Morning everyone -
I had to disappear for a bit last night, but I think we're super close on this thing.
According to the stove owner, two guys were up there to work on the stove (prior to her getting me involved). The first guy cleaned/emptied/oiled/refilled everything, but never found the bad switch (and also never messed with any other wiring), so he moved on. The second guy came to address the switch, but got frustrated and bailed - but supposed never messed with any of the other wiring. She thinks all the rest of the stove's wiring is just as it has been for years.
There a lot of questions I need to catch up....first of all, the mystery wire leads from the double pole/double throw switch area to the therm-controlled switches. The wire wasn't rough, necessarily, but it's all older, cloth covered wiring. Those are found at the back of the unit, near the top. There's an access panel approx 4 X 6 inches or so. It was tough to determine exactly where it went, as it runs behind the back panel of the unit, and is clustered with several other wires. From using a continuity test, we BELIEVE that it was/is this wire here:
Interestingly enough, the wire just to the left of the hightlighted wire also tested continuous with the highlighted wire, like the switch was already closed (even though the stove was off at the time). Not sure if that's correct or not - just pointing that out. I may need to recheck my details on this, but I think that's what I recall.
Now - the two temp switches/limit switches: they do have adjustable dials on them. If my memory serves me (again - I'll have to check to confirm) the one on the right (as we're looking at them in the photo) was set a bit lower, around 150 degrees - I THINK. The one on the left was a bit higher, set at 170. I may have that backwards. I can check pretty easily, and will do so later this afternoon. I'm not sure what amount of voltage the switches are/were getting when the main switch is set to "heat". I can check. Honestly, I wasn't sure where one limit switch began and ended. Am I correct in that there are 2 switches there, and the wire comes in at then out at the center, with the two terminals on the same switch divided by that small plastic wall? If that's the case, then the switch on the left was already in closed position, even with the stove not being hot, as it tested continuous right away.
I like your idea to jumper the switch, Scottscoaled. That makes good sense, and will give each wire its own terminal. The way you described to wire it all is just what we'd suspected it should be. In fact, we've wired it all just like that, save for the fact that our auger/comb fan AND circulation fan wires are sharing a terminal (simply because I hadn't thought to jumper that center power terminal). Thank you for the detailed description!
At this point, I think we've got it wired exactly right. It was obviously a broken main switch that set this whole process in motion, and I think we're in good shape on that front (I'll get it jumpered today). I just want to check that her fan limit switch is working and doing its job, since I've never seen the fan come on at all when the main switch is set to "heat". Either we never got it hot enough to call for the fan, or the limit switch is bad (or perhaps just improperly adjusted). Is there an easy way to test the limit switch? Hit it with a hot hair dryer/heat gun? Anyone know what the two temp dials should be set to? Scottscoaled suggested that the right one should be at/near 160. What about the left one?
When we left the stove yesterday afternoon, it was functioning just fine, save the circulation fan. The wall thermo was calling for heat just fine, and was stopping the heat once the room reached temps. The auger/comb fan were working great, doing what they should when they should. Not sure what the hold fire timer was doing just yet; we'll address that once we get this circulation fan dialed in. The stove was radiating heat very nicely, and we put a box fan near the stove to help move the warm air further into her home. She was very pleased to have even that, and I was confident that she would have SOMETHING to help keep her warm during these freezing cold temps that we've been having. (As a side note, did I mention that she was heating with her electric stove when we walked in? The oven door was open and the top burners were glowing red. Yikes - that's not safe/affordable at all. This whole scenario makes me VERY thankful for you guys and your help!)
Once we get that limit switch right where we want it (functional and set for correct temps), then she ought to be ready to go for the duration of the winter, right? I'll take a look at the hold fire timer, but I'm betting it's trucking along like the rest of the stove.