GE 16224640 Telephone User Manual
Contents
1. 2 A prewired conduit is connected to the comfort con trol center for the circulating blower The opposite end is to be connected in the junction box on the blower motor Connect like colored wires Secure conduit to junction box with box connector 3 The comfort control is factory wired to the forced draft motor optional on Model 526 If you have the forced draft locate a wall thermostat in the desired location of you house and run 18 thermostat wire not furnished from this thermostat to R and G terminals of the trans 25 INSTALL CIRCULATING BLOWER AND FILTER former in the comfort control These connections have been routed to a terminal strip on the outside of the comfort control box for convenient connection Make sure the heat anticipator on your thermostat is set at 0 3 4 The circulating blower limit control is factory wired to the comfort control center Jumper removed normal fan limit control settings are 160 F ON and 110 F OFF 5 Route 110VAC power through conduit from your power supply to the comfort control center box Route through box connector provided and connect hot L1 to BLACK Neutral to WHITE and ground to GREEN as shown on figure 22 You must provide a power discon nect in the power supply line to your furnace which is within sight of the Woodchuck and not more than 30 feet away Your circuit breaker at the power supply may meet these requirements AWARNING ELECTRICITY CAN KILL SHOCK2. ri ite GE ee Ee su ete PARE TR EE ERR Ee xU Pr eie REESE eed Di 18 ase El Uie OE 19 Woodchuck Final Assembly uuu u OE EE EE N EE EE 20 Optional Shaker Grate Installation Model 526 ee ee ee ee ee RR Re ee ee ee 20 Install Shaker Grate Handle Model 2900 ee U U u u ee 21 Instal ElrebriekK a 22 Install Optional Catalytic CombUSTOF u LL ESE I a canbe De Ee EER AB Ge Ee Re ae 22 Assemble Manual Draft Model 526 23 Install Comfort Control Center And Forced Draft Blower 23 Install Circulating 24 Assemble Filter BOX EE RR ER OE EN 24 ON EA ER EE 25 m ET M 27 AFURNACE SAFETY THERE ARE INHERENT HAZARDS ASSOCIATED WITH THE OPERATION OF WOOD COAL FURNACES FOR YOUR SAFETY READ UNDERSTAND AND HEED THE FOLLOWING DANGER RISK OF FIRE OR EXPLOSION DO NOT BURN GARBAGE GASOLINE DRAIN OIL OR OTHER FLAMMABLE LIQUIDS FAILURE TO HEED MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH DANGER NEVER USE CHEMICALS OR FLUIDS SUCH AS GASOLINE CHARCOAL LIGHTER FLUID DRAIN OIL FUEL OIL OR KEROSENE TO LIGHT A FIRE IN YOUR WOODCHUCK FAILURE TO HE
3. The large surface area of the firebox and secondary heat exchanger provide for efficient transfer COMFORT Comfort and efficiency are closely related The more efficient the heating system is the more comfortable you and your family are Not only are the Woodchuck furnaces efficient they can actually increase the effi ciency of your home On a furnace with a conventional single speed blower the speed of the blower is a compromise be tween comfort and efficiency If the blower has a large enough capacity to heat the home in the cold est weather it will cycle rapidly in milder weather so the system air is not as warm If this air is moved too rapidly it can actually feel cool Air that is moving at 3 ft per second will feel 4 cooler than stationary air at the same temperature If the blower capacity is enough to operate properly in mild weather it will not be large enough to keep the house warm in cold weather This could cause the furnace to overheat and a loss of heat up the chimney The result then is a compromise which is neither efficient or com fortable Woodchuck furnaces however have a three speed circulation blower which can be adjusted via a three position rotary switch on the Comfort Control Center This allows the user to select the blower speed to meet the air movement requirements of the installa tion In addition when the weather is mild and the fur nace is operating at a lower output the blower can be set
4. 08 0100 3 Cover 3 08 0029 Therm O Disc 4 08 0017 Fan Relay Center 5 08 0026 3 Speed Switch 6 08 0089 Switch Toggle 7 08 0106 Terminal Strip 8 08 0015 Fan Limit Control 9 08 0036 Temp Gauge Optional 10 08 0006 60 CFM Draft Blower 11 08 0084 Flue Temperature Gauge 31 PERSONAL DATA INFORMATION FOR FUTURE REFERENCE Model No Of Unit Date Of Purchase Serial No Of Unit Date Of Installation Dealer Name Name Of Installer Address Address Phone Phone Equipment Options Filter Box Shaker Grate Domestic Coil 32 33 LIMITED WARRANTY hat is covered Meyer Manufacturing Corporation warrants to the original owner only all parts in his model Woodchuck solid fuel appliance to be free from defects in material and orkmanship For how long For a period of one 1 year from date of purchase of normal use dditional Coverage In addition Meyer Manufacturing Corporation separately warrants the firebox for n additional five 5 years on a prorated basis Proration will begin with the 13th month of ownership Exclusions he firebrick and grates which are expendable and replaceable parts as well as cosmetic changes due to normal operation are not covered What the Customer must do In the event a Woodchuck solid fuel appliance is defective in workmanship or ma4 terials Meyer Manufacturing Corporation will repair or at our option replace the defective part To obtain a
5. CONTROL SECURE CONDUIT WITH CONDUIT CLAMPS AND 10 SHEET METAL SCREW PRE WIRED FLEXIBLE CONDUIT TO CIRCULATING BLOWER 3 With filter box set against back of furnace bend down the tabs on the support angles so they lock be hind the flanges of the top and bottom panels of the box 4 Install the access door Install filter not supplied and install a cold air return system to the filter box filter side opening 5 Route flexible conduit from comfort control through hole in top panel and to box connector on blower con nection box Connect wires to blower motor by joining wires of the same color SLIDE FLANGES OF CIRCULATING BLOWER BEHIND ANGLES ON BACK OF FURNACE ELECTRICAL CONNECTION BOX o ai A D FORCE FLANGE OF SUPPORT ANGLE INTO GROOVE ON FURNACE MOUNTING STRIP HOLE FOR CONDUIT FILTER NOT SUPPLIED ACCESS DOOR FILTER ANGLES GROOVE IN FURNACE MOUNTING STRIP BOTH SIDES SP SUPPORT ANGLE BEND TABS ON SUPPORT ANGLE OVER BEHIND FLANGE ON FILTER BOX TOP amp BOTTOM FIGURE 21 ELECTRICAL HOOKUP FIGURE 22 1 If you have an optional temperature gauge to monitor heat exchanger temperature in your comfort control center then the thermocouple wires must be connected to the gauge when installing the control See figure 20 IMPORTANT Remove the wire ground clip from the ter minals of the gauge and connect White wire to termi nal and Red wire to terminal See figure 22
6. OR BURN DISCONNECT AND LOCKOUT POWER SOURCE BEFORE SERVICING OR INSTALLING ELECTRICAL COMPONENTS FAILURE TO HEED MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH ACAUTION ALL WIRING MUST MEET LOCAL STATE AND NATIONAL CODES AND BE INSTALLED BY A QUALIFIED ELECTRICIAN WALL THERMOSTAT 19 THERMOSTAT BLACK FAN LIMIT CONTROL 3 SPEED CIRCULATION BLOWER BROWN BROWN CAPACITOR DRAFT BLOWER DRAFT BLOWER ON OFF SWITCH SWITCH NOTE 1 NORMAL EN 3 BLACK WIRES ON LEFT BLUE WIRES ON RIGHT FIGURE 22 ELECTRICAL WIRING DIAGRAM 26 KEY NO PART NO 01 0526 03 5262 03 5263 03 5261 08 0005 06 1001 02 5261 02 5262 06 1014 06 5261 06 5262 06 0200 05 0004 REPAIR PARTS BASIC UNIT FOR MODEL 526 DESCRIPTION Welded Assembly Shroud Right Side Shroud Left Side Shroud Top Circulation Blower Ash Pan Fuel Door Ash Door Door Knob Fuel Door Gasket Ash Door Gasket 1 4 Door Pin Handle Access Cover 801 2520 1 5Z 1 4x1 1 2 Bolt 27 PART NO 06 0215 814 2520 Z 05 0002 05 0001 07 5263 07 5262 07 5261 07 5260 01 0526 19 03 5264 06 5263 05 0005 06 0221 DESCRIPTION Spring 1 4 Lock Nut Small Grate Large Grate Front Brick Kit 2 pc Rear Brick Kit 2 pc Side Brick Kit 18 pc Complete Brick Kit Heat Exchanger Gate Z Lock 25 1 2 Heat Exchanger Rod Manual Draft Butterfly Stainless Steel Cot
7. Procedure In The Event of Power Failure ee 8 Operating Your Woodchuck Furnace croient aaa eo sU ovra ed Pk Ese enemies 9 AR HT EO EER EO RE Mo 9 Burning Wood In Your WoodchUuck eiiis dek Ek ge Ed ee asss 9 ale Na p ETE 10 Ash Removal AE N EE RE N 10 Burning Coal In Your 11 Slarting A Coal Fir RR 11 bet N 11 11 Bituminous Feecharging UUU LLL ee nennen ee nee inneren 11 ase alc ER 11 ASN REMOVA 12 MAINTENANCE ER EO N 12 Trouble Shooting M qM DR 13 C S 15 General Requirement EA 15 Placement And Minimum u L 15 Chimney Installation N EE EE IN 17 Installing Your WOOdOChUCK GR OE EE EE EE OR EE 18 Stove Pipe Installation ee ad 18 Installatiom OFA Barometric Draft
8. Two rods are welded at 90 and they point to ward the rear of the firebox NOTCHES IN EXHAUST PIPE CATALYTIC ELEMENT RODS ON RETAINER OPTIONAL CATALYTIC COMBUSTOR TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE SOLUTION 1 Main blower vibrating Loose Allen screw on squirrel cage Tighten Allen screw be sure squirrel when in use cage did not move to one side or the Bad motor bearings Weights on squirrel cage wheel moved in ship ment other Return blower to your local dealer for a replacement Try to adjust it yourself or return blower for replacement 2 Main blower continues to run Manual control turned on fan limit control Check fan limit control switch Push for manual pull for auto If in auto position replace fan limit control 3 Main blower won t turn Defective fan limit control Replace on Defective 3 speed blower switch Replace Defective circulation blower motor Replace 4 Draft blower staying on Wall thermostat bad check by turning temp to 60 then check if draft blower is running Short in thermostat wire Home not getting heat needed to satisfy wall thermostat Heat anticipator not set properly on thermo stat Replace wall thermostat Check all wiring again Check on spec s chart to be sure your unit is large enough for your home Be sure installation is proper check with your local heating man Adjust anticipator to 0 3 5 Draf
9. fall the weather is mild which will al low you to burn very large loads of wood for long peri ods of time and hence accumulate very large amounts of creosote KEY Stack temperature should be 300 F 400 F for good burning An external flue temper ature thermometer Woodchuck part 08 0084 is in cluded in the owner s manual package for monitoring stack temperature Install the flue temperature ther mometer at the rear of the furnace on the smoke pipe where it connects to the collar on the back of the Woodchuck 300 400 degrees should be maintained when the Woodchuck is operating in the burn cycle with the forced draft blower running to eliminate a creosote build up If the unit has a manual draft or a natural draft monitor the flue temperature when the drafts are in the open position Depending on the weather you may not need a full load of wood for a good over night burn You will get best efficiency when you add only the amount of wood needed until the next time you are available to load Always try to place the logs so air can flow between them this will enhance combustion considerably ASH REMOVAL When burning wood run your poker over top of the grate to be sure grate slots are clear of burnt fuel This should be done every morning when there is just a bed of hot coals AACAUTION NEVER LET ASHES BUILD UP TO GRATE LEVEL THIS WILL GREATLY REDUCE THE LIFE SPAN OF YOUR GRATE Wood ash is useful as a fertilizer partic
10. on low to gently move the air Similarly when it is cold and the furnace is operated at higher levels of heat output can be switched to higher speeds But how can all this improve the efficiency of your home As figure 1 illustrates heated air rises away from the living area and stratifies This causes large temperature differentials between the ceiling where heat is lost rapidly through conduction and the floor where children often play By allowing for continuous air movement even during periods of low heat output this stratification is not allowed to take place You are DISCOMFORT ZONE FIGURE 1 more comfortable and lose less heat through your ceil ings as illustrated in figure 2 This situation can be especially troublesome in multi level homes as illustrated in figure 3 As soon as the blower shuts off the air in the home begins to strat ify warm air rising to the upper levels and cool air col lecting in the lower levels The lower levels become increasingly uncomfortable until the blower turns on again Unfortunately the upper levels are still warm so they become uncomfortably warm before the blower turns off By allowing for a steadier more continuous operation of the blower the entire house stays at a more constant and comfortable level figure 4 ADDITION COMFORT AND SAVING Options are available for your Woodchuck furnace and one of these deserve special mention The Aqua Si phon is capable of pre heating you
11. product damage close manual draft completely Forced draft and natural draft are pre set In the event of a runaway fire close all drafts Close smoke damper halfway DOUBLE LATCH COMFORT LOADING DOOR COMFORT HEAT EXCHANGER CONTROL CENTER CONTROL CENTER CONTROL ROD SHAKER GRATE FAN LIMIT FAN LIMIT DOUBLE LATCH LOADING DOOR DRAFT CHANNEL SELECTOR 80 20 MANUAL DRAFT NP COMBUSTION AIR gt M Forced Draft Is OS RATIO CONTROL Optional eS MODEL 526 fe MODELS YS md 2900 4000 ASH DOOR ASH DOO FORCED DRAFT BLOWER SHAKER GRATE CRANK SHAKER GRATES ARE OPTIONAL FIGURE5 WOODCHUCK CONTROLS OPTIONAL TEMPERATUR E GAUGE CIRCULATING BLOWER MED Q UN BYPASS DN AUTD DRAFT BLOWER DRAFT BLOWER MANUAL SWITCH LO LIMIT OFF AUTO FIGURE 6 COMFORT CONTROL CENTER OPERATING YOUR WOODCHUCK FURNACE STARTUP Never leave ash pan in unit Use only when cleaning out ashes First thing is to check that your main blower and draft blower are in proper working order before lighting a fire To check main blower push button on fan limit control for manual override testing When finished reset to au tomatic position figure 5 Next turn thermostat upstairs to high temperature so draft blower turns on NOTE All models are equipped with a low limit which will not allow the auto draft to operate when the unit is
12. right front bar OPTIONAL SHAKER GRATE INSTALLATION has shorter extension shaft at front to a rear bar Slide a FOR MODEL 526 gear onto the front shaft 3 Set this assembly into the front frame first and then into 1 Remove standard grates from firebox Assemble com the rear frame plete shaker grate kit outside of unit Figure 16 20 4 Assemble the right front bar to a rear bar Slide a gear onto the front shaft aligning it to engage the gear on the left bar Place the front bar onto the front frame and then setting the rear bar onto the rear frame To house 4 Hot air b To house 5 Place rear retainer in place then the center and the pe front retainers Place all four bolts through retainers and frame Secure with locknuts To prevent binding it is ad Added visable to snug the locknuts but do not over tighten Oil or gas wood Furnace or coal 6 Try moving the shaker grate bars with the handle furnace NOTE Both bars in normal position should be flat If not one or the other gear is not aligned correctly 7 To install the assembly into the unit place the front end of the assembled grate on the loading door lower frame The grate should be the upside down position Slide the grate front end first into the firebox allowing the front end to lower into the hearth area Once the back end of the grate has cleared the door frame flip it over toward the rear of the unit If necessary reach into the ash
13. ED MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH DANGER DURING OPERATION LOADING AND ASH DOORS AND EXPOSED FIREBOX ARE EXTREMELY HOT NEVER TOUCH THESE PARTS WHEN HOT FAILURE TO HEED MAY RESULT IN SERIOUS PERSONAL INJURY CAUTION Risk Of Fire Do Not Operate With Fuel Loading Or Ash Removal Doors Open Do Not Store Fuel Or Other Combustible Material Within Marked Installation Clearances Under Certain Conditions Of Use Creosote Buildup May Occur Rapidly Inspect And Clean Flues And Chimney Regularly Wait 10 Seconds On First Latch Before Refueling Opening Loading Door Rapidly Can Cause A Flame To Flash Out The Door Use Caution When Opening Loading Door Unsafe To Load Coal Above Top Of Brick Keep Ash Pan Out Of Unit During Operation Ash Pan Can Get Very Hot Ash Can Must Be Placed On A Noncombustible Surface Never Use Anything But An Air Tight Metal Container To Dump Your Ashes In Every Year Many Fires Are Caused By Emptying Ashes Into Cardboard Boxes Or Paper Bags e Proven Fact Small Red Embers Buried In Ash Cans Stay Red Hot For Days Ashes Are A Good Thermal Insu lator And Keep Enough Oxygen Away So Embers Do Not Burn Out THERE ARE ADDITIONAL HAZARDS ASSOCIATED WITH IMPROPER INSTALLATION OF WOOD COAL FUR NACES AND WITH SERVICE AND MAINTENANCE OF WOOD COAL FURNACES FOR YOUR SAFETY READ UNDERSTAND AND HEED THE FOLLOWING A WARNING DISCONNECT APPLIANCE FROM ELECTRICAL SUPPLY BEFORE SERVICING UNIT FAILURE TO HEED MA
14. INSTRUCTION AND PARTS BOOK FOR MODELS 526 2900 amp 4000 Installation must be made in accordance with local and state codes which may differ from manual Save these instructions WOODCHUCK WOOD COAL FURNACES The Undefeated Heavyweight Champion ete das NE m 1 Model 526 Model 2900 Model 4000 Manufactured by Meyer Mfg Corp Phone 715 654 5132 Fax 715 654 5513 07 97 Dorchester Wisconsin 54425 INTRODUCTION Dear Woodchuck Owner Congratulations on your purchase of a Woodchuck heating appliance Un doubtedly you have given much consideration to your purchase and we re proud that you have selected a Woodchuck Pride in craftsmanship and engi z neering have made your Woodchuck the finest heating appliance available to unn dehuck day Solid fuels are abundant and inexpensive Wood is our only renewable WES source of fuel and conservative estimates put our coal reserves at 800 years Our dual fuel units provide the savings and comfort of solid fuels and the con venience of electric heat in one attractive package There is no substitute for quality That is why thousands of people like you have purchased a Woodchuck They also felt it was the best equipment to serve their heating needs now and in years to come We ask that you follow our policy of safety first and we strongly suggest that you read through the owner s manual before installing and operating your furnac
15. RATE FOR MODEL 526 KEY NO KEY NO 1 2 3 4 ON KEY NO PART NO DESCRIPTION 526 2900 4000 1 04 2900 6 04 2900 6 Door 2 04 5260 7 04 2900 7 Cabinet Assy 3 04 2905 04 2905 Mounting Cleat 30 PART NO DESCRIPTION 801 2520 1 25Z 1 1 2 1 4 Bolt 05 5265 05 5266 05 5268 05 5263 05 5262 05 5264 05 5267 05 5261 814 2520 Z PART NO 05 2902 05 2903 05 2904 05 2905 05 4001 05 2906 05 4003 05 2908 05 2907 06 1014 End Retainer S 5 Center Retainer S 6 Rear Bar Female S 3 Front Bar w Extension S 2 1 Front Bar Male S 2 Gears S 4 Handle S 7 Front Frame S 1 1 4 Lock Nut DESCRIPTION Side Rail W 9 End Rail W 10 Shaker Bar CC 130 Shaker Rail WC 2900 Shaker Rail WC 4000 Sleeve WC 2900 Sleeve WC 4000 Handle WC 2900 E423 Handle WC 4000 Knob 801 2520 1 52 1 4x1 1 2 Bolt 814 2520 Z 05 2901 1 4 Lock Nut Linkage FILTER BOX 1 CIRCULATING BLOWER KEY NO PARTNO DESCRIPTION COMFORT CONTROL 2 2 08 0002 Capacitor DRAFT BLOWER 3 08 0005 Blower Assembly no motor 4 08 0048 Electrical Connection Box g 5 08 0004 Capacitor Boot Scorer 6 08 0003 Capacitor Bracket not shown 7 7 08 0049 Electrical Box Cover 8 08 0005 2 Large Motor Mount Bracket 9 08 0005 3 Short Motor Mount Bracket 10 08 0005 4 Motor Clamps KEY NO PART NO DESCRIPTION 1 08 0100 1 Box Enclosure 2
16. SA B366 Listings UL391 CSA B366 1 M 1 M ETLM Firebox Chamber 7 70 cu ft Firebox Chamber 9 10 cu ft DISCLAIMER NOTICE The heating capacity specifications are provided as guidelines only and in no way guarantee the output or capacity of the units The actual BTU output depends on the type of fuel being burned and its condition the thermostat set ting the draft adjustments and the chimney that the unit is installed into GENERAL INFORMATION Woodchuck furnaces represent the ultimate in solid fuel and dual fuel heating appliances From the mas sive model 4000 to the economy model 526 each unit is designed to be attractive durable and efficient while providing the safety and comfort you and your family deserve HIGH QUALITY CONSTRUCTION Constructed of high grade heavy gauge hot rolled steel plate the firebox is continuously welded for an airtight seal and structural strength The heavy duty cast iron doors are equipped with a positive latching device for your safety The loading door has a two step safety latch The large cast iron grates pro vide for durability and help promote efficient combus tion of the fuel The firebox is lined with heavy duty firebrick and is done so without any retainers to warp or burn out These features together with high quality electrical components provide the safety efficiency and total control possible only in a Woodchuck Total control mean
17. T IT HELPS TO PREVENT DOWNDRAFT WHILE PROVIDING ADEQUATE EXHAUST DRAFT TOP OF CHIMNEY MUST BE AT LEAST 2 HIGHER THAN PEAK OR HIGHEST PORTION OF ROOF WITHIN 10 HORIZONTALLY ALSO SEE FIGURE 9 A CHIMNEY WHICH RISES WITHIN HOUSE IS BETTER INSULATED THAN A CHIMNEY WHICH IS LOCATED OUTSIDE THE HOUSE AND IS EXPOSED TO WEATHER THE CHIMNEY FLUE MUST HAVE A CROSS SECTIONAL AREA AT LEAST EQUAL TO OR LARGER THAN THAT OF THE STOVES FLUE COLLAR BUT NO MORE THAN TWICE THAT AREA THE CHIMNEY THIMBLE SHOULD BE CONSTRUCTED OF FIRE CLAY AND SHOULD HAVE AN INSIDE DIAMETER WHICH IS NOMINALLY EQUAL TO THE OUTSIDE DIAMETER OF THE SMOKE PIPE TO ASSURE A REASONABLY AIR TIGHT FIT THE THIMBLE MUST NOT EXCEED BEYOND THE FLUE LINING MIN 3 FROM TOP OF CHIMNEY TO POINT AT WHICH IT PASSES THROUGH THE ROOF _ GN RECOMMENDED MIN HEIGHT APPROX 20 FLUE SHOULD BE OF CONSTANT CROSS SECTIONAL AREA THROUGHOUT ITS LENGTH CLEANOUT DOOR SHOULD BE PROVIDED AND IT MUST HAVE AN AIRTIGHT FIT IT SHOULD NOT BE LEFT OPEN FOR ANY LENGTH OF TIME WHEN STOVE IS IN OPERATION FIGURE 8 TYPICAL CHIMNEY CHECKLIST 16 Your unit should be place on a non combustible floor or 3 8 thick fireproof millboard or equivalent which ex tends at least 8 from the sides and rear and extends 24 from the front Leave a minimum clearance of 36 in front of your unit This is for safe easy loading and cleaning of your unit Also be sure to allow eno
18. T STORE FUEL OR OTHER COMBUSTI BLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES e INSPECT AND CLEAN FLUES AND CHIMNEY REGULARLY e UNDER CERTAIN CONDITIONS OF USE CREO SOTE BUILDUP MAY OCCUR RAPIDLY e WAIT 10 SEC ON FIRST LATCH BEFORE RE FUELING e LOAD FUEL CAREFULLY OR DAMAGE MAY RE SULT IF YOU HAVE CHIMNEY FIRE Meyer Mfg Corp recommends the following actions 1 Shut any doors and air inlet dampers and draft con trol This should take no longer than a few seconds CLOSED 2 Alert everyone in the house gt diy 3 Call the fire department MANUAL NOTE Emptying large box of baking soda will slow down the fire in your Woodchuck Keeping your chimney and stove pipe clean is the best insurance against chimney fires IMPORTANT OPERATION PROCEDURE IN THE EVENT OF POWER FAILURE Your Woodchuck can operate and produce heat without electric power This is one of the features built into ev ery Woodchuck The following steps should be taken in the event of an electrical power failure 1 Locate all heating duct dampers not smoke pipe damper if any to open position CLOSED LAT SN MANUAL DRAFT 2 Turn manual draft controls to this position Ash door should never be used in power failure 3 Remove filter box service access cover allowing cooler air to move hot air through the furnace cooling the plenum and the house hot air duct system If power fails to avoid
19. T extend beyond the warranty stated above tate Law Rights Some states do not allow limitations on how long an implied warranty lasts 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 chuck P O Box 405 Dorchester Wisconsin 54425 34 Card must be completed and maded within 10 days of the purchase of your Woodchuck for your warranty 10 come into effect NAME ADORESS CITY ape STATE MEYER MANUFACTURING CORPORATION MANUFACTURERS OF WOOD COAL FURNACES Box 405 Dorchester Wisconsin 4425 zp DATE OF INSTALLATION PRICE PAID STATE _ MODEL NO DATE PURCHASED __ SERIAL NO INSTALLER NAME ADDRESS Have you ever owned a wood heater before Oves SZtbS ursuo2siA 2915942200 50 xog Od NOILVHOdHOO SNIHNLOVANNVW H3A3M _ woodehuc Manufactured By MEYER MANUFACTURING CORPORATION P O Box 405 Dorchester Wisconsin 54425 715 654 5132 35
20. The use of wet frozen or unseasoned wood The use of soft wood particularly those of high resin content such as plywood or blandex with glue Poor natural draft or an obstruction in the stove pipe or chimney flue Too long of burning times Inadequate amount of oxygen supplied to the combustion chamber Low fire or flue gas temperatures Uninsulated stovepipe or chimney flues espe cially if construction is exterior to the house Air leaks in the stove pipe or chimney If you have to use wet wood make loads smaller and burn them hotter Avoid using if possible Measure draft with gauge Should have a minimum of 04 06 water columns of draft Smaller and hotter fires Adjust draft for hotter fires or in some homes it has been deter mined there was not enough in the basement due to such an air tight home We recommend 4 round hole to the outside with a screen on to keep varmints out Smaller loads of wood and hotter fire Stack temps should maintain minimum 300 to 400 Never use uninsulated pipe for chimneys installed on the outside of the house INSULATE Check chimney from top to bot tom NOTE Creosote is a tarry liq uid or solid coming from distillation of wood during the combustion process The heavier buildups the greater chance of a chimney fire NOTE No matter how seasoned the wood no matter how good the draft you always will get a small amount of soot buildup Should be cleaned before wi
21. These details will be provided af ter stove pipe and air duct installation STOVE PIPE INSTALLATION Install your Wood Coal unit as close to the chimney as possible with a minimum of elbows We recommend no more than two elbows The maximum horizontal run should not exceed 6 feet with a 1 2 rise per foot The pipe should maintain a 72 rise per foot and NEVER be installed closer than 18 from combustibles Exceeding these recommendations normally represents creosote build up a smoking furnace or one with poor draft When connecting stove pipe all joints should be se cured with at least three 10 sheet metal screws NOTE If it is absolutely necessary to make a run greater than 6 feet not recommended use extra sup port brackets every 3 ft The connection to the wood furnace s collar must also be more than just a snug fit Drill holes through the Woodchuck s collar and secure with sheet metal screws Mark each connection for cleaning This will prevent frustration when matching up your hole pattern again DAMPERS IN STOVE PIPES A manual damper may be installed at a safe convenient place between the barometric damper and the chimney In the event of chimney fire it can quickly be closed reducing draft to the chimney See figure 10 SUGGESTED TYPE DAMPER INSTALLATION OF A BAROMETRIC DRAFT Some codes and NFPA require draft regulators in the chimney connector of wood or coal furnaces and boil ers and manufact
22. Y RESULT IN SERIOUS PERSONAL INJURY OR DEATH CAUTION e Equipment Must Be Installed By A Qualified Heating Person e Only class A All fuel Or Solid Fuel Chimneys Intended Foe Use With Your Woodchuck Should Be Used e Furnace Must Be Installed On A Noncombustible Floor Or 3 8 Thick Fireproof Millboard Or Equivalent FAILURE TO HEED MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH SPECIFICATIONS MODEL 526 Height 42 5 Width 24 Depth 26 Blower 850 to 1850 CFM Max BTU Capacity 120 000 Log Size 22 Loading Door Size 14 x12 Weight Approx 445 Ibs Warm Air Plenum 20 x23 Flue Outlet 6 Dia Flue Collar Height 41 Overall Height Secondary Heat Exchange YES Listings UL391 CSA B366 1 M ETLM Firebox Chamber 6 10 cu ft MODEL 2900 MODEL 4000 Height 48 5 Height 51 5 Width 26 Width 26 Depth 28 Depth 33 Blower 850 to 1850 CFM Blower 850 to 1850 CFM Max BTU Capacity 150 000 Max BTU Capacity 180 000 Log Size 22 Log Size 24 Loading Door Size 15 x13 Loading Door Size 15 x13 Weight Approx 700 Ibs Weight Approx 815 Ibs Warm Air Plenum 20 x23 Warm Air Plenum 20 x23 Flue Outlet 8 Dia Flue Outlet 8 Dia Flue Collar Height 47 Overall Height Flue Collar Height 50 Overall Height Secondary Heat Exchange YES Secondary Heat Exchange YES Listings UL391 C
23. air needed 5 Coal not sized to furnace We recommend 1 to 3 di ameter pieces of coal 6 Ashes if allowed to accumulate in the ash pit will not allow the required air for combustion Keep ash pit clean ASH REMOVAL Ash should always be put into an air tight metal con tainer CAUTION KEEP ASH PAN OUT OF UNIT DURING OPERA TION ASH PAN CAN GET VERY HOT ASH PAN MUST BE PLACED ON A NONCOMBUSTIBLE SURFACE NEVER USE ANYTHING BUT AN AIR TIGHT METAL CONTAINER TO DUMP YOUR ASHES IN EVERY YEAR MANY FIRES ARE CAUSED BY EMPTYING ASHES INTO CARDBOARD BOXES OR PAPER BAGS PROVEN FACT SMALL RED EMBERS BURIED IN ASH CANS STAY RED HOT FOR DAYS ASHES ARE A GOOD THERMAL INSULATOR AND KEEP ENOUGH OXYGEN AWAY SO THE EMBERS DO NOT BURN OUT Coal firing produces much more ash than wood These ashes must be removed often possibly daily in order to avoid piling up too closely to the grates Removal of the coal ash will prevent warpage and damage to grates and allow passage of primary air to the coal bed Unlike wood ash coal ash cannot be used as fertilizer All coal contains small amounts of dangerous elements It is therefore essential that your coal ash be disposed of in municipally designated areas MAINTENANCE A WARNING DISCONNECT APPLIANCE FROM ELECTRICAL SUPPLY BEFORE SERVICING UNIT FAILURE TO HEED MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH Keep chimney and smoke pipe clean by cleaning at least twice duri
24. angle points toward the rear of the firebox SLOTS IN EXHAUST PIPE FIGURE 18 INSTALL OPTIONAL CATALYTIC COMBUSTOR MODEL 2900 4000 ASSEMBLE MANUAL DRAFT MODEL 526 ONLY Using a 1 4x1 1 2 bolt and locknut mount manual draft control onto the draft channel figure 19 If you are going to install optional forced draft disregard Do not tighten too tight to damper draft adjustment but not too loose to let more air in than required DO NOT remove knockout on draft channel Locknut can be held with wrench in serted through air opening 1 4 LOCKNUT DO NOT REMOVE KNOCKOUT MANUAL DRAFT CONTROL dj 1 4x1 1 2 BOLT so FIGURE 19 INSTALL MANUAL DRAFT MODEL 526 INSTALL COMFORT CONTROL CENTER AND FORCED DRAFT BLOWER 1 Install all knobs to control levers and door handles See figure 20 2 The comfort control center is factory wired to the fan limit control and the forced draft blower It has a prewired flexible conduit for connection to the circulating blower 3 If you have optional temperature gauge on your con trol then strip 72 of insulation from the two leads of ther mocouple wire protruding through the rectangular opening on the furnace side Connect these leads to the terminals on the temperature gauge of the control IM PORTANT Remove the wire ground clip from the termi nals of the gauge and connect White wire to terminal and Red wire to terminal See figure 22 4 Mount the control to the sid
25. e For a lifetime of satisfaction thank you for not compromising with quality Sincerely Donald A Meyer President MEYER MANUFACTURING CORP We are constantly improving and updating our product in order to provide the highest quality and value possible Consequently pictures might sometimes dif fer slightly from the actual product TRANSPORTATION DAMAGES Before reading this manual and proceeding with the installation inspect your new Woodchuck to make sure there were no shipping damages If you find there have been damages incurred call your dealer immediately He will then take a course of action to correct the problem TABLE OF CONTENTS MEM EE AR OR EE N 2 Table of Se GE n 3 PUP ACS Salety C se 4 iere 5 General Ee EE 6 High Quality eende ie EE eee cct pe EE 6 einn TM 6 nl p e AN 6 Additional Comfort And 5 7 Operation AA Ad ME EE OR EE 8 SONS Cas cca 8 NTF You Have Chimney Fite ec 8 Important Operation
26. e of the furnace with four 10 sheet metal screws 5 Remove the knockout section of the draft channel on model 526 by striking sharply with a hammer Be careful so you do not damage the mechanism inside the chan nel and directly behind the knock out DO NOT allow the knock out to fall inside the draft channel 6 Align the forced draft blower outlet flange over the knockout and secure with three 10 sheet metal screws 7 Secure conduit to furnace side using conduit clamps and 10 sheet metal screws 23 THERMOCOUPLE WIRE INSTALL ALL CONTROL AND HANDLE KNOBS KNOCKOUT IN DRAFT CHANNEL REMOVED FORCED DRAFT BLOWER FIGURE 20 INSTALL COMFORT CONTROL CENTER AND FORCED DRAFT BLOWER INSTALL CIRCULATING BLOWER The flanges on the circulating blower simply slide be hind the angle mounts welded to the rear of the fur nace Slide in from the top side figure 21 INSTALL FILTER BOX The filter box is standard on Model 526 Installation in structions are included with Model 526 filter box 1 The filter box can be installed with the filter on either side The access door will fit the opening either side and the handle should face forward 2 Find two factory shipped support angles Force sup port angle sides without tabs into the groove of the mounting strip on both rear sides of the furnace Posi tion at correct height to accept filter box figure 21 24 COMFORT CONTROL CENTER FAN LIMIT
27. h your unit and instal lation PROBLEM POSSIBLE CAUSE SOLUTION 9 Excessive amounts of smoke coming out loading Improper draft Measure with draft gauge should have 04 to 06 water column door when loading Chimney cap too close to top of chimney Relocate Too long of run of smoke pipe from Woodchuck Relocate Woodchuck closer to to chimney chimney 10 Puffing of smoke through draft control Improper draft Down draft on chimney Plugged chimney Check draft with gauge Should be 04 to 06 water column Check for cold spots on chimney or obstruction outside chimney Trees or other buildings Check with mirror in clean out door or send cleaning brush down chimney Check stovepipe con nections 11 Excessive dirt build up around air vent in home Too much smoke escaping out of loading door when loading Bad weld in fire box of unit No return air ducting Check problem No 9 Call dealer immediately Install return air duct 12 Improper seal around door Door rope not sealing on door frame Loose door from shipment Check door rope so that all parts of door frame are sealed espe cially corners Simply bend door latch in to tighten door seal 13 Excessive creosote build up A reminder whatever kind of fuel you burn there is some kind of residue build up on the furnace and chimney Same with wood no matter how good the conditions
28. hese problems by limiting the flow of combustion air into the appliance and by adding cooling air to the hot flue gases However the cooling air may result in more creosote accumulation and if a chimney fire does start it will be more intense because of the draft regulator Large flows of air into the regulator will fan the fire in the chimney Thus the net effect of barometric draft regulators is unclear they help in some aspects and hurt in others Note though that if a chimney is clean so that chimney fires are impossible a draft regulator does no harm and does help limit the intensity of the fire in the appliance and it helps prevent the flue gases in the chimney from getting too hot Barometric draft regulators are recommended by JFPA for hand fired thermostatically controlled solid fuel furnaces MANUAL DAMPER MAY BE INSTALLED BETWEEN BAROMETRIC DAMPER AND CHIMNEY FIGURE 10 A BAROMETRIC DRAFT REGULA TOR AND ITS INTENDED EFFECT AIR DUCT INSTALLATION SPECIAL AIR FLOW WOOD COAL FURNACES CONSIDERATIONS FOR With Wood Coal furnaces a special concern is pre venting wood joists and flooring close to the hot air ducts and plenum from overheating A fire hazard is created by the hot air flow circulating through ducts not designed for such high temperatures Most Wood Coal furnaces produce much hotter air than oil or gas fired units So most clearances from the existing ducts and plenum are usually inadequate with a su
29. hould be re moved with gloves or tongs and as always put into a metallic air tight container BITUMINOUS RECHARGING Because bituminous coal has a higher percent of sul phur and lower percent of fixed carbon than anthracite recharging should be as follows Gently shake down grates with drafts open and a good flow of primary air entering below the grates Push the hot coals to the rear of the fire box and position fresh coal on the grate in front of the banked coal As the fresh coal begins to burn wood may be added to the top of the coal NOTE Woodchuck recommends coal 1 inch to 3 inches in diameter Ashes may be sifted through a mesh screen to reclaim particles of unburned coal HELPFUL HINTS Burning coal will provide a lesson in patience Take the time necessary to experiment and understand the oper ation of your Woodchuck wood coal furnace Too much draft air will cause clinkering of coal and will waste heat up the chimney Shut draft down to as low a point as you can and still heat your home 1 NEVER stand in front of loading door when opening it Stand to the side 2 NEVER completely cover the live fire with fresh coal Always leave a generous area of burning coal at the top of the fire and at the rear 3 Always keep the ash pit clean If the fire goes out or does not hold overnight look for 1 Poor draft 2 Incorrect damper settings 3 Improper firing methods for coal being used 4 More combustion
30. ng a heating season Keeping your chimney and stove pipes clean is the best insurance against chimney fires If you clean your own chimney and stovepipe Meyer Manufacturing Corp recommends purchasing the same equipment professionals use Brushes are available in enough sizes and shapes to snuggly fit inside any com mon flue Replace any cracked or deteriorated firebrick This will prolong the life expectancy of the firebox Check door gasket and replace as needed Oil blowers every 6 months of use SAE 10 motor oil re quired Keep ash pit clean especially when burning coal Turn on your regular furnace once every month to keep it tuned up and limber OPTIONAL CATALYTIC COMBUSTOR FOR MODELS 2900 4000 NOTE Optional catalyst not recommended for Model 2900 4000 with 6 flue adapter Smoke spillage may oc cur out of door when refueling Even with complete combustion there is a small amount of residue Eventually enough will collect on the combustor to interfere with its operation Therefore it is necessary to clean it periodically To clean the combustor simply remove from unit and run tap water through it until no sign of residue remains The combustor simply slides up into the exhaust pipe stub which protrudes down into the firebox There are three rods on the combustor which engage slots in the pipe and then turn slightly to lock in place These rods are not symmetrical so observe their orientation when you re move it
31. not be used in add on installations Once it has been determined that your existing furnace will accept an add on installation we recommend a parallel installation with direct ducted feed of return air to the Wood Coal furnace see figure 12 The back flow prevent damper assures that when either unit is operating by itself the hot air will flow into the home and not flow back through the other furnace Figure 13 shows a central installation We do not recommend supplemental wood furnace installations with series connection These types of installation are not advisable in spite of their simplicity see figure 14 Plenum Solid fuel furnace To house 4 house Back flow Cool preventor return gt Oil or gas air Furnace Added wood or coal furnace PARALLEL INSTALLATION Hot Air Duct NFPA recommended clearances to combustible materials from handfired wood or coal furnace plenums and horizontal ducts Vertical ducts or risers may be in stalled starting 6 feet from the plenum and should have Xs inch clearance from all combustible materials or be of double wall construction with a Xeinch air space between walls FIGURE 11 HOT AIR DUCT CLEARANCE REQUIREMENTS To house Added wood or coal furnace CENTRAL INSTALLATION FIGURE 12 PARALLEL ADD ON INSTALLATION FIGURE 13 CENTRAL ADD ON INSTALLATION WOODCHUCK FINAL ASSEMBLY 2 Assemble the left front bar different from
32. not warm To start auto draft turn Lo Limit toggle switch on comfort control center to On figure 6 Now you are ready to light a fire BURNING WOOD IN YOUR WOOD CHUCK 1 Adjust draft channel selector figure 5 to appropriate fuel setting on model 2900 4000 On Model 526 with manual draft open it Place several pieces of crumpled paper in the center of your Woodchuck Criss cross a couple of handfuls of dry kindling wood 3 4 thickness then several small dry pieces of firewood Ignite the pa per and close the door Do not attempt to open the door immediately after igniting the fire There could be a flame flash out 2 It will take 5 10 minutes for the fire to establish itself Once you have some good red hot burning embers add larger pieces of wood All chimneys and hookups are different After 3 4 fires you ll find out how your unit works for the best starting 3 After about 30 40 minutes you can adjust the draft according to your needs Adjust smoke pipe damper ac cording to your needs also NOTE On airtight units the burning time is controlled mostly by the draft controls on the furnace contrary to the old type of pot belly stoves where the smoke pipe damper controlled the burning time NOTE With new steel there is a small amount of oil or dirt on the metal and you may smell an odor Provide adequate ventilating to home during the first operation Your new Woodchuck is capable of putting out many BTU s so t
33. nter firing and during mid winter s firing INSTALLATION GENERAL REQUIREMENTS ACAUTION EQUIPMENT MUST BE INSTALLED BY A QUALIFIED HEATING PERSON ACAUTION ONLY CLASS A ALL FUEL OR SOLID FUEL CHIM NEYS INTENDED FOR USE WITH YOUR WOOD CHUCK SHOULD BE USED FIRST AND ABOVE ALL is safety for you and your family MUST USE Class A Masonry or ULC listed manufac tured Class A All Fuels Chimney RECOMMENDED SIZE Rectangular 8 x12 or Round 8 DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE The Woodchuck is to be used in conjunction with a listed gas or oil fired furnace or as a central furnace ELECTRICAL SUPPLY 115 volts 60HZ 1 Phase less than 12 amps Install system with 0 2 static pressure Flue setting 06 W C Max to 04 W C Min Wood or coal related fires are caused almost exclu sively by installation operation or maintenance errors but not by unsafe equipment IMPORTANT Check with your local state and federal codes on installation at your local fire department PLACEMENT AND MINIMUM CLEAR ANCES ACAUTION FURNACE MUST BE INSTALLED ON A NON COM BUSTIBLE FLOOR OR 3 8 THICK FIREPROOF MILL BOARD OR EQUIVALENT Locating your unit is very important for proper draft and most efficient heating possible See figure 7 7 Z 2 lt 7 1 2 MODEL 4000 q 52 FIGURE 7 LOCATING THE WOODCHUCK THE CAP SHOULD BE SUCH THA
34. o be sure it is spreading through the coal bed RECHARGING Gently shake grates down Open drafts and establish a good flow of primary air below the grates When re charging fresh coal tends to give off large quantities of volatile gas This gas may accumulate and possibly ig nite causing a backpuff To reduce back puffing open the fire door to the first safety latch position for 15 20 seconds before opening fully Spread fresh coal evenly over existing coal leaving some hot coals exposed in the center of the firebox Be careful not to smother your existing coals Never allow coal to build up above the top of the firebrick When blue flame creeps up between the coals drafts may be adjusted to maintain burn level If the coal fire dies down before recharging a fresh sup ply of kindling may have to be added BANKING Banking allows you to recharge in such a manner as to retain a hot coal bed throughout the night Approxi mately an hour before retiring for the night push the coals to the rear of the firebox with the coal tapered down in the front Add a new layer of coal Always leave some hot coals exposed in the front This allows for more coal to be added to the firebox A coal fire should not be poked or broken up as this tends to bring ash to the surface of the coal bed where it may fuse If the ash fuses clinkers will form It may be necessary to remove all unburned material and ash from the firebox to remove clinkers These s
35. pit door and pull the front of the grate forward until it lodges into place To house Gad INSTALL SHAKER GRATE HANDLE ca MODEL 2900 ONLY air Oil or gas Furnace 1 Open the door ash door Slide the shaker grate handle through the opening in the side of the door frame and guide it through the actuator arm and into the receiving boss on the opposite side of the frame 2 Secure handle to actuator with 1 4x1 1 2 bolt and nut Bl es See figure 15 SHAKER GRATE HANDLE Hot air ACTUATOR ARM gt j RECEIVING BOSS gt To house Oil or gas 7 Furnace 1 4x1 1 2 BOLT Added wood or coal furnace ALIGN HOLES ASH DOOR FRAME FIGURE 14 POOR INSTALLATIONS FIGURE 15 INSTALL SHAKER GRATE HANDLE 21 RETAINER REAR BAR REAR FRAME LOCKNUTS FRONT FRAME FIGURE 16 INSTALL FIREBRICK Place firebrick into unit as follows 1 Place two longer bricks with bevel cuts against the rear wall of the firebox See figure 17 2 Place remaining two bricks with bevel cuts against the front wall of firebox 3 Place rectangular brick along side walls of firebrick as illustrated If Rectangular bricks are two different widths then an equal number of each will go on both sides of firebox INSTALL OPTIONAL CATALYTIC COMBUSTOR MODEL 2900 4000 NOTE Optional catalyst not recommended with 6 flue adapter Smoke spillage may occur out of door when refueling Greater efficiency can be obtained
36. pplemental Wood Coal furnace installation When installing the air duct follow recommended clearances shown in figure 11 The plenum on the Woodchuck should be 20 x23 and no less than 18 high while maintaining a minimum of 18 clearance to the ceiling or other combustible mate rial In a power outage situation excessive heat buildup at the plenum top may be dangerous so make sure clearances are maintained For the Model 4000 allow at least 4 from ceiling to plenum The ducts fittings grilles and registers should be sized so that the total external static pressure does not ex ceed 02 W C inches while developing air velocities of With no draft in chimney regulator is closed no air gets in Moderate suction in chimney pulls regulator open enough to maintain desired draft for appliance Excessive suction in chimney pulls regulator further open allowing substantial air into chimney connector 600 ft min to 1000 ft min at the registers NEVER sup ply less than 150 sq in of heated air outlet area Cold air returns must be at least equal in size to the heated air outlets and preferably 10 larger Every Wood chuck furnace MUST be installed with a cold air return ADD ON INSTALLATIONS Before installing your Woodchuck furnace consult your furnace man and local state building codes to de termine if your furnace will accept an add on applica tion Some small furnaces and especially counter flow furnaces may
37. r domestic water free of charge during the heating season for additional saving to you EE UNCOMFORTABLY UNCOMFORTABLY COLD FIGURE 3 FIGURE 2 FIGURE 4 OPERATION COMMON SENSE Please read the following before firing your furnace It is most important that you follow these suggestions and limitations in order to maintain your warranty and guar antee the long life of your furnace NOTE Smoke detectors and fire extinguishers should always be a part of your equipment This furnace is an airtight unit designed to burn 6 8 hours per load of wood or coal If the furnace is being fired hot constantly with full flames and operating at only 2 4 hour burn cycles it may be over fired Your home heating needs may be too great for the size of furnace you have purchased Your furnace can be dam aged if fired at extremely high temperatures Forced firing or abuse can be detected upon inspection AND WILL VOID YOUR WARRANTY AADANGER RISK OF FIRE OR EXPLOSION DO NOT BURN GAR BAGE GASOLINE DRAIN OIL OR OTHER FLAMMA BLE LIOUIDS FAILURE TO HEED MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH AANDANGER NEVER USE CHEMICALS OR FLUIDS SUCH AS GASOLINE CHARCOAL LIGHTER FLUID DRAIN OIL FUEL OIL OR KEROSINE TO LIGHT A FIRE IN YOUR WOODCHUCK FAILURE TO HEED MAY RE SULT IN SERIOUS PERSONAL INJURY OR DEATH ACAUTION e RISK OF FIRE e DONOT OPERATE WITH FUEL LOADING OR ASH REMOVAL DOORS OPEN e DO NO
38. reat it with respect Don t fully load your fur nace or open all drafts fully until you have become thor oughly familiar with the operation of the furnace NOTE A full load does not always give the best results for your needs 4 When loading your Woodchuck with existing hot coals rake red hot embers over grates evenly Put a few small pieces of wood on the coals first then load up 5 If you have the automatic draft control turn low limit by pass switch to On Turn thermostat up to activate auto draft and proceed as with manual draft Once the unit is warmed up you can turn the low limit by pass switch to OFF This will allow the auto draft to shut off if the unit runs out of fuel while you are gone ACAUTION WAIT 10 SECONDS ON FIRST LATCH BEFORE RE FUELING OPENING LOADING DOOR RAPIDLY CAN CAUSE A FLAME TO FLASH OUT THE DOOR THIS OCCURS WHEN THERE IS UNBURNT FUEL AND LARGE AMOUNT OF GASES ON TOP OF THE FIRE BOX WHEN THE DOOR IS OPEN OXYGEN IS COM BINED WITH GASES AND IGNITES USE CAUTION WHEN OPENING LOADING DOOR HELPFUL HINTS Adjust the draft to the proper setting for your home needs The chimney hookups and kind of wood will also be a factor Your Woodchuck is capable of holding very large logs DO NOT try to add a log that is larger than you can easily place in the furnace You will get the best effi ciency when you add only the amount of wood needed for a 6 to 8 hour burn In the spring and
39. remedy the purchaser must ship the part s freight pre paid to MEYER MANUFACTURING CORPORATION P O Box 405 Dorchester Wisconsin 54425 All claims must be accompanied by a proof of purchase substantiating date of pur chase In the event date of purchase cannot be obtained Meyer Manufacturing Corporation will assume it to be 90 days after date of production hat We will do and will not do Meyer Manufacturing Corporation will ship the repaired or replacement part to the Purchaser freight collect The Purchaser is responsible for service removal and reinstallation labor cost ther Conditions he warranty applies only if the unit is installed and operated as recommended in he owners manual and used with a class A all fuel chimney The draft from the himney must be 04 to 06 inches W C draft The warranty will not apply if the nit is used for commercial purposes if damage is caused by abuse accident im proper installation overheating or negligence or from an attempt to repair the unit by any person not expressly authorized by Meyer Manufacturing Corporation to do he repair Limit of Obligation No one is authorized to make any other warranties on behalf of Meyer Manufac uring Corporation We will NOT be responsible for any promises NOT in our war ranty Any special incidental or consequential damages are excluded to the xtent permitted by law Any implied warranty including merchantability or fitness or a particular purpose shall NO
40. s and more Here is how when combustion air enters a Woodchuck furnace it enters into a draft channel Here it comes into contact with the hot fire box front and is warmed before entering the firebox The draft channel is equipped with adjustable orifices which provide for the 80 20 distribution of the combus tion air A lever on the front of Models 2900 4000 al lows for quick and easy adjustment of these orifices to correspond to the fuel being used As the air enters the firebox it strikes a deflector which creates a turbu lence and causes the oxygen to mix thoroughly with the gases for complete combustion Finally Woodchuck Model 2900 4000 furnaces are de signed to accept a catalytic combustor This device will cause the small amount of unburned fuel to ignite be fore entering the secondary heat exchanger The ben efits of all this are threefold A You obtain very high combustion efficiencies meaning you use less fuel B You reduce the amount of unburned fuel that can collect in your chimney as creosote and hence reduce the hazard of a chimney fire C You virtually eliminate pollution of the air we all breathe Transfer efficiency refers to how effectively we transfer the heat generated inside the firebox to the rooms we want to heat Insufficient blower capacity will result in poor transfer allowing the unused heat to escape up the chimney This is why we utilize a blower with such large air handling capacity
41. s that you can better avoid overheating the unit and developing excessive and unsafe temper atures Woodchuck furnaces are subjected to the most strin gent test criteria applicable by an independent third party testing laboratory and listed labeled as having met or exceeded those standards Finally any ma chine even this Woodchuck is only as safe as the person operating it This is why we have compiled this comprehensive manual to assist you in operating your Woodchuck properly and safely Please read and fol low all instructions EFFICIENCY The total efficiency of a unit is broken down into com bustion efficiency and transfer efficiency We know that when woodburning 20 of it burns as fixed car bon The other 80 is in the gaseous state as it burns Therefore to obtain efficient combustion of the wood it is necessary to introduce 20 of the oxygen under the fire to promote combustion of the solid material and 80 over the fire where it can readily react with the gaseous material Coal burns just the opposite of wood 80 of it burns as fixed carbon and 20 burns in the gaseous state Therefore before a furnace can burn coal or wood efficiently it must provide the 80 20 ratio of combustion air and allow the operator to re verse the ratio depending on the fuel being used Combustion air must be warm when it enters the fire box to further promote complete combustion Your Woodchuck furnace provides all these feature
42. t blower not turning on NOTE Be sure switch on blower is on Switch blower to the off position Bad wall Ther mostat check by turning it up to 80 and if the draft blower does not turn on replace thermo stat Lo limit bypass on off Replace thermostat When starting up it is necessary to turn toggle switch on front of comfort control center to on until unit warms up 6 Smell an odor from the New steel small amounts of residue on the This will disappear in a matter of first fire in the furnace steel hours Bad weld if smell continues for two weeks of Contact dealer immediately burning 7 Not getting heat in the home Unit may be too small for your home check specification chart Improper insulation in home allowing heat to escape Improper hookup to furnace Ducting not sized properly for unit Replace with a larger unit or have regular furnace help Reinsulate Check installation drawings and or consult your local heating man 8 Flames coming out the door when loading Excessive amount of gases on top of the fire box and igniting when given oxygen from open door NOTE This is one of your Woodchuck safety features built into every unit with a dou ble latch system Large amounts of unburned wood Try to load when fire is at its lowest point but have enough embers left for a good start again NOTE Only you will know this time after some experience wit
43. ter Pin BASIC UNIT FOR MODEL 2900 10 7 KEY NO PARTNO DESCRIPTION KEY NO PARTNO DESCRIPTION 1 01 2900 Welded Assembly 13 02 2901 Fuel Door 2 03 2901 Shroud Top 14 06 2902 Fuel Door Gasket 3 03 2904 Shroud Front 15 07 2901 Side Brick Kit 4 pc 4 03 2902 Shroud Right Side 16 07 2902 Rear Brick Kit 2 pc 5 03 2903 Shroud Left Side 17 07 2903 Front Brick Kit 2 pc 6 05 2908 Shaker Handle 18 07 2900 Complete Brick Kit 7 06 1001 Ash Pan 19 06 2907 Insulation Front 8 06 1013 80 20 Selector Knob 20 06 2906 Insulation Side 9 06 0200 1 4 Door Pin 21 08 0005 Circulation Blower 10 06 2903 Ash Door Gasket 22 03 2905 Z Lock 28 1 2 11 02 2902 Ash Door 23 03 2906 Z Lock 44 3 4 12 06 1014 Handle Knob Large 28 BASIC UNIT FOR MODEL 4000 11 KEY NO PARTNO DESCRIPTION KEY NO PART NO DESCRIPTION 1 01 4000 Welded Assembly 12 06 0200 Door Pin 2 03 4001 Shroud Top 13 02 2901 Fuel Door 3 03 2904 Shroud Front 14 06 2902 Fuel Door Gasket 4 03 4003 Shroud Left Side 15 02 2902 Ash Door 5 03 4002 Shroud Right Side 16 06 2903 Ash Door Gasket 6 06 4001 Insulation Side 17 07 4003 Front Brick Kit 2 pc T 06 2907 Insulation Front 18 07 4002 Rear Brick Kit 2 pc 8 08 0005 Circulation Blower 19 07 4001 Side Brick Kit 4 pc 9 06 1014 Handle Knob Large 20 07 4000 Complete Brick Kit 10 06 1013 80 20 Selector Knob 21 03 4004 Z Lock 34 1 4 11 06 1001 Ash Pan 22 03 4005 Z Lock 48 29 OPTIONAL SHAKER G
44. ting the furnace to the chimney maintain a chimney flue section giving these minimum areas or larger but not exceeding twice this area Some common sizes that are acceptable are 8 round 10 round or 8 x12 rectangular All Woodchuck furnaces must be in stalled into a chimney developing a minimum of 04 W C to a maximum of 06 W C inches of draft To maintain this range of draft a barometric damper should be in stalled see pgs 18 20 on each unit when the draft from the chimney is capable of exceeding 06 W C inches of draft Insufficient draft can contribute to smoke spillage when the loading door is opened and to rapid creosote accu mulation Excessive draft can cause high flue gas tem perature loss of overall efficiency and effect the degree of control the operator can exert on the unit APPROVED CHIMNEY STOVE PIPE FRONT VIEW FIGURE 9 CHIMNEY ROOF CLEARANCE TYPICAL STOVE PIPE INSTALLATION When using approved factory built metal chimneys you must have at least 2 of clearance when going through a wall or next to a wall A typical factory chimney instal lation is shown on figure 9 INSTALLING YOUR WOODCHUCK Most of the Woodchuck furnace is factory assembled The factory assembly should be located as detailed in the PLACEMENT AND MINIMUM CLEARANCES sec tion and on figure 7 Remaining assembly will consist of mounting the con trols draft and circulating blowers filter box if used and electrical connection
45. ugh room at the rear of the Woodchuck for installation of the circulating blower and filter box If using your unit as an add on 6 minimum clearance is required from your present furnace One very important step in locating your wood coal fur nace is how much distance you will be from your new or existing chimney The unit should be installed as close to the chimney as possible with a minimum of elbows no more than 2 and no more than 6 feet horizontally with 1 2 rise per foot CHIMNEY INSTALLATION It is extremely important that your Woodchuck furnace be installed into a CLASS A CHIMNEY ONLY These chimneys consist of a flue lined masonry chimney or an approved Class A All Fuel factory built metal type Any other installation constitutes a fire hazard as wood and coal burning units have stack temperatures as much as 300 to 1000 and may also deposit creosote 6 OR 7 PIPE FOR MODEL 526 8 PIPE FOR MODELS 2900 4000 SIDE VIEW which can ignite and cause severe damage to any chimney MAKE SURE YOUR WOODCHUCK IS IN STALLED INTO A PROPER CHIMNEY For maximum safety and efficiency never install the Woodchuck furnace into the same chimney serving an other appliance A typical chimney checklist of requirements is depicted on figure 8 The Model 526 furnace is equipped with a 6 flue collar having 28 sq in of exhaust area Models 2900 and 4000 have an 8 flue collar having 50 sq in of exhaust area When connec
46. ularly because of its potassium content Ashes will also decrease the acidity of garden soil AACAUTION e KEEP ASHPAN OUT OF UNIT DURING OPERA TION ASH PAN CAN GET VERY HOT e ASH CAN MUST BE PLACED ON A NONCOMBUSTIBLE SURFACE NEVER USE ANYTHING BUT AN AIR TIGHT METAL CONTAINER TO DUMP YOUR ASHES IN EVERY YEAR MANY FIRES ARE CAUSED BY EMPTYING ASHES INTO CARDBOARD BOXES OR PAPER BAGS e PROVEN FACT SMALL RED EMBERS BURIED IN ASH CANS STAY RED HOT FOR DAYS ASHES ARE A GOOD THERMAL INSULATOR AND KEEP ENOUGH OXYGEN AWAY SO THE EMBERS DO NOT BURN OUT BURNING COAL IN YOUR WOOD CHUCK Never attempt to burn coal without a shaker grate Shaker grates are standard on Models 2900 and 4000 but optional on Model 526 A barometric draft control in the smoke pipe must be used when burning coal ACAUTION UNSAFE TO LOAD COAL ABOVE TOP OF FIRE BRICK STARTING A COAL FIRE Open all draft controls on your Woodchuck Build a fire using dry wood kindling and establish a bed of coals Add several small shovels of coal over the wood coals After the coal fire is established and spread throughout the firebox add larger amounts of coal to build up the coal bed Gently shake the grate until live coals fall into the ash pan area Allow your Woodchuck to operate with drafts open for approximately 15 minutes or until fresh coal ignites When the coal is properly ig nited adjust the drafts accordingly Check the fire peri odically t
47. urers recommend their use with some stoves There is some doubt among wood heat experts as to whether use of barometric draft regulators is wise Draft regulators limit the draft the suction pulling air into the appliance A pivoted counter balanced flap is pulled open by the draft when the draft reaches a criti cal amount figure 10 This permits air to enter the chimney thus preventing the draft in the appliance from rising any higher Use of draft regulators with oil fired equipment is com mon One objective is to keep the oil flame from being blown out by excessive draft This is more an annoy ance than a safety problem since most oil burners have primary safety controls which stop the fuel flow into the burner whenever the flame goes out and modern flame retention burner design makes draft regulation al most unnecessary for this objective A second objective is to limit the amount of air passing through the system in order to maintain high heat trans fer efficiency Another desirable consequence is a de crease in peak chimney temperatures due to the added air entering through the regulator High draft does not blow out the flames but fans them in wood and coal burning equipment An especially hot fire can result Control of the fire may be difficult partic ularly if the wood burner is not airtight Energy efficien cies may be adversely affected and chimney fires may be ignited A barometric draft regulator can alleviate t
48. when burning wood by use of a catalytic combustor In addition it will de crease the accumulation of creosote and diminish the possibility of a chimney fire 22 CENTER RETAINER RETAINER LEFT FRONT BAR RIGHT FRONT BAR NOTE LONG SHAFT ON FRONT AN HANDLE GEARS INSTALL OPTIONAL SHAKER GRATE FOR MODEL 526 BEVEL CUT BRICKS RECTANGULAR FRONT amp BACK BRICKS ON SIDES BEVEL CUT BRICKS RECTANGULAR FRONT amp BACK BRICKS ON SIDES FIGURE 17 INSTALL FIREBRICK The pyrolysis of wood produces certain substances which will not burn unless the temperature in the firebox reaches 1000 F or higher Under normal conditions these temperatures are not attained and these sub stances simply escape up the chimney as wasted energy and can form deposits in the chimney By forcing these unburned substances to come into contact with a cata lyst we can cause them to burn at much lower tempera tures that are easily attainable during normal operation Installation and removal of the combustor is simple the element fits inside a retainer The retainer fits inside the furnace exhaust pipe which extends down into the fire box The assembled combustor slides up into the ex haust pipe stub which protrudes down into the firebox There are three rods on the retainer which engage slots in the pipe and then turn slightly to lock in place These rods are not symmetrical Two rods are welded together to form a 90 angle This
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