Country Flame HR-01 User Manual

COUNTRY FLAME TECHNOLOGIES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

HARVESTER BIOMASS SOLID FUEL STOVE

MODEL HR-01

Country Flame Technologies

A Division of American Products, LLC

900 George Street Marshfield, MO 65706 417-859-0990 417-859-0192

www.countryflame.com

USA & CANADA TEST: TESTED BY: ASTM E1509-03, ULCS627-M90 WARNOCK HERSEY

ULCS628-M92, UL 1492, Oregon Administrative Rules 814-23-909

WARNING: If the directions in this manual are not followed exactly, a fire

may result causing property damage, personal injury or loss of life.

FOR YOUR SAFETY

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.

MOBILE HOME APPROVED

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SAFETY NOTES

The Harvester Model HR-01 biomass fuel stove is significantly different from a conventional woodburning 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. This understanding should be completed and followed before installation or operation of the HR-01 is attempted. Failure to follow installation and operation instructions may result in property damage, bodily injury, or even death. Country Flame strongly recommends that a certified professional install the Harvester Model HR-01.

ARNING: THE AUTHORITY HAVING JURISDICTION (such as a municipal building

department, fire department, or fire prevention bureau, etc

BEFORE BEGINNING INSTALLATION. A PERMIT MAY BE REQUIRED IN ORDER TO PERFORM INSTALLATION.

ARNING: It is recommended that a smoke detector be installed in the vicinity of the HR-01.

ARNING: Country Flame Technologies has no control over installation maintenance procedures;

therefore, Country Flame grants no warranty, implied or written, for the installation or maintenance of the HR-01. Further, Country Flame assumes no responsibility for any consequential damage resulting from said installation or maintenance of this product.

ARNING: After operation, always allow the Harvester stove to completely cool before performing

any maintenance operations.

ARNING: The HR-01 stove requires reliable electric energy to properly operate. If electrical power

is not available, DO NOT operate a Harvester stove with only natural draft.

ARNING: Only a certified professional should install the HR-01 stove and only a qualified service

technician should perform maintenance on this stove. Any parts removed for installation or servicing must be replaced prior to operational use of this stove.

ARNING: Modification of this product is not authorized and any modification voids the Country

Flame warranty.

ARNING: The Harvester must be connected to a code compliant grounded 120-volt, 15 ampere, and

60 hertz electrical outlet. Use of a dedicated circuit is recommended. NEVER use an adapter, extension cord or cut or remove any prong from the power cord.

ARNING: NEVER place or store any combustible or flammable products on or near the Harvester.

ARNING: The Harvester is designed to immediately shutdown in the event the front door is opened.

Keep the viewing and ash removal door tightly closed during operation. Always clean the HR-01 after the stove has been allowed to return to normal room temperature.

ARNING: Do not connect the Harvester to a chimney flue serving another stove of any type.

ARNING: FOLLOW all operating instructions in this manual. Short cuts in operating procedures,

of any kind, can be dangerous.

) SHOULD BE CONSULTED

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ARNING: Maintain all minimum safety clearances of the Harvester stove and chimney system.

Never install the Harvester in a sleeping room.

ARNING: The Harvester is designed and approved for burning of number 2 yellow shelled corns

with a maximum moisture content of 14% or biomass pellet fuel. Any fuel used in this stove must meet or exceed APFI standards. Do not burn untested fuels, seed corn, or foreign materials in this product. Failure to comply with this restriction voids Country Flame’s warranty and the safety listing of the unit. Poor quality fuel will directly (and adversely) affect efficiency and cleanliness of operation. Country Flame’s local authorized dealer can help in recommending a quality fuel

ARNING: NEVER use gasoline, lantern fuel, kerosene, charcoal lighter fluid or other combustible

liquids to start or “freshen up” the fire in this product. Do not store or use gasoline or other flammable liquids or allow combustible vapors in the vicinity of product.

ARNING: NEVER put foreign objects in the hopper and NEVER burn trash or unapproved material

in the Harvester. Using improper fuel voids the Country Flame warranty and damage to the stove resulting from foreign objects is not covered by warranty.

ARNING: Ensure free and adequate airflow to and around the Harvester. This stove is a combustion

system that requires continuous flow of fresh air for proper operation. Failure to provide an adequate fresh air supply can lead to operational problems such as: negative pressure in the home, poor operation of this or other home combustion appliances, or a host of other issues. Remember that other combustion appliances compete for fresh air in the home. Consult with a professional to ensure positive air flow is provided to the stove during operation.

ARNING: The Harvester’s exhaust system works with a negative combustion chamber pressure and a

low positive chimney pressure. It is very important that the stove’s exhaust and chimney system be airtight and properly installed. The chimney joints should be sealed with 500 degrees Fahrenheit (500

F or 260 OC) silicone sealant (RTV) and secured with at least (3) sheet metal screws. An improperly installed stove or chimney system is the major cause of a home fire.

ARNING: When installed in a mobile home, the Harvester must be grounded to the steel chassis of

the mobile home. In addition, the stove must be bolted to the floor. A mobile home installation of the Harvester should be in accordance with the Manufactured Home and Safety Standard (HUD), CFR 3280, Part 24. Consult the local code authority.

ARNING: SOOT AND FLY ASH: The products of combustion will contain small particles of fly

ash. The fly ash will collect in the exhaust venting system and restrict the flow of the flue gases. Incomplete combustion, such as occurs during start-up, shut down, or incorrect operation of the Harvester will lead to soot formation in the exhaust venting system. The exhaust venting system should be inspected at least twice every year to determine if cleaning is necessary.

ARNING: ASH REMOVAL: The ash pan is designed to be emptied every day. If the ash pan is not

emptied regularly, ash will build up and restrict the flow of fresh air to the combustion chamber. The ash pan door should not be opened for prolonged periods of time (greater than 3 minutes.) If the ash pan door is opened for long periods of time an unrestricted supply of air can flow into the combustion chamber. This unrestricted air flow can cause

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an over fire condition. The airtight seal of the ash pan door ensures a combustion process per the stove design.

CAUTION: Operate the Harvester with the fuel hopper lid closed at all times. Failure to keep the

hopper lid closed during operation may result in the release of combustion gasses into the home from the hopper under certain conditions. Maintain any hopper seal in good condition and do not overfill the hopper.

CAUTION:

THE HARVESTER IS HOT WHILE IN OPERATION. DO NOT TOUCH. KEEP CHILDREN, CLOTHING, AND FURNITURE AWAY. CONTACT WITH HOT SURFACES MAY CAUSE SEVERE SKIN BURNS

. REFER TO THE SAFETY LABEL FOR INSTRUCTIONS.

NOTE: RETAIN this MANUAL for future reference as needed and ensure that the model and

serial number of the Harvester is written down for use in the future should maintenance be required.

EPA STANDARDS

The Country Flame Harvester meets rigorous emission standards. All Country Flame Harvester Model 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 E150903, ULCS627-M90, ULCS628-M92, UL 1492 standard and Oregon Administrative Rules 814-23-909. This listing is for installation into residential dwellings, including standard construction units, mobile home units, or modular home units. The Harvester Model HR-01 was tested to standards by Intertek Testing Services, NA, Inc., 8431 Murphy Drive, Middleton, WI 53562.

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CERTIFICATION SAFETY LABEL (sample)

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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 ..................................................................................................9

HARVESTER LIMITED WARRANTY (continued)............................................................................10

THE HARVESTER OPERATION .........................................................................................................12

FEATURES....................................................................................................................... ......................12

SAFETY FEATURES.............................................................................................................................13

BATTERY BACKUP SYSTEMS ..........................................................................................................13

FUEL REQUIREMENTS.......................................................................................................................15

HARVESTER STARTUP.......................................................................................................................15

PRIMING............................................................................................................................................15

FIRST FIRE ........................................................................................................................................15

ASH REMOVAL....................................................................................................................................16

CONTROL BOARD...............................................................................................................................16

STOVE ELECTRICAL DIAGRAM.......................................................................................................21

STOVE SPECIFICATIONS ...................................................................................................................22

ELECTRICAL REQUIREMENTS.........................................................................................................22

PLATED (Gold or Nickel) DOOR CARE..............................................................................................22

OPTIONAL FEATURES........................................................................................................................22

OPTIONAL THERMOSTAT OPERATION..........................................................................................22

HARVESTER IS COLD.....................................................................................................................22

HARVESTER IS HOT........................................................................................................................23

CHANGE HEAT LEVEL (thermostat active)....................................................................................23

CHANGE HEAT LEVEL (thermostat inactive).................................................................................23

COMBUSTION FRESH AIR CONTROL .............................................................................................23

INSTALLATION......................................................................................................................................24

INSTALLATION PREPARATION .......................................................................................................24

STOVE CLEARANCES.........................................................................................................................24

MINIMUM CLEARANCES............................................................................................................... 24

VENT SYSTEMS ...................................................................................................................................25

FACTORY-BUILT CHIMNEY..............................................................................................................25

MASONRY BUILT CHIMNEY.............................................................................................................25

ALCOVE INSTALLATION...................................................................................................................26

FLOOR PROTECTION REQUIREMENTS ..........................................................................................27

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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

GLASS-CERAMIC SPECIFICATIONS................................................................................................40

GASKET REPLACEMENT...................................................................................................................40

APPENDIX A: TROUBLESHOOTING GUIDE..................................................................................41

APPENDIX A: TROUBLESHOOTING GUIDE (CONT’D) ..............................................................42

APPENDIX B: MAINTENANCE GUIDE.............................................................................................43

APPENDIX B: MAINTENANCE GUIDE (CONT’D).........................................................................44

APPENDIX B: MAINTENANCE GUIDE (CONT’D).........................................................................45

APPENDIX C: TECHNICAL SPECIFICATIONS..............................................................................46

APPENDIX D: HARVESTER THEORY OF OPERATION ..............................................................47

STARTUP PHASE..................................................................................................................................47

BURN PHASE........................................................................................................................................47

APPENDIX D: THEORY OF OPERATION (cont’d)..........................................................................48

COOL DOWN PHASE...........................................................................................................................48

FAULT PHASE ......................................................................................................................................48

RESET CONDITION..............................................................................................................................48

SYSTEM MAINTENANCE...................................................................................................................48

APPENDIX E: COMBUSTION BASICS..............................................................................................50

APPENDIX F: REPLACEMENT PARTS ............................................................................................54

REPLACEMENT PARTS ......................................................................................................................54

REPLACEMENT PARTS ......................................................................................................................55

APPENDIX G: LABELS.........................................................................................................................56

REPLACEMENT LABELS....................................................................................................................56

REPLACEMENT LABELS....................................................................................................................57

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FORWARD

INTERNATIONAL ISSUES

Global concerns about climate change, along with rising world oil prices, are creating unprecedented interest in the development of economical and convenient renewable energy fuel burning products. For decades there has been a “grass roots” effort to utilize biomass feedstock as a viable heating fuel. Use of agricultural products such as corn, switch grass, and other annual crops can abate greenhouse gas emissions by increasing carbon storage in the surrounding landscape while displacing fossil fuel use in combustion heating products. Agricultural based pellet fuel is capable of sustained high volume throughput rates that use less energy to produce when compared to the present wood industry. Long term, biomass pellet fuel will become a key part of the global community’s effort to reduce if not reverse the greenhouse effect. This is especially true when emerging third world countries, their growth rates, and their demand for energy is factored into the greenhouse equation.

AMERICA

United States and Canadian stove manufacturers are approaching three decades of providing wood pellet fuel and wood pellet burning products to the hearth industry market. The maturity of this market has ensured a continuous supply of both pellet fuels and pellet appliances while world fossil fuel issues have ensured an ever increasing market demand for more of these products.

These same American and Canadian manufacturers continue to innovate and improve wood pellet products with each passing year. At the same time, an ever increasing demand for the wood fuel puts pressure on both sustaining the volume and the quality of fuel raw materials needed to meet the needs of the fuel market. Transportation costs associated with moving the raw materials to the pellet mill significantly impact the local and regional availability of pellet fuel. Research has proved that there are many agricultural based crops and crop byproducts that can be utilized to fuel biomass heating stove products to meet this ever growing market demand. Demand for biomass burning fuel stoves will grow in the coming years.

COUNTRY FLAME

Country Flame has worked for at least two decades in researching and developing pellet fuel burning stove products. Today, Country Flame offers both freestanding and fireplace-insert model pellet fuel stoves. Country Flame has a dedicated research effort underway to produce advanced pellet stove products capable of burning a wide variety of biomass fuel. In 2002, Country Flame was selected for national recognition for the design and development of its 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.

THE PURCHASE OF A COUNTRY FLAME HARVESTER BIOMASS FUEL STOVE IS A VOTE TO REDUCE AMERICA’S DEPENDENCE ON FOREIGN OIL. THE USE OF A COUNTRY FLAME HARVESTER BIOMASS FUEL STOVE WILL AID IN CURBING THE GREENHOUSE GAS PROBLEM OUR WORLD IS FACING. Country Flame is very proud of this American born, American tested, and American made product. With pride and dedication, Country Flame employees wish you and your family a lifetime of happiness and warmth through the use of this product.

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HARVESTER LIMITED WARRANTY

2. Products/Components Warranted. Country Flame makes the following warranties regarding its Model

3. Terms, Conditions and Restrictions.

4. Remedies in the Event of Failure. In the event a Harvester Model HR-01 fails to perform as warranted,

To Whom Extended: Country Flame Technologies; hereafter known as Country Flame, warrants, with proof of purchase and proper filing of the warranty card, the Model HR-01 to the original retail purchaser only.

HR-01 Corn/Pellet Stove Heaters and Inserts: (a) Heating Units. Except as set forth below, Country Flame warrants the Harvester Model HR-01

to be free from defects in materials and workmanship for a period of (5) years from date of purchase, so long as the unit is owned by the original consumer purchaser, subject to terms, conditions, and restrictions set forth below.

(b) Blowers, Fan Speed Controls and Electrical Components. Country Flame warrants the

blowers, fan speed controls and electrical components of its Model HR-01 to be free from defects in materials and workmanship for a period of one (1) year from the date of retail purchase or not more than (2) years from date of manufacture, whichever occurs first, subject to the terms, conditions and restrictions set forth below.

(a) Products Not Covered. The above warranties do not apply to glass, refractory materials such as

refractory cement or firebrick, gaskets, and irons, paint, and standard accessories, and all parts not permanently attached to the heating unit. Parts not permanently attached to the heating unit are those items designed to be removed from the unit, including those removable with common hand tools.

(b) Exclusions. The above warranties do not apply to the following conditions or circumstances:

(1) To conditions resulting from the Harvester Model HR-01 being installed other than in

accordance with the instructions and specifications included in the operating and maintenance instructions.

(2) To conditions resulting from failure to provide reasonable and necessary maintenance

for the Harvester Model HR-01 in accordance with the operating and maintenance instructions.

(3) To conditions resulting from the alteration or modification of any Harvester Model HR-

01 by anyone other than an authorized Country Flame representative with written instructions to complete such alteration or modification.

(4) To conditions resulting from failure to use and operate the Harvester Model HR-01 in

accordance with Country Flame operating and maintenance instructions or as a result of misuse of the product.

(5) To conditions not resulting from defects in material or workmanship of the Harvester

Model HR-01.

(6) To conditions resulting from the improper firing or burning of materials in a Harvester

Model HR-01.

unless the Warranty Registration Card provided with the owner’s manual is properly completed and mailed by the original retail customer and received by Country Flame within thirty (30) days subsequent to the date of original retail purchase.

the following terms and conditions will apply: (a) Heating Unit. Country Flame will repair, or at its option, replace any warranted part of the

heating unit that fails to perform as warranted for the lifetime of the original retail purchaser, subject to the term, conditions and restrictions set forth herein.

(b) Blowers, Fan Speed Controls and Electrical Components. If the blowers, fan speed controls

or components of the Harvester Model HR-01 fail to perform as warranted for one (1) year subsequent to the date of retail purchase, Country Flame will repair, or at its option, replace the defective product or component.

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HARVESTER LIMITED WARRANTY (continued)

provided by any Country Flame authorized dealer or distributor. If there is no authorized dealer or distributor in the original retail purchaser’s area, the original retail purchaser may notify Country Flame at 900 George Street, Marshfield, Missouri, 65 706 of any defect by providing the following information:

1. The Serial Number of the Harvester Model HR-01

2. The date of original purchase

3. The name of the dealer where the product was purchased

4. The date of installation; and

5. A description of the nature of the defect or problem. If service is required, the original retail purchaser must send the product or component, freight or postage prepaid, to Country Flame or a designee of Country Flame’s choice. Country Flame will not pay freight or postage costs relating to products or components returned for warranty service.

(d) Repairs. All repairs made by Country Flame or its authorized dealers or distributors will be

to the original manufacturing specifications.

(e) Cost of Repair or Replacement. Country Flame will repair, or at its option, replace the

defective products or component pursuant to the conditions set forth above. The original retail purchaser is responsible for payment of any costs and expenses of disassembly, removal and reinstallation of any defective product or component and any other services involved. Such costs o r expenses are NOT covered by this warranty and Coun try Flame is not liable for any of them.

5. Limits on Damages. In no event shall Country Flame be liable for damage to property, lost

profit, injury to goodwill, or any other special, incidental or consequential damages resulting from any defective Harvester Model HR-01product or any breach of the above express warranties. Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you.

6. Limitation of Implied Warranties. Country Flame expressly limits all implied warranties.

Implied warranties include but are not limited to warranties of merchantability or fitness for a particular purpose to one year from the date of original retail purchase. Some states do not allow limitations of how long an implied warranty lasts, so the above limitation may not apply to you.

7. Legal Rights. This warranty gives you specific legal rights, and you may also have other rights

that vary from state to state.

8. No Other Warranty – These Remedies Are Exclusive. Unless otherwise explicitly agreed to

in writing, it is understood that this is the only warranty given by Country Flame, and Country Flame neither assumes or authorizes anyone to assume for it any other obligations or liability in connection with this Country Flame product.

9. Additional Information. If you wish to obtain additional information or resolve questions

concerning the interpretation of any warranties of Country Flame, please write:

email@countryflame.com

Country Flame

900 George Street

Marshfield, MO 65706

417-859-0990 phone

417-859-0192 facsimile

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Place

Stamp

Here

Country Flame Technologies A Division of American Products, LLC

900 George Street Marshfield, MISSOURI 65706

Name Address City Dealer Dealer’s Name City Date of Purchase Model 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.

Signature

Fold Here

State Zip

Serial No.

Date

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THE HARVESTER OPERATION

FEATURES

Country Flame designed and built the Harvester stove to burn 100% shelled corn. Unlike conventional pellet stoves, the Harvester is capable of handling larger amounts of ash. This means the Harvester can burn corn, wood pellets, switchgrass pellets, and other biomass fuel while not being choked out by ash. Country Flame customers who own the Harvester claim they have successfully burnt a wide variety of different biomass fuels. Although Country Flame is pleased that customers are finding wide success in burning locally available fuels, Country Flame cannot support or warranty the burning of untested fuel or seed corn in the Harvester.

Before beginning to install or operate the Model HR-01 Harvester, please consult with the local building authority to obtain a permit. A certified professional should install this product. Before a homeowner operates this stove, a thorough operational understanding should be obtained from reading and understanding this manual. Failure to adhere to all safety notes and instructions contained herein can impact homeowner insurance, void warranty, and create hazardous situations leading to smoke damage, fire, or even death.

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. Once installed, the Harvester is remarkably simple and safe to operate. FIGURE 1, shown without legs or pedestal, defines some of the Harvester components. From a relatively small firebox the Harvester generates a very beautiful flame with lots of heat being produced into the room where the unit is installed. Clean certified or AFPI approved fuel is to be loaded into the hopper. A motor turns an auger that delivers fuel to the combustion chamber on a timed basis. Corn, pellets, or a combination of any solid fuels can be fed into the Harvester burn pot.

Hopper Lid

Door (Cast, standard or

Gold, optional)

Ash Pan

FIGURE 1: HARVESTER MODEL HR-01 (corn, biomass, or pellet)

Ceramic Glass

Hearth Plate

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SAFETY FEATURES

The Harvester comes standard with a number of advanced safety features; however, the first step in ensuring maximum safety is to install the stove properly according to all national and local codes. The Harvester requires a fresh air supply. This fresh air is used in the combustion process to achieve thorough burn of all fuel. The Harvester needs a sealed and properly designed “all fuel” vent system. This vent system will be used to remove combustion gasses from the combustion chamber to outside the home. REMEMBER: one of the leading causes of house fires is due to improper installation or improper operation of a stove product. Proper installation and operation of the Harvester is required to obtain homeowner insurance coverage. And, the Harvester needs a reliable source of electrical power. Without reliable utility power or a means to ensure reliability, the Harvester operation will be problematic.

The second step to safe operation is for the homeowner to thoroughly understand the operating characteristics of the Harvester. More importantly, the operator needs to know how to control each one of the stove’s operations. The Harvester has an electronic control system whose “brain” is constantly monitoring stove operations in order to optimize the fuel efficiency and heat output of this product. The Harvester’s electronic control provides a simple one stop location for the homeowner to control Harvester performance and heat output. In order to ensure the safest operation, the Harvester’s electronic control is constantly monitoring pressure and heat activated switches, and input power to ensure proper operation. Additional features include an enclosed firebox, high temperature ceramic glass, optional thermostatic control, a high temperature wiring harness, making the 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. Is power quality, power reliability, or routine winter storm conditions a cause of power problems in a specific locale? If it is, the homeowner will need to provide backup power to ensure stable operation of the Harvester. Fortunately, there are simple and reliable power backup solutions readily available. Today, a homeowner can choose from a variety of cost effective power conditioning systems from a number of reliable outlets today. For example, Home Depot, Circuit City, Best Buy, WalMart, or many other stores carry standard power conditioning equipment. Two good quality power conditioning equipment manufacturers are APC and TrippLite. Their uninterruptible power supplies (UPS) include the capability to handle power failures, brown outs, power surges, and line noise. These products sell for around $35 to $150. UPS system cost is largely defined by the features included in the system. The amount of time (battery size) the system must operate before recharging occurs directly relates to cost. UPS systems are usually sold by the number of electrical outlets and the volt-amperes (watts) the system is rated to provide. FIGURE 2 provides a description of the major electrical and operational components.

What does the Harvester stove require from a UPS system in order to sustain proper operation during a power outage? To answer that question, the homeowner has to decide how long they want the Harvester to operate in the absence of utility power. At the same time, an inexpensive solution that will handle a large percentage of the issues would cost less than $100. This UPS product will operate a Harvester for close to an hour. This same UPS system should provide an audible, as well as visual alarm, to alert the homeowner to local utility interruptions or power outages. The homeowner can then make the decision to continue to operate the Harvester or shut it down until the local utility restores local power. Further, this UPS system will ensure that minor utility glitches do not cause “nuisance” shutdowns or faults in a Harvester stove. If a homeowner wants specific information concerning the size and quality of a specific battery backup system for their Harvester stove, contact Country Flame or one of its local authorized dealers who will assist in providing a specific solution.

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FIGURE 2: HARVESTER COMPONENTS

(

Auger motor

3” Exhaust tube

250-degree over-temp

heat sensor

Hopper

79 CFM exhaust motor

Vacuum tube

orange)

Stir-rod

motor

110-degree exhaust

heat sensor

(Right - rear)

Hopper

110-degree room air

heat sensor

22-tooth sprocke

Stir rod chain

11-tooth sprocke

Potentiometer

Wiring harness

160 CFM room air

blower

(Left – rear)

Vacuum switch

Mounted on

inside of back

panel above

outside air tube

(Inside rear panel) (Outside rear panel)

1 ½”

outside air

120V receptacle

6-ampere fuse

hermostat plu

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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%. USING SEED CORN AS

FUEL IS DANGEROUS TO OCCUPANTS AND BURNI NG SEED CORN VOIDS THE COUNTRY FLAME WARRANTY.

If pellet fuel (wood or other solid biomass pellet fuel) is used in the Harvester, Country Flame recommends no more than 8% moisture content. If there are any questions about fuels to be used in the Harvester, please contact a local authorized Country Flame Dealer for assistance.

HARVESTER STARTUP

The first step in preparing the Harvester corn-burning stove is to remove it from its shipping crate. Ensure that all materials packed in the burn chamber have been removed and that the Gold (optional) door and its glass have been cleaned per enclosed instructions included in this manual.

NOTE:

(1) Failure to properly pre-clean the Gold (or any plated) door and the glass before lighting the

first fire could permanently damage either or both of these items.

(2) DO NOT burn seed corn as it is dangerous and voids the Country Flame warranty.

PRIMING

If this is the first time that the Harvester has been burnt or the stove has run out of corn fuel from a previous burn, priming must be completed in order to fill the auger tube with corn fuel. The Harvester prime mode can be entered by holding the on-off button for approximately 30 seconds or until the auger light starts flashing and the temperature lights start climbing from the lowest light to the highest light showing that the system is “filling the auger.” Once corn fuel starts dropping into the burn pot, the system should be shut off. Once priming is completed, the next step is to prepare the Harvester for burning corn.

FIRST FIRE

Country Flame recommends using wood pellets to start the Harvester Corn Stove. Pellets should be added in layers with igniter gel or igniter bricks sandwiched between the pellets inside the burn pot. It is important that the firebox has a hot pellet fire going before corn fuel is fed into the burn pot. This hot pellet fire is required due to the higher combustion temperatures required for corn fuel.

Wood pellets should be layered with igniter fluid at least level with the bottom of the stir pot arm inside the burn pot. Once the wood pellets and igniter material are layered in the burn pot, the on-off switch should be pressed for approximately 5 seconds or until the on-off light turns from red to green. Release the on-off switch once the light changes to green. At this time the red igniter light will be slowly blinking on and off. This blinking light is an indication that it is okay to light the wood pellets that have already been prepared in the burn pot. Once the wood fuel has been ignited, close the Harvester stove door. Monitor the wood pellet fire until a good blaze has been established.

In order to enhance the startup process, you can press both the up and down heat arrows at the same time. Pressing these buttons simultaneously will cause the stir rod to turn. If the stir rod does not turn, the buttons are not being pressed simultaneously or there is a defect in the Harvester stir rod system.

Stirring the wood pellets, by pressing both heat buttons at the same time, will cause the stir rod to turn and will ensure quicker combustion by adding turbulence to the combustion process. Upon obtaining a strong wood pellet fire, hold the on-off button for approximately 5 seconds or until you see the igniter light move from a slow blinking action to a fast blinking action. Once the igniter light blinks rapidly you can let go of the on-off switch. If the igniter light returns to a slow blink, then the Harvester stove has not reached proper

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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.

Based on the heat setting on the control board, the Harvester will automatically turn the stir rod at a predetermined rate to ensure turbulence and proper mixing of the fuel during the burn process. The stir rod will ensure that “clinkers” are minimized if not completely eliminated. In addition, the stir rod ensures that the fuel and flame are constantly agitated within the burn pot so as to ensure proper mixing with combustion air. The Harvester burn pot has been designed to ensure maximum efficiency of burn while minimizing the amount of ash being produced while at the same time minimizing the clinkers that can choke out a fire. Testing by Country Flame has shown that the unit can be operated for several days to up to two weeks without requiring cleaning depending on the type of fuel being burnt. It should be recognized that environmental variables as well as the type of fuel can have drastic effects on the amount of ash or clinkers formed during the burn cycle. Burn pot cleaning will depend upon the quality, quantity, and moisture content of the fuel. Ash removal will be required from time to time depending on the amount of usage and the heat desired. The Harvester stove should be shut down and cooled before cleaning or removing the ash pan.

ASH REMOVAL

The Harvester stove has an ash pan located on the underside of the firebox. Access to the Harvester ash pan is obtained below the ash lip at the bottom front of the stove. The door on the front of the ash box is a locking handle with a gasket seal. The seal provides an airtight fit and the locking handle ensure the ash door doesn’t vibrate open. Lift up on the handle and make a ¼ turn to unlock the handle. Once the ash pan cover is pulled forward, lay the ash pan handle back against the face of the cover. This allows the ash pan cover to be lowered to the floor allowing easing removal of the ash pan itself.

Always remove ashes after they have been allowed to cool properly. Hot ash is dangerous to both surrounding areas and occupants and can cause fires or severe burns. Wait until the fire has been out for several hours before removing the ash pan. After the ash has been allowed to cool, remove the ash pan for cleaning. Protective gloves should be worn anytime the ash pan is removed. Dump the ash in a proper ash container and remove to a safe outdoors area. Remember that although the ash may look and feel cool to the touch, a smoldering ember can start a fire. CAUTION: Care should be used to store any ash in a proper container with an approved airtight lid. If ash is taken outside, water should be poured over the ash to ensure no fire flare up can occur.

CONTROL BOARD

In 2001 Country Flame introduced its own control board technology, the “

Intelli-Choice.” This control

board technology was introduced across all Country Flame wood pellets and corn stove product lines. The

Intelli-Choice control board is being used exclusively on Country Flame product. Country Flame developed

its own control board in order to enhance its product offering and provide better support to customers. Country Flame’s control board technology is defined as an “open system.” Country Flame will seek to provide the most advanced controls while maintaining the look and feel distributors, dealers, and customers have come to know and expect. This also means a purchase of today’s Country Flame product will provide an upgrade path for newer and more advanced technology if the customer chooses to obtain it. Country Flame is committed to its customer base. That means bringing enhancements that provide more heat and improved burn efficiency while lowering the cost of operation. Country Flame will strive to make the service support process easier through systematic troubleshooting procedures and repair events that should allow for evolving “plug n play” operations. Country Flame’s goal is to ensure a properly trained and certified service technician can diagnose and repair any stove problem in less than 30 minutes whether the stove is one year or ten years old. FIGURE 3 depicts control board basic theory and FIGURE 4 provides a brief description of sensor controls.

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INPUT VOLTAGE

120 Volts AC 60 Hz

15-Ampere Circuit

VACUUM SENSOR

Fuse

6 – 9

Amperes

EXHAUST

TEMPERATURE

SENSOR

FIGURE 3: CONTROL BOARD BLOCK DIAGRAM

Input Voltage

Fuse Vacuum Sensor

Exhaust Temperature Sensor

Room Air Temperature Sensor

Overtemp Sensor Fuel Control

Room Air Control

Combustion Air Control

Igniter

OVERTEMP

SENSOR

FUEL

CONTROL

COMBUSTION AIR CONTROL

THERMOSTAT

(Optional)

CONTROL BOARD

ON/OFF SWITCH

TEMPERATURE CONTROL

POWER/FUEL/IGNITER/ INDICATORS

ROOM AIR TEMPERATURE SENSOR

Alternating Current (AC) Input provided by the local power company. This source of energy must provide a 120 Volt input signal with a frequency of 60 Hertz and a maximum branch current capacity of 15 Amperes. If other devices are connected to the branch, interference or over current may cause circuit breaker to trip. The AC fuse should be rated between 6 and 9 amperes. The recommended fuse is a Little Fuse Model _______. Ensures that no blockage of the combustion input or combustion exhaust air occurs. If the vacuum sensor does not operate properly, the Control Board will not allow the stove to operate. Presently, this sensor is a snap disk operating at 110o F +/- 20o F. This sensor ensures proper exhaust temperature has been reached and that a fire is present in the burn pot before the control system begins the burn cycle. Presently, this sensor is a snap disk operating at 110o F +/- 20o F. This sensor ensures that a proper amount of heat is available at the heat exchanger before the room fan is allowed to operate. If the sensor allows the fan to come on to early, the combustion chambers temperature could drop to the point that self-combustion (ignition temperatures) cannot be maintained. Presently, this sensor is a snap disk operating at 250o F +/- 20o F. The purpose of this sensor is to shut the entire system down in the event the firebox causes an overheat condition. The fuel control is a signal provided from the Control Board to the Auger Feed Motor. The Control Board controls the amount of time that the Auger Feed Motor is on and thereby controls the amount of fuel fed to the fire pot. The room air control is a signal provided from the Control Board to the Room Air Fan. The Control Board controls the phase angle and thereby the amount and time an AC voltage is applied to the Room Air Fan. This signal controls the speed of the room air passing over the heat exchanger tubes and the amount of heat delivered to the living space. The combustion air control is a signal provided from the Control Board to the Combustion Fan. The Control Board controls the phase angle and thereby the amount and time an AC voltage is applied to the Combustion Air Fan. This signal controls the speed of the combustion air passing through the burn pot for the different heat settings An AC heating element used to provide initial heat to the pellet combustion process. Once the Control Board senses combustion, the Igniter is shut off to conserve energy usage.

ROOM AIR

CONTROL

IGNITER

STOVE

Thermostat (optional)

A thermostat input is provided on the back of each Country Flame product. The Control Board has individual personality modules that allow for stand-alone, semi automatic, or fully automatic thermostat operation.

FIGURE 4: STOVE COMPONENT DEFINITIONS

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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.

Igniter Symbol Igniter Light, Red when

Igniter is on Auger Feed Symbol Auger Feed Light, Green

when Auger is on

* Heat Up Switch High Heat Setting Red When Lit

Medium Heat Setting Yellow When Lit

Low Heat Setting Yellow When Lit *Heat Down Switch

*ON/OFF Switch *DC Power on Light Red, System Off Green, System On Yellow, System Dirty

FIGURE 5: CONTROL BOARD FACE PLATE

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+ 39 hidden pages

Country Flame HR-01 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual