By SMARTFIRE TECHNOLOGY BY UNITED STATES STOVE COMPANY Assembly and Operating Instructions Models: HCPG561 & HCPG442 A MAJOR CAUSE OF FIRES IS FAILURE TO MAINTAIN REQUIRED CLEARANCES (AIR SPACE) TO COMBUSTIBLE MATERIALS. IT IS OF UTMOST IMPORTANCE THAT THIS PRODUCT BE INSTALLED ONLY IN ACCORDANCE WITH THESE INSTRUCTIONS. Safety Notice: FOR OUTDOOR USE ONLY! Please read this entire manual before installation and use of this pellet fuel-burning appliance. Failure to follow these instructions could result in property damage, bodily injury or even death. Contact local building or fire officials about restrictions and installation inspection requirements in your area. Save these instructions. Manufactured for: United States Stove Company 227 Industrial Park Road, South Pittsburg, TN 37380 Phone #: (800) 750-2723 852076F-1102G
Introduction The entire family of United States Stove Company would like to thank you for purchasing your new pellet burning grill. At U.S. Stove, we build all of our products with a hands-on approach to detail and quality. Our old world team of Craftsmen take great pride in their superior workmanship to ensure you have years of trouble free use out of your pellet grill. Use only wood pellet fuel specified by the manufacturer. It is important to use only pellet fuel that is dry and free from dirt or other impurities. The pellet fuel industry has established standards for wood pellet manufacturers. We recommend that pellet fuel used in all U.S. Stove pellet burning grills meet or exceed the following specifications: Use ONLY pelletized fuel formulated for cooking Do Not Use Pellet Fuel Labeled as Having Additives Fines (fine particles)... Maximum through a 1/8 screen Bulk Density... Minimum 40 lbs per cubic foot Size... Maximum 3/8 Diameter by 1-1/2 length Ash Content... 1% Maximum (Premium grade) 3% Maximum (Standard grade) Moisture Content... 8% Maximum Heat Content... Minimum 8,200 btu s per hour Using cooking pellets will increase flavor and efficiency It is important to note that the ash content of the fuel and frequency of operation will determine the frequency of which you will be required to clean your pellet grill. A high ash fuel may result in daily cleaning, while a low ash content fuel may result in less frequent cleaning. Occasionally, impurities in the fuel will cause a hard mass build up in the burn pot of your Pellet Grill. Impurities, such as silica, can virtually form little glass balls when subjected to the high heat generated in the burn pot. When allowed to collect, a hard base build up may block air flow through the burn pot, which will significantly affect the performance and efficiency of your Pellet Grill. It is a good idea to check the burn pot for any hard mass buildup or other blockage on a daily basis, and if necessary, let the burn pot cool and then clean the burn pot. U.S. Stove Company realizes that it cannot control the quality of pellet fuel you choose to use in your Pellet Grill; U.S. Stove assumes no responsibility for that choice. CAUTION: BE SURE TO STORE PELLET FUEL A MINIMUM OF 3 FEET (914.5MM) AWAY FROM THE PELLET GRILL. RADIANT HEAT CAN IGNITE THE FUEL. Please note that the rating label is located on the inside of the hopper lid. -2-
Safety Information IMPORTANT: Read this entire manual before A power surge protector is required. This unit must installing and operating this product. Failure to do be plugged into a 110-120V, 60 Hz grounded so may result in property damage, bodily injury, or electrical outlet. Do not use an adapter plug even death. Proper utilization of this grill is crucial or sever the grounding plug. Do not route the for safe and efficient operation. electrical cord underneath, in front of, or over the Warning: do not operate this grill under a ceiling or grill. Do not route the cord in foot traffic areas or overhang. pinch the cord under any object. Contact your local building officials to obtain Unplug the grill when not in use. a permit and information on any additional The grill will not operate during a power outage. If installation restrictions or inspection requirements in a power outage does occur, check for unsafe burn your area. conditions that might have occurred. Do not throw this manual away. This manual has Never block free airflow through the open vents of important operating and maintenance instructions the unit. that you will need at a later time. Always follow the Keep foreign objects out of the hopper. instructions in this manual. The moving parts of this grill are propelled by high This appliance is designed for the use of pelletized torque electric motors. Keep all body parts away fuel that meet or exceed the standard set by the from the auger while the grill is plugged into an Pellet Fuel Institute(PFI). The use of other fuels will electrical outlet. These moving parts may begin to void warranty. move at any time while the grill is plugged in. Use only pelletized fuel formulated for cooking. Do not place clothing or other flammable items on Never use gasoline, gasoline-type lantern fuel, or near this grill. kerosene, charcoal lighter fluid, or similar liquids to This appliance is not intended for commercial use. start or freshen up a fire in this appliance. Keep all Warning: Operate your pellet grill only on a such liquids well away from the appliance when in noncombustible floor or provide floor protection use. adequate to provide ember protection around grill. Do not unplug the grill if you suspect a malfunction. Creosote-Formation and need for removal. When Turn the ON/OFF SWITCH to OFF and contact your wood pellets are burned slowly, they produce dealer. tar and other organic vapors that combine with Your grill requires periodic maintenance and expelled moisture to form creosote. The creosote cleaning (see MAINTENANCE ). Failure to maintain vapors condense in a relatively cool oven flue and your grill may lead to improper and/or unsafe exhaust hood of a slow burning fire. As a result, operation. creosote residue accumulates on the flue lining Disconnect the power cord before performing any and exhaust hood. When ignited, this creosote maintenance! NOTE: Turning the ON/OFF Switch makes an extremely hot fire. to OFF does not disconnect all power to the When grease or creosote has accumulated, it electrical components of the grill. should be removed to reduce risk of fire. Never try to repair or replace any part of the Do not use accessories not specified for use with grill unless instructions for doing so are given in this appliance. this manual. All other work should be done by a Follow these guidelines to prevent this colorless, trained technician. odorless gas from poisoning you, your family or Allow the grill to cool before performing any others. maintenance or cleaning. Know the symptoms of carbon monoxide Disposal of ashes Ashes should be placed in a poisoning: headache, dizziness, weakness, nausea, metal container with a tight-fitting lid. The closed vomiting, sleepiness, and confusion. Carbon container of ashes should be placed on a noncombustible floor or on the ground, well away from oxygen. Low blood oxygen levels can result in loss monoxide reduces the blood s ability to carry all combustible materials, pending final disposal. of consciousness and death. When the ashes are disposed by burial in soil or See a doctor if you or others develop cold or flu-like otherwise locally dispersed, they should be retained symptoms while cooking or in the vicinity of this in the closed container until all cinders have appliance. Carbon monoxide poisoning, which thoroughly cooled. can easily be mistaken for a cold or flue, is often Do not touch the hot surfaces of the grill. Educate detected too late. all children on the dangers of a high-temperature Alcohol consumption and drug use increase the grill. Young children should be supervised when effects of carbon monoxide poisoning. they are in the vicinity as the grill. Carbon monoxide is especially toxic to mother The hopper and grill top will be hot during and child during pregnancy, infants, the elderly, operation; therefore, you should always use some smokers, and people with blood or circulatory type of hand protection when refueling your grill. system problems, such as anemia, or heart disease. -3-
Clearance to Combustibles Warning: Install your pellet grill only on a noncombustible floor or provide floor protection adequate to provide ember protection as shown below. Your pellet grill must be installed with 24 (609mm) REAR WALL clearance to combustibles as shown below. Warning: Do not operate this grill under a ceiling or overhang. 24 24 REAR WALL SIDE WALL SIDE WALL FLOOR PROTECTOR 12 12 12 12 FLOOR PROTECTOR 12 FLOOR PROTECTOR 12 48 FLOOR PROTECTOR -4-
Assembly Instructions READ ALL INSTRUCTIONS BEFORE INSTALLING AND USING THE APPLIANCE Tools and Materials Needed For Installation: You will need a #2 phillip screw driver for assembly. Using a drill with a phillips bit will speed the assembly process. Two (2) 7/16 socket/wrench to install wheels. A 5mm hex drive to install the handles. Use proper assembly technique, when installing bolts start all bolts first and then tighten appropriately. The assistance of a second person is strongly recommended. You will have to remove the grill contents for assembly. Do Not Remove The Searing Station. STEP 1 BASE AND PEDESTAL ASSEMBLY 1. Attach the swivel wheels to base using four (4) 1/4-20 x 3/4 bolts. Insert the axel through the base and slide on wheels, then use acorn nuts provided to fasten. 2. Assemble the pedestal using the provided six (6) 1/4-20 x 3/4 bolts. The bolts will screw into the already attached threaded inserts. 3. Attach the pedestal to the base using six (6) 1/4-20 x 3/4 bolts along the bottom. 4. Attach main grill body to assembled pedestal with six (6) 1/4-20 x 3/4 bolts. Screw bolts along bottom of grill body into the rivet nuts already installed in the pedestal pieces. Parts List Description Qty Pedestal, Right Side 1 Pedestal, Left Side 1 Pedestal, Center 1 Base (HCPG561) 1 Base (HCPG442) 1 Caster Wheel 2 Fixed Wheel 2 1/4-20 Bolt x 3/4 32 1/4-20 Nut 6 1/4-20 Bolt x 1-1/4 6 Smoke Stack 2 Side Handle 1 Smoke Stack Flap 2 Acorn Nut Wheel Installation STEP 2 SMOKE STACK/BAFFLE 1. Install smoke stacks and baffle in grill lid as shown. (Stack goes up through lid) 2. Line up holes of the exhaust baffle to the smoke stack. Insert three (3) 1/4-20 x 1-1/4 bolts per stack into holes in the top of the grill lid. Screw on 1/4-20 nuts. 3. Attach smoke pipe flaps to top of smoke stack. Exhaust Baffel A 1/4-20 Nut Threaded Inserts 1/4-20 x 1-1/4 Bolt Pedestal Smoke Stack Pedestal and Base Assembly Smoke Stack Installation Note: There are three cushion pads installed between the lid and the body of the unit are for shipping purposes only. Please remove them. Smoke Pipe Flap Flat and Lock Washer STEP 3 HANDLES ASSEMBLY 1. Attach front lid handle to grill lid using supplied bolts. 2. Attach side handle to main grill body using supplied bolts. Insure the beauty rings are on the handle. Handle Installation -5-
STEP 4 SIDE TABLE ASSEMBLY 1. Route Temperature probe wires out the obround hole on the side of grill. 2. Attach the side table to the grill using four (4) ¼-20 x 3/4 bolts. 3. Insert the temperature probe wires thru the grommet on electrical plate and make wiring connections. 4. Install ¼-20 nuts to hold wiring harness in place. Poke excess wire from temp probe into side table Insure all electrical connections are inside the table before securing the electrical plate. Parts List Description Qty Side Table 1 1/4-20 Nut 2 1/4-20 x 0.75 Bolt 4 MAIN WIRING HARNESS TEMPERATURE PROB WIRES ELECTRICAL PLATE STEP 5 GRILL SURFACE, DRIP PAN, AND FLAME PLATE ASSEMBLY Place flame plate in bottom of grill body. Center cutout in flame plate around auger body. Flame plate is marked to show the front. Insure flame plate is level. WARNING: If flame plate is installed incorrectly the pellets may burn back into the Q hopper, and/or the grill may smoke excessively during cook mode and may not maintain set cooking temperature properly. Place right drip pan onto grease drain support, with flange toward the side of the grill. Y Place left drip pan onto drip pan mounts. (left drip pan rests on top of right drip pan.) Place main grilling surface on grill mounting bracket. Align with searing station. *HCPG442 does not have the searing station. A second grill surface is provided. SAVE THESE INSTRUCTIONS Wiring Harness Connections S Description TINNERMAN CLIPS ON SIDE TABLE Parts List Qty Flame Plate 1 Right R Drip Pan (HCPG561) 1 Right Drip Pan (HCPG442) 1 Left Drip Pan (HCPG561) 1 Left Drip Pan (HCPG442) 1 Main Grill (HCPG561) 1 Main Grill (HCPG442) 1 Searing Station (HCPG561) Small Grill (HCPG442) 1 1 W -6-
Initial Firing Procedure TO BE USED ON INITIAL FIRING (Searing Station, if installed, is installed by Manufacturer. DO NOT remove.) 1. Open the lid and remove the grilling surface, drip pan and flame plate. 2. Open the pellet hopper lid and check for foreign objects in the hopper. 3. Plug the grill into a three wire, grounded wall outlet. 4. Press the power button to turn the unit on. DO NOT TOUCH THE AUGER OR THE IGNITOR! Look to see that the auger is turning. DO NOT TOUCH. 5. Open the hopper lid and check to see that the auger is turning freely - approximately 2 rpm. 6. Place your fingers over the burnpot and feel the air movement from the combustion blower. Ignitor will glow within 1 minute. 7. Press the Power Button to turn the unit off. 8. Before replacing the removed components, Clean all items with soap and water, then rinse and allow to dry. Re-install components. DO NOT TOUCH THE IGNITOR OR THE AUGER. PREPARING TO USE YOUR GRILL Important: You must season the grill before cooking any food on your grill for the first time. The unit must be operated at maximum temperature for 1 hour with the lid closed. This allows any oil residue from the manufacturing process to burn off and also allows the high temperature paint to cure. Avoid placing any items on the unit during this period as the paint could be permanently damaged. -7-
Standard Use Operating Instructions Always make certain that the grill is setting level or is slightly tilted towards the drip bucket. STANDARD STARTUP SEQUENCE 1. Fill the hopper with pellets. Be sure to close and latch the hopper lid. Burn only pellets that are specifically manufactured for use in pellet grills and cookers. Never leave pellets in the hopper. Only use the amount of pellets needed to cook for any given time. 2. Open the grill lid and press the Power button. The Cook or Smoke mode lights will begin to flash indicating that the grill is in its startup sequence in the respective mode. The grill will automatically light 5 to 8 minutes after pressing the Power button. The button located on the control panel labeled Prime is used to prime the auger. When pressed it causes the auger to spin and feed pellets. NOTE: The startup mode will last approximately 15 minutes. It is normal for the grill to smoke excessively during startup. 3. Set the control board to the desired cooking temperature using the Cook Temp buttons on the control board. Temperature settings are in 5 F increments. 4. Once the grill ignites, you will hear a flowing sound slightly louder than the blower motors of the grill. You should also notice a significant reduction in the amount of smoke being produced. Close the grill lid once ignition has occurred. NOTE: Allow the grill lid to remain closed during the pre-heat and as much as possible during cook time. Feed rates during run mode are determined by temperature readings, so each time the lid is opened, the temperature goes down, and thus, the auger feeds more. This can lead to potential overcooking of food. 5. You can easily check the actual temperature compared to the set-point temperature by using the Display button on the control board. This allows you to determine when the grill has preheated to your desired cooking temperature. NOTE: During the startup, the grill temperature can exceed the set-point temperature. So, it is recommended that you leave the display in Actual to monitor the temperature readings and avoid overcooking or burning. You can easily tell if the stove is still in startup by the Cook or Smoke light blinking (depending on which mode you have the grill set). 6. When startup time (15 minutes) has been met and the grill has reached its set-point temperature, you are now ready to add food. NOTE: As previously mentioned, keep lid closed as much as possible to maintain constant cooking temperature. Temperature may fluctuate slightly.!! NOTICE!! During operation, the technology in this grill s programming learns the fuel rate needed to sustain the selected cooking temperature. Therefore, start-up times may vary based on outside ambient temperature and fuel quality or type (flavored or not). Using the Prime button may help facilitate a quicker start-up time. STANDARD SHUTDOWN SEQUENCE 1. When you are ready to turn the grill off, make sure the searing station is off. The light will be off when the searing station is off. 2. Press the Power button. 3. The display will go blank and the grill will enter a shutdown mode where the blower will continue to run until it has reached a safe temperature. NOTE: The Cook light will remain solid and the Smoke light will flash during this sequence. Shutdown sequence can take up to 1 hr depending on the cook temperature and the outside temperature. DO NOT TURN THE GRILL OFF BY UNPLUGGING IT. SAVE THESE INSTRUCTIONS. Power Patent Pending Change between "Cook" and "Smoke" Mode Primes the auger Adjust cook temperature Change temperature display -8-
Operating Tips When the grill is plugged in, the control board will flash through a sequence of letters and numbers before going to a blank display screen. When you turn the grill ON the Mode in which the grill is in flashes for 15 minutes, until startup sequence is finished. Grill operating temperatures are 180 F to 500 F. When grill is first turned ON, the control board will go to 350, on first ignition. If grill has been used, the control board will go to the last setting used. Smoke mode is from 180 to 295. The combustion blower does pulsate during Smoke Mode but only after startup mode is reached (the blower does not pulsate for first 15 min of operation). The concentration of smoke will vary depending on the temperature selected. You will notice a higher concentration of smoke at lower settings than when operating at higher temperatures for smoke mode. Combustion blower is on constant during Cook Mode and does not vary in speed. If you turn the grill off during Startup Mode, everything shuts off without a shutdown sequence. If the flame plate is installed improperly, a burn back may occur due to the airflow restrictions at the burnpot. The Searing Station control is operable from the toggle switch only. Only turn on the searing station for the needed time of use. Make sure to turn the searing station off when not in use. The searing station will function even if the grill is not in operation. Always unplug the grill when not in use. It is not recommend using the Searing Station during your general cooking needs, as it can interfere with the temperature sensor. Only use the searing station to quickly sear your food and then turn it off. The searing station takes approximately 5 minutes to reach a searing temperature during use in the grill Cook settings. If you are in Cook mode and change to Smoke mode, the temperature will automatically go to 295. If you are in Smoke mode and change to Cook mode, the temperature will automatically go to 300. Temperature control doesn t begin to read and control feed rate for 15 minutes, due to the 15 minute start up sequence. Make sure to unplug your grill only after it has gone through the shutdown sequence, cooled off, and is not in use. DO NOT unplug your grill during use or to shorten the shutdown sequence. Note: These are suggested approximations only and intended as guidelines only. For best results please follow appropriate recipe. Meat Type Cut Suggested Cooking temp. Suggested Cook Time Beef Hamburgers 425 F Approx. 10 min. on each side Beef T-Bone/Ribeye 450 F Beef Tenderloin 400 F Beef Brisket 225 F Approx. 4-6 hrs Beef Filet Mignon 450 F Beef Flank Steak 450 F Beef Ribs 225 F Approx. 3-4 hrs Pork Loin 350 F Approx. 1 to 1.5 hrs Pork Baby Back Ribs 325 F Approx. 2 hrs Pork Shoulder Steak 325 F Approx. 35 to 40 min Pork Ground Pork 300 F Approx. 45 min Pork Pork Chops 325 F Approx. 45-50 min. Approx. 10 to 20 min (depending on degree of doneness desired) turning once Approx. 25 to 30 min (depending on degree of doneness desired) Approx. 10 to 15 min (depending on degree of doneness desired) turning once Approx. 10 to 15 min (depending on degree of doneness desired) turning once Chicken Breast 350 F Approx. 25-30 min, turning once 1/2 way through Chicken Thighs 350 F Approx. 40-45mins Chicken Whole Chicken 4-5lbs 450 F Approx. 70-90 mins Turkey 10-12lb Turkey 325 F Approx. 3hrs Turkey Legs 225 F Approx. 4-5 hrs Lamb Rack of Lamb 400 F Approx. 30 min, for Rare, longer if desired Lamb Lamb Chops 450 F Approx. 12 min, turn once 1/2 way through Salmon Filet 350 F Approx. 25-30 min. Cod Loin 400 F Approx. 20 min Scallops Scallop 450 F Approx. 8-10 min Shrimp Whole Shrimp 450 F Approx. 2-3 min/side Lobster Tail 400 F Approx 25-30 min -9-
Troubleshooting Failure to clean and maintain this unit as indicated may result in poor performance and hazardous situations. The maintenance schedule must be adjusted based on use to insure proper operation and maximum efficiency of your pellet grill. When you are performing any maintenance on your grill, make sure the unit has been turned off, allowing full shutdown sequence, and then unplugged from the power source. Operation Clean drip pan Maintenance Schedule Inspect and clean burn pot Inspect hopper for fines (sawdust) Ash removal Inspect and clean combustion air blower Interval Daily Daily Biweekly Daily Annually CLEAN DRIP PAN Note: Let the unit cool to ambient temperature before inspecting or cleaning your grill. 1. Remove the main grilling surface. (DO NOT remove the searing station.) 2. Scrape drippings down grease drain and into grease bucket provided. 3. Clean drip pan with food safe de-greasing agent. 4. Insure all cleaning solvents and chemicals are rinsed thoroughly after cleaning. 5. Empty grease bucket if necessary. 6. Reinstall grilling surface. INSPECT AND CLEAN BURN POT Note: Let the unit cool to ambient temperature before inspecting or cleaning your grill. 7. Remove the main grilling surface, drip pan, and flame plate. (DO NOT remove the searing station.) 8. Inspect the burn pot to check that the combustion air holes have not become plugged. If necessary, clean thoroughly. 9. Replace the flame plate, drip pan, and grilling surface. INSPECT HOPPER FOR FINES Note: Let the unit cool to ambient temperature before inspecting or cleaning your grill. Periodically check the hopper for pellet dust (fines) build up. The accumulation of fines can reduce the efficiency of your grill, increase the chance of hopper fires, and other unsafe operating conditions. If dust (fines) accumulate sufficiently, vacuum out and reload hopper with new pellets. ASH REMOVAL Note: Let the unit cool to ambient temperature before inspecting or cleaning your grill. 10. Vacuum to remove ashes from burn pot and bottom of grill body. BE SURE THAT THE ASHES ARE COOL TO THE TOUCH BEFORE VACUUMING. Some vacuums may leak ash. Your vacuum should have a special filter or bag to eliminate leakage. 11. Dispose of ashes into metal container. DISPOSAL OF ASHES Ashes should be placed in a steel 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. If the ashes are disposed of by burial in soil or otherwise locally dispersed, they should be retained in the closed container until all cinders have been thoroughly cooled. Do not place other waste in the same container. INSPECT AND CLEAN COMBUSTION AIR BLOWER Note: Let the unit cool to ambient temperature before inspecting or cleaning your grill. DANGER: RISK OF ELECTRIC SHOCK. DISCONNECT POWER BEFORE SERVICING UNIT. Over time ash or dust may accumulate on the blades of the fans. The fans should be inspected and if any accumulation is present vacuumed clean as the ash or dust can impede the fans performance. 1. Open the service panel by removing the two screws, then tilting down. 2. Inspect the fan for dust or ash build up. Clean if necessary. 3. Close the service panel and reinsert screws. -10-
Troubleshooting ERROR CODES Possible Causes 1. Error Code 1 - Over Temperature - The measured temperature has exceeded the overtemp set point. 2. Error Code 2 - No Start - The grill did not reach the warm condition set point before the timer expired (15 Min.) 3. Error Code 3 - Power Failure - The power failed while the grill was operating and the grill temperature was below the warm set point when power was returned. Possible Remedies (Unplug stove first when possible) Call Customer service (800) 750-2723. Visually inspect the ignition system. Try to start the grill again. If the grill fails to start a second time call customer service (800) 750-2723. Press the power and the prime button at the same time to resume standard operation. GRILL ENTERS SHUTDOWN MODE UNEXPECTEDLY Possible Causes 1. The convection blower is overheating and tripping the internal temperature shutoff. 2. The grill is being left on the highest setting for extended periods of time. 3. Fuel other than wood pellets is being burned in the stove. 4. Power surge or brown out situation. Possible Remedies (Unplug stove first when possible) Clean any dust off of the windings and fan blades. If oiling the blower does not help, the blower may be bad. If operating the grill on the highest heat setting, the room temperature could increase enough and lead to potential overheating situations. If this happens, try operating at a lower heat setting. This pellet grill is designed and tested to use cooking wood pellets. Check for signs of fuel other than wood pellets. No other types of fuel have been approved for this pellet grill. If there are signs of other types of fuel being used, stop using them immediately. A power surge, spike, or voltage drop could cause the thermocouple to malfunction. Use a surge protector 5. Thermocouple is malfunctioning. If the other items check out OK, replace the thermocouple. AFTER GRILL HAS BEEN ON FOR A WHILE, THE BURNPOT OVERFILLS Possible Causes 1. Grill is dirty, which restricts airflow through the burnpot. Possible Remedies (Unplug stove first when possible) Follow all cleaning procedures in the maintenance section of the owner s manual. 2. Burnpot holes are blocked. Remove the burnpot and thoroughly clean it. 3. Blockage in air intake pipe. 4. Combustion blower is not spinning fast enough. 5. Bad Pellets. Visually inspect the air intake that leads into the burnpot for foreign material. Clean fan blades and inspect bearings for wear. Ensure the fan is free of any obstructions. The brand of pellets or the batch of pellets that are being used may be of poor quality. If possible, try a different brand of pellets. You might also want to try a brand that is made from a different type of wood (softwood vs. hardwood). Different woods have different characteristics when being burned. -11-
Troubleshooting POWER FAILURE DURING USE Possible Causes 1. Power goes out during operation. 2. To restart unit after power outage. Possible Remedies (Unplug stove first when possible) Observe the grill to make certain unsafe burning conditions do not occur during the outage. Press the power and the prime button at the same time to resume standard operation. STOVE FEEDS PELLETS, BUT WILL NOT IGNITE Possible Causes 1. Bad igniter element. 2. The control board is not sending power to the igniter. Possible Remedies (Unplug stove first when possible) Put power directly to the igniter element. Watch the tip of the igniter from the front of the stove. After about 2 minutes the tip should glow. If it does not, the element is bad. Check the voltage going to the igniter during startup. It should be 110-115 volts. If the voltage is lower than full voltage, check the wiring. If the wiring checks out good, the board could be bad. STOVE WILL NOT FEED PELLETS Possible Causes 1. Thermocouple is defective. 2. Bad Auger Motor. 3. Auger Jam. 4. Loose wire or connector. 5. Bad control board. Possible Remedies (Unplug grill first when possible) Wait for the stove to cool for about 30-45 minutes. Check the thermocouple to see if it s bad. Check resistance with volt meter. Remove the two retaining screws in the service panel and swing out of the way. Remove the auger motor from the auger shaft and try to run the unit. If the motor will turn, the shaft is jammed on something. If the motor will not turn, the motor is bad. Start by emptying the hopper. Then remove the auger motor by removing the auger pin. Remove the two screws holding the auger bushing. Gently pull the auger shaft straight out so that the end of the auger shaft comes out. After you have removed the shaft, inspect it for bent flights, burrs, or broken welds. Remove any foreign material that might have caused the jam. Also, check the auger tube for signs of damage such as burrs, rough spots, or grooves cut into the metal that could have caused a jam. Check all wires and connectors that connect to the auger motor, thermocouple, and the fan. If the fuse is good, the wires and connectors check out good, and the high limit switch did not trip, test for power going to the auger motor. If there is not a full current going to the auger motor when the fuel feed light is on, you have a bad control board. -12-
Parts Diagram 1 2 3 29 4 5 6 28 7 27 10 8 26 9 11 25 15 12 24 13 23 16 14 22 17 18 21 19 20-13-
Replacement Parts Key Part No. Description Qty 1 69860 Flap, Smoke Pipe 2 2 69835 Stack, Smoke 2 3 4 69828 (HCPG561) 1 Lid Weldment, Grill 69840 (HCPG442) 1 26578 (HCPG561) 26630 (HCPG442) Exhaust Baffle 1 5 26577 Warming Grill 1 6 80633 (HCPG561) Station, Searing 1 892277 (HCPG442) Small Grilling Grate 1 7 69981 Drip Pan, Right 1 8 26141 Plate, Flame 1 9 892216 Engine Assy., Pellet Grill 1 10 69830 Assembly, Hopper 1 11 26588 Hopper Cover Panel 1 12 80062* 90 Conduit Clamp 1 13 80061* Wire Conduit 4.3 Ft 14 80086* Conduit Fitting 3 15 892221 Handle, Side 1 16 892223 Bucket, 4 1 17 26583 Pedestal, Right Side 1 18 69927 (HCPG561) 1 Weldment, Base 69936 (HCPG442) 1 19 892332 Caster Wheel 2 20 892331 Fixed Wheel 2 21 86686 Wheel axel 1 22 26585 Pedestal, Center 1 23 26584 Pedestal, Left Side 1 24 69852 Assy, Main Conduit 1 25 69834 Weldment, Side Table 1 26 27 28 80634 80634 Rtd, Temperature Probe (Grill) Rtd, Temperature Probe (Grill) 26154 (HCPG561) 1 Drip Pan, Left 26146 (HCPG442) 1 892219 (HCPG561) 1 Grate, Grilling 892218 (HCPG442) 1 29 892220 Handle, Lid 1 1 1 * Searing station, wiring and controls are optional on the HCPG442 and standard on the HCPG561 In order to maintain warranty, components must be replaced using original manufacturers parts purchased through your dealer or directly from the appliance manufacturer. Use of third party components will void the warranty. -14-
Parts Diagram Key Part No. Description Qty. 1 80628 Assembly, PCB - Board 1 2 80636* Searing Station Control 1 3 26126 Electrical Plate, Side Table 1 4 69855 Side Table Bottom 1 5 69834 Weldment, Side Table 1 6 80638 Auger Motor 1 7 892235 Auger Bushing 1 8 892234 Auger 1 9 80640 Ignitor Cartridge 1 10 892217 Burnpot 1 11 80639 Induction Fan 1 5 1 2 4 10 3 9 6 7 8 11 In order to maintain warranty, components must be replaced using original manufacturers parts purchased through your dealer or directly from the appliance manufacturer. Use of third party components will void the warranty. -15-
Wiring Diagram (With Searing Station) -16-
Wiring Diagram (Without Searing Station) -17-
Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. SERVICE PROVIDER Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer s instructions. Always use the manufacturer's specified spare part when replacement is necessary. Service 01 Date: Engineer Name: License No.: Company: Telephone No.: Stove Inspected: Chimney Swept: Items Replaced: Service 02 Date: Engineer Name: License No.: Company: Telephone No.: Stove Inspected: Chimney Swept: Items Replaced: Service 03 Date: Engineer Name: License No.: Company: Telephone No.: Stove Inspected: Chimney Swept: Items Replaced: Service 04 Date: Engineer Name: License No.: Company: Telephone No.: Stove Inspected: Chimney Swept: Items Replaced: Service 05 Date: Engineer Name: License No.: Company: Telephone No.: Stove Inspected: Chimney Swept: Items Replaced: Service 06 Date: Engineer Name: License No.: Company: Telephone No.: Stove Inspected: Chimney Swept: Items Replaced: Service 07 Date: Engineer Name: License No.: Company: Telephone No.: Stove Inspected: Chimney Swept: Items Replaced: Service 08 Date: Engineer Name: License No.: Company: Telephone No.: Stove Inspected: Chimney Swept: Items Replaced: 18
Limited Warranty Electric / Gas / Pellet / Solid Wood Patio & Cooking Appliances / Infrared Heaters The operation of this appliance in a manner inconsistent with the owner s manual will void the warranty and is also against federal regulations. United States Stove Company warrants to the original purchaser its products against premature failure of any component due to workmanship, quality, or materials as follows: TIME PERIOD: PG30 / PG36 Body...Three Years All Other Applicable Products...One Year CLAIM PROCEDURE Any defects should be reported to United States Stove Company or its dealer and/or distributor giving descriptions and pertinent data, including proof or purchase which will be returned upon request. Providing the heater has been installed and used in accordance with the Owners Manual supplied with the heater, United States Stove Company will either: 1) Replace the defective part free of charge 2) Replace the heater free of charge 3) Where the defect is of a cosmetic (non-functional) nature, United States Stove Company will bear reasonable expense to refurbish the heater, including such items as welding, painting, and incidental labor. A Reasonable is defined by terms of this warranty as $30.00/hour with full refund for any purchase of parts from U.S. Stove Company. NOT COVERED Specifically not covered under terms of this limited warranty or any other warranty are problems relating to smoking or creosote. Smoking is attributable to inadequate draft due to the design or installation of the flue system or installation of the heater itself. Creosote formation is largely attributable to improper operation of the unit and/or draft as mentioned above. Also, not covered are: 1) Removal and re-installation cost. 2) Service calls to diagnose trouble (unless authorized in writing by the manufacturer, distributor, or dealer). 3) Painted or plated surfaces. 4) Damage or defect caused by improper installation, accidents, misuse, abuse (including overfiring) or alteration. 5) Transportation or shipping costs. LIMITATIONS AND EXCLUSIONS 1) United States Stove Company shall not be liable for incidental, consequential, special, or contingent damages anyone might suffer as a result of their breach of this written warranty or any implied warranty. 2) Should the heater be replaced by United States Stove Company free of charge, all further warranty obligations are thereby met. 3) Parts and/or service replacements made under the terms of this warranty are warranted only for the remaining period of the original heater warranty. 4) Without specific written exclusionary waivers, no one has authority to add to or vary this limited warranty, or to create for United States Stove Company any further obligation of liability in connection with this heater or any other applicable accessory. Any further warranty implication applicable to this heater or any applicable accessory is limited in duration to the same time period as the original statement in the above schedule. YOUR DUTIES 1) This heater, including all applicable accessories, must be installed and operated in accordance with local authorities having jurisdiction and the instructions furnished with the Owners Manual. 2) You should keep as permanent record your proof of purchase (or canceled check or invoice). PROBLEM/RESOLUTION 1) As purchaser, you must first contact the dealer and/or distributor from whom you purchased your heater. 2) If within a reasonable period of time you do not receive satisfactory service from the distributor and/or dealer, write or call United States Stove Company, Customer Service Department, including complete details of the problem and/or problems you are experiencing, details of your installation, your proof of purchase, and the heater serial number or test agency code number. WARRANTOR The warrantor of record is United States Stove Company, PO Box 151, 227 Industrial Park Road, South Pittsburg, Tennessee 37380. Phone number: (800)-750-2723 Website: www.usstove.com NOTE This warranty gives you specific legal rights; and, you may also have other rights which vary from state to state. Register your product on line at www.usstove.com. Save your receipt with your records for any claims. IMPORTANT We congratulate you on your selection of United States Stove Company and its products. As the oldest solid fuel manufacturer in the United States (since 1869), the United States Stove Company is very proud of its products, service, employees, and satisfied customers. We would like to hear from you if you are not satisfied with the manner in which you have been handled by our distributor, dealer, representative, customer service department, parts department, or sales department. Please reach out to us by using any of the contact information listed above. 19 852222B
How to Order Repair Parts This manual will help you obtain efficient, dependable service from your Grill, and enable you to order repair parts correctly. Keep this manual in a safe place for future reference. The full model number is located on the nameplate attached to the grill. When ordering repair parts, always give the following information as shown in this list: 1. The part number: 2. The part description: 3. The model number: 4. The serial number: United States Stove Company 227 Industrial Park Road South Pittsburg, TN 37380 (800) 750-2723 www.usstove.com