in the proper direction....

  • Page 36: Ibc-3.1 Components

    17 outdoor furnace. The ibc assembly receives continuous electrical power (interrupted only by a high limit safety thermostat) and, through the use of a mounted thermistor type temperature sensor, the controller assembly monitors the furnace water temperature. When the water temperature falls to les...

  • Page 37: Circuit  Detail

    18 ibc-3.1 microcontroller and communication circuit detail the microcontroller and communication circuit section features a microchip technology microcontroller, rs-232 serial communications circuitry along with a proprietary communications port, a microcontroller programming port, an operating mod...

  • Page 38: Pcd And Ibc Maintenance

    19 correct. The firmware is written in a state machine format wherein the inputs from the various sensors are read and processed. Based on the data from these sensors as well as the currently active state machine state and also based on elapsed time, the various machine states are activated and deac...

  • Page 39: Visual Inspection

    20 if you have any questions on proper operation please consult your dealer. If it is working fine you do not need to perform any maintenance. If needed, the catalyst may be cleaned with compressed air (which does not contain oil) at no more than 65 pounds per square inch (psi) pressure. A shop vacu...

  • Page 40

    21 check outlets to insure proper wire polarity. A simple plug-in connector can be obtained to insure that the cable between the furnace and the breaker box are wired properly. A reversed line and neutral wire will cause a controller relay failure and will permanently damage the ibc. Ground test che...

  • Page 41: Feature

    22 furnace to overheat. Oxygen sensor test check millivolts from the oxygen (o 2 ) sensor to insure proper operation. The o 2 sensor puts out a milli-volt signal that will indicate the amount of oxygen available post combustion. The value for o 2 is close to zero at ambient atmosphere levels of betw...

  • Page 42

    23 if this switch is noted to be in the actuated position upon power-up, the controller will not start furnace operation and an led error flash cadence is set to indicate the problem. Further, during a reset operation the electromechanical reset switch must not only be actuated for one second or lon...

  • Page 43

    24 this is expected under annual system start up. If this occurs during normal operation then make sure the furnace is working properly and contact your earth factory service representative. Standby led on continuously: the purpose of the standby mode is to prevent extended heating of the catalyst a...

  • Page 44

    25 this alarm indicates that the thermocouple under range. Try the following operations to isolate the problem: manually inspect yellow cable for breaks or shorted connections. Disconnect the thermocouple plug at the stack and restart. Disconnect the yellow cable from the ibc and restart. If the ove...

  • Page 45

    26 range. • check to see if boiler has overheated. • power board off and check for water jacket sensor resistance. • check for defective sensor (500 omhs with power off). • check for defective sensor (0.0v at terminal block with power on). • press the reset switch for one second to recover. Blue led...

  • Page 46: Technician Troubleshooting

    27 • replace board if the problem persists. • cycle the power to recover. • the flashing alert/alarm led indications that appear with a continuously illuminated lockout led can be recovered from by cycling the power to the ibc-3.1. • if the lockout led is illuminated without the alert/error led, thi...

  • Page 47: Catalyst Back Pressure

    28 catalyst back pressure • check catalyst for clogging from objects such as birds, leaves and bees. • check to see if the heater is performing properly. • check for excess air causing fly ash problems. • check exhaust pipe dimension to insure proper sizing of pipe. Balanced system performance every...

  • Page 48: Best Burn Procedure

    29 not touch the inside of the pcd or ibc-3.1 enclosure, high voltage. Caution! Electrical shock can result from removal of the enclosure covers. Refer servicing to qualified service personnel. The circuits inside the pcd assembly and the intelligent bio- fuel controller (ibc-3.1) panel have been pr...

  • Page 49

    30 caution: keep small children away from heater. System check prior to every cold start we would like you to do the following: 1. Test the power coming into the unit to ensure you have 120/220v (what ever voltage required). 2. Check all wiring to ensure that they are in good shape and nothing has b...

  • Page 50

    31 most efficient burn. It is recommended that the firebox is never filled more than 50% to allow room for oxygen. It is recommended that larger logs are placed in the middle of the firebox and smaller pieces are placed on the sides and the top to reduce bridging. Bridging occurs when the inside of ...

  • Page 51

    32 for more efficient burning, use seasoned firewood. Seasoned firewood is wood that has been cut and stored properly and has aged for at least six months. Use only the type of fuel recommended by the manufacturer. Do not burn the following: trash, treated wood, plastics, gasoline, petroleum treated...

  • Page 52

    33 burning, dry, seasoned firewood with a moisture content of 20% or less can save money and help reduce harmful air pollution. Wet wood is a waste brochure: http://www.Epa.Gov/burnwise/pdfs/wetwoodwastebrochure. Pdf this tri-fold brochure provides colorful illustrations of the four easy steps to dr...

  • Page 53

    34 manufacturer’s limited warranty this limited warranty applies to clearstak products sold by earth outdoor or its authorized distributors. The term “clearstak products” does not include earth outdoor products or earth outdoor furnace parts. All non- clearstak products or non-clearstak peripherals ...

  • Page 54

    35 choosing that is the same or equivalent to the clearstak- brand product in performance or (2) to provide a refund of the purchase price instead of a replacement. This is the exclusive remedy for a defective product. It is mandatory that the unit product number and serial number are made available...

  • Page 55

    36 include problems that arise due to improper burn practices, such as burning garbage. Please refer to the clearstak model 150 series installation and user guide. The most updated version of the clearstak model 150 series installation and user guide can always be found online by scanning the qr cod...

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    37 manufacturer..

  • Page 57

    38 clearstak, llc 90 route 171 p.O. Box 875 woodstock, ct 06281 www.Clearstak.Com www.Facebook.Com/clearstakllc.