Corn Flame Energy Corn Stove Model 3000 Installation and

Corn Flame Energy
Corn Stove
Model 3000
Installation and Operation
Guide
Read thoroughly before starting installation.
Save this manual for future reference.
SAFETY NOTICE
If this stove is not properly installed, a house fire may
result. For safety follow the installation directions.
Contact your local building or fire officials about restrictions and installation requirements in your area.
Table of Contents
UNIT PREPARATION
4
REFERENCE
4
MODEL 3000 SPECIFICATIONS
5
FREESTANDING/DIRECT HORIZONTAL VENTING
6
OPERATING INSTRUCTIONS
11
ROUTINE MAINTENANCE
14
BIMONTHLY MAINTENANCE
15
WIRING DIAGRAM
16
WARRANTY
17
SAFETY REQUIREMENTS
• SAFETY NOTICE: IF this stove is not properly installed, a house fire may result. For your safety, follow the installation directions. Contact your local building
or fire officials about restrictions and installation requirements in your area.
• The manufacturer assumes no responsiblity for equipment installed in violation of
either this manual or local codes and ordinances.
• During the first start up, curing of the heat exchanger and paint will take place. You
may have some smoke and odor for a short period. Open windows for ventilation
until process is complete.
• Use clean shelled corn for fuel only. Do not use seed corn. DO NOT USE ANY
OTHER TYPE FUELS!
• Never burn the unit without the burner box in place.
• WARNING: DO NOT CONNECT STOVE’S FLUE TO A CHIMNEY FLUE
SERVICING ANOTHER APPLIANCE.
• Do not install a flue damper in the exhaust venting of this unit.
• Inspect and clean flues and chimney regularly. Inspections should be conducted once
a month during heating season.
• CAUTION: NEVER USE GASOLINE TYPE FUELS, LANTERN FUELS,
KEROSENE, DIESEL FUEL, OR SIMILAR FUELS TO START A FIRE.
KEEP ALL SUCH FLAMMABLE LIQUIDS AWAY FROM THE UNIT WHILE
IN USE.
• Use smoke detectors around the unit and locate a fire extinguisher rated for class “A”
fires nearby.
• At the end of each heating season remove all corn from hopper and auger system.
• Do not extend the Direct Vent Flue more than 15 feet without consulting the manufacturer. Do not have more than two offsets in the flue. Intake air could become
restricted or overheated. Use UL listed type L pipe for extending the flue. DO NOT
USE ALUMINUM LINERS.
• Always set POWER switch to “RUN/AUTO OFF“ position and rotate FUEL switch
to “OFF” position (a positive click occurs) for timed shut down, or smoke may spill
into the home as the fire dies.
• Corn Flame Energy is not liable for any smoke or soot damage.
• CAUTION: Due to risk of electrical shock, unplug unit before removing any access panel for servicing.
UNIT PREPARATION
• Check stove for possible shipping damage. If any damage is found notify the
dealer from whom stove was purchased.
• Remove all items (clinker tool, etc...) from the hopper.
• Using either hole in the top of the stove, store the clinker tool when not is use.
• Close door and check for proper seal. Adjust by rotating the handle clockwise to
loosen and counter-clockwise to tighten. Do not over-tighten.
REFERENCE
Slide open for
Hopper Door
Door
Clinker Tool Holder
Control Panel
MODEL 3000 SPECIFICATIONS
DIMENSIONS
A
20 1/2
521
Inch
mm
WEIGHT
EXHAUST
RATING
A
B
4 1/4
108
C
24
610
D
24
610
E
8
204
180 Lbs
3 Inch
120 Volts, 60 Hz, AC Only
/L
82 Kg
76 mm
C
D
B
E
C
Top View
Side View
MINIMUM CLEARANCES TO COMBUSTIBLES
Sides
5 Inches (127 mm)
Back
2 Inches (51 mm)
Front
8 Inches (204 mm)
Above
12 Inches (305 mm)
Combustible Wall
2”
30”
FLOOR PROTECTION REQUIREMENTS
The floor protector shall be 20 x 30 inches (508
x 762 mm) minimum and must extend 8 inches
(204 mm) in front of stove. Material must be
3/8 inch (10 mm) minimum thickness noncombustible material listed to UL standards.
5”
8”
20”
FREESTANDING/DIRECT HORIZONTAL VENTING
Note: For direct horizontal venting you must use manufacturer’s zero clearance venting system CF-900.
• SAFETY: Carefully read and follow all safety requirements previously set forth under
SAFETY REQUIREMENTS before continuing with the following information.
• CAUTION: WHEN PASSING THROUGH WALLS, DO NOT INTERFERE WITH
WIRING, PIPES, OR STRUCTURAL ELEMENTS.
LOCATION PREPARATION
For this type of installation the stove must be located near an exterior wall and should be located for best
heat circulation through the room. The exhaust vent should not be placed on a wall that receives strong
winds.
Review location inside of home and check outside where vent pipe will be passing through for any
obstructions that may prevent proper exhausting.
Consider the design and construction of the building so as to minimize the need to pass through existing
structural supports, ect...
Be sure that the exit termination of the combined outside air/exhaust system is located in accordance with
the following:
• Not less than 3 feet (915 mm) above any forced air inlet located within 10 feet (3048 mm) to
either side.
• Not less than 4 feet (1220 mm) below, 4 feet (1220 mm) horizontally to either side, or 1 foot
(305 mm) above any door, window, or gravity air inlet into any building.
• Not less than 2 feet (610 mm) from an adjacent building and not less than 7 feet (2134 mm)
above grade when located adjacent to public walkways.
• The bottom of the vent terminal shall not be less than 12 inches (305 mm) above grade.
• The exit termination must be arranged such that flue gases are not directed so they could
jeopardize people, overheat combustible structures, or enter buildings.
• The exit termination must be located at least 12 inches (305 mm) from any opening into a
building.
FREESTANDING/DIRECT HORIZONTAL VENTING
MARKING AND CUTTING HOLE IN EXTERIOR WALL
. Temporarily position the stove on the floor protector in it’s final location.
. Determine the centerline of the stove’s 5 inch (127 mm) combustion air intake (For
corner application determine by measuring the centerline location of the 5 inch (127
mm) elbow). On the same centerline, mark a center point on the wall.
3. Using the point marked on the wall as a center point, cut a 5 inch (127 mm) hole
through the exterior wall. This can be accomplished with a variety of tools. Your
needs will depend upon the type of wall material
•
CAUTION: WHEN CUTTING
THROUGH WALLS INSURE THERE IS
NO INTERFERENCE WITH WIRING,
PIPES, STRUCTURE, ECT...
Note: For corner installation, it will be necessary to temporarily install the adjustable elbow
pipe into the 5 inch (127 mm) intake pipe from
the stove with the crimped end fitting into the
intake pipe.
Exhaust Centerline
Side View
Exhaust Centerline
Top View
FREESTANDING/DIRECT HORIZONTAL VENTING
VENT KIT INSTALLATION PROCEDURES
Note the placement of parts in order to facilitate reassembly
Interior Trim
Collar
Vent Cap
Outside
Flange
Telescoping
Intake Tube
Telescoping
Exhaust Tube
Note that the vent kit has two telescoping tube sections. This allows for a range of adjustment
between the wall and the stove without the need to cut and fit to exacting dimensions. Also notice
that the intake tube is larger that the exhaust tube and creates an air gap between them when
installed. This air gap allows the zero clearance mounting of the vent kit. DO NOT MODIFY
this vent kit in any way that may compromise this air gap.
. Begin vent kit installation by placing
the self-adhesive gasket at the end
of the LARGE telescoping exhaust
tube. Trim gasket to length if
necessary.
Self-adhesive
gasket
FREESTANDING/DIRECT HORIZONTAL VENTING
. Place a small bead of caulk
around the back perimeter of the
outside flange to prevent air and
moisture infiltration.
3. From outside, push the outer
flange with the 5 inch (127 mm)
extension through the wall and
secure to the wall with screws.
(The type and length of the screws
required will depend on wall
materials.)
Silicone
Caulk
Exterior
Wall
4. Place the end of the telescoping
exhaust tube prepared in step 1
into the vent cap and tighten with
a screwdriver.
Clamp Screw
Access Hole
FREESTANDING/DIRECT HORIZONTAL VENTING
5. Place a bead of high temperature silicone caulk around the 3 inch (76 mm) stove exhaust tube.
6. Place the trim collar on the 5 inch (127 mm) extension pushed through in step 3.
7. Place the exhaust tube and vent cap through the outer flange and push onto the stove’s 3 inch
(76 mm) exhaust tube about 2 inches (52 mm).
8. Slide the telescoping 5 inch (127 mm) intake tube onto the stove’s intake tube.
9. Push the vent cap onto the outside wall flange and secure with 2 provided screws.
Caulk
Trim
Collar
10
OPERATING INSTRUCTIONS
CONTROL DESCRIPTIONS AND FUNCTIONS
POWER
On position
Turns on the combustion air blower and energizes the
stove’s electrical system.
Off position
Turns the power supply off to all components.
Auto Off position
Applies main electrical power to an Auto Off thermostat.
This is selected during a shut down.
FUEL
FUEL
A rotary control combining on/off and fuel feed control
functions.
When in the Off (fully counter-clockwise) position, the
control turns off power to the auger feed system. This
prevents fuel feeding into the burner box.
When rotated clockwise from the Off position, the control
turns on power to the auger feed system. Continued rotation clockwise increases the fuel feed rate.
ROOM
AIR
PRIME
ROOM AIR
A rotary control that controls the air flow through the heat
exchanger.
ON
OFF
AUTO
OFF
PRIME
A pushbutton switch that, when pressed, manually operates the auger feed system.
11
POWER
OPERATING INSTRUCTIONS
FIRST TIME AND SEASON START-UP
. Fill hopper with clean, shelled corn.
. Set POWER switch to “ON“ position.
3. Prime the feed system by pressing
and holding the PRIME button until
corn enters the burner box. Release
PRIME button.
4. Set POWER switch to “OFF“
position before following the
Lighting Procedure.
Adjustable Bracket
Note: Corn should distribute evenly in
burner box as it strikes the corn divider.
If necessary, adjust the divider to achieve
even distribution.
Screws
Corn Divider
LIGHTING PROCEDURE
. Fill hopper with clean, shelled corn. Remove ashes from burner box if necessary.
. Fill burner box 1/2 full with solid fire starter blocks or starter log pieces (can be purchased
from grocery stores, ect...).
3. Ignite solid fire starter blocks and close door.
4. Set POWER switch to “ON“ position.
5. Set FUEL control to “2” and set ROOM AIR control 1/2 on.
6. When heat exchanger reaches a preset temperature, auger will begin to feed corn.
Approximately 5 minutes after corn starts to flow, reset FUEL and ROOM AIR controls for
comfort.
7. Occasionally solid fire starter blocks will leave a haze on the door glass. To clean, turn off
POWER switch, open door and carefully wipe glass with a dry paper towel. Close the door
and turn POWER switch on. Normal operation should resume.
SHUT DOWN PROCEDURE
. Set FUEL control to “OFF” position.
. Set POWER switch to “AUTO-OFF” position. All fans will automatically shut off when heat
exchanger temperature drops to a preset level.
12
OPERATING INSTRUCTIONS
SEASON SHUT DOWN PROCEDURE
Burn or otherwise remove all corn from hopper. Insure auger is empty of corn, by use of the
PRIME button.
WARNING:
•
•
•
THIS UNIT IS DESIGNED TO USE SHELLED CORN ONLY!
TO START FIRE USE ONLY SOLID FIRE STARTER BLOCKS. DO NOT USE ANY
LIQUID FUELS OR ANY OTHER TYPE OF MATERIAL TO START FIRE.
ALWAYS TURN POWER SWITCH OFF BEFORE OPENING COMBUSTION
CHAMBER DOOR
REMOVING THE CLINKER
During the combustion of corn, what is known as a clinker will form in the bottom of the burner
box. A clinker is best described a fused ash, almost glassy in appearance, conforming to the
shape of the bottom of the burner box. If not removed, it will eventually extinguish the fire.
For best results, remove the clinker every 12 to 24 hours of use. This can be accomplished while
a fire is burning, however it must be done quickly (about a minute) to restore fuel and air to the
burner box.
. Turn POWER switch to “OFF” position, then open door.
. Remove clinker by placing the point of the clinker tool in the front corner of the burner box.
Push down to bottom of box, making sure that the tool point slips beneath the clinker.
3. Turn clinker upright so that the burnable ashes and corn fall back into the burner box. Lift
clinker out of the burner box and onto the ash pan.
4. Close the door and turn POWER switch to “ON” position.
This procedure requires some practice to master. If the flame is lost, simply shut down stove and
relight.
13
ROUTINE MAINTENANCE
CLEANING GLASS DOOR
Although the stove is equipped with an air glass wash system, and burns clean, the glass will
cloud up. For best results when hot use a dry towel to clean glass. For best results when cool use
glass cleaner. Heat from the fire will not break the glass, however, the glass should be handled
with care. Rough handling may cause damage.
REMOVING AND CLEANING THE
BURNER BOX
. Turn POWER switch to “AUTO-OFF”
position.
. Wait until heater shuts down and cools.
3. The burner box is attached by hooks
to the inner wall. To remove, lift the
burner box upward and pull forward.
4. Empty ashes into a metal container.
REMOVING ASHES
. Shut down the stove. Wait until the stove completely cools. Open door and remove burner
box.
. Using a brush (i.e. paint brush, ect...), brush ashes from both side walls to the center.
3. To remove, lift ash pan from the stove. Or vacuum loose ashes from the chamber floor.
14
BIMONTHLY MAINTENANCE
NOTE: The frequency of the following cleaning will depend on usage.
HEAT EXCHANGER / EXHAUST CLEANING
.
.
3.
4.
Shut down the stove. Wait until the stove completely cools.
Open the door and remove burner box.
Remove clean-out cover plate.
From inside the combustion chamber, using a brush, clean the heat exchanger tubes and all
walls of the combustion chamber. Vacuum loose debris thoroughly from the floor of the
chamber and exhaust pipe.
Clean Behind
Vacuum
END OF SEASON MAINTENANCE
IMPORTANT: Using the PRIME button, remove all corn from the hopper and auger system.
BLOWERS LUBRICATION
•
SAFETY: Unplug the stove before performing the following instructions.
Always disconnect the power supply before servicing the blower or any other portion of the unit.
The motor bearings should be relubricated every 6 months with a few drops of SAE 10W or 20W
nondetergent oil (ML - TYPE) or with electric motor oil.
15
16
Power
Switch
Primer
Switch
Fan Speed
Control
Timer
ON/OFF &
Duty
Cycle
Timer
9
11
1
13
10
12
7
1
2
3
8
5
4
13
10
7
4
FUSE
6
5
3
17
11
14
AUTO OFF
95° F
14
OVER TEMP
200° F
CornFlame 3000
6
15
16
ROOM BLOWER
95° F
12
9
2
AUGER MOTOR
95° F
THERMODISCS
17
15
19
16
ROOM AIR
BLOWER
18
COMBUSTION
BLOWER
19
18
AUGER
MOTOR
WIRING DIAGRAM
WARRANTY
LIMITED WARRANTY
PLEASE READ CAREFULLY
WARRANTY IS NOT TRANSFERABLE
PRODUCTS NOT COVERED:
This warranty does not cover the following: Standard and optional gold trim, glass, gasket
material and will not cover any damage and/or failure caused by abuse or improper use or
improper installation of the product covered.
(A) Period I
For the period of the first one (1) year from the date of purchase, we will replace or repair, at our
option, any part defective in materials or workmanship affecting the operation of the heating
system. The cost of parts only are included. The customer pays any labor or transportation
charges.
(B) Period II
For the period of the first three (3) year from the date of purchase, we will replace or repair, at
our option, any portion of the firebox which has been damaged due to heat thereby affecting the
heating system operation. The cost of parts only are included. The customer pays any labor or
transportation charges.
PROCEDURE
Should you feel your heating system is defective, please contact your heating system dealer.
They will instruct you in the proper procedures, depending on which warranty period (A or B)
applies.
CONDITIONS AND EXCLUSIONS
A. There is no other expressed warranty. All implied warranties of merchantability and fitness
for use are limited to the duration of this limited warranty. Some states do not allow
limitations on how long an implied lasts, so the above limitations may not apply to you.
B. The manufacturer is not liable for indirect, incidental, or consequential damages in connection
with the use of the product including any cost or expense of providing substitute equipment
or service during periods of malfunction or non-use. Some states do not allow the exclusion
of incidental or consequential damages, so the above limitation or exclusion may not apply to
you.
C. This warranty applies only to parts or components which are defective and does not cover
repairs necessary due to normal wear, misuse, accident or lack of proper maintenance.
OTHER RIGHTS
This warranty gives your specific legal rights, and you may have other rights, which vary from
state to state.
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