AES MagnuM 6500 Service manual

AES Technical Bulletin # F-0404 Date of Issue 02/13/2006
AES TECHNICAL BULLETIN
MagnuM 6500 Furnace Operation / Clinkering / Changes
The purpose for this bulletin is to discuss the MagnuM 6500 Furnace operation in relation to clinkering, buildup in
the firepot, what causes these things to happen and what is the solution. We have found that once customers are
instructed and understand how to operate the furnace expected results will be consistent with the design of the
unit. The installation and operations manual clearly explains how the unit is supposed to operate and what
maintenance is involved. Following these procedures will enable the operator to have trouble free operation.
The following list explains the different situations where excessive clinkering or buildup in the firepot may occur.
Remember that the MagnuM 6500 Furnace does not have a self cleaning firepot and needs to have the clinker
manually removed every 12-24 hours depending on fuel quality, quantity, installation of product and operator
habits.
1. Fuel quality: If your fuel is high in starch it is not going to burn quickly or completely. This will cause the
firepot to fill up quicker than normal. If the fuel is wet (over 15%), it will contribute to a rapid concentration
of clinkers and plugging of the air holes. If the fuel has a high test weight (over 56 Ibs per bushel), it
could be dumping more fuel into the firepot than the unit is capable of burning. This would require a fuel
feed rate test to see if this is happening. Corrective action is to make sure the fuel is dry and clean, try to
get good quality fuel as possible and every 6-8 hours knock the clinker down with the cleaning tool. You
do not have to take the clinker out right away but need to stir the fuel around in the firepot which will break
up the clinker and knock the buildup down to size. The firepot would have to be cleaned out every 8-12
hours to have proper operation. This can be done without losing the fire.
2. Ash buildup: It is important to shake down the ash (front shaker rod) every 8-12 hours to allow enough air
to get around the firepot. Do not wait until you are ready to empty the ash drawer. If the firepot cradle is
full of ash it will cause the air to only go into the back side of the firepot and this will cause uneven
combustion and possible firepot warping. Corrective action is to shake down the fuel every 8-12 hours
and check the ash area underneath the firepot every 1-2 days.
3. Shaker grate not sealing: If the shaker grate is not laying right on the bottom of the firepot cradle, it will
re-direct the air out the bottom of the firepot and the fire will not burn properly. This can be caused by the
slide not manufactured properly, customers beating on it when they cannot get it to move (normally
caused by lack of maintenance) or unburnt fuel getting underneath it. Corrective action would be to
check to make sure that the slide is setting flat and correct it if it is not setting flat. This can be done
easily by tapping on the rod to bend the plate downward. Dislodge any fuel that is setting underneath the
plate. Also make sure that the customer is sliding the plate all the way back when the unit is burning.
4. Door or Ash drawer not sealing: If the door or ash drawer door is not sealed it will take air pressure away
from the firepot. Corrective action is to do the paper test or a leak test to make sure that all gaskets are
sealing. If the gaskets are leaking, replace with new gaskets or repair existing gasket.
5. Firepot not sealing: If the firepot is not sealing against the top of the firepot cradle, the air pressure will
drop and the fire will not get enough air. Corrective action would be to grind the area that is causing the
firepot not to seal and allow the firepot to sit correctly in the firepot cradle. Before grinding the cradle
make sure that the firepot itself is not warped.
6. Incorrect Air intake venting: If the outside air is not hooked up or is not properly sized for the application
you will not get adequate combustion air. If there are more than 2 elbows or if the air run is more than 10
feet, you need to be using 4” air intake venting. If the venting is being obstructed, contaminated by
exhaust or otherwise not allowing correct air to the unit, you will need to change the system so that it is
correct. Testing for this would be done with an air flow instrument or you can do a preliminary test by

AES Technical Bulletin # F-0404 Date of Issue 02/13/2006
unhooking the outside air and opening a door or window for a few hours to see if the combustion air is an
issue.
7. Incorrect Venting for exhaust: If the venting has more than 2 elbows or has an equivalent length of more
than 10 feet, it is recommended to go with 4” venting. If the venting is restricted by outside elements it
has to be changed. Corrective testing would need to be done by taking the unit out of the environment
that it is in and making sure that it does run correctly. If the glass gets dirty quickly (under 1 hour) the
venting is not correct. MagnuM 6500 Furnaces after January of 2006 must use 4” venting.
8. Environmental conditions: In most cases, the home itself is causing the problem. If the unit is being used
in any way to supply air to the home, it will not work correctly. If the home has not been balanced so that
there is no negative pressure, it will have to be done or the unit will not operate on the higher settings and
may not operate correctly on the lower settings.
9. Draft/Exhaust blower: If the exhaust blower is not operating correctly it will affect the fire. Corrective
action would be to do an air flow test (should be around 75 cfm) and an amp draw test (should be around
.95 amps). Always check the label on the product for correct cfm and amps. Check for gasket leakage
between the draft/exhaust blower and the housing.
10. Plugged heat exchanger/plugged venting: If the venting or heat exchangers or draft/exhaust blower is
plugged (normally caused by lack of maintenance, improper combustion air, improper venting, negative
air pressure, and wet fuel) this will cause the firepot to fill up prematurely on higher settings. Corrective
action would be to identify these items and correct.
11. It is important to daily move the heat exchanger cleaner rod back and forth to eliminate the plugging of
the heat exchangers. Do not force the heat exchanger rod as you will bend or break the heat exchanger
plate. This is a time consuming and costly repair that his not covered by warranty. If you have plugged
your heat exchanger tubes you might have to take the appliance outside and wash out the heat
exchanger area. Consult your local dealer for inspections and corrective action to be taken.
12. Operator Error: It is important that proper installation, maintenance and operation practices are followed.
If the appliance is not installed correctly, proper fuel used or proper operation ignored, the firepot will fill
up after a short time of operation. Continued use with the above problems and the appliance will plug up,
venting will become plugged, draft blower could become plugged and extensive damage to the appliance
could occur. The appliance is not covered under warranty for operator error, lack of maintenance and
improper installation.
13. The unit will burn fine on the higher settings for about 8-12 hours and then it needs the clinker knocked
down or taken out. The longest that the unit will burn without clinker removal would be app. 24 hours if all
conditions are perfect and proper fuel is being burned. The unit works the most efficient on the #2-3
setting for maximum heat impact but will burn on 4-5 if operated and installed correctly.
The MagnuM 6500 Furnace has been tested to perform at the BTU level that is on the test plate. It has been
tested to run according to the operations manual guidelines. If the unit is not installed, vented or operated
according to these requirements, it will not perform properly. It is the responsibility of the homeowner to contact
the dealership to make sure that all of the items listed above are checked out and are not affecting the
performance of the furnace. Anything less than this could cause damage to the unit and or the customers’ home.
Clinker removal: The clinker needs to be removed when it builds up to app. 1” thick. This normally would be done
every 12 hours or so. The clinker can be removed with the fire burning by tapping lightly on the top of the firepot
and then placing your removal tool underneath the clinker and roll the clinker toward the back of the firepot. Once
the clinker is loose you can tip the clinker to the side using a fireplace tong to pour the fire back into the firepot
and then safely remove the clinker. This action will take a little practice to get good at doing it.
Dispose of the clinker by either placing it on either side of the firebox chamber so that it cools and crumbles into
the ash pan or take the clinker out and place in a fireproof container.
Proper operation of the MagnuM 6500 Furnace is essential. Please contact your local dealer to get questions
answered and proper operating techniques.