6039 tech manuals and other tips and tricks

[bluewolf]

4 Digit 6039 Multifuel Stove Control
Technician Refrence Firmware Revision 0.15

NEW style 4 button Panel Technical manual

(For old style "ABC" panel, scroll half way down page)


6100 C codes (by jawquin) at the bottom.

6300 and 6500 C Codes by tinman
http://forum.iburncorn.com/viewtopic.php?t=859&start=30





































OLD "ABC" MANUAL

pg.2

pg.3

pg.4

pg.5

pg.6

pg.7

pg.8

pg.9

pg.10

pg.11

pg.12




6100 C codes (by jawquin)

Here are the C settings for firmware rev 5.04

C- 1 - Reset to defaults (hold Mode and Auger Delay buttons for 3 seconds to
reset all to defaults)
•
C- 2 - Fuel Lbs Per Hour HR 1 (0-8.0) - This is the fuel rate in pounds per hour
for a heat range setting of 1. The default is 2.0lbs.
•
C- 3 - Fuel Lbs Per Hour HR 9 (0-8.0) - This is the fuel rate in pounds per hour
for a heat range setting of 9. The default is 6.0lbs. The fuel rates used between
settings 1 and 9 are linearly interpolated between these two settings.
•
C- 4 - Agitator On Percentage HR 1 (0-50) - This is the Percent On time for the
Agitator for a setting of 1. The default is 25%.
•
C- 5 - Agitator On Percentage HR 9 (0-50) - This is the Percent On time for the
Agitator for a setting of 9. The default is 50%. The percent on time for the
Agitator used between settings 1 and 9 are linearly interpolated between these two
settings.
•
C- 6 - Draft Fan Level HR 1 (0-500) - This is the Draft fan output level for a draft
fan setting of 1. The default is 215/500.
•
C- 7 - Draft Fan Level HR 9 (0-500) - This is the Draft fan output level for a draft
fan setting of 9. The default is 225/500. See next parameter for disbursement.
•
C- 8 - Draft Fan Full On at Setting 9 (0-1) - If this parameter is set to 1, the setting
for C7 is used for a fan speed of 8, and a value of 500 is used for a fan speed of 9.
If the parameter is set to 0 (default), the setting for C7 is used for a fan speed of 9,
and all remaining fan speeds are set based on the interpolation between C6 and
C7.
•
C- 9 - Ramp Seconds for Increasing Level (0-300) - When the heat range setting
is adjusted, the control will ramp from the current setting to the target setting to
avoid abrupt changes in the outputs that could cause problems with the flame
quality. The Ramp Seconds value sets the amount of time to spend on each heat
range setting (1-9 pseudo ranges not 1-3 user ranges) as the current setting is
ramping toward the target. If the current setting is ramping down toward a lower
target, the ramp value is half this number. The default value is 90 seconds.
•
C-10 - Startup Minutes for Detecting Warm Furnace - (10-60) This is the amount
of time the control will wait for the furnace to reach the warm temperature (110
Degrees F) after the furnace has been started before shutting down and reporting
an Error condition Err3. The default is 30 minutes.
•
C-11 – Overtemp Setpoint (above ambient) - (0-300) This is the number of
degrees above ambient that the measured flue gas temperature can reach before an

overtemp condition exists. If the measured temperature is higher than ambient +
this setpoint, the control will stop augering fuel until the temperature returns to a
safe operating point. The default is 255 degrees above ambient.

•
C-12 – Cutback Setpoint (above ambient) - (0-280) This is the number of degrees
above ambient that the measured flue gas temperature can reach before a cutback
condition exists. If the measured temperature is higher than ambient + this
setpoint, the control enforces the PID temperature control algorithm. The default
is 220 degrees above ambient.
•
C-13 – Room Fan On Setpoint (above ambient) - (0-200) This is the number of
degrees above ambient that the measured flue gas temperature can reach before a
the flue controlled foom fan turns on. If the measured temperature is higher than
ambient + this setpoint, the control will turn on the flue controlled room fan. This
variable also serves to indicate to the control that the stove is warm. If the
measured temperature is higher than ambient + this setpoint, the stove is
considered warm and will not create an Er 3. Whether or not the stove is warm
also determines if the unit will recover from a power failure. If the stove is warm
when power is lost and cold when it returns, it will shutdown with an Er 4 error.
The default is 80 degrees above ambient.
•
C-14 – Cold Stove Setpoint (above ambient) - (0-100) This variable is used to
determine when the furnace is cold and ready to be shut down. If during the
shutdown sequence the measured temperature is less than this value + ambient,
the furnace will stop running the fans to cool it off. The default is 40 degrees
above ambient.
•
C-15 – Low Temp Vent Setpoint – (70-200) This variable is used to control the
vent controlled room fan. If the measured vent temperature is greater than the
Low Temp Vent Setpoint, the vent controlled room fan will turn on. If the
measured vent temperature is less than the Low Temp Vent Setpoint – 5, the vent
controlled room fan will turn off. The default for this setpoint is 115 degrees.
•
C-16 – High Temp Vent Setpoint – (70-250) This variable is used to limit the
maximum vent temperature. If the measured vent temperature is greater than the
High Temp Vent Setpoint, the furnace will reduce the heat range by 1. If the vent
temperature falls below the setpoint – 5, the heat range will ramp back to normal.
The default for this setpoint is 180 degrees (subject to change).
•
C-17 – Calculate Ambient – (0-1) If set to 1 (default), the ambient temperature
sensor and flue gas temperature are combined to calculate the ambient
temperature outside the furnace. If set to zero, the ambient temperature is
assumed to be 70 degrees F.
•
C-18 – Proportional PID Constant – (0-1000) Proportional constant for cutback
temperature control. Default is 80.
•
C-19 – Differential PID Constant – (0-1000) Differential constant for cutback
temperature control. Default is 100.
•
C-20 – Integral PID Constant – (0-1000) Integral constant for cutback
temperature control. Default is 50.
•
C-21 – Blast Cleanout Period – (0-1800) Number of seconds between blast
cleanout periods. The default is 900 seconds = 15 minutes.

•
C22 – Blast Cleanout Duration – (0-300) Number of seconds to perform the blast
cleanout function. The default is 60 seconds.



Re-lubricating the Agitator gearbox by SidecarFlip (photos by me.)

1. Press the off button on the touch pad and allow the stove to shutdown. Open the door and remove the hairpin that connects the agitator and the drive input. Then unplug the appliance.

2. Remove the control board side panel by removing the self tapping screws (2 on top and 2 on the backside). Remove the panel being careful with the control board harness. Then, remove the 2 spade terminals from the upper snap disk and the 2 spade terminals from the agitator motor. With the same socket you removed the side panel with, remove the 2 self tapping screws that attach the crossbar that keeps the agitator motor in place and remove the crossbar. Then remove the agitator motor by pulling straight out.

3. Secure the motor gearbox assembly in a vise, clamping lightly on the black motor laminations with the output (agitator shaft) pointing up. The diecast aluminum gearbox housing will be completely in the open, above the motor. Don't clamp it too tight, just enough to secure it.

4. Take a small punch and drive the roll pin from the shaft coupler, remove the coupler and set aside the pin and the coupler.

5. Take a Torx bit and remove the 6 black colored self tapping screws visible in each corner and in the middle and set aside.

6. Carefully separate the upper half of the case from the lower half, pulling upward while wiggling it. Keep your thumb on the output shaft end and apply a little pressure to keep the gear set in the lower case. When the upper case comes free, there will be a loose flat washer and 2 small lengths of colored plastic spacers. The spacers go on each axle near the motor end of the gearbox (they only fit on their respective axles) and the flat washer is the thrust washer for the output shaft.

All your grease will be in the lower end of the housing. There is no need to remove the gear sets, just remove as much of the old stuff as possible from the case and the half you removed.

7. You will need a 1/4"x28 Zerk (Alemite) right angle fitting, a 1/4"x28 tap, a No.3 drill and a No.60 drill.

8. Take the No.3 drill and drill a hole in the case that is attached to the motor (the one you have in the vise), about 1/2' from the bottom and tap it 1/4"x28. Carefully remove any chips that may have got on the inside of the case half. When I reference the hole, I mean drill and tap a hole 1/2" from the bottom edge of the case half you have held in the vise and 1/2" fro the bottom on the vertical side of the case half.

9. Thread the Zerk fitting in the threaded hole and tighten with the end pointing down.

10. Take the other case half and at the top (the top is above the output shaft hole), drill a hole with the No.60 drill for grease relief.

11. Re-assemble the case haves. Put a smear of grease on the output shaft before you slide the case haves together. Re-install the 6 self tapping Torx screws, attach the coupler and drive in the roll pin. Remove the assembly from the vise and fill the case with grease until it comes out the relief hole. Wipe off the excess grease and reinstall the gearbox motor assembly in reverse order. I put a little extra grease on the coupler where it rides in the bronze bush in the stove wall.

Every spring when you shut the unit sown and clean it, just give the Zerk a few strokes of the grease gun until clean grease appears from the weep hole and wipe the excess off. I used synthetic high temperature grease, but I suspect any good quality bearing grease will do nicely.

The auger gearbox assembly is the same so you can apply the same method to lubricate it as well. However, the auger isn't subjected to the heat factor like the agitator gearbox is, so lubrication should not be a concern.

This was VERY easy to do. I recomend EVERYONE do it.
Your motor/gearbox will last indefinitely.

Here are some pics.

Driving out the pin.



Opening the case.

Like the man said, hold your finger on the shaft when opening the case to keep the gears in place.
Thought there would be more grease than that, but it was in good condition for almost 3 years old.



Zerk installed and showing the blue spacers.



Grease coming out the weep hole.


Motor reinstalled in stove



Thanks to "SidecarFlip" for the instructions



Affordable Replacment Motors
If you compare the Fasco part numbers to the AES corn stove part numbers you will see they are the same.
USSC 6039 is almost identical to the AES countryside and magnum models and use most the same parts.

MF3542 DRAFT INDUCER BLOWER
MF3541 CENTRIFUGAL BLOWER


AES parts. (note part numbers)
https://www.americanenergysystems.com/motors.cfm

AES Service Bulliten pdf
http://www.americanenergysystems.com/Stock/LibraryFiles/i-0030modelinformation.pdf

Burden Surplus Center.
https://www.surpluscenter.com/

This is the room fan. (AES part# MF3541)
https://www.surpluscenter.com/item.asp?Item=16-1386

This is the draft inducer fan. (AES Part #MF3542)
https://www.surpluscenter.com/item.asp?Item=16-1384

This is the auger motor & gearbox. (AES #MF3573)
https://www.surpluscenter.com/item.asp?Item=5-1740

This is the agitator motor & gearbox. (AES #MF3540)
https://www.surpluscenter.com/item.asp?Item=5-1737
_________________
__________________________USSC 6039________________________

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[jawquin]

bluewolf,

Thanks for posting the info. I have not reviewed all of the info but I find page 5 to be interesting as well as page 7 about the fuel rate. Thanks again for the info.

[cornburningcop]

thanks to both of you for the work.

i dont know why those greedy s.o.bs at the factory would not send me one. oh well, i have it now.
_________________
us stove model 6039
keep it burning

[deere2440]

O. K. I have been off here a day or two becoming a dad again so im out of the loop. While I was gone I got the new chip for my old stove with the A B C code on the panel in the mail. Is this the manual that is used for that chip?
_________________
Aman Morgan
Darwin IL
Installing an LDJ 165k Boiler
Formerly a US Stove 6039

[Random Task]

And thanks to bluewolf for hosting.
I hope everyone can now tweak to thier hearts content. Don't forget to share what you learned that works.

This manual addresses chip revision #34, with A B C control panel.
_________________
FIRE.... GOOD...COLD...BAD....

[Random Task]

To all the new guys: please download and read, esp. pgs 3 and 7.
This should get you started.
_________________
FIRE.... GOOD...COLD...BAD....

[Random Task]

I've asked JA to make this a sticky since it keeps moving down the page...I hope the new guys can find this ok.
_________________
FIRE.... GOOD...COLD...BAD....

[Random Task]

Looks like I have to keep posting here to move this topic up the page. I guess JA is too busy to sticky it.
Newbies, please, please, please read this from start to finish. If you see this topic start to slide down the page, please post something here to move it back up so it won't get lost in the sauce.
Thx
_________________
FIRE.... GOOD...COLD...BAD....

[Random Task]

Ja,
Please make this a sticky in USSC section.

http://forum.iburncorn.com/viewtopic.php?t=859
_________________
FIRE.... GOOD...COLD...BAD....

[bluewolf]

Thanks for the sticky

_________________
__________________________USSC 6039________________________

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----------------------------------1/20/13 The End Of An Error!----------------------------------

[Random Task]

Thanks JA...
_________________
FIRE.... GOOD...COLD...BAD....

[Nancy]

Is the new manual for the 6039 for the newer control panel? Is that an upgrade on usstove's part or is it an option to purchase the the newer control panel? I have the old control panel & I personally do not like it. To tweak it, boggles me.
_________________
Nancy

[bluewolf]

[Nancy]

Bluewolf1111

I have tried to copy your manual to no luck. I get the real small verson on FileHigh or if I try to copy it to Word. It's too big. Can you email me a good copy, I really need this bad. My husband is home today & this would help him & myself alot. This is for the old ABC tech manual.

Thanks again.
_________________
Nancy

[Random Task]