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COUNTRY FLAME TECHNOLOGIES HR-01 Installation, Operation And Maintenance Manual

Harvester biomass solid fuel stove
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Version 6.0d
COUNTRY FLAME TECHNOLOGIES
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
HARVESTER BIOMASS SOLID FUEL STOVE
USA & CANADA TEST:
ASTM E1509-04, UL 1482,
ULC S627, ULC/ORD C1482 (and ULC S628
if listed for fireplace insert installation in Canada)
Oregon Administrative Rules 814-23-909
WARNING:
may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammables (vapor or liquids) in or
around the vicinity of this appliance.
Installation and repair must be performed by a qualified service agency.
Always check with local jurisdiction or code agency before installing this
product. Local jurisdiction may require a permit prior to installation.
© 2009
MODEL HR-01
If the directions in this manual are not followed exactly, a fire
FOR YOUR SAFETY
1
TESTED BY:
WARNOCK HERSEY
MOBILE HOME APPROVED
COUNTRY FLAME

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  • Page 1 COUNTRY FLAME TECHNOLOGIES INSTALLATION, OPERATION AND MAINTENANCE MANUAL HARVESTER BIOMASS SOLID FUEL STOVE MODEL HR-01 USA & CANADA TEST: TESTED BY: ASTM E1509-04, UL 1482, WARNOCK HERSEY ULC S627, ULC/ORD C1482 (and ULC S628 if listed for fireplace insert installation in Canada)

  • Page 2: Safety Notes

    The Harvester Model HR-01 biomass fuel stove is significantly different from a conventional wood- burning stove. One major difference is that the HR-01 requires a reliable source of electrical energy to properly operate. The owner, installer, and operator must understand this manual and read it in its entirety.
  • Page 3 Maintain all minimum safety clearances of the Harvester stove and chimney system. ARNING Never install the Harvester in a sleeping room. The Harvester is designed and approved for burning of number 2 yellow shelled corns ARNING with a maximum moisture content of 14% or biomass pellet fuel. Any fuel used in this stove must meet or exceed APFI standards.

  • Page 4: Epa Standards

    HR-01 stoves conform to United States Environmental Protection Agency standards. LISTING/TESTING AGENCY The Harvester Model HR-01 has been independently tested and listed in accordance with ASTM E1509- 04, UL 1482, ULC S627, ULC/ORD C1482 (and ULC S628 if listed for fireplace insert installation in Canada) and Oregon Administrative Rules 814-23-909.

  • Page 5: Certification Safety Label (Sample)

    CERTIFICATION SAFETY LABEL (sample) Version 6.0d...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTES............................2 EPA STANDARDS ..........................4 LISTING/TESTING AGENCY ........................4 CERTIFICATION SAFETY LABEL (sample) ..................5 TABLE OF CONTENTS..........................6 FORWARD..............................8 INTERNATIONAL ISSUES ........................8 AMERICA..............................8 COUNTRY FLAME ..........................8 HARVESTER LIMITED WARRANTY ............ Error! Bookmark not defined. HARVESTER LIMITED WARRANTY (continued)........ Error! Bookmark not defined. THE HARVESTER OPERATION ......................12 FEATURES.............................12 SAFETY FEATURES..........................13...
  • Page 7 PELLET (ALL FUEL) VENT SYSTEMS....................28 OUTSIDE AIR COMBUSTION......................31 MOBILE HOME INSTALLATION .......................32 MOBILE HOME RULES ........................32 MOBILE HOME CLEARANCES......................32 MOBILE HOME STOVE ATTACHMENT...................33 MOBILE HOME FLOOR PROTECTION .....................34 MOBILE HOME CHIMNEY AND DUCTS..................35 MAINTENANCE REQUIREMENTS ....................38 GENERAL REQUIREMENTS.......................38 STOVE DOOR INSTALLATION......................38 STOVE DOOR ADJUSTMENT......................39 STOVE DOOR GLASS CLEANING.....................39 GLASS REPLACEMENT ........................39...

  • Page 8: Forward

    Harvester HR-01 biomass burning fuel stove by the Hearth Industry Association. The Harvester HR-01 was designed to burn shelled corn and biomass pellet fuel (switchgrass.) At the same time, Country Flame customers claim to have test burnt a wide variety of agricultural products that are available in different locales around the United States.
  • Page 9 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...
  • Page 10 THE WARRANTY PRINTED ABOVE IS THE ONLY WARRANTY APPLICABLE TO THE PRODUCT. ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE DISCLAIMED. IT IS UNDERSTOOD AND AGREED THAT AES’S LIABILITY UNDER THIS WARRANTY SHALL BE LIMITED TO THE PROVISION OF REPLACEMENT PARTS AND SHALL NOT INCLUDE LIABILITY FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES.
  • Page 11 Model No. Serial No. The express warranties made by Country Flame Technologies do not apply unless this warranty card is received by Country Flame Technologies from the original retail purchaser no later than thirty (30) days subsequent to the date the Country Flame product was originally purchased.

  • Page 12: The Harvester Operation

    The Model HR-01 was designed as a freestanding model stove. The stove has optional legs or a pedestal base. The legs come in a variety of finishes. Contact Country Flame or one of its local authorized dealers to discuss and select product options.

  • Page 13: Safety Features

    Harvester an extremely safe stove. BATTERY BACKUP SYSTEMS The Country Flame Harvester Model HR-01, like all pellet or biomass fuel stoves, relies on electrical energy (wall power outlet) to properly operate. Without electrical energy or with interruptions to the source of electrical energy, the Harvester stove’s operation will be erratic at best.
  • Page 14 FIGURE 2: HARVESTER COMPONENTS Stir-rod Hopper motor 110-degree room air 79 CFM exhaust motor heat sensor Vacuum tube (orange) 22-tooth sprocket Stir rod chain Auger motor 11-tooth sprocket 3” Exhaust tube 110-degree exhaust heat sensor Wiring harness (Right - rear) Hopper 250-degree over-temp heat sensor...

  • Page 15: Fuel Requirements

    FUEL REQUIREMENTS The Harvester Model HR-01 was designed to burn multiple types of fuel, including corn, switch grass and wood pellets. Country Flame recommends number 2 yellow shelled corn be used as fuel. This corn’s moisture content should be limited to no more than 14% moisture content. Country Flame recommends corn fuel moisture content be maintained somewhere in the range of 10% to 12%.

  • Page 16: Ash Removal

    combustion temperature and you will have to repeat holding the on-off button once the Harvester system is allowed to gain additional firebox heat. Upon reaching proper temperature, pressing the on-off button will cause the thermostat lights to light up and cause the auger light to blink green and flash on and off corresponding to the feeding of corn fuel into the burn pot.

  • Page 17: Combustion Air Control

    THERMOSTAT VACUUM OVERTEMP FUEL COMBUSTION Hopper (Optional) SENSOR SENSOR CONTROL AIR CONTROL Switch INPUT VOLTAGE 120 Volts AC 60 Hz 15-Ampere Circuit CONTROL BOARD ON/OFF SWITCH TEMPERATURE CONTROL Fuse POWER/FUEL/IGNITER/ INDICATORS 6 – 9 Amperes STOVE EXHAUST ROOM ROOM AIR TEMPERATURE TEMPERATURE CONTROL...
  • Page 18 FIGURE 5 displays the Country Flame Control Board front panel. Each function of the Control Board is identified.. Controls having more than a single function are identified with asterisks. All control board functions are explained in FIGURE 6. “Intelli-Choice” Country Flame Logo, AC Power is present when logo is lit.
  • Page 19 ON/OFF SWITCH The ON/OFF Switch serves to turn the system on and off by holding the switch for approximately 5 seconds. The ON/OFF Switch can also be used to initiate the FUEL PRIME MODE by holding it for approximately 30 seconds. When in the prime mode the Thermostat lights will sequentially light from top to bottom simulating a “filling action”...
  • Page 20 Version 6.0d...

  • Page 21: Stove Electrical Diagram

    Hopper Switch FIGURE 8: ELECTRICAL DIAGRAM Version 6.0d...

  • Page 22: Stove Specifications

    TABLE 1: HARVESTER, HR-O1 SPECIFICATIONS ELECTRICAL REQUIREMENTS The Harvester Model HR-01 requires a UL Approved dedicated home electrical outlet rated at a minimum of 120 volts at 60 hertz and capable of delivering 15 amperes. Although the Harvester draws only a fraction (much less than 6 amperes on average) of the 15 amperes rating, it is recommended that a dedicated circuit versus a branch electrical circuit be provided for the stove.

  • Page 23: Harvester Is Hot

    • If the homeowner makes a change to the control board heat setting before the thermostat calls for heat, the new heat setting becomes the Thermostat (call for heat) heat level setting. HARVESTER IS HOT • If the heat level is greater than 1 when the thermostat calls for heat, that heat level becomes the new Thermostat Heat Level.

  • Page 24: Installation

    INSTALLATION INSTALLATION PREPARATION The first step is to ensure the Harvester has been installed properly. Improper installation will create long-term operational and maintenance problems that will plague the homeowner until corrected. If an exhaust vent system is run over ten feet, Country Flame recommends a four-inch versus three-inch vent pipe be used in the exhaust vent system.

  • Page 25: Vent Systems

    VENT SYSTEMS A Harvester must be vented into a non defective, clean, and properly lined masonry chimney or must be installed using any one of a number of different manufacturer’s factory-built vent pipe product. If a masonry chimney system is used, it must conform to all local building codes and must be properly lined with an approved pellet (all fuel) stainless steel liner.

  • Page 26: Alcove Installation

    ALCOVE INSTALLATION All freestanding Harvester stove models are approved for alcove installation using double-wall Type L or Type PL UL listed vent systems. An alcove must not be greater than four feet deep as measured from the alcove face wall to the alcove back wall. In addition, the alcove must have at least seven feet of clearance when measured from the floor to the alcove ceiling.

  • Page 27: Floor Protection Requirements

    FLOOR PROTECTION REQUIREMENTS 1. All Country Flame freestanding Harvester stoves require a listed floor protector that is noncombustible. Country Flame Harvester stoves were tested with a listed floor protection that had an R-value equal to or greater than 1.5. Ensure that any floor protection equals or exceeds R = 1.5 or greater.

  • Page 28: Pellet (All Fuel) Vent Systems

    PELLET (ALL FUEL) VENT SYSTEMS Harvester installations requiring a connection from the product through a combustible wall require either a UL Listed thimble (wall penetration assembly) or other methods as outlined in the National Fire Protection Association (NFPA) Standard 211. Pellet (all fuel) vent system installations fall into 3 basic categories: Direct Vent Installation Flexible Liner Vent Installation...
  • Page 29 FIGURE 12 demonstrates a direct connect (simplest) vent system attached to a Country Flame Harvester. There are a number of critical factors that need to be considered when using the direct connect method. What is the clearance from the ground to the jet cap? What amount of snow (or drift) can be expected (anything blocking the exhaust will inhibit proper Harvester combustion?) What is the exterior covering on the house (combustible or non-combustible?) What are the prevailing wind directions (strong winds blowing directly into the exhaust pipe will cause combustion problems?) What...
  • Page 30 FIGURE 14: VERTICAL VENT SYSTEM (below grade) INSTALLATION FIGURE 14 demonstrates a Harvester installed below grade (such as in a non-walkout basement.) Do not substitute an elbow (of any angle) in place of the clean out tee shown in FIGURE 14. Use of an elbow will limit exhaust gasses and cause the combustion chamber to operate inefficiently.

  • Page 31: Outside Air Combustion

    Be fire safe and maintain proper clearances to all combustibles from a pellet vent system. Always ensure proper bracing and support for the pellet vent system and verify and conform to all local building codes. Once installed, have the vent system inspected by a certified professional. A chimney connector shall not pass through an attic, roof space, closet, floor, ceiling, or similar concealed space.

  • Page 32: Mobile Home Installation

    MOBILE HOME INSTALLATION WARNING: DO NOT INSTALL A COUNTRY FLAME FREESTANDING HARVESTER STOVE IN ANY MOBILE HOME SLEEPING ROOM. WARNING: THE STRUCTURAL INTEGRITY OF THE FLOOR, WALL, CEILING AND ROOF MUST BE MAINTAINED DURING THE INSTALLATION OF A COUNTRY FLAME HARVESTER STOVE IN A MOBILE HOME.

  • Page 33: Mobile Home Stove Attachment

    barriers. Manville’s CERAFORM 126 is an example of an approved insulated wall protector. This product has a K equal to .27 and is a half-inch thick. Total thermal resistance should exceed 1.5 for any material used to ensure proper thermal protection of a combustible wall. MOBILE HOME STOVE ATTACHMENT 1.

  • Page 34: Mobile Home Floor Protection

    FIGURE 16: MOBILE HOME LEG INSTALLATION BOLT PEDESTAL TO FLOOR FIGURE 17: MOBILE HOME PEDESTAL INSTALLATION MOBILE HOME FLOOR PROTECTION 1. A mobile home floor must be protected against stray sparks, radiant heat build up, or from damage during general use. 2.

  • Page 35: Mobile Home Chimney And Ducts

    defined for a specific model listed in this manual. In the event there are floor protection questions, contact Country Flame or one of its local authorized dealers for assistance. MOBILE HOME CHIMNEY AND DUCTS 1. ALL chimney connectors, parts, attachments, and ducts should by TYPE L or PL rated vent. One of the UL 641 criteria is that a Type L or PL chimney component withstands temperatures that do not exceed 570 F.
  • Page 36 manufacturers for the latest specifications and the cost of mobile home chimney system parts or a mobile home chimney kit. TABLE 4: MOBILE HOME (minimum) VENT SYSTEM REQUIRED PARTS PART NUMBER DESCRIPTION 4PRC VERTICAL CHIMNEY CAP 4” OVER TEN FEET STANDARD ROOF FLASHING 4P36 THREE FOOT VENT PIPE, 4”...
  • Page 37 FIGURE 18: MOBILE HOME HARVESTER (FREE STANDING VENT) INSTALLATION Version 6.0d...

  • Page 38: Maintenance Requirements

    MAINTENANCE REQUIREMENTS GENERAL REQUIREMENTS The Harvester Model HR-01 has minimal maintenance requirements; however, failure to perform cleaning or maintenance items will lead to degraded performance and potential safety hazards for both the home and its occupants. The Harvester stove should not be operated routinely without thorough monthly cleaning (or more often) depending on frequency of use.

  • Page 39: Stove Door Adjustment

    STOVE DOOR ADJUSTMENT The Harvester door may require fine adjustment due to variations in the door, the gasket material, due to hinge wear, or to maintain a center-aligned appearance. The Harvester door needs to remain airtight to ensure proper firebox operation. The Harvester door can be adjusted up or down and left or right with the adjustable hinge pins as shown in FIGURE 19.

  • Page 40: Glass-Ceramic Specifications

    the door glass. Removal of these glass retaining clips can be accomplished with household tools. Order the necessary replacement screws or glass clips when ordering glass to ensure worn parts are replaced. GLASS-CERAMIC SPECIFICATIONS Manufacturer Euro Kera Window Type Glass-Ceramic, Kera Lite® KERA LITE®...

  • Page 41: Appendix A: Troubleshooting Guide

    APPENDIX A: TROUBLESHOOTING GUIDE Shut off the power to the unit and allow it to cool off when performing cleaning and maintenance. PROBLEM SOLUTION Ignition The Stove power indicator does not Check the power supply. flash red. The starter fire in the firepot has not ignited or is Stove does not switch on not burning properly.

  • Page 42: Appendix A: Troubleshooting Guide (Cont'd)

    APPENDIX A: TROUBLESHOOTING GUIDE (CONT’D) Firepot Lid Lifts during the lighting This may happen until the corn has started to burn. cycle. This is normal and may occur at other times. This aids in keeping the corn from sticking to the stirring paddles until the fire is established.

  • Page 43: Appendix B: Maintenance Guide

    APPENDIX B: MAINTENANCE GUIDE Shut off the power to the unit and allow it to cool off when performing cleaning and maintenance. The firepot can be removed for cleaning by Regular Cleaning Removing and cleaning the Firepot loosening the bolt holding the stirring rod in place. Slide the keeper sleeve off of the gear shaft exposing the connector piece.

  • Page 44: Appendix B: Maintenance Guide (Cont'd)

    APPENDIX B: MAINTENANCE GUIDE (CONT’D) To clean glass, use a mild non-abrasive cleaner Cleaning the Glass when the stove and glass are cool. Creosote builds up on glass quickly when fire is burned at lowest settings. DO NOT use abrasive cleaners on glass. (Glass may crack if subjected to cold liquid cleaners while the glass is still hot.

  • Page 45: Appendix B: Maintenance Guide (Cont'd)

    APPENDIX B: MAINTENANCE GUIDE (CONT’D) Replacing the Door / Glass Gaskets To replace the gaskets, remove the door by lifting it straight up off its hinge pins and laying it face down on a soft surface. Remove the door gasket (you may need to use pliers) and then remove the glass retaining clips and remove glass.

  • Page 46: Appendix C: Technical Specifications

    APPENDIX C: TECHNICAL SPECIFICATIONS Fuel Type: #2 Yellow Shelled Corn Fuel Wood Pellet Fuel Moisture Content: 14% or less (12% preferred) A.P.F.I. residential fuel Heat Content: 10,000 Btu/lb* Heat Content: 8200 BTU/lb Ash Content: 3% maximum Ash Content: 1% max Bulk Density: 40 lb./cubic ft.

  • Page 47: Appendix D: Harvester Theory Of Operation

    APPENDIX D: HARVESTER THEORY OF OPERATION STARTUP PHASE Startup procedure assumes that proper electrical power is being provided from the grid and the stove is in proper working order. Approaching the control panel two red lights should be illuminated. One is the Country Flame logo located at the top of the board and the second red light is located at the bottom right of the control board next to the on/off switch.

  • Page 48: Appendix D: Theory Of Operation (Cont'd)

    APPENDIX D: THEORY OF OPERATION (cont’d) COOL DOWN PHASE Any time the system is switched off by holding the on/off switch for more than 3 seconds during normal stove operation, the control system will revert to the cool down phase. During the cool down phase the room, exhaust, and stir pot motors will be operated at high speed.
  • Page 49 on/off switch at which time the system will revert to the off state. The prime state is utilized only for filling the auger with fuel and can only be utilized from an “off state.” The Manual Stir Control can only be operated during two states: (a) when the system is shutdown, and (b) when the system is in the startup phase.

  • Page 50: Appendix E: Combustion Basics

    APPENDIX E: COMBUSTION BASICS An understanding of Combustion Basics will assist in resolving problems with a variety of fuels, changing product and environmental conditions during the operational life of a stove. Just exactly what are pellet or corn stove products suppose to do? PROVIDE A CONVENIENT PLACE FOR STORAGE OF FUEL.
  • Page 51 Combustion Temperature: The temperature required to ensure the release of flammable vapors. To sustain combustion, the heat evolved must maintain this temperature to provide a constant supply of vapors. Excess Air: Any air added to the combustion process above the theoretical value defined as 100% efficiency.
  • Page 52 The obvious advantage of wood pellets over conventional chopped wood logs is the consistency of the fuel both from a size and moisture content. Thus, wood pellets burn more efficiently than their log counterparts. The heat generated in the burn process, once combustion is achieved, sustains the process as more fuel is added.
  • Page 53 As a final note, the four basic stages of wood burning are: Up to 212 F the wood is boiling of the moisture. Near 575 F gasification of the solid wood fuel occurs. The wood will simply seem to disappear. Very little energy is released in these first two stages and external energy must be applied to sustain any combustion that is occurring.

  • Page 54: Appendix F: Replacement Parts

    APPENDIX F: REPLACEMENT PARTS REPLACEMENT PARTS Part Number Description Number per HARVESTER CB-43 BURN POT SCREEN CB-74 STIR ROD ASSEMBLY CB-145 BURN POT ASSEMBLY PP-353 EXHAUST MOTOR ASSEMBLY PP-355 ROOM AIR MOTOR ASSEMBLY PP-352 VACUUM SENSOR SWITCH PP-347 F OVER TEMPERATURE SENSOR PP-12 F EXHAUST/ROOM AIR SENSOR 25-0052-00...

  • Page 55: Replacement Parts

    APPENDIX F: REPLACEMENT PARTS (cont’d) REPLACEMENT PARTS Part Number Description Number per HARVESTER PP-538G SIDE TRIM, GOLD PP-538N SIDE TRIM, NICKEL PP-538 SIDE TRIM, BLACK PP-53 SIDE GLASS, NON-ETCHED PP-54 SIDE GLASS, ETCHED PP-185 SIDE TRIM, CUSTOM Version 6.0d...

  • Page 56: Appendix G: Labels

    APPENDIX G: LABELS REPLACEMENT LABELS Part Number Description Number per HARVESTER PP-483 CAUTION LABEL PP-484 CAUTION LABEL PP-35-0300-13 ATTENTION LABEL Version 6.0d...

  • Page 57: Replacement Labels

    APPENDIX G: LABELS (cont’d) REPLACEMENT LABELS Part Number Description Number per HARVESTER PP-486 ELECTRICAL LABEL Version 6.0d...

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