Volume 7.1 COUNTRY FLAME TECHNOLOGIES Smart Fireplace Furnace Products, FP-33, FP-37, FP-42 (Wood Burning Only) Optional Parts Shown Installation, Operation & Maintenance Manual Version 7.
Installation, Operation & Maintenance Manual SMART FIREPLACE FURNACES (FP-33, FP-37, FP-42) WOOD BURNING PRODUCT ONLY © 2005 Country Flame Technologies A Division of American Products, L.L.C. 900 George Street, Marshfield, Missouri 65706-2364 www.countryflame.com Phone 417 859-0990 • Fax 417 859-0192 FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other fireplace appliance.
TABLE OF CONTENTS COUNTRY FLAME LIMITED WARRANTY ...................................................................................................................................III FOREWARD............................................................................................................................. ERROR! BOOKMARK NOT DEFINED. SAFETY NOTES ........................................................................................................................................................
COUNTRY FLAME LIMITED WARRANTY 900 George Street, Marshfield, MO. 65706 Country Flame Technologies warrants to you, the original consumer purchaser, that this product’s stove body is free from defects in material and workmanship for a period of six years from the original purchase date, and that the product’s remaining components including electrical parts, are free from defects in material and workmanship for a period of one year from the original purchase date.
Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damage, so the above limitations may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. This warranty is in effect on all products sold after 02/01/2007. (Please keep a copy for your personal records) Version 7.
Country Flame Technologies A Division of American Products, LLC ----------------------------------------------------------------- WARRANTY INFORMATION Name ___________________________________________________________ Address________________________________ City _____________________ State: __________ Zip ____________ Phone Number ________________ Authorized Dealer __________________________________________________ Dealer Telephone #: __________________________________________________ Date Purchased: _
FOREWORD 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 products. With pride and dedication, Country Flame employees wish you and your family a lifetime of happiness and warmth through the use of this product.
SAFETY NOTES 1. Country Flame Technologies has no control over the installation or proper care of your unit. Failure to properly install a Country Flame product can create unsafe conditions for both property and human life. Country Flame Technologies grants no warranty, implied or written, for the installation or maintenance of your unit. As such, Country Flame Technologies assumes no responsibility for any consequential damage resulting from improper installation or improper care of any specific unit. 2.
15. Due to high temperatures, the fireplace furnace should 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 accumulations from a fireplace, always place them in a metal container with a tight fitting lid. The closed container must be placed on a non-combustible surface well away from all combustible materials, pending final disposal.
FIREPLACE FURNACE SAFETY LABEL (PP-741) Model FP33, FP37, FP42 Solid (Wood) Fuel Fireplace/Furnace Tested to UL 391, UL 127, UL 1482 Listing Report #32048002-E Electrical Rating: 120 V, 6.5 Amps, 60/50 Hertz W/N 11667 INSTALLATION: Use only chimneys suitable for solid fuel. The use of air filters is not required. Place only on non-combustible flooring with adequate support.
INTRODUCTION T he fireplace is an American tradition. It remains a central feature of many homes and provides comfort and enjoyment for years to come, if designed and installed properly. Country Flame continues an American Tradition with decades of experience in manufacturing high quality practical fireplaces.
1 Chapter WHAT’S INCLUDED WITH YOUR SMART FIREPLACE? Unpack all material provided with the Country Flame product. Important materials and small components are located inside the fireplace furnace. Ensure that every item listed below is present during the unpacking process. If you find extra items or believe some items are missing, please contact your Country Flame Dealer, Distributor, or Country Flame to verify and obtain all parts necessary for proper installation.
FIREPLACE FURNACE SPECIFICATIONS Country Flame manufactures a number of different Smart Fireplace Furnace models. Table 1 and FIGURE 1 provide general information for each of the specific models manufactured by Country Flame. Crosscheck and refer to this table and FIGURE 1 when determining the installation requirements for a particular model you purchased. All installation specifications must be met in order to ensure you maintain your warranty.
TABLE 2 Room Size (ft x ft) 10 x 14 12 x 16 12 x 20 12 x 24 14 x 28 16 x 30 20 x 36 Width of Fireplace Furnace In short wall In long wall 24 28 to 36 32 to 36 32 to 36 32 to 40 36 to 40 40 to 48 24 to 32 32 to 36 36 to 40 36 to 48 40 to 48 48 to 60 48 to 72 Table 2 is provided to assist in the proper selection of the fireplace furnace model that is right for your home. These specifications are to be used as a basic guide.
9 STEPS TO INSTALL A SMART FIREPLACE STEP 1 - FOOTINGS AND FOUNDATIONS A Country Flame manufactured fireplace furnace is designed for installation in a masonry fireplace hull in accordance with the Uniform Building Code. Only qualified installation personnel should install the fireplace furnace unit. Qualified installation personnel shall be knowledgeable in fireplace construction, air-handling ductwork, heating systems and both local and national building code requirements.
FIGURE 2: SINGLE OPENING FIREPLACE SYSTEMS FIGURE 2a shows a fireplace installation where the floor joists are located below the hearth (raised hearth system.) FIGURE 2b shows a fireplace installation where the floor joists are located at the same level as the hearth. Note the changes in hearth depth required for these two different types of installations. FAILURE to observe proper clearances will increase the potential for a fire in the home due to improper installation. Version 7.
STEP 2 – CONCRETE PAD & HEARTH EXTENSIONS Determine whether the fireplace is to be installed on an outside wall or an inside wall. The clearances for an inside wall installation differ from an outside wall installation. The type of wall installation will impact the size of the concrete pad and hearth extension to be poured. Ensure conformance to all local building codes.
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 inches deeper than FIGURE 3 shows to allow for additional air space required for inside wall installation. 2.
STEP 3 – FIREPLACE POSITION ON THE CONCRETE PAD In order to accomplish Step 3, it is assumed that 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 combustible forms have been removed the fireplace furnace is ready for installation on the concrete pad.
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 chimney to combustibles below the roofline. 10. The fireplace cavity must remain open, unobstructed, and free from any combustibles from the top of the fireplace through the attic space. 11. NOTE: Country Flame’s optional log grate is shown in FIGURE 5.
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 required across the interior masonry walls when using factory-built insulated chimney materials. 13. The innermost masonry walls must extend the equivalent of one block above the top of the fireplace. 14.
MASONRY CHIMNEY CONSTRUCTION – Refer to FIGURE 7 and TABLE 4 for the procedures and materials required to construct a masonry chimney. Masonry chimney construction also requires a qualified and knowledgeable chimney mason that understands masonry construction, local codes, and local site conditions. A masonry chimney must be positioned and sealed correctly to ensure an effective flue draft occurs once fireplace operation begins.
FIGURE 7A: MASONRY CHIMNEY INSTALLATION The two longest pieces of angle iron are to be set on top of the block support 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 of the fireplace, extending four inches to the sides of the flue lip and a halfinch higher than the masonry-supporting wall.
that this block is centered on the edge of the angle 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 clearances, each successive clay flue tile, and courses of chimney brick can be added until the chimney cap height is reached. Check local building code for specifics on masonry chimney installations.
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 properly grounds the Smart Fireplace blowers. Once the brick mason has completed the face, no access to the blower wiring is possible. Bolt blower mounts to the concrete footing in order to minimize movement or vibration of the blower assembly as shown in FIGURE 8A. 2.
FIGURE 9A: HEAT DISCHARGE BOOT FIGURE 9B: ADJUSTABLE HEAT DISCHARGE BOOT (OPTIONAL) FIGURE 9A shows the proper assembly of the standard 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 optional slide in FIGURE 9, Item B, allows for a lintel adjustment from 4 inches to 7 inches.
STEP 7 – COMPLETION OF MASONRY 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 been met and that all insulation provided by Country Flame has been installed correctly. Refer to local codes for any limitations of fireplace fronts before completing the system. The following steps are provided as minimum requirements in completing the fireplace furnace front installation. 1. 2. 3. 4. 5. 6.
STEP 8 – FLUE DAMPER CONTROL INSTALLATION 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 acts as a valve, closing off the opening to the chimney when a fire is not burning. Closing the damper reduces the amount of home heat or air conditioning that will be lost through the chimney.
INSTALLING DAMPER DOOR - 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 damper rod sleeve (C) will be embedded in the masonry veneer and cannot turn. Follow the steps below to complete the installation of your rotary controlled damper. 1. Begin with the damper door (G) in the fully open position.
1. 2. 3. Reach through unit and remove screw in yoke. Swing yoke down out of the way. Lift Damper Door up and rotate slightly to slide through the opening. (See illustrations). Clean out creosote and debris. Replace Damper Door. Return yoke to its normal position and screw in place. Insure that the damper rod functions as intended. NOTE: At installation, ensure the Damper Handle tab is mortared in place to prevent it from turning during use. Refer to FIGURE 11b for more detail on the Damper Handle.
STEP 9 – ELECTRICAL SYSTEM Country Flame’s Smart Fireplace Furnace comes standard with two blowers each rated to move 525 cubic feet of room air per minute. The blower system includes all necessary parts, except some additional wire, required for a local certified electrician to install the blowers, speed controls, and the thermostat. The fireplace’s electrical system SHOULD BE tested before final brickwork is completed.
Included with this blower system as: a) b) c) d) e) f) g) Two multi-speed blowers rated at 120 volts, 60Hz, 6.5 amperes, and 525 CFM each. Two ducts for mounting blowers to fireplace. Two blower grille covers with rheostat fan speed controls pre-mounted. 10 wire nuts. One Wall mountable thermostat. One air discharge snap disc mounted & wired in front air discharge duct (right side.) Electrical box, right side to connect snap disk to thermostat connection.
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 with oil, grease, hot surfaces, or chemicals. Utilize the two high temperature wires (red and white) provided by Country Flame to connect the air discharge snap disc to the electrical system as shown in FIGURE 14. Use the high temperature wire (green/yellow) to ground the fireplace to the right blower box.
2 Chapter DUCTING OPTIONS Properly ducting the Smart Fireplace Furnace will provide years of comfort because properly ducted fireplaces will allow for a more uniform distribution of heat throughout the home. Many ducting options are possible with the Smart Fireplace Furnace. Which option is selected depends on your installer’s knowledge, local codes, and the desired results expected from the completed system.
Holes in brick masonry should be a half-inch larger diameter hole than the duct pipe to be utilized. This will allow an area for expansion of the duct pipe as it heats up. Example: if ducting a Country Flame Model 33, a 6-½ inch diameter hole should be cut in the masonry for the duct: whereas, for the Model 37 and the Model 42, an 8-½ inch diameter hole should be cut in the masonry for the duct. All clearances listed in Table 1, page 2 must be strictly adhered to.
FIGURE 16b: DUCTING SYSTEMS EXAMPLES Version 7.
3 Chapter FIREPLACE FURNACE OPERATIONAL REQUIREMENTS Immediately after your Country Flame Fireplace has been properly installed it should be tested for draft. A draft test is a simple method used to ensure air is moving up the chimney (positive air flow versus a house that may have negative pressure.) Wad up one or two sheets of clean dry newspaper. Set this paper in the middle of the firebox. Ensure that the rotary control damper is turned fully open (clockwise).
Step 4 On top of both the newspaper and the lighter wood, place two well seasoned, smallsized 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 smothering the fire. Step 5 After the fire starts to burn, leave damper open and close fireplace doors (optional), if installed. If equipped with Fireplace Doors (optional) open the door’s draft control and bring the fire to desired burn with these controls.
makes an extremely hot fire. It is the responsibility 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 maintenance required to prevent fires and creosote formation. WOOD You may purchase wood by the stack, by the rick, by the pickup load, and by the cord. Buying wood can be frustrating if you do not know what to expect or how to avoid problems.
4 Chapter FIREPLACE FURNACE 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. Visual inspections of the fireplace furnace, the chimney, the chimney connectors and the chimney cap on a semi-annual basis will reduce the probability of a fire or accident. A visual inspection should be made on monthly basis. All dampers and moving parts should move freely without sticking.
Whenever power is restored to a home, the blowers will automatically turn on; assuming a proper amount of heat is present in the firebox so the air discharge snap disc has closed to complete the electrical blower circuit. If fireplace doors (optional) have been installed on a Country Flame Fireplace Furnace, then the fireplace door’s air draft control should be open at least one turn while doors are in closed position with fire burning.
TROUBLESHOOTING GUIDE PROBLEM Fireplace smokes CAUSE Chimney cap restricted Damper not adjusted Downdraft Obstruction Atmospheric conditions Chimney obstruction Too many flues to a chimney Paint curing Leaky chimney Wet wood Normal buildup Position of fire Lack of Heat Add a chimney cap designed to prevent downdrafts. Remove tree limbs or obstruction at least 10’ from top of chimney or increase chimney height.
PROBLEM CAUSE SOLUTION Lack of Heat (continued) Severely cold weather Overdraft Draft controls adjusted not Bad wood Blower Inoperative Controls Sensor switch Excessive creosote Poor quality wood Heater Controls shut down too tight Humidifier Brass tarnishes Version 7.1 Normal 32 Naturally you will require more fuel in the middle of winter than in the fall. Turn the rotary damper toward the closed setting until the draft is reduced. Combustion is restricted when the air is restricted.
5 Chapter REPLACEMENT PARTS PART NUMBER DESCRIPTION NUMBER per FIREPLACE 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 Logo Handle “Country Flame” 1 PP-35 Insulation K Wool, 4’ by 15’ by 2” 1 PP-559 Aluminum Clean Out Door 8” x 8” 1 FP-0000-916
REPLACEMENT PARTS (cont’d) PART NUMBER DESCRIPTION NUMBER per FIREPLACE FP-0000-918 Damper Rod Sleeve (goes over rod) 1 FP-0000-920 Damper Rotary Rod Assembly 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 Grille: 5.25” x 30.975” 1 PP-560 Air Intake Grille: 13.5” x 13.
PART DRAWINGS ____________________________________________________________________________________________________ PP-703 ELECTRICAL HARDWARE ___________________________________________________________________________________________________ Version 7.
________________________________________________________________________ PP-558 BLOWER, 525 CFM (2 each per fireplace,) PP-558 _____________________________________________________________________ FP-0000-902 110 CERAMIC SNAP DISK, PP-91 _____________________________________________________________________ PP-350 RHEOSTAT (2 each per fireplace,) PP-350 _______________________________________________________________________ Version 7.
_______________________________________________________________________ PP-563 THERMOSTAT, PP-563 _______________________________________________________________________ PP-80 FP - RHEOSTAT KNOB (2 each per fireplace blower,) PP-80 _______________________________________________________________________ PP-37 DAMPER LOGO HANDLE, PP-37 _______________________________________________________________________ Version 7.
_______________________________________________________________________ PP-35 INSULATION FOR TOP, SIDES, FRONT, AND BACK, PP-35 _______________________________________________________________________ PP-559 ALUMINUM CLEAN OUT DOORS, 8” x 8,” PP-559 _______________________________________________________________________ Version 7.
_______________________________________________________________________ FP-0000-916 ASH DUMP COVER, FP-0000-916 ____________________________________________________________________________ FP-0000-921 DAMPER DOOR ASSEMBLY, FP-0000-921 Version 7.
_______________________________________________________________________ FP-0000-923 YOKE BRACKET ASSEMBLY, FP-0000-923 _______________________________________________________________________ FP-0000-918 DAMPER ROD SLEEVE, FP-0000-918 Version 7.
_______________________________________________________________________ FP-0000-917 DAMPER ROD, FP-0000-917 _______________________________________________________________________ FP-0000-920 DAMPER ROD ASSEMBLY, FP-0000-920 _______________________________________________________________________ PP-564 DAMPER SCREW, PP-564 Version 7.
_______________________________________________________________________ F-218 (Optional) FP-33 & FP-37 FLUE TO HT CHIMNEY ADAPTER, F-218 _______________________________________________________________________ F-42-218 (Optional) FP-42 FLUE TO HT CHIMNEY ADAPTER, F-42-218 _______________________________________________________________________ Version 7.
_______________________________________________________________________ FP-0000-32 & 33 GRILLE BACK, FP-0000-33 GRILLE FRONT, FP-0000-32 TOGETHER: HEAT DISCHARGE GRILLE ASSEMBLY, FP-0037--910 Version 7.
_______________________________________________________________________ F-560 AIR INTAKE GRILLE, PP-560 _______________________________________________________________________ FP-0000-924 AIR INTAKE GRILLE FRAME, FP-0000-924 Version 7.
_______________________________________________________________________ FP-0000-925 ADJUSTABLE HEAT DISCHARGE BOOT (OPTIONAL,) FP-0000-925 _______________________________________________________________________ 25-0051-00 OWNERS MANUAL, PP-359 Version 7.
_______________________________________________________________________ FP-0000-49 LOG GRATE (optional), LG-900 _______________________________________________________________________ Version 7.
WARNING LABELS _______________________________________________________________________ PP-1333 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. The finish of the hearth floor will affect the way a fireplace door (optional) will mount to the fireplace.
WARNING LABELS (cont’d) _______________________________________________________________________ PP-1333 GRATE WARNING LABEL WARNING FIREPLACE MODELS, FP-33, FP-37, OR FP-42 REQUIRE AN ANDIRON/LOG GRATE. USE A COUNTRY FLAME LOG GRATE P/N FP-0000-49, OR USE A LOG GRATE WITH MINIMUM 3.0” (H) x 21.0” (W) DIMENSIONS. FAILURE TO USE A LOG GRATE VOIDS THE PRODUCT WARRANTY _______________________________________________________________________ Version 7.
Fold Here ----------------------------------------------------------------Place Stamp Here Country Flame Technologies A Division of American Products, LLC 900 George Street Marshfield, MO 65706 Version 7.
REQUIRED WARRANTY INFORMATION Name ____________________________________________________________ Address ________________________________ City ____________________ State: __________ Phone Number_____________ Zip _____________ Authorized Dealer __________________________________________________ Date Purchased: __________________________________________________ Model No# ___________________ Installed By: __________________________________________________ Trained By: _______________________________
