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American Energy Systems MAGNUM 7500 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 lisenced/trained factory approved installer
When installing your Magnum 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.
All minimum clearances to combustibles must be followed.
The Magnum 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.
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 surge protection is not installed before operating this unit
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 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 7500
OWNER'S MANUAL
DAMAGE, BODILY INJURY OR EVEN DEATH.
CONSEQUENTIAL DAMAGE(S).
Web Site:
www.hearthdirect.com
®
Rev. date 02/01/04

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  • Page 1 All minimum clearances to combustibles must be followed. The Magnum 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………….………………………………………..CLEAN BURN CORN ADDITIVE…………………………………………………………. ESTIMATED FUEL FEED RATE CHART…………………………………………………. UNPACKING YOUR MAGNUM 7500 CORN/PELLET FURNACE / SAFETY STEPS…. BURNING SOLID FUELS (SHELLED CORN AND WOOD PELLETS)……………..…... 9-10 CLEARANCE TO COMBUSTIBLES………………………………………………………. FLOOR PROTECTION………………..………..............GUILDELINES FOR EXHAUST VENTING SYSTEMS DESIGNS………………………...

  • Page 3: Specifications

    Please read this Owners Manual carefully before using this appliance and if you have any questions contact your local Magnum 7500 reseller. We appreciate your business and wish you many warm days and nights with your new Magnum 7500 Corn/Wood Pellet Furnace..

  • Page 4: Introduction & Specifications

    *BTU input will vary, depending on the brand of fuel, size of fuel, quality of fuel and moisture content. Consult your authorized Magnum 7500 reseller for information on the best fuel to use to get the best results. CLEAN BURN CORN ADDITIVE AMERICAN ENERGY SYSTEMS INC.

  • Page 5: Clean Burn Corn Additive

    GIVE CLEAN BURN A TRY. YOU WILL BE PLEASANTLY SURPRISED. CLEAN BURN...

  • Page 6: Estimated Fuel Feed Rate Chart

    The Magnum 7500 is certified to burn shelled corn and wood pellets. The Magnum 7500 will burn other fuels such as Cherry Pits, Barley, Oats, Wheat and other identified fuels but the feed rates and safe operation are not warranted.

  • Page 7: Unpacking Your Magnum 7500 Corn/Pellet Furnace / Safety Steps

    If there was shipping damage, be sure to report it to your Magnum 7500 reseller, and the shipping company that delivered your unit. Freight damage claims must be made to the Freight Company immediately. If parts are missing contact your local Magnum 7500 reseller or contact the factory right away.
  • Page 8 Minimum clearances to combustibles must be maintained. Your Magnum 7500 reseller is required to go over in detail with the owner/operator as to the correct operation of the furnace and its components.
  • Page 9 THE MAGNUM 7500 CORN/WOOD PELLET FURNACE IS COMPATIBLE WITH THE FOLLOWING (gas, oil, electric) INPUT SIZES: 50,000 to 200,000 BTU. The Magnum 7500 Corn/Wood Pellet furnace should only be installed on a furnace duct system and venting that is in good operating condition.

  • Page 10: 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 7500 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 11 ALWAYS ASK FOR CORN WITH 11-12% MOISTURE CONTENT. If you are having trouble finding clean Corn, contact your local Magnum 7500 Reseller and ask them to get you an “Energy Sifter” corn cleaning system. Cleaning your corn with the Energy Sifter from American Energy Systems will assure clean corn and a more consistent burn rate.

  • Page 12: Clearance To Combustibles

    CLEARANCE TO COMBUSTIBLES CLEARANCE TO COMBUSTIBLES Back 1” Supply Plenum 2” Side 1” Class L Vent 3” Corner 1” Front 48” Combustible Ceiling Minimum clearance above the ductwork on the Corn Furnace to the floor joists is 2” 3” 14” x 24” cold air return Floor protection must be provided because of possible spillage of ashes and burning fuel.

  • Page 13: Floor Protection

    FLOOR PROTECTION The Magnum 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 14: Guildelines For Exhaust Venting Systems Designs

    GUIDELINES FOR EXHAUST VENTING SYSTEMS DESIGN It is required that only authorized licensed installers install your Magnum 7500 furnace. The following installation guidelines must be followed to ensure conformity with both the safety listing of this furnace and to local building codes.
  • Page 15 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 16 CHIMNEY AND VENTING Chimney required for the Magnum 7500 Corn Furnace is 3 or 4" 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 3 or 4"...

  • Page 17: 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.

  • Page 18: Installation Configurations

    2) A Supplementary heating system (Add-On Furnace) 3) A Central heating system (Primary Heating) Note: Recommend additional primary heat source. The Magnum 7500 Corn/Wood Pellet furnace is not intended to be used as a primary heat source. WARNING DO NOT INSTALL IN SLEEPING ROOM...
  • Page 19 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 around vent 24”...
  • Page 20 Storm Collar Design system to accommodate the cold air return (app. 24” of room needed)

  • Page 21: Ducting

    STAND ALONE OR SHOP FURNACE The Magnum 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 22 CF-28 Add-On Furnace (Supplementary Heat installation) To install the Magnum 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 23 Hopper lid (minimum 16” clearance to bottom of warm air plenum) Filter Box Magnum 7500 Furnace Magnum 7500 Make sure that when the warm air plenum is installed that there is adequate room to open and load the hopper lid. Place furnace so that maintenance and operation of the unit can be...

  • Page 24: Glass Maintenance, Adjustment, Removal And Replacement

    GLASS MAINTENANCE, ADJUSTMENT, REMOVAL AND REPLACEMENT Your Magnum 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 is held...

  • Page 25: Stove Controls

    STOVE CONTROLS Front view Sliding heat exchanger tube cleaning rod. Pull in and out to clean heat exchanger tubes. Adjustable Door Handle Adjustable hinges. Loosen locking lifts up and turns to the nut and move in or out to adjust. right to open Ash clean outs Pull out to empty ashes out of firebox area...

  • Page 26: Combustion Enhancement System (Ces)

    It is important that whenever operating the Magnum 7500 that the CES is in place. You can however remove the CES for cleaning, maintenance and startup of the fire.

  • Page 27: Lighting Instructions

    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 28: 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 29: 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 30 CREOSOTE – FORMATION AND NEED FOR REMOVAL: With the low operating temperatures of the Magnum 7500 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 Excessive ash on the corners of the firebox. exchanger will cause diminished heat output. The Magnum 7500 furnace has (2) front cleanout slides that must be in the closed position when burning the unit. WEEKLY MAINTENANCE Set the furnace on high fire.
  • Page 32 might have built up in the system or air intake. Remove your brick board when the fire pot is removed. Inspect the rear air chambers (remove the cleanout plugs) and clean if necessary. If this area plugs with ash improper air flow will occur and cause the furnace to burn dirty or shut it down. Cleaning of the exhaust system will depend upon the ash and debris content of your fuel.

  • Page 33: Automatic Safety Features

    Always replace with a fast acting fuse. The Magnum 7500 is equipped with a fan limit control system that is installed 10” above the top of the unit. This fan limit control must be operational and not set on manual fan operation. The fan limit control will turn the room air blower on and off with the correct temperature and will shut the fuel feed off if the unit overheats or there is an obstruction in the duct work.
  • Page 34 The circuit board is located on the left side of the unit. Remove the ¼” hex head screw and pull circuit board towards you. Lift the circuit board out of the housing. Do not crimp or stretch the wires leading from circuit board pigtail. (Unplug the power cord before working on unit) Reinstall in reverse procedure.

  • Page 35: Magnum 7500 Wiring Diagram

    Magnum 7500 Wiring Diagram 2 wire low voltage thermostat Circuit Gray Board Blue Control White neutral Note: Purple wire is capped and not used Honeywell # L4064B 2228 Brown Grainger # 2E818 5” insertion AES # AES # CF23 MF3593...

  • Page 36: Trouble Shooting Guide

    Replace combustion exhaust blower if necessary. NOTE: Negative pressure in a home is a serious issue. All Magnum 7500 furnaces need to be installed with outside air. If the home has severe pressure problems the furnace could become the house air conduit causing...
  • Page 37 Fuel feed high or low. Adjust the damper to reduce combustion airflow. Have your Magnum 7500 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.
  • Page 38 PROBLEM CAUSES SOLUTIONS ? Blower will not operate. ♦ No power to stove. Check to see that the stove is plugged into the wall outlet. Check to see if your circuit breaker has “tripped”. ♦ Blower is defective Check wire connections to make sure that all are connected.
  • Page 39 Check all cleanouts and exhaust venting Combustion motor going out. for obstructions. Refer to cleaning section of this manual. Use combustion enhancement system Call your Magnum 7500 reseller to inspect installation and operation. Replace any bad parts. On higher heat settings combustion enhancement system will keep ash volume down.

  • Page 40: Setting The Circuit Board

    WARNING: This section is only for qualified technicians. SETTING THE CIRCUIT BOARD If the low fire heat setting is too low for the fuel that you are burning and the fire goes out, the number 1 or Heat Setting 2 heat setting can be adjusted through the access hole located next to the system indicator light.

  • Page 41: Warranty Information

    # 10 bolt with 5/16 hex head The normal operation of the Magnum 7500 would be with the Draft Slide Gate open fully as shown. When the gate is in the fully open position, the plate will be against the mounting plate as shown.
  • Page 42 This limited warranty will not become effective unless you have returned the attached warranty card within 30 days of your purchase. If you fail to do so, you may make no claim under this warranty. American Energy Systems, Inc. excludes and disclaims all implied warranties including, but not limited to, the implied warranty of merchantability.

  • Page 43: Service Record

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

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