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Magnum 6500 Owner's Manual

Corn/wood pellet furnace
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CORN/WOOD PELLET FURNACE
THIS APPLIANCE HAS BEEN TESTED AND APPROVED TO CSA B 366.1-M91-CAN/USA & UL 391-99
Installation – Operation – Maintenance Instructions
WARNING: THIS INSTRUCTION MANUAL MUST BE SAVED FOR FUTURE REFERENCE
PLEASE READ THIS ENTIRE MANUAL BEFORE INSTALLATION AND USE OF THIS CORN/WOOD PELLET
BURNING FURNACE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PROPERTY
REFER TO ADDITIONAL MARKINGS ON APPLIANCE FOR ADDITIONAL INSTRUCTIONS
IMPORTANT: Always contact your local dealer/installer with questions before contacting the factory.
When you call have your serial number, purchase date, who installed the unit and a list of questions.
This appliance must be installed by a HVAC licensed/trained factory approved installer
 When installing your Magnum 6500/7500 Corn/Wood Pellet Furnace, particular attention needs to be
made in regards to fire protection. If the unit is not properly installed, a house fire may result. For your
safety, follow the installation and operation instructions provided, and if a question arises contact local
building or fire officials about restrictions and installation requirements in your area.
 Read the operations and fuel section of this manual before plugging in your unit.
 Always unplug the unit before attempting any service work.
 Do not connect the unit to a chimney flue already serving another appliance.
 When installing the chimney pipe to the unit, it is important to remember that the unit operates on a
negative pressure and the chimney on a positive pressure. All chimney connections, elbows and fittings
must be airtight. (proper venting practices must be followed. Consult with a venting professional)
 Ashes must be disposed of in a metal container with a tight fitting lid. Do not let ashes build up in ashpan.
 All minimum clearances to combustibles must be followed. Ductwork clearances must be maintained.
 The Magnum 6500/7500 Corn/Wood Pellet Furnace is tested for operation with 14% or less moisture
corn or with wood pellets with an ash content of no more than 3%. It is recommended that Corn with
11-12% moisture or wood pellets with an ash content of 1% or less be used for efficient operation of
this unit. Corn over 12% moisture has a lower BTU value and will be hard to burn on the lower
settings. Fuel over 12% moisture will dramatically reduce the heating ability of this appliance.
 It is important to use fuel that is clean, dry and consistent. Make sure that your supplier is giving you
the same fuel each time that you purchase. It is recommended that you purchase your entire heating season
supply of fuel at one time so that the fuel will be the same.
 A voltage surge protector or ground fault outlet is required for this unit. The warranty on the
circuit board will be voided if proper surge protection is not installed before operating this unit
 Proper voltage, polarity and grounding must be assured for appliance to operate correctly. Consult
with your electrician before operating this appliance to assure electrical is proper.
AMERICAN ENERGY SYSTEMS, INC. GRANTS NO WARRANTY, IMPLIED OR STATED, FOR THE
INSTALLATION OR MAINTENANCE OF THE STOVE AND ASSUMES NO RESPONSIBILITY FOR ANY
Disclaimer Notice: No guarantee is made regarding the heating capacity of this unit. The actual area that this unit will heat depends on
factors such as fuel quality, fuel moisture, installation configuration, venting and fresh air configuration, operational practices, conditions of
the building, heat loss, type of construction, amount and type of insulation, type of air movement, and the location of the Furnace.
AMERICAN ENERGY SYSTEMS, INC. -150 Michigan Street SE - HUTCHINSON, MINNESOTA 55350
MAGNUM 6500
OWNER'S MANUAL
DAMAGE, BODILY INJURY OR EVEN DEATH.
CONSEQUENTIAL DAMAGE(S).
Web Site:
www.magnumheat.com
®
®
/ 7500
Rev. date 11/01/11

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Summary of Contents for Magnum 6500

  • Page 1  All minimum clearances to combustibles must be followed. Ductwork clearances must be maintained.  The Magnum 6500/7500 Corn/Wood Pellet Furnace is tested for operation with 14% or less moisture corn or with wood pellets with an ash content of no more than 3%. It is recommended that Corn with 11-12% moisture or wood pellets with an ash content of 1% or less be used for efficient operation of this unit.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS PAGE INTRODUCTION & SPECIFICATIONS………….………………………………………..UNPACKING YOUR MAGNUM 7500 CORN/PELLET FURNACE / SAFETY STEPS…. BURNING SOLID FUELS (SHELLED CORN AND WOOD PELLETS)……………..…... CLEARANCE TO COMBUSTIBLES………………………………………………………. FLOOR PROTECTION………………..………..............GUILDELINES FOR EXHAUST VENTING SYSTEMS DESIGNS……………………… 11-13 DESIGN GUIDELINES FOR OUTSIDE COMBUSTION AIR CONNECTION…………...

  • Page 3: Introduction & Specifications

    *BTU input can vary from 10-60 percent, depending on the brand of fuel, size of fuel, quality of fuel and moisture content. Improper installation, venting configuration, combustion air configuration and maintenance practices will seriously decrease the heating ability of this appliance. Consult your authorized Magnum reseller for information to get the best results out of your Magnum appliance.

  • Page 4: Unpacking Your Magnum 7500 Corn/Pellet Furnace / Safety Steps

    This furnace has to be exhausted with 4” class L vent. Furnace cannot be vented with another appliance. 4” venting is recommended on the model 7500 and required on the model 6500 furnace.  DISCONNECT THE POWER CORD BEFORE SERVICING THIS FURNACE. A power surge protector is required.
  • Page 5 Minimum clearances to combustibles must be maintained.  Your Magnum reseller is required to go over in detail with the owner/operator as to the correct operation of the furnace and its components.
  • Page 6 THE FOLLOWING (gas, oil, electric) INPUT SIZES: 50,000 to 200,000 BTU.  The Magnum 6500/7500 Corn/Wood Pellet furnace should only be installed on a furnace duct system and venting that is in good operating condition. It is recommended and sometimes necessary to install separate ductwork because the existing ductwork might not support the proper air flow or temperature.

  • Page 7: Burning Solid Fuels (Shelled Corn And Wood Pellets)

    Proper draft setting will be discussed later in this manual. The point we wish to make here is that your Magnum furnace, due to the nature of solid fuels, will require brief periodic attention. Please do not expect to light your furnace and walk away from it until you want to shut it off in the spring.
  • Page 8 OTHER AGRICULTURAL RATED FUELS: Your Magnum furnace will burn a variety of agra fuels such as switch grass, oats, wheat, barley and rye. It is important to work with your local dealer on how to burn these fuels as you will have to burn on lower heat settings due to the smaller kernel size and burning nature of the fuels.

  • Page 9: Clearance To Combustibles

    This installation is operation. acceptable only if Sometimes you there are no other may have to run appliances hooked in 6500 or 7500 separate ductwork and the venting goes furnace to comply with all the way out the codes top of the existing chimney.

  • Page 10: Floor Protection

    FLOOR PROTECTION The Magnum 6500/7500 Corn/Wood Pellet Furnace may be installed on a combustible floor, with proper floor protection, or on a masonry hearth. The hearth or non-combustible floor protector must extend a minimum of (6) six inches in front of and (6) six inches from each side of the ash removal door.

  • Page 11: Guildelines For Exhaust Venting Systems Designs

    NOTE: We recommend that you use listed Type PL “CORN Rated” venting to assure long life and tight seal.  A listed 4” (4” required on 6500, recommended on 7500) type “PL” Corn vent exhaust system must be used for installation and attached to the pipe connector provided on the back of the stove.
  • Page 12 GUIDELINES FOR EXHAUST VENTING SYSTEMS DESIGN, CONT…… 1) Determine the “equivalent pipe length” for each component used according to the comparison chart below. Add the “equivalent pipe length” of all components to get the “total equivalent pipe length”. 2) Determine the altitude at which you are installing the stove. 3) Cross-reference the “total equivalent pipe length”...
  • Page 13 CHIMNEY AND VENTING (4” diameter is required) Chimney required for the Magnum Corn Furnace is 4" (4” required on 6500) Class "L" (also known as PL vent). A starting collar must be used to attach the venting system to the furnace. When connecting into a Class "A" or masonry chimney an approved 4"...

  • Page 14: Design Guidelines For Outside Combustion Air Connection

    DESIGN GUIDELINES FOR OUTSIDE COMBUSTION AIR CONNECTION OUTSIDE MAKE-UP AIR FOR COMBUSTION IS REQUIRED ON ALL INSTALLATIONS 1) For all Furnace installations, it is REQUIRED that the furnace combustion air intake be connected to a fresh air intake outside. If the home is newer or has been tightly insulated it is imperative to the operation of the unit to install outside combustion air and also have makeup air provided for the home.

  • Page 15: Installation Configurations

    (Most building codes and insurance codes require a primary heat source in addition to a solid fuel appliance. The home owner accepts all responsibility if they install the Magnum furnace as their sole source of heat. The Magnum 6500/7500 Corn/Wood Pellet furnace is not intended to be used as a SOLE heat source. WARNING...
  • Page 16 Storm Collar NOTE: It is not recommended to install vertical venting on 36” on a flat roof the outside of the wall without enclosing the venting in an insulated chase way. Whenever possible run the venting on the interior. 3” clearance (or venting mfg.
  • Page 17 Storm Collar Design system to accommodate the cold air return (app. 24” of room needed)
  • Page 18 STAND ALONE OR SHOP FURNACE The Magnum 6500/7500 Corn/Wood Pellet Furnace may be installed as a stand-alone system as long as the unit is in a non-confined area. An unconfined space would be an area with 8’ ceiling height minimum and 650 square feet minimum open floor space.
  • Page 19 CF-28 Add-On Furnace (Supplementary Heat installation) To install the Magnum 6500/7500 as an “add-on furnace” first set the unit along side the existing primary forced-air up flow furnace and position so that all maintenance and operational functions can be performed.

  • Page 20: Ducting

    Magnum 6500/7500 Furnace Installation configuration when using the Magnum 6500/7500 furnace as an independent ductwork installation separate from the existing primary furnace. The Magnum Furnace is not intended to be installed as the sole source of heat and is not allowed to be the sole source of heat in most states and building/ insurance codes.

  • Page 21: Glass Maintenance, Adjustment, Removal And Replacement

    GLASS MAINTENANCE, ADJUSTMENT, REMOVAL AND REPLACEMENT Your Magnum 6500/7500 Corn/Wood Pellet Furnace comes to you with the glass door installed in place, ready for use. The glass is surrounded on the edges with a gasket and seated in a glass channel. It...

  • Page 22: Stove Controls

    Turn horizontal to decrease or Vertical to increase draft NOTE: The manual draft adjustment control on the 6500 is on the rear of the There is a scraper provided with the unit, right side. unit for cleaning out the ash. This...

  • Page 23: Lighting Instructions 7500

     NOTE: Even if you are burning corn or other fuels in your Magnum 7500; wood pellets make an excellent source of starter fuel. Corn takes too much starter gel to get lit and up to temperature.

  • Page 24: Circuit Board Functions

    Then the entire system shuts down. Before starting up the Magnum 7500 Corn/Wood Pellet unit again, it is important to remember to shut off the fuel stirrer so that the fire can be started properly. It will also ensure that the fuel stirrer will...

  • Page 25: Setting The Draft

    “dancing” flame. If moving the damper does not change the fire, you might have negative pressure in the home. Consult with your Magnum 7500 installer.  The base of the flame should be blue in color and the top of the flame should be yellow.

  • Page 26: 6500 Lighting Instructions /Circuit Board Functions/Setting Draft

     NOTE: Even if you are burning corn or other fuels in your Magnum , wood pellets make an excellent source of starter fuel. Corn takes too much starter gel to get lit and up to temperature.
  • Page 27 Then the entire system shuts down. Before starting up the Magnum 6500 Corn/Wood Pellet unit again, it is important to remember to clean out the firepot so that the fire can be started properly. It will ensure that the fuel will start properly.
  • Page 28 “dancing” flame. If moving the damper does not change the fire, you might have negative pressure in the home. Consult with your Magnum installer.  The base of the flame should be blue in color and the top of the flame should be yellow.

  • Page 29: Maintenance Instructions

    AES highly recommends our additive called “Clean Burn” be added to your corn to eliminate these clinkers. Contact your local Magnum reseller for availability and cost. Clean burn is not normally needed for the model 6500 furnace.
  • Page 30 CREOSOTE – FORMATION AND NEED FOR REMOVAL: With the low operating temperatures of the Magnum furnace and if the venting is on an exterior installation, creosote may form. Creosote is a tar –like substance combined with other organic vapors, which combine with expelled moisture to form creosote.
  • Page 31 WEEKLY MAINTENANCE  Set the furnace on high fire. Open the draft to 100% and allow the furnace to burn for 15 minutes. Resume desired heat and draft setting. Make sure to monitor your fire during this time to make sure that the additional draft does not put your fire out.

  • Page 32: Automatic Safety Features

    Always replace with a fast acting fuse. The Magnum furnace has a fan limit and high limit controls located inside of the unit on the left side. IMPORTANT: Make sure that the power source conforms to the requirements of the furnace. It is highly recommended that you run a separate circuit to assure constant power.

  • Page 33: Thermostat Installation

    THERMOSTAT INSTALLATION  The Magnum 6500/7500 can be installed with and operated by a wall-mounted thermostat. However, a wall thermostat is not provided with the furnace. A wall thermostat can be purchased from your reseller or at most home improvement centers or hardware stores. We recommend the Honeywell model T87F or equivalent low voltage thermostat ...

  • Page 34: Magnum 7500 Wiring Diagram

    Magnum 7500 Wiring Diagram 2 wire low voltage thermostat Circuit Gray Board Blue Control White neutral Brown AES # MF3593 Black High Limit Fan heat sensor Green sensor Orange Fuel Stirrer Gear motor AES# MF3540 MF3650 2-speed exhaust blower to be wired using the white and black leads red lead is not used.

  • Page 35: Magnum 6500 Wiring Diagram

    Magnum 6500 Wiring Diagram (See figure 17 for detailed position for wire harness) 2 wire low voltage thermostat Circuit Gray Board Blue Control White neutral AES # MF3594 is Black High Limit Fan limit used on 6500 sensor sensor Green...
  • Page 36 o Control Board molex connector o Auger Motor black wire to Vacuum Pressure switch (Com) grey wire to one lead o Electrical Plug double white wire to inside terminal (top, right side) Black/orange wire to outside terminal (top, left side) green wire to bottom terminal other end of green wire screwed to base of unit.

  • Page 37: Trouble Shooting Guide

     Replace combustion exhaust blower if necessary. NOTE: Negative pressure in a home is a serious issue. All Magnum furnaces need to be installed with outside air. If the home has severe pressure problems the furnace could become the house air...
  • Page 38 Fuel feed high or low.  Adjust damper reduce combustion airflow.  Have your Magnum reseller adjust the fuel control. Open all registers. Too much heat Hot air vents are closed in supply lines has caused in line sensor to shut system down. Make sure filter is clean to let enough air pass thru system.
  • Page 39 PROBLEM CAUSES SOLUTIONS ? Blower will not operate.  Check to see that the stove is No power to stove. plugged into the wall outlet.  Check to see if your circuit breaker has “tripped”.  Check wire connections to make Blower is defective sure that all are connected.
  • Page 40 Outside air is not hooked up A chimney restrictor may need to be Positive or negative pressure in home is installed. Consult with your Magnum affecting the furnace operation dealer. The cold air return is not hooked up or is...

  • Page 41: Setting The Circuit Board

    IMPORTANT: Electrical work must be performed by an authorized technician. WARNING: This section is only for qualified technicians. SETTING THE CIRCUIT BOARD (fuel stirrer option is not used on the 6500 furnace) If the low fire heat setting is too low for the fuel that...

  • Page 42: Draft Slide Gate Corrector Install And Adjustment

    CF13 Filter, Cold Air Return, MagnuM 6500 & 7500 CF22 CF23 Fan Limit Control, MagnuM 7500 furnace 2004 or earlier, 2E232 (control only, wiring harness sold separate) Blower/Fan, Room, Complete Assembly (when purchased separate from unit) CF25 CF26 Motor, Auger Feed Gear, 8 rpm (MagnuM 7500 only)

  • Page 43: Repacement Parts List

    AMERICAN ENERGY SYSTEMS INC. LIMITED PRODUCT WARRANTY This warranty is in effect on all products sold after 01/01/2009 and supersedes any and all warranties currently in existence. Please keep a copy of this warranty for your personal records or in the event of a claim American Energy Systems Inc., hereinafter referred to as (AES), warrants to you, the original consumer purchaser, that this product is free from defects in material and workmanship for a period of five (5) years from the original purchase date minus any time past one (1) year from manufacturing date, and that the product’s electrical parts and steel firepot, are...

  • Page 44: Warranty Information

    SERVICE RECORD DATE SERVICE OR CLEANING PERFORMED This record must be sent in when any warranty claims are made.

This manual is also suitable for:

7500

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