Country Flame HR-01 manual

Version 2.0b 1 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, ULCS6 27-M9 0 WARNOCK HERSEY ULCS628-M92, UL 1492, Oregon Adm inistrative R ules 814-23-9[...]

Version 2.0a 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 electric al energy to properly operate. The owner, installer, and operator mu st understand this manual and read it in its entirety. This u[...]

Version 2.0b 3 W ARNING : Maintain all minimum safety clearances of the Harvester stove and chimney system. Never install the Harvester in a sleeping room. W 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 mee[...]

Version 2.0b 4 an over fire condition. The airtight seal of the ash pan door ensure s 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 certa[...]

Version 2.0b 5 CERTIFICATION SAFETY LABEL (sample)[...]

Version 2.0b 6 TABLE OF CONTENTS SAFETY NOTES................................................................................................................... ...................... 2 EPA STANDARDS .................................................................................................................. ................ 4 LISTING/TESTI NG[...]

Version 2.0b 7 PELLET (ALL FUEL) VENT SYSTEMS.............................................................................................. 28 OUTSIDE AIR COMBUSTION ......................................................................................................... .... 31 MOBILE HOME IN STALLATION ............................................[...]

Version 2.0b 8 FORWARD INTERNATIONAL ISS UES Global concerns about climate change, along with rising world oil prices, are creating unprecedented interest in the development of economical and convenient renewable en ergy fuel burning products. For decades there has been a “grass roots” effort to utilize biomass feedstock as a vi able heating fu[...]

Version 2.0b 9 HARVESTER LIMITED WARRANTY 1. To Whom Extended: Country Flame Technologies; hereaf ter known as Country Flame, warr ants, with proof of p urchase and prope r filing of t he warranty card , the Model HR- 01 to the ori ginal retail purc haser only. 2. Products/Components Warranted. Country Flame m akes the following warranties regardin[...]

Version 2.0b 10 HARVESTER LIMITED WARRANTY (continued) (c) Warranty Service and Freight Cos ts . Service on a Harvester Model HR-01 will be provided by any Count ry Flame autho rized dealer or distribut or. If there i s no authori zed dealer or distributor in the original retail pu rchaser’s area, the original retail purchaser may notify Country [...]

Version 2.0b 11 Country Flame Technologies A Division of American Products, LLC 900 George Street Marshfield, MISSOURI 65706 Fold Here N a m e Address City State Zip D e a l e r D e a l e r ’ s N a m e City State Zip D a t e o f P u r c h a s e Model No. Serial No. The express warra nties made by Count ry Flame Technologi es do not apply unless t[...]

Version 2.0b 12 THE HARVESTER OPERATION FEATURES Country Flame designed and built the Harvester stove to bur n 100% shelled corn. Unlike conventional pellet stoves, the Harvester is capable of handling larger am ounts of ash. This means the Harvester can burn corn, wood pellets, switchgrass pellets, and othe r biomass fuel while not being choked ou[...]

Version 2.0b 13 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 accordi ng 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 o[...]

Version 2.0b 14 FIGURE 2: HARVESTER COMPONENTS (Right - rear) (Left – rear) (Inside rear panel) (Outside rear panel) Hopper Hopper 110-degree exhaust heat sensor 79 CFM exhaust motor Au g er motor 110-degree room air heat sensor 250-degree over-temp heat sensor 160 CFM room air blower 1 ½” outside air Vacuum tube ( oran g e ) 3” Exhaust tube[...]

Version 2.0b 15 FUEL REQUIREMENTS The Harvester Model HR-01 was designed to burn multip le types of fuel, including corn, switch grass and wood pellets. Country Flame recomme nds number 2 yellow shelled corn be used as fuel. This corn’s moisture content should be lim ited to no more than 14% moisture content. Country Flame recommends corn fuel mo[...]

Version 2.0b 16 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 reachi ng 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 t[...]

Version 2.0b 17 FIGURE 3: CONTROL BOARD BLOCK DIAGRAM Input Voltage 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 H ertz and a maximum branch current capacity of 15 Amperes. If other devices are connected to the branch, interference or over curre[...]

Version 2.0b 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 func tion are identified with asterisks. All control board functions are explained in FIGURE 6. “Intelli-Choice” Country Flame Logo, AC Power is present wh en logo is lit. Igniter S[...]

Version 2.0b 19 FIGURE 6: CONTRO L BOARD FUNCTIONS Country Flame’s control board provides reliable control of stove functions with minimal human intervention required. This control technology provides flexibility in adapting to future ch anges and improvements in technology. Finally, this control technology offers a simple interface between the o[...]

Version 2.0b 20 In order to utilize the full capabilities of the Contro l Board, the homeowner should be familiar with the backside of the Control Board. FIGURE 7 provides additional information about the m ajor components on the component side of the control board. AC Transformer Converts 120VAC To 9.6VAC for Board operation. 7 Segment Display Use[...]

Version 2.0b 21 STOVE ELECTRICAL DIAGRAM FIGURE 8 provides the Harvester electrical schematic of the components and sensors that are either operated or monitored by the Country Flame control bo ard. Please refer to this diagram when necessary. FIGURE 8: ELECTRICAL DIAGRAM[...]

Version 2.0b 22 STOVE SPECIFICATIONS HARVESTER DIMENSIONS (IN INCHES) STOVE HEIGHT 22.75 “ STOVE DEPTH 24.50 “ STOVE WIDTH (Rea r) 25.50 “ STOVE WIDTH (Widest Point) 30.75 “ STOVE HEIGHT (With Pede stal) 33.75 ” STOVE HEIGHT (On Legs ) 31.25” STOVE WEIGHT 400 pounds SHROUD WIDTH Not Applicable SHROUD HEIGHT Not Applicable TABLE 1: HARVE[...]

Version 2.0b 23 • If the homeowner makes a change to the control board heat setting before the thermostat c alls for heat, the new heat setting becomes the Thermo stat (call for heat) heat level setting. HARVESTER IS HOT • If the heat level is greater than 1 when the ther most at calls for heat, that heat lev el becomes the new Thermostat Heat [...]

Version 2.0b 24 INSTALLATION INSTALLATION PREPARATION The first step is to ensure the Harvester has been installed properly. Improper installation will creat e long-term operational and maintenance problems that will plague the homeowner until corrected. If an exhaust vent system is run over te n feet, Country Flame reco mmends a f our-inch versus [...]

Version 2.0b 25 VENT SYSTEMS A Harvester must be vented into a non defective, clean, and properly lined masonry chimney or m ust be installed using any one of a number of different ma nufacturer’s factory-built vent pipe product. If a masonry chimney syste m is used, it must conform to all local building codes and must be properly lined with an a[...]

Version 2.0b 26 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 mu st 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 cleara[...]

Version 2.0b 27 FLOOR PROTECTION REQUIREMENTS 1. All Country Flame freestanding Harvester stoves require a listed floor pr otector 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. En sure that any floor protection equals or exceeds R = 1.5 or greater.[...]

Version 2.0b 28 PELLET (ALL FUEL) VENT SYSTE MS 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[...]

Version 2.0b 29 FIGURE 12 demonstrates a direct connect (simplest) vent system attached to a Country Flame Harvester. There are a number of critical factors t h at 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 ex[...]

Version 2.0b 30 FIGURE 14: VERTICAL VENT SYS TEM (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 F IGURE 14. Use of an elbow will limit exhaust gasses and cause the combustion chamber to operate i[...]

Version 2.0b 31 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 ve nt s ystem inspected by a certified professional. A chimney connector shall not pass through an[...]

Version 2.0b 32 MOBILE HOME INSTALLATION WARNING: DO NOT INSTALL A COUNTRY FLAME FREESTANDING HARVES TER STOVE IN ANY MOBILE HOME SLEEPING ROOM. WARNING: THE STRUCTURAL INTEGRITY OF THE FLOOR, WAL L, CEILING AND ROOF MUST BE MAINTAINED DURING THE INSTALLATION OF A COUNTRY FLAME HARVESTER STOVE IN A MOBILE HOME. WARNING: A FREESTANDING HARVESTER STO[...]

Version 2.0b 33 barriers. Manville’s CERAFORM 126 is an example of an appr oved 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. Install combustion air to [...]

Version 2.0b 34 FIGURE 16: MOBILE HOME LEG INSTALLATION 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. This floor protection must meet certain minim um re quirements as a thermal barrier. Calculation[...]

Version 2.0b 35 defined for a specific model listed in this manua l. In the event there are floor protection questions, contact Country Flame or one of its local authorized dealers for assistance. MOBILE HOME CHIMNEY AND D UCTS 1. ALL chimney connectors, parts, attachments, a nd ducts should b y TYPE L or PL rated vent. One of the UL 641 criteria i[...]

Version 2.0b 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 QTY 4PRC VERTICAL CHIMNEY CAP 4” OVER TEN FEET 1 4PF STANDARD ROOF FLASHING 1 4P36 THREE FOOT VENT PIPE, 4” 1 4PRS ROOF SUPPO[...]

Version 2.0b 37 FIGURE 18: MOBILE HOME HARVESTER (FREE STANDING VENT) INST ALLATION[...]

Version 2.0b 38 MAINTENANCE REQUIREMENTS GENERAL REQUIREMENTS The Harvester Model HR-01 has minimal maintenance re quirements; 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 thor[...]

Version 2.0b 39 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 n eeds to remain airtight to ensure proper firebox operation. The Harvester door can be adjust ed up or down and left or right with[...]

Version 2.0b 40 the door glass. Removal of these glass retaining clips can be accom plished with household tools. Order the necessary replacement scr e ws or glass clips when or dering glass to ensure worn parts are replaced. GLASS-CERAMIC SPECIFICAT IONS Manufacturer Euro Kera Window Type Glass-Ceramic, Kera Lite® KERA LITE® glass-ceramic has a [...]

Version 2.0b 41 APPENDIX A: TROUBLESHOOTING GUIDE Shut off the power to the unit and allow it to cool off wh en performing cleaning and maintenance. PROBLEM SOLUTION Ignition The Stove power indicator does not flash red. Check the power supply. Stove does not switch on The starter fire in the firepot has not ignited or is not burni ng properly . Us[...]

Version 2.0b 42 APPENDIX A: TROUBLESHOOTING GUIDE (CONT’D) Firepot Lid Lifts during the lighting cycle. This may happen until the corn h as started to burn. This is normal and m ay occur at other times. T his aids in keeping th e corn fro m sticking to th e stirring paddles until the fire is established. Stirring Paddles do not turn The chain dri[...]

Version 2.0b 43 APPENDIX B: MAINTENANCE GU IDE Shut off the power to the unit and allow it to cool off wh en performing cleaning and maintenance. Regular Cleaning Removing and cleaning the Firepot The firepot can be removed for cleaning by loosening the bolt hol ding the stirring rod in place. Slide the keeper sleeve off of the gear shaft exposing [...]

Version 2.0b 44 APPENDIX B: MAINTENANCE GU IDE (C ONT’D) Cleaning the Glass To clean glas s, use a mild non-abrasive cleaner when the stove and glass are cool. C reosote builds up on glass quic kly when fire i s burned at lowest settings. DO NOT use abra sive cleaners on glass. (Glass may crack if subjected to cold liquid c leaners while the glas[...]

Version 2.0b 45 APPENDIX B: MAINTENANCE GU IDE (C ONT’D) Replacing the Do or / Glass Gaskets To replace the gaskets, rem ove 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. Strip of f old[...]

Version 2.0b 46 APPENDIX C: TECHNICAL SPECIFICATIONS Fuel Type: #2 Yellow Shelled Corn Fuel Wood Pellet Fuel Moisture Content: 14 % or less (1 2% preferred) A.P.F. I. reside ntial fuel Heat Content: 10,000 Btu/lb* Heat Content: 8200 BTU/lb Ash Content: 3% maximum Ash Content: 1% max Bulk Density: 40 lb./cu bic ft. min M o i s t u r e C o n t e n t [...]

Version 2.0b 47 APPENDIX D: HARVESTER THEORY OF OPERATION STARTUP PHASE Startup procedure assumes that proper electrical power is being provided from the gr id and the stove is in proper working order. Approaching the control panel two red lights should be illum inated. One is the Country Flame logo located at the top of the board and the second re[...]

Version 2.0b 48 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 co ol down phase. During the cool down phase the room, exhaust, and stir pot motors will be operated at high speed. T[...]

Version 2.0b 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. The[...]

Version 2.0b 50 APPENDIX E: COMBUSTION BASICS An understanding of Combustion Basics will assist in resolving problems with a variety of fuels, changing product and environm ental conditions dur ing the operational life of a stove. Just exactly what are pellet or corn stove products suppose to do? PROVIDE A CONVE NIENT PLACE FOR STORAGE OF FUE L. PR[...]

Version 2.0b 51 Combustion Temperature: T he temperature required to ensure the release of flammable vapors. To sustain combustion, the heat evolved must maintain this tem perature to provide a constant supply of vapors. Excess Air: Any air added to the combustion process above the theoretical value defined as 100% efficiency. A combustion system o[...]

Version 2.0b 52 The obvious advantage of wood pelle ts over conventional chopped wood l ogs is the consistency of the fuel both from a size and moisture content. Thus , wood pellet s 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. As [...]

Version 2.0b 53 As a final note, the four basic stages of wood burning are: a) Up to 212 o F the wood is boiling of the m oisture. b) Near 575 o 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 [...]

Version 2.0b 54 APPENDIX F: REPLACEMENT PARTS REPLACEMENT PARTS Part Number Description Number per HARVESTER CB-43 BURN P OT SCREEN 1 CB-74 STIR ROD ASSEMBLY 1 CB-145 BURN POT ASSEMBLY 1 PP-353 EXHAUST MOTOR ASSEMBLY 1 PP-355 ROOM AIR MOTOR ASSEMBLY 1 PP-352 VACUUM SENSOR SWITCH 1 PP-347 250 0 F OVER TEMPERATURE SENSOR 1 PP-12 110 0 F EXHAUST/ROOM [...]

Version 2.0b 55 APPENDIX F: REPLAC EMENT PARTS (cont’d) REPLACEMENT PARTS Part Number Description Number per HARVESTER PP-538G SIDE TRIM, GOLD 2 PP-538N SIDE TRIM, NICKEL 2 PP-538 SIDE TRIM, BLACK 2 PP-53 SIDE GLASS, NON-ETCHED 2 PP-54 SIDE GLASS, ETCHED 2 PP-185 SIDE TRIM, CUSTOM 2[...]

Version 2.0b 56 APPENDIX G: LABELS REPLACEMENT LABELS Part Number Description Number per HARVESTE R P P - 4 8 3 C A U T I O N L A B E L 1 P P - 4 8 4 C A U T I O N L A B E L 1 PP-35-0300-13 ATTENTION LABEL 1[...]

Version 2.0b 57 APPENDIX G: LABELS (cont’d) REPLACEMENT LABELS Part Number Description Number per HARVESTE R PP-486 ELECTRICAL LABEL 1[...]