ALASKA KAST CONSOLE III User manual

INSTALLATION /OWNER’S MANUAL

for

KAST CONSOLE III, CHANNING III, LIBERTY,

MODEL 140 PADDLE FEED,

MODEL 140 AUGER FEED

5/06

STOVE COMPANY

Established 1977

3162 Columbia Blvd., Bloomsburg PA 17815

TURN TO LAST PAGE IN MANUAL FOR CLEARANCE SPECIFICATIONS!

MODEL 140 AUGER FEED CAN BURN COAL OR PELLETS

CHANNING III, CAST CONSOLE III, LIBERTY, MODEL 140 (STANDARD FEED) ARE FOR COAL ONLY

UNDERSTANDING YOUR STOKER STOVE

Your Stoker Stove operates utilizing “continuous air” with a time feed mechanism.

The advantage of a constant air feed system over any thermostat type operations are:

1) A longer burning season.

2) Your fuel burns better.

3) The auto heat control box allows you to increase and decrease fire size.

NOTE: Chimney should match stove exhaust pipe size.

CAUTION:

STOVE DOORS MUST REMAIN CLOSED AT ALL TIMES WHILE STOVE IS IN OPERATION.

Entire vent system should be cleaned at least ONCE PER MONTH. Fossil fuel burning can create lethal

doses of carbon monoxide gas. This gas has no odor or color. Purchase a carbon monoxide alarm for

detection. Have your chimney cleaned professionally before burning any coal stove.

STOVE COMPANY

FEEDER ASSEMBLY

Locate unit (See Fig. 1 on page 3 and Fig. 2 on page 2).

Check that strongback gasket is positioned properly as

shown in Fig 1. The strongback gasket position is critical

in that it prevents air escape to the hopper area which

could result in “hopper fire” or warpage to the overplate.

The cast iron grate should sit snug to the housing. The

gear motor moves the feed bar in a paddle like fashion,

to push the coal across the grate. A separate motor with a

plastic fan blows air through the grate for the combustion

process. Wiring should be connected as shown below.

NOTE: Your feeder unit should come to you fully

assembled and ready to plug in.

RHEOSTAT - is used to control the speed of your air

distribution fan and allows you the air push you desire.

NOTE: Strongback is gray in color. make sure it’s

pinched between the grate and the feeder housing.

As shown below. IMPORTANT: Paddle should be

greased at least twice per year with standard grease

(see grease fitting position below). Grate gasket should

be applied to feeder housing.

WIRING: Locate plug connections below, connect

the male and female plugs with matching letters

(example A.M. to A.F.) connect C.M. to a 110 volt

wall outlet.

FEEDER ASSEMBLY

PARTS LIST

1. Auto Heat Control Box

2. Feeder Housing

3. Grate

4. Half Moon Feed Paddle

5. Plastic Wheel (Combustion Wheel)

6. Airmotor Tray

7. Cover Plate Bolt 1/4" x #20 x 2"

8. (4) #10/32 Nuts

9. Ball Joint Feed Arm

10. Feed Motor

11. Feed Motor Block

12. 1/2 Moon Feed Block

13. (2) 1/4" x #20 Wing Nuts

14. Strongback Gasket

15. Removable Feed Motor Tray

16. Airmotor / Combustion Motor

17. Grate Gasket 2' X Channel Gasket

18. Triple Plug Adapter

19. Paddle Plate (Note: 2 screws w/nut

3/8" x flat head not shown)

20. (2) 1/4" x #20 x 1" cap screws

21. Grease Fitting

22. 4' x 3/8" Rope Gasket

FIGURE 2

22 19

Hopper

Gasket

B.M.

B.F.

C.M.

FIGURE 1

Grate Air Holes

In Grate

911

15 CM

612 20 2

READ ENTIRE MANUAL

ASSEMBLY OF TOP VENT KAST CONSOLE III, CHANNING III

PADDLE FEED

ADJUSTING THE FIRE SIZE - The Auto Heat Box is

your fire size control. The box is numbered 1 to 5.

Generally a setting of 1 will maintain a minimum fire.

A setting of approximately 5 will give you a full

efficient fire (85,000 BTUs). A setting of less than 1 may

cause your fire to go out. A setting of over 5 may cause

hot burning coals to spill off the grate before it is fully

burned. Select a setting between the low burn of 1 and

the high burn of 5 until your home is comfortable.

Allow ample time for fire to adjust. A maximum fire

should not exceed and inch of ash on the end of the grate.

AUGER FEED

Auto heat box for the Auger Feed may be adjusted higher

than the 5 setting to achieve a full fire.

Read this page before installing your stove.

• Masonry or factory built class “A” chimney may be

used. A height of at least 15' from floor to top of

chimney with an inside opening of a least 6" is required.

• This Stoker can also be installed using our “Alaska

Vent” system. Ask your dealer for details.

•Make sure your chimney is free of any obstructions.

The clean out door should be sealed and securely

attached. Have your chimney cleaned and inspected

before starting your stove.

• Be sure to purchase and install a carbon monoxide

detector before you start to burn your stove.

• Contact your local building code officer, or your fire

safety inspector to insure you’re in compliance with

local codes as they can vary.

• Alaska Company recommends that you install your

stove with a Barometric Damper. We also recommend

a minimum draft of .04" of water column, although

this stove may draft at lower measurements. It may not

function properly, by following these requirements it

will help regulate your draft in high wind conditions

and allow your stove to burn more efficiently.

• Fresh air is important to the function of your stove, an

over insulated (air tight) house may not allow enough

combustion air for the proper performance of your

stove. This can be corrected by slightly opening a

window or installing a fresh air inlet.

•Glass Cleaning and Care - Stove glass is high temp

ceramic which can be fragile. Do not use cold water to

clean. Do not slam door shut as fracturing could occur.

Abrasive cleaners will scratch the glass. Do not clean

glass while hot. Use a ceramic glass cleaner and soft

cloth.

•Brass and Gold Plating Care - Be sure to clean all

fingerprints and oils from these surfaces before lighting

your stove. Do not use an abrasive cleaner. Denature

alcohol and a soft cloth are suggested. Any other

cleaning products should be used according to the

manufacturer’s instruction.

CAUTION: If you are installing your Stoker Stove in a

basement and your home uses a “heat pump” system,

return air must be provided to the basement area.

EXAMPLE: Do not pull air out of the basement with

provision for return air or you could reverse the chimney

draft of the stoker causing sulfur dioxide and carbon

monoxide to enter living area.

NOTE: Most stoves are preassembled.

STEP 1 Remove all parts from box and stove body.

Locate feeder plate (See Fig. 3). Remove the 4 bolts from

the feeder plate. Align the feeder assembly with the holes

in the feeder plate. Insert the 4 bolts and tighten.

STEP 2 Position the hopper gasket around the top

edge of the feeder housing. Locate and remove the

hopper bolts and spacers from the back of the stove body

(Fig. 3). Place the hopper on the feeder housing. Be

sure the 4 tabs on the hopper fit inside the opening of

the feeder housing. Bolt the hopper to the stove as

follows: Place a washer over bolt. Insert bolt into hole

inside hopper. Apply another washer as the bolt comes

through the hopper. Put a spacer over the bolt and insert

into hole in stove body (Fig. 3) Snug bolt but do not

tighten. Affix the 2nd bolt using the same procedure.

Press down on the hopper to set into the gasket. Tighten

the 2 bolts.

STEP 3 Blower attachment - Placer blower under

angle bracket. Insert bolts and tighten.

STEP 4 Remove Viewing Door from stove body.

INSTALLATION GUIDE FOR

ALASKA THERMOSTAT SYSTEM

STEP 1 Locate wall thermostat and

thermostat control box. Plug timer control

box into Feeder/Feeders. Attach timer

control box securely to hopper or wall.

STEP 2 Light stove as described in stove

manual. Be sure thermostat wire leads are

not connected together. Adjust lower

knob, to number 4 and allow fire to

stabilize. Adjust lower knob down

allowing 15 to 20 minutes between

adjustments until you have about 1 inch

of burning coal on the grate from side to

side.

STEP 3 Connect thermostat wire leads

together. Adjust top know to number 4.

Allow fire to stabilize. Slowly adjust upper

knob higher, until desired fire size is

achieved.

STEP 4 Disconnect thermostat wire

leads. Run wire to desired location, attach

wall thermostat. Adjust wall thermostat to

desired temperature.

NOTE: Low fire and high fire setting may

vary depending on desired heat output.

Locate Glass Box which will include gaskets and

instructions. Install glass. Re-hang door. NOTE: Some

models come with glass installed. If your stove is ordered

with the optional clean glass system, locate stainless steel

screen (packed inside stove body). This screen helps to

prevent fly ash from attacking the glass. Install the screen

so the bottom rests on the Channel inside the stove body

below the View door, and the top will lean against the

metal plate welded to the top of your stove. NOTE:

Install screen after stove is lit. Use hearth or stove gloves

to install screen.

Top Vent Stove Only - This unit is sent to you with a

brick attached to the inside back of stove. This

component is removable which serves two purposes:

a) Slide brick, opens for cleaning of fly ash and to allow

you to adjust for better draft on warm days (Keep closed

in colder months. Slide open in warmer months.)

b) For access to clean the stove’s vent system. Please

locate brick at this time. Open viewing door, look inside

stove through door opening. The brick will be between

two metal channels, about 4" from the top of your stove.

Locate holes in back of stove body. This is where your

stove vents. The two holes should be cleaned every 4

to 6 weeks with a vacuum or brush. NOTE: Entire

vent system should be cleaned every 4 to 6 weeks.

This may vary depending on chimney draft.

STEP 5 Attaching Power Cords - Plug the female cord

from the rheostat into the male cord coming from the

blower. NOTE: The rheostat acts as a speed control and

an off/on switch for the blower. It can be attached to the

side of the hopper or wall using Velcro tape. Plug the

male end of the feeder cord into a 110v wall outlet (See

Fig. 2 C.M.)

STEP 6 Position Stove - Align stove pipe and screw

pipe to vent hole (See Assembly of Stove Pipe).

STEP 7 Place the steel of optional cast top on stove. If

you have a Kast Console III model, the top comes in 3

pieces. Position the center piece first, then the sides.

Channing III has a single piece tope.

COAL OR PELLET FUEL BURNING SYSTEM

ASSEMBLY NOTES

OPERATING INSTRUCTIONS AUGER FEED SYSTEM

The Model 140 is pre-assembled, except for the blower.

Follow Page 8, Step 5 for blower assembly.

The Model 140 may also be disassembled allowing the

unit to be placed through small door openings and

cellar entrances.

CAUTION: Care must be taken during reassembly.

Improper assembly may cause smoke leakage or a

hopper fire.

*See Page 9 for Installation Instructions

REINSTALLING THE HOPPER

STEP 1 Make sure gasket on hopper casting is in good

condition.

STEP 2 Place hopper on hopper casting, center

hopper, attach bolts and tighten.

STEP 3 Make sure there are no spaces or gaps between

base of hopper and top of hopper casting.

NOTE: All fuel, coal or pellet must be thoroughly

cleaned from feed system before switching from one

fuel to another. NEVER USE SOAKING WET COAL!

Soaking wet coal will cause condensation in the hopper.

COAL BURNING

STEP 1 Fill hopper with dry coal. Plug auger feed

system into 110V outlet. Turn auto heat box knob

clockwise until it stops. Allow pot to fill with coal, then

turn auto heat box to 3.

STEP 2 Light fire as instructed. See page 10.

STEP 3 Use the high setting for combustion blower

when burning coal.

STEP 4 Hopper lid must be shut and latched for

auger feed system to operate (make sure hopper lid seal is

kept in good condition.)

STEP 5 Adjust auto heat knob to desired position. With

1 being approximately a low fire, turn knob clockwise

until it stops. This is approximately a full fire. NOTE:

These settings are approximate and will vary.

PELLET BURNING

STEP 1 Fill hopper with pellets. Plug auger feed

system into 110V outlet. Turn auto heat box knob

clockwise until it stops. Allow pot to fill about half way,

then turn auto heat box to 3.

STEP 2 Turn combustion blower off.

STEP 3 Light pellets (use a propane torch or alcohol

gel.)

STEP 4 After pellets are burning, turn combustion

blower to the low setting. Adjust auto heat knob to

desired position. With 1 being approximately a low

fire, turn knob clockwise until it stops. This is

approximately a full fire. NOTE: These settings are

approximate and will vary.

NOTE: SEASONAL / END OF YEAR CLEANING

STEP 1 Empty hopper.

STEP 2 Empty auger.

STEP 3 Remove ash dump bolt and plate. Vacuum all

ash from pot casting. (This may need to be done during

burn season).

STEP 4 Clean pipe and elbows several times during

burn season.

FEEDER ASSEMBLY PARTS LIST

ABOUT THE AUGER FEED SYSTEM

1. Feed Motor

2. Auto Heat Control Box

3. Auger

4. 6 Piece Grate System

5. Ash Dump Plate

6. 2 Speed Combustion Blower

7. Auger Hub

8. Auger Shaft Collar

9. Motor Stop Support Bracket

10. Ash Ring

11. Pot Casting

13. Hopper Casting

14. Combustion Blower Shut Off Switch

The Auger Feed System is capable of burning rice coal

or wood pellets. The fuel is fed from the hopper

through the auger and out of the burn pot. Unburned

fuel residue is either blown out of the pot by the 2 speed

blower or forced out by fresh unburned coal.

ADJUSTING THE FIRE SIZE

The fire size is regulated by the Auto Heat Box. The box

is numbered. The approximate minimum fire number

is 1. The knob may be turned higher than the 5th

setting as long as hot or burning coals are not being

forced off the edges of the grate. This is the

approximate highest fire setting.

ASSEMBLY OF YOUR MODEL 140

NOTE: The stove comes assembled.

STEP 1 Remove all parts from inside the stove body and

the parts box. Remove the 8 bolts from the frame of the

feeder plates (4 from each plate). Align Feeder Assembly

holes with feeder plate holes. Insert bolts and tighten (See

Fig. 6). If you purchased a Model 140 with one feeder,

mount the feeder plate cover over one opening.

STEP 2 Place Hopper Gasket around Top edge of

Feeder Housing.

STEP 3 Remove hopper bolts and spacers from jacket

above feeders.

STEP 4 Place hopper over openings in the feeder

assemblies, the hinged lid toward the stove body (See Fig.

7). Place a bolt with a washer though the hole from

inside the hopper, add a washer and a spacer on bolt,

thread into stove body. Use same procedure for second

bolt. Push down on hopper to seat firmly on gasket.

Tighten the bolts. The hopper tabs should be inside the

feeder housing (Fig. 6). If you have purchased a one

feeder unit, use the hopper plate cover to seal the open

hopper opening.

STEP 5 Install blower - locate blower hole at bottom

back of stove. Remove the 1/4"x20x1/2" self threading

screws. Position blower in hole and attach with screws.

Locate 2'x3/8" Rope Gasket. Remove cover tape from

adhesive on gasket. Place gasket around outside top of

blower. Locate blower shroud, place blower shroud over

blower and attach with screws.

STEP 6 Refer to drawing for approximate location of

wiring harness bracket. Hold bracket in position, attach

with self-taping screws provided (See Fig. 7) Plug blower

motor into the junction box cord (long female cord). Plug

feeder(s) into short female cord (use triple plug adapter if

stove is ordered with 2 feeders). Plug into a 110 volt

receptacle and test for motor operation (See Fig. 8). (If

you purchased Model 140 with optional hot air fan limit

switch, instructions are contained in box). Your Model 140

can be used as a hot air system. Contact your Alaska

dealer for details. Cold air return may be accomplished

by returning air into immediate area of distribution

blower. A box could be constructed over the blower and

cold air returns. Connect pipe to ensure fit. Place 3

screws at each joint. We also recommend a bed of high

temperature silicone at each joint (optional), once your

stove is positioned properly attach pipe at top of stove.

STEP 7 Remove view door from stove body. Locate

glass box which will include gasket and instructions.

Install glass. Re-hang door.

NOTE: The rheostat on the wire harness bracket is to

control the speed of your air distribution fan. Allowing

for more or less air push.

ASSEMBLY OF YOUR MODEL 140

STEP 1 Place stove body on hearth. Allow proper clearance

to flammable surfaces. See last page for clearances.

STEP 2 Place a piece of pipe over the vent hole, crimped

end up. For Model 140 an elbow may be placed on the

stove body (See Fig. 8).

STEP 3 Locate Barometric Damper (See Fig. 5). Assemble

and set in accordance with manufacturer’s directions.

Proceed as follows:

Model 140 - Place barometric damper on elbow, crimped

end up, pointed in the direction of thimble from the

chimney (See Fig. 8).

Top Vent Stove - Place barometric damper over the pipe

already on stove. Be sure your attachment is plumb. (See

Fig. 5).

STEP 4 Place a length of pipe into Wall Thimble (See Fig.

4). This pipe should go through wall and into the Flue

Liner. Do not allow pipe to pass through the flue liner. Seal

all openings where pipe entered wall with fiberglass. Place

“Trim Collar” over pipe and snug tight to wall (See Fig. 4).

STEP 5 Place an elbow into the pipe coming out of wall,

take a measurement from the top end of the barometric

damper to the bottom of the elbow - add 3" to your

measurements. This will be the length of pipe you will need

cut (if necessary) and assemble.

NOTE: We suggest an initial Barometric Draft Setting of

.04. Once your fire is burning, check manufacturer’s

directions before final adjustment - use Rc-Bt Ul Listed

Barometric if available.

STARTING YOUR STOKER STOVE FIRE

CAUTION: Dry out your masonry chimney before

starting your stove.

CHIMNEY SYSTEM - Make sure it is clean and free of

any debris. Moisture in a new chimney or a cold chimney

does not allow for proper drafting of flue gas. Dry out

and warm up a chimney by:

• Open clean-out door, build a small wood fire for ten

minutes. OR place wadded newspaper on floor of

Stoker and burn paper for 10 minutes… Add paper as

needed.

• If you should smell sulfur at any time - Turn the unit

off - Open doors and windows.

• Initial burning of your stove will cause the paint to cure

(smoke). Ventilate area by opening window.

• If your home is well-insulated, have a fresh air inlet

installed - open a window (1") while your stove is

operating.

• On your first day of operation, we suggest you start

your stove early in the day to allow the curing process to

occur and to allow time to understand your stove.

1) Fill hopper with dry coal

2) Dry out your masonry chimney with a separate wood

kindling fire for twenty minutes. Build this fire in

cleanout door or on bottom of stoker.

3) Mount your Auto Heat control box securely to a wall

near your stove. Do not mount on stove body!

4) Place fire starter on grate, cover with coal, light tail

close viewing door and wait until starter head is

burning.

5) Plug power cord into your wall outlet.

6) Set your “Auto Heat” dial to setting #2.

7) In 20-30 minutes your fire becomes fully established.

8) Adjust your Auto Heat dial to your comfort -

REMEMBER - a setting of 1 is approximately a

low fire.

Always operate stoker with both doors closed.

Always test your gas alarm as per instruction.

BEFORE YOU CALL US…

Not Enough Heat

• Check to see if holes in grate are clogged… clean. Make

sure under grate is free of coal fines. This can be done

by lifting the grate off the feeder housing.

CAUTION: Make sure when replacing grate, the gasket

material is in place both around the bottom of grate

and on rear of grate (See Fig. 3).

• Make sure there are no cracks in grate.

• Make sure plastic wheel on gear assembly is intact and

clean of any dirt or dust

Black Dust

• Dirty coal or dry coal should be dampened.

• Turn off blower rheostat or unplug main cord when

pouring coal into hopper or changing ash buckets.

• Make sure air space is between top of stove and main

stoker body is clear of coal dust.

Sulfur Fumes

• Make sure hopper is not being filled with soaking wet

coal.

NOTE: Allowing moisture to build up in Hopper

will cause rusting and severely damage your feed

system, voiding all warranties.

• Make sure space between the hopper and stoker is clear

of coal.

• Make sure gasket is intact.

• Make sure stove pipe is clear of fly ash.

• Important - check elbow closest to stove.

• On Channing III clean behind draft tubes by grate.

Hopper Fire

• Do you have a Barometric Damper on Stove?

• Check grate - is there a crack?

• Is the gasket and/or strongback intact on grate?

• Is gasket between feeder and hopper missing?

• Check size of coal - it might be too large. You should

use rice coal.

Moisture in Hopper

• Check behind slide brick for fly ash buildup.

• Do you have excessively wet coal?

• Is your stove pipe blocked?

• Do you have good draft?

• Remove Pipe; clean exhaust holes.

INSTALL A GAS ALARM!!!

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