Country Flame FP42 manual

COUNTR Y FLAME TECHNOLOGIES Smar t Fireplace Fur nace Products, FP- 33, FP-37, FP-42 (W ood Bur ning Onl y) Optional Parts Shown Installation, Operation & Maintenance Man ual Volume 7.1 Version 7.1[...]

Installa tion, Oper a tion & Maintenance Manual SMART FIREPLA CE FURN ACES (FP-33, FP-37, FP-42) W OOD BURNING PR ODUCT ONL Y © 2005 Country Flame Technologies A Division of Am erican Products, L.L.C. 900 George Street, Marshfield, Missouri 65706 -2364 www.countryflame.com Phone 417 859-0990 • Fax 417 859-0192 FOR YOUR SAFE T Y Do not store [...]

TABLE OF CONTENTS COUNTRY FLAME LIMITED WARRANTY ............................................................................................................................... ....III FOREWARD ............................................................................................................................. ERROR! BOOKMARK NOT DEFINED. S[...]

COUNTRY FLAME LIMITED W ARRANTY 900 George Street, Marshfield, MO. 65706 Country Flame Technologies warrants to you, the or iginal consumer purchaser, that this product’s stove body is free from defects in material and workmanship for a period of six years fro m the original purchase date, and that the product’s remaining components including e[...]

Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or con sequential damage, so t he above lim itations may not apply to you. This warranty gives you specific legal rights, and you m ay also have other rights which vary from state to state. This warranty is in effect on all produc[...]

Country Flame Technologies A Division of American Products, LLC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - WARRANTY INFORMATION Name ________________ ______________________ _____________________ Address_______________ _________________ City __ ___________________[...]

FOREW ORD Country Flame and all its employees would like to thank you for selecting a Country Flame Smart Fireplace Furnace product for your home. All of us at Country Flame are very proud of our American born, American tested, and American produced pr oducts. With pride and dedication, Country Flame employees wish you and your family a lifetime of[...]

SAFETY NO TES 1. Country Flame Technolog ies has no control over the installation or proper care of yo ur unit. Failure to properly install a Cou ntry Flame product can create unsafe condi tions for both property and human life. Country Flame Technol ogies grants no warranty, implied or written, for the installation or m aintenance of your unit. As[...]

Version 7.1 viii 15. Due to high temperatures, the fireplace furnace shou ld be located out of traffic and away from furniture and draperies. 16. Clothing or other flammable material should not be placed on or near the fireplace furnace. 17. When disposing of ash accumulati ons from a fireplace, always place them in a m etal container with a tight [...]

FIREPLA CE FURNA CE SAFETY LABEL (PP-741) Version 7.1 ix Model FP33, FP37, FP42 Solid (Wood) Fuel W/N 11667 Fireplace/Furnace Tested to UL 391, UL 127, UL 1482 Listing Report #32048002-E Electrica l Rating: 120 V, 6.5 Amps, 60/50 Hertz INSTALLATION: Use only chimneys sui table for solid fuel. The us e of air filters is not required. Place only on n[...]

INTR he fireplace is an American tradition. It rema ins a central feature of many homes and provides comfort and enjoyment for years to come, if de signed and ins talled properly. Country Flame continues an American Traditi on with decades of experience in manufacturing high quality practical fireplaces. To get the most out of a Smart Fireplace Fur[...]

Chapter 1 WHA T’S INCLUDED WITH Y OUR SMART FIREPLACE? Unpack all material provided with the Country Flame product. Important ma terials and small components are located inside the firepl ace furn ace. Ensure that every item listed below is present during the unpacking process. If yo u find extra items or believe some items are missing, please co[...]

FIREPLA CE FURNA CE SPECIFICA TIONS Country Flame manufactures a number of different Sm art Fireplace Furnace models. Table 1 and FIGURE 1 provide general information for each of the specific models ma nufactured by Country Flame. Crosscheck and refer to this table and FIGURE 1 when determining th e installatio n requirements for a particular model[...]

TA B L E 2 Room Size Width of Fireplace Furnace (ft x ft) In short wall In long wall 10 x 14 24 24 to 32 12 x 16 28 to 36 32 to 36 12 x 20 32 to 36 36 to 40 12 x 24 32 to 36 36 to 48 14 x 28 32 to 40 40 to 48 16 x 30 36 to 40 48 to 60 20 x 36 40 to 48 48 to 72 Table 2 is provided to assist in the proper selection of the fireplace furnace model that[...]

9 STEPS T O INST ALL A SMART FIREPLA CE STEP 1 - FOOTINGS AND FOUNDA TIONS A Country Flame manufactured fireplace furnace is designed for installation in a masonry fireplace hull in accordance with the Uniform Bu ilding Code. Only qualified installation personnel should install the fireplace furnace unit. Qualified installation personnel shall be k[...]

FIGURE 2: SINGLE OPENING FIREPLACE SYSTEMS FIGURE 2a shows a fireplace installatio n where the fl oor joists are located below the hearth ( raised hearth system.) FIGURE 2b shows a fi replace instal lation where the floor joists are located at the same level as the hearth. Note the changes in h earth depth required for these two different types of [...]

STEP 2 – CONCRETE P AD & HEAR TH EXTENSIONS Determine whether the fireplace is to b e installed on an outside wall or an inside wall. The clearances for an inside wall installation differ from an outside wall installation. The ty pe of wall installation will impact the size of th e concrete pad and hear th extension to be poured. Ensure confo[...]

Refer to FIGURE 2 for the depth requirements of a hearth extension. Hearth extension requirements vary according to where the floor joists meet the hearth and what local code requires. FIGURE 4: INSIDE WALL PAD INSTALLATION NOTES: 1. If installing a fireplace furnace on an inside wall, refer to FIGURE 4. An inside wall concrete pad must be six inch[...]

STEP 3 – FIREPLACE POSITION ON THE CONCRETE P AD In order to accomplish Step 3, it is assumed th at all combustible forms have been removed from the fireplace foundation, the ash pit, the combustion air void (if designed in for fireplace,) the concrete pad, and the hearth extension. Once all co mbustible forms have been removed the fireplace furn[...]

8. A minimum of 24” sidewall clearance must be maintained between combustibles and the inside firewall of the firebox. 9. Maintain a 4” clearance from the masonry ch imney to combustibles below the roofline. 10. The fireplace cavity must rema in open, unobs tructed, and free from any combustibles from the top of the fireplace through the attic [...]

12. Install the HT Adapter as shown in FIGURE 6. This optional square to round adaptor can be obtained from your Country Flame Dealer or direct from Country Flame. The 4” wide pieces of angle iron are not require d across the interior masonry walls when using factory-built insulated chimney materials. 13. The innermost masonry walls must extend t[...]

MASONRY CHIMNEY CONSTRU CTION – Refer to FIGURE 7 and TABLE 4 for the procedures and materials required to constr uct a masonry chim ney . Masonry chimney construction also requires a qualified and k nowledg eable chimney ma son that understands masonry construction, local codes, and local site conditions. A masonry chimney must be positioned and[...]

FIGURE 7A: MASONRY CHIMNEY INSTALLATION The two longest pieces of angle iron are to be set on top of the block sup port walls as shown in FIGURE 7A. The two shortest angle irons pieces are to span between the two long angle iron pieces as shown in FIGURE 7A. Before installing these angle iron pieces, mortar should be spread around the flue opening [...]

Version 7.1 that this block is centered on the edge of the angl e iron and maintains a distance of ½ inch from the clay flue tile face. Once the clay flue tile and first course of brick are checked and verified for proper installation, proper level, and proper clearan ces, each successive clay flue tile, and courses of chimney brick can be added u[...]

1. Attach one blower mount to the Smart Fireplace on the right side as shown in FIGURE 8A. Repeat the process for installing the blower mount and fan on the left side. NOTE: Ensure an electrician wires and prope rly grounds the Smart Fireplace blowers. Once the brick mason has completed the face, no acc ess to the blower wiring is possible. Bolt bl[...]

FIGURE 9A: HEAT DISCHARGE BOOT FIGURE 9B: ADJUSTABLE HEAT DIS CHARGE BOOT (OPTIONAL) FIGURE 9A shows the proper assembly of the stan dard heat discharge boot. FIGURE 9B shows the optional adjustable heat discharge boot that is required in the event anything but 4” wide brick is used to complete the masonry work. The optiona l slide in FIGURE 9, I[...]

STEP 7 – COMPLETION OF MASONR Y BRICK FRONT The fireplace furnace front can be finished in many different ways to enhance the appearance of your heating system. Ensure that all clearances have be en met and that all insulation provided b y Country Flame has been installed correctly. Refe r to local codes for any limitations of fireplace fronts be[...]

STEP 8 – FLUE DAMPER CONTROL INST ALLA TION Country Flame’s rotary controlled flue damper should be assembled as shown in FIGURE 10 after the fireplace is completely installed. The flue damper is extremely important to energy savings, reducing heat loss, and controlling a fire. The flue damper a cts as a valve, closing off the opening to the ch[...]

INSTALLING DAMPER DO OR - The rotary controlled damper of your Country Flame Fireplace should be assembled as shown in FIGURE 10 after the fireplace is completely installed. At this time the adjustable da mper rod sleeve (C) will be em bed ded in the masonry veneer and cannot turn. Follow the steps below to complete the installation of your rotary [...]

1. Reach through unit and remove screw in y oke. Swing yoke down out of the way. Lift Damper Door up and rotate slightly to slide through the opening. (See illustrations). 2. Clean out creosote and debris. 3. Replace Damper Door. Return yoke to its normal position and screw in place. Insure that the damper rod functions as intended. NOTE: At instal[...]

STEP 9 – ELECTRICAL SYSTEM Country Flame’s Smart Fireplace Furn ace comes standard with two blowers each r ated to move 525 cubic feet of room air per minute. The blower system includes all necessary parts, except some additional wire, required fo r a local certified electrician to install the blowers, speed controls, and the thermo stat. The f[...]

Included with this blower system as: a) Two multi-speed blowers rated at 120 volts, 60Hz, 6.5 amperes, and 525 CFM each. b) Two ducts for mounting blowers to fireplace. c) Two blower grille covers with rheostat fan speed controls pre-mounted. d) 10 wire nuts. e) One Wall mountable thermostat. f) One air discharge snap disc mounted & wired in fr[...]

clear of sharp objects. Further, ensure that the power cables or motor leads are not kinked. Never allow the power cables or motor leads to come in contact wit h oil, grease, hot surfaces, or chemicals. Utilize the two high temperature wir es (red and white) provided by Country Flame to connect the air discharge snap disc to the electrical sy stem [...]

Chapter 2 DUCTING OPTIONS Properly ducting the Smart Fireplace Furnace will pr ovide years of comfor t because properly ducted fireplaces will allow for a more uniform distribution of heat throughout the home. Many ducting options are possible with the Smart Firepl ace Furnace. Which option is selected de pends on your installer’s kn owledge, loc[...]

Holes in brick masonry should be a half-inch larger d iameter hole than the duct pipe to be utilized. This will allow an area for expansio n of the duct pipe as it heats up. Example: if ducting a Co untry Flame Model 33, a 6-½ inch diam eter hole should be cut in the masonry for the duct: whereas, for the Model 37 and the Model 42, an 8-½ inch di[...]

FIGURE 16b: DUCTING SYSTEMS EXAMPLES Version 7.1 25[...]

Chapter 3 FIREPLA CE FURNA CE OPERA TIONAL REQUIREMENTS Immediately after your Country Flame Fireplace has be en properly installed it should be tested for draft. A draft test is a s im ple method used t o ensure air is movi ng up the c him ney (positive air flow versus a house that may have negative pressure.) Wad up one or two sheets of clean dr [...]

Step 4 On top of both the newspa per and the lighter wood, place two well seasoned, small- sized logs; one at the front, one directly behind it, and another small one in the middle top of the other two. A small log on the top avoids s mothering the fire. Step 5 After the fire starts to burn, leave damper open and close fireplace doors (optional), i[...]

makes an extremely hot fire. It is the responsibilit y of the owner to periodically clean the chimney as regular maintenance. Local chimney sweeps can provide such a service. In any event, owners of wood burning fireplaces should become aware of care and m a intenance required to prevent fires and creosote formation. WOOD You may purchase wood by t[...]

FIREPLA CE FURNA CE MAINTENANCE REQUIREMENTS SYSTEM The majority of fires and accidents occurring with solid fuel-wood burning appliances are a result of improper maintenance of a fireplace. V isual inspect ions of the fireplace furnace, the chimney, the chimney connectors and the chimney cap on a semi-annua l basis will reduce the probability of a[...]

Whenever power is restored to a home, the blowers will automaticall y turn on; assuming a proper amount of heat is present in the firebox so the air disc harge snap disc has closed to complete the electrical blower circuit. If fireplace doors (optional) have b een installed on a Country Flame Fi replace Furnac e, then the fireplace door’s air dra[...]

TR OUBLESHOO TING GUIDE Version 7.1 31 PROBLEM CAUSE SOLUTION Fireplace smokes Chim ney cap restricted Clean the chimney cap and remove any debris that may have accumulated in the screen. Damper not adjusted Secure the damper into the open position. Downdraft Add a chimney cap designed to prevent downdrafts. Obstruction Remove tree limbs or obstruc[...]

PROBLEM CAUSE SOLUTION Lack of Heat (continued) Severely cold weather Naturally you will require more fuel in the middle of winter than in the fall. Overdraft Turn the rotary damper toward the closed setting until the draft is reduced. Draft controls not adjusted Combustion is restricted when the air is restricted. Be certain that the air intake is[...]

REPLA CEMENT P AR TS PART NUMBER DESCRIPTION NUMBER per FIREPLAC E PP-703 Electric Hardware 1 FP-0000-924 Air Intake Grille Frame 2 PP-558 Blower Motor – 525 CFM 2 PP-91 Heat Sensor – 110 Ceramic Snap Disk 1 PP-350 Rheostat, Variable Speed (No Off) 2 PP-563 Thermostat – 120V Wall Thermostat 1 PP-80 Control knob for Rheostat-FP 2 PP-37 Damper [...]

REPLA CEMENT P ARTS (cont’ d) PART NUMBER DESCRIPTION NUMBER per FIREPLAC E FP-0000-918 Damper Rod Sleeve (goes over rod) 1 FP-0000-920 Damper Rotary Rod Asse mbly 1 FP-0000-917 Damper Rotary Rod Only 1 PP-564 Damper Screw (goes over rod) 1 F-218 Flue adapter for Model 33 or 37 1 F-42-218 Flue adapter for Model 42 1 FP-0037-910 Hot Air Discharge [...]

PA R T D R A W I N G S _______________ ______________________ _____________________ ________________________ __________________ ELECTRICAL HARDWARE _______________ ______________________ _____________________ ________________________ _________________ Version 7.1 35 PP-703[...]

_______________ ______________________ _____________________ ______________ BLOWER, 525 CFM (2 each per fireplace,) PP-558 _______________ ______________________ _____________________ ___________ 110 CERAMIC SNAP DISK, PP-91 _______________ ______________________ _____________________ ___________ RHEOSTAT (2 each per fireplace,) PP-350 ____________[...]

_______________ ______________________ _____________________ _____________ THERMOSTAT, PP-563 _______________ ______________________ _____________________ _____________ FP - RHEOSTAT KNOB (2 each per fireplace b lower,) PP-8 0 _______________ ______________________ _____________________ _____________ DAMPER LOGO HANDLE, PP-37 _______________ ______[...]

_______________ ______________________ _____________________ _____________ INSULATION FOR TOP, SIDE S, FRONT, AND BACK, PP-35 _______________ ______________________ _____________________ _____________ ALUMINUM CLEAN OUT DOORS, 8” x 8,” PP-559 _______________ ______________________ _____________________ _____________ Version 7.1 38 PP-35 PP-559[...]

_______________ ______________________ _____________________ _____________ ASH DUMP COVER, FP-0000-916 __ _ __ _ __ __ __ _ __ _ __ __ __ _ __ _ __ __ __ _ __ _ __ ___________________ ___________________ DAMPER DOOR ASSEMBLY, FP-0000-921 Version 7.1 39 FP-0000-921 FP-0000-916[...]

_______________ ______________________ _____________________ _____________ YOKE BRACKET ASSEMBLY, FP-0000-923 _______________ ______________________ _____________________ _____________ DAMPER ROD SLEEVE, FP-0000-918 Version 7.1 40 FP-0000-918 FP-0000-923[...]

_______________ ______________________ _____________________ _____________ DAMPER ROD, FP-0000-917 _______________ ______________________ _____________________ _____________ DAMPER ROD ASSEMBLY, FP-0000-920 _______________ ______________________ _____________________ _____________ DAMPER SCREW, PP-564 Version 7.1 41 FP-0000-917 FP-0000-920 PP-564[...]

_______________ ______________________ _____________________ _____________ FP-33 & FP-37 FLUE TO HT CHIMNEY ADAPTER, F-218 _______________ ______________________ _____________________ _____________ FP-42 FLUE TO HT CHIMNEY ADAPTER, F-42-218 __________ ______________ ________________ ______________ ________________ _ Version 7.1 42 F-218 (Option[...]

_______________ ______________________ _____________________ _____________ GRILLE BACK, FP-0000-33 GRILLE FRONT, FP-0000-32 TOGETHER: HEAT DISCHARGE GR ILLE ASSEMBLY, FP-0037--910 Version 7.1 43 FP-0000-32 & 33[...]

_______________ ______________________ _____________________ _____________ AIR INTAKE GRILLE, PP-560 _______________ ______________________ _____________________ _____________ AIR INTAKE GRILLE FRAME, FP-0000-924 Version 7.1 44 F-560 FP-0000-924[...]

_______________ ______________________ _____________________ _____________ ADJUSTABLE HEAT DISCHARGE BOOT (OPTIONAL,) FP-0000-925 _______________ ______________________ _____________________ _____________ OWNERS MANUAL, PP-359 Version 7.1 45 25-0051-00 FP-0000-925[...]

_______________ ______________________ _____________________ _____________ LOG GRATE (optional), LG-900 _______________ ______________________ _____________________ _____________ Version 7.1 46 FP-0000-49[...]

WARNING LABELS _______________ ______________________ _____________________ _____________ ATTENTION: FIREPLACE INSTALLER/CONTRACTOR Ensure when building the hearth that the finished surface of the hearth is flush with the inside floor of the fireplace unit. The finished surface of the hearth may NOT be higher than the inside floor of the fireplace.[...]

WARNING LABELS (cont’ d) _______________ ______________________ _____________________ _____________ GRATE WARNI NG LABEL _______________ ______________________ _____________________ _____________ Version 7.1 48 PP-1333 WARNING FIREPLACE MODELS , FP-33, FP-37, OR FP-42 REQUIRE AN ANDIR ON/LOG GRATE. USE A COUNTR Y FLAME LOG GRATE P/N FP-0000-49, O[...]

Fold Here - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Country Flame Technologies A Division of American Pr oducts, LLC 900 George Street Marshfield, MO 65706 Version 7.1 49 Place Stamp Here[...]

REQUIRED WARRANTY INFORMATION Name ________________ ______________________ ______________________ Address _______________ _________________ City ____________________ State: __________ Zip _____________ Phone Number_____________ Authorized Dealer ________________ __________________________ ________ Date Purchased: ____________ ______________________[...]