Daka Corporation 521FB User Manual

MODEL 521FB

WOOD-BURNING FURNACE MANUAL

Manufactured in the U.S.A. by

DAKA CORPORATION

955 Industrial Street NE

Phone: [phone] xx Fax: [phone]

Pine City, Minnesota 55063

www.dakacorp.com

DAKA 521FB Manual Page 1 of 31 January 2009
Rev. 1, June 2011

I. LIMITED WARRANTY

SAVE

INSTRUCTIONS.

This furnace meets
U.S. Test Standard: UL 391-2010

This model has been tested and listed in accordance with

Underwriters Laboratories Standard UL 391-2010

for Solid Fuel Central and Supplementary Furnace by

Intertek Testing Services/Warnock Hersey Inc.

International Conference of Building Officials (ICBO) Report No. TL116
Council of American Building Officials (CABO) Report No. NER QA219

Purchase Date:

Purchased From:

THESE

Model #:

Serial #:

DAKA Corporation warrants the combustion chambers of its supplementary and central furnaces to be free of

defects in material or workmanship for five years
electronics, gaskets and grates, are covered in the same manner for a period of one year

DAKA Corporation will repair or replace defective components, at our option, at no charge for parts and labor,
and will pay freight charge for one-way shipment for warranty claims during the first year. In second and
subsequent years, only parts and labor will be provided at no charge. DAKA Corporation is not responsible for
installation or dismantling costs.

The warranty is void if unit is not used in a residential service connected to conventional basement-type upflow
central heating system, if non-approved fuels are used in firing of units, or if unit is damaged due to accident,
improper installation or negligence.

For service under this warranty, contact selling dealer or DAKA Corporation, Customer Service Dept.,
955 Industrial St. NE, Pine City, MN 55063; telephone [phone] or email [e-mail].

Implied warranties including that of merchantability are expressly limited in duration to the duration of this
warranty. DAKA Corporation disclaims any responsibility for consequential damages. Some states do not allow
limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential
damages, so this limitation and exclusion may not apply to you.

This warranty gives you specific legal rights and you also may have other rights that vary from state to state.

This is our exclusive written warranty.

(non-prorated) from date of sale. All other components, including

.

DAKA 521FB Manual Page 2 of 31 January 2009
Rev. 1, June 2011

II. TABLE OF CONTENTS

DAKA 521FB

WOOD-BURNING FURNACE MANUAL

I. LIMITED WARRANTY .................................................................................................. 2

II. TABLE OF CONTENTS ............................................................................................... 3

III. FEATURES .................................................................................................................. 4

IV. SPECIFICATIONS ........................................................................................................ 5

V. OPTIONAL FURNACE ACCESSORIES ...................................................................... 6

VI. GENERAL WOOD-BURNING SAFETY ................................................................... 7, 8

VII. CHECKING SHIPMENT ............................................................................................... 9

VIII. PLANNING YOUR INSTALLATION ...................................................................... 10-14

A. General
B. Clearances
C. Chimney
D. Supplementary Add-on
E. Central

IX. ASSEMBLY INSTRUCTIONS ............................................................................... 15-20

A. Components (Main)
B. Electrical components (Fan Control, Wiring)
C. Cold Air Return Filter Box

X. INSTALLATION ..................................................................................................... 21-25

A. Connecting to Ductwork

1. Supplemental Add-On

2. Central

3. Alternative Connection Options
B. Connecting to Chimney

XI. OPERATING INSTRUCTIONS ............................................................................. 26, 27

A. General
B. Operating Controls: Snap Disc Fan Control & Automatic Damper Control
C. Emergency

XII. MAINTENANCE INSTRUCTIONS .............................................................................. 28

XIII. TROUBLESHOOTING ............................................................................................... 29

XIV. PARTS LIST & EXPLODED VIEW ............................................................................. 30

DAKA 521FB Manual Page 3 of 31 January 2009
Rev. 1, June 2011

III. FEATURES

5

5
firebox; 1 year on all other materials.
See

Snap Disc Thermostat

highly reliable independent
snap disc thermostat controls
blower.

Heavy Duty Cast Iron Grates –
High heat resistance provides
longer life.

2
Back Fire Brick
Lining

Durable
construction for
long life and
consistent heat.

UL Tested by WHI –

Tested to UL Standard
391

2010. Ensures

safety and efficiency.

42,000 to
105,000 BTU’s –

Offers wide range
of heat output.

8 Hour Burn

For average heating
output, up to 12 hours

of “overnight” heating

needs.

Complete 7

gauge (3/16”)

steel throughout
Firebox

– Most

competitors offer
only a 10

-gauge
firebox; approx.
half the strength of
a DAKA Furnace.

Heats Homes up
to 2,6

–

Largest heating
capacity for the
price available in
the market.

USE AS AN ADD-ON or CENTRAL FURNACE

– Add-on utilizes existing central ductwork and distribution system

– Central application has its own ductwork.

NOTE: Return Cold Air Filter Box included but not
shown. The filter box improves indoor air quality.

Large Fire Box
holds 90 lbs

of

22” logs

Allows
for maximum burn
time.

Automatic Damper Control – For
maintenance free, consistent heat;
automatically adjusts air supply to fire.

Backdraft Damper

Factory-installed warm air
back draft damper is
included with every
521FB furnace.

Full Length Ash Pan – Makes ash handling
more convenient and reduces spillage; no
back on ash pan for ease of dumping.

2-8” Warm Air Outlets

–

for secure connection

of 8” round duct pipe.

Heavy Duty Cast Iron
Door

Prevents warping

and maximizes efficiency.

Blower, 550 CFM –

1/10 HP helps maintain
CFM at higher static
pressures. Totally
enclosed, permanently
lubricated ball-bearings.

Sides and

–

-

00 sq. ft.

.

–

Time –

– A

–

DAKA 521FB Manual Page 4 of 31 January 2009
Rev. 1, June 2011

–

-Year Warranty –

-year non-prorated warranty on

Written Warranty for details.

IV. SPECIFICATIONS

DAKA MODEL 521FB WOOD-BURNING FURNACE SPECIFICATIONS

Manufacturer:

DAKA Corporation

Model:

521FB

U.L. Approval:

Tested to U.L. Standard 391–2010 by WHI

Fuel Type:

Wood / Coal

Dimensions:

44” Height x 24” Width x 25-½” Depth

BTU Output:

42,000 – 105,000 per hour

Fuel Capacity:

22” Log Length / 90 lb.

Air Outlet Size:

2 – 8” round

Flue Outlet Size:

6” round

Weight:

432 lbs.

DAKA 521FB Manual Page 5 of 31 January 2009

Rev. 1, June 2011

V. OPTIONAL FURNACE ACCESSORIES

DAKA CORPORATION

273

For installations requiring additional air pressure, such as
for use as a central furnace. Kit includes one 550

cfm split­capacitor blower, wiring
models 521FB/621/622, many earlier deluxe models.

258 – DUAL BLOWER RETURN COLD AIR FILTER BOX

W

ith No. 273 twin blower kit installed, this galvanized filter
box covers both blowers. Takes one 14" x 25 x 1” paper
furnace filter (not included.).

218

Mounts on side of furnace to provide increased air delivery
for higher static pressure central furnace applications. Kit
includes a 1580

drive motor,

galvanized steel return

223

Connects to present domestic hot water tank to provide
gallons of piping hot water. Weldless boiler pipe has working
pressure of 1200lbs./sq. in. Kit includes pre
hardware,

238D - SOFT COAL SHAKER GRATE KIT
Replaces wood

-burning grate to permit burning of
bituminous and sub-bituminous coal in Deluxe models
311/411/521FB/621/622 above, many earlier models.
Includes extra -thick 3-section shaker grates and shaker rod
assembly

& fire door with spinner knob.

`

253 - FORCED DRAFT CONVERSION KIT
Adds convenience of living area control of heat output of
Deluxe models 521FB and 621, many earlier models.

Kit
includes 35-cfm draft blower, wall thermostat,
transformer/relay, controls, wiring and instructions.

283

Installs in chimney connector to help provide constant draft
control, extend burn times, save fuel, avoid

firing, and
reduce creosote formation. Adjustable from .02" to .08"
updraft. For 6" pipe. U.L. Listed.

955 Industrial St NE, Pine City MN 55063

Telephone: [phone] Fax: [phone]

Email: [e-mail] Website: www.dakacorp.com

Visit our website or call 1-800-884-3252

for pricing and shipping information.

- TWIN 550-CFM BLOWER KIT

and instructions. For use with

- LARGE BLOWER & FILTER BOX KIT

-cfm blower with 1/4-HP belt­cold air filter box. 115V AC.

-

- HOT-TUBE™ DOMESTIC HOT WATER PREHEATER

-heater pipe,

gaskets and instructions.

- BAROMETRIC DRAFT REGULATOR

over-

DAKA 521FB Manual Page 6 of 31 January 2009

Rev. 1, June 2011

VI. GENERAL WOOD--BURNING SAFETY

STOP FOR SAFETY!

Safe assembly, operating and maintenance practices should

always be followed whenever using any equipment.

READ THROUGH THE ENTIRE MANUAL BEFORE BEGINNING

YOUR INSTALLATION OR OPERATING YOUR FURNACE.

FOLLOW ALL STEPS EXACTLY!

WARNING: Disconnect all power before making

electrical connection. For power supply connections,
use No. 14 AWG or larger wires acceptable for at
least 105qC. Check local codes for acceptable
components.

WARNING: Do not over fire the furnace. Over firing
will happen if the fire door or ash door is left open
during operation. Such actions can result in very
dangerous operating conditions.

WARNING – Risk of fire! Do not operate with flue
draft exceeding .06” WC. (measured in water

column). Use of a draft gauge is highly

recommended. Follow gauge manufacturer’s

instructions. Gauges to measure chimney draft are
readily available at furnace shops and are
economical to purchase or rent. If a draft gauge is
not available, with the draft regulator fully installed
and a good fire burning, adjust the counterbalance
weight closer to the gate for as low a draft setting as
possible, without the fire dying or getting smoke­back with the stove door slightly open. To obtain
higher heat levels, move the weight away from the
gate to increase the setting.

WARNING: Do not operate with fuel loading or ash
removal doors open. Do not store fuel or other
combustible material within marked installation
clearances. Inspect and clean flues and chimney
regularly.

WARNING: Do not operate furnace while under the
influence of drugs or alcohol.

WARNING: For further information on using your
furnace safely, contact the National Fire Protection
Association (NFPA) at www.nfpa.org.

WARNING: To prevent burns, always wear
protective clothing, leather hearth gloves and eye
protection, while tending the fire.

WARNING: While in operation, keep the fire door
and ash door closed at all times except while
tending the fire.

WARNING: Burn wood only or burn coal only.

CAUTION: Hot Surfaces! Keep children away. Do

not touch during operation. Maintain clearance to
combustibles as listed on nameplate. Refer to
product nameplate and manual for additional
information.

CAUTION: During a power failure, set auto damper
no higher than EPF setting. Remove furnace air
filter. Air jacket top and sides may be removed to
keep the firebox from overheating. DO NOT expect
the furnace to keep the house as warm as when
power is on. Do not attempt to increase heat output
by

opening ash door or fire door.

CAUTION: Turn off all power to furnace
before cleaning.

DAKA 521FB Manual Page 7 of 31 January 2009
Rev. 1, June 2011

VI. GENERAL WOOD--BURNING SAFETY

SAFETY NOTICE

IF THIS FURNACE IS NOT PROPERLY

INSTALLED, A HOUSE/BUILDING FIRE

MAY RESULT. FOR YOUR SAFETY,

CONTACT LOCAL BUILDING OR FIRE

OFFICIALS ABOUT PERMITS,

RESTRICTIONS

AND INSTALLATION

REQUIREMENTS FOR YOUR AREA.

REFER TO MARKING ON APPLIANCE

Building Codes: Check local building and mechanical codes prior to installation to ensure

conformance with all requirements.

Home Insurance: Review home insurance policy for coverage.

Paint Odor: During initial start-up, the unit may omit fumes as the paint outside shell cures. Please

provide outside ventilation throughout the home to help clear the odor.

Ash Disposal: Ashes should be placed in a metal container with a tight-fitting lid. The closed
container of ashes should be placed on a non-combustible floor or on the ground – well away from all
combustible materials pending final disposal. The ashes may be disposed of by burial in the soil or
otherwise locally dispersed. They should be retained in the closed container until all cinders have
thoroughly cooled.

Creosote: Formation & Need for Removal

When wood is burned slowly, it produces tar and other organic vapors that combine with expelled
moisture to form creosote. The creosote vapors condense in the relatively cool chimney flue of a slow­burning fire. As a result, creosote residue accumulates on the flue lining. When ignited, this creosote
makes an extremely hot fire.

The chimney connector and chimney should be inspected at least twice monthly during the heating
season to determine if a creosote buildup has occurred. If creosote has accumulated, it should be
removed to reduce the risk of a chimney fire.

DAKA 521FB Manual Page 8 of 31 January 2009
Rev. 1, June 2011

FOR ADDITIONAL INFORMATION.

VII. CHECKING SHIPMENT

FIG. 2

FIG. 1

UNPACKING

DO NOT LIFT FULL CARTON THAT
CONTAINS FIREBRICK AND BLOWER FROM
INSIDE THE FIREBOX.

Open box and remove individual firebricks and
blower first.

Check piece count against parts list in back of
manual.

MISSING OR DAMAGED PARTS

PLEASE DO NOT RETURN THE PRODUCT
TO THE STORE WHERE PURCHASED.

CALL DAKA CORPORATION DIRECTLY.

1-800-884-3252 Monday through Friday

8:00 AM to 4:30 PM Central Time

It is our goal to send replacement parts to you
immediately after we receive your order.

In order to assist our Customer Service
Representative, please have the following
information available.

x Furnace Model Number
x Product Part Number
x Description
x Furnace Serial Number

We are committed to customer satisfaction and
are dedicating our efforts to earn your
continued support.

DAKA 521FB Manual Page 9 of 31 January 2009
Rev. 1, June 2011

VIII. PLANNING YOUR INSTALLATION

FIG. 3

Dimensions shown are minimum
clear distances for floor protector or
non-combustible floor.

PLANNING YOUR INSTALLATION

Read through the entire manual before
beginning your installation. Follow all steps
exactly. Your Model 521FB Furnace can be
installed as a supplementary Add-on Furnace
or as a free-standing central furnace with its
own plenum and ductwork.

Review the location options below and
determine how you are going to install your
system.

A. GENERAL

1. The DAKA 521FB wood-burning furnace is
designed for use only in conventional up
flow systems. It must deliver heated air to a
supply (warm air) plenum – never to
ductwork. When installed as an Add-On
furnace, the warm air supply from this
furnace must never be connected to the
cold-air return inlet of the primary furnace;
components of the primary furnace may
overheat causing damage to the primary
furnace.

2. Check local building and mechanical codes
prior to installation to insure conformance
with all requirements. Review home
insurance policy for coverage.

3. A qualified individual familiar with solid-fuel
systems must install this furnace.

4. Installation of this furnace in mobile homes
is prohibited.

5. For garage installation, check your local
building code ordinance.

6. Do not operate as a room heater.

B. CLEARANCES

1) FLOOR PROTECTION

1. This furnace must be installed on a non­combustible floor surface such as solid

concrete or 3/8” non-combustible floor protector
board. This surface must extend at least 16” in
front and 8” to both sides of the furnace and

also extend at least 2” out from the sides of the
chimney connector. See FIG. 3 for details.

DANGER – Risk of fire or

explosion – Do not burn garbage,
gasoline, drain oil or other
flammable liquids.

DAKA 521FB Manual Page 10 of 31 January 2009
Rev. 1, June 2011

VIII. PLANNING YOUR INSTALLATION

FIG. 4

Dimensions shown are minimum

combustibles walls.

B. CLEARANCES – continued

2) Wall Clearances to Combustibles

See FIG. 4.

x Furnace to sidewall: 18”

x Flue to sidewall: 27”

x Furnace to back wall: 32 ½”

x Flue to back wall: 23”

x Furnace to front wall: 48”

distances to stay clear from

DAKA 521FB Manual Page 11 of 31 January 2009
Rev. 1, June 2011

C. CHIMNEY

1) General

Chimney Requirements:

1) Minimum 6” inside diameter

2) “Type HT” (High Temperature)-listed

appliance-type chimney or a code-complying
tile-lined masonry chimney.

3) Chimney must extend 3’ above roofline and
be at least 2’ higher than any point of roof within
10’. See FIG. 5.

DO NOT install more than two 90° degree
elbows in the flue pipe to help maintain proper
draft.

This furnace requires its own independent
chimney. DO NOT connect to a chimney flue
serving another appliance. See FIG. 6.

All horizontal runs must have a minimum
upward rise of ¼” per foot.

The chimney connector (smoke pipe leading to
chimney flue) must be of minimum 24-ga. pipe
with each section joined with three sheet metal
screws. All fissures should be sealed with
furnace cement. Do not use galvanized pipe as
the coating could melt and cause toxic fumes.

A stack thermometer is recommended. Stack
temperatures can be checked with a simple
surface-mounted or probe-type thermometer. It
is recommended to maintain normal operating
range of 300-600 ° F. Temperatures lower than
300° F indicate insufficient draft or inadequate
combustion air and may result in creosote
formation in chimney flue.

The maximum draft setting is a maximum of
.06” W.C. (measured in water column). Use of
a gauge is highly recommended. Follow gauge

manufacturer’s instructions. Gauges to

measure chimney draft are readily available at
furnace shops and are economical to purchase
or rent. If a draft gauge is not available, with
the draft regulator fully installed and a good fire
burning, adjust the counterbalance weight
closer to the gate for as low a draft setting as
possible, without the fire dying or getting
smoke-back with the stove door slightly open.
To obtain higher heat levels, move the weight
away from the gate to increase the setting.

[An optional DAKA barometric regulator #283 may be used in the
chimney connector to help increase furnace efficiency by maintaining
a consistent draft. See FIGS. 5 & 6 on page 12.]

VIII. PLANNING YOUR INSTALLATION

C. CHIMNEY – continued

2) Chimney Options

FIG. 5

a) Masonry – Before using an existing masonry

chimney, have the chimney inspected, cleaned
and make all necessary repairs before attaching
the furnace. The flue pipe and fittings you will
need to connect your furnace directly to a
masonry chimney are shown in FIG. 5. If the
flue pipe must go through a combustible wall or
ceiling before entering the masonry chimney,
consult a qualified mason or chimney dealer.
The installation must conform to all local building
and fire codes and the latest edition of the
National Association of Fire Protection (NFPA)
Publication 211. If there is a cleanout in the
base of the chimney, close it tightly. The
chimney flue pipe must not pass through an
attic or roof space, closet, or any concealed
space, or floor, ceiling, wall or combustible
construction. See FIG. 5.

b) Factory Built – Factory built chimneys are

FIG. 6

generally stainless steel, insulated, multi-wall
pipes. Chimney must be listed to UL103 and

carry a rating of “HT” (High Temperature). The

top of the chimney must be at least three 3 feet
above the roof and be at least two 2 feet higher
than any point of the roof within ten feet – See
FIG. 6. A factory-built chimney must be
installed to the manufacturer’s specs.

If you have any questions regarding venting your
furnace, request a copy of the National Fire
Protection Association’s (NFPA) Publication 211
[Standard for Chimneys, Fireplaces, Vents &
Solid Fuel-based Appliances].

National Fire Protection Association
1 Battery March Park, Quincy MA 02169-7471,
1-617-770-3000 or online at www.nfpa.org.

DAKA 521FB Manual Page 12 of 31 January 2009
Rev. 1, June 2011

NOTE:

This furnace must be connected to a minimum 6”

listed Type HT (High Temp) appliance-type chimney
or a code-compliant tile-lined masonry chimney.
Connection to a chimney flue serving another
appliance is prohibited.

VIII. PLANNING YOUR INSTALLATION

FIG. 7

This furnace model is designed for a conventional up flow residential central force air heating
system. It may be installed in one of the following ways:

1) SUPPLEMENTARY ADD-ON or 2) CENTRAL FURNACE APPLICATION.

This furnace model is designed to operate with a maximum warm air duct pressure of 0.2” water

column and a maximum warm air duct temperature of 250° degrees F. The warm air supply duct
system must be constructed of materials with a minimum temperature rating of 250° degrees F.
Plenums installed to the furnace must be constructed of metal. Do not use flexible pipe.

D. SUPPLEMENTARY ADD-ON FURNACE APPLICATION

When installed as an Add-On, this DAKA furnace model is designed to work in conjunction with a
conventional up flow residential central forced air heating system. See FIG. 7.

NOTE: When used as a Supplementary Add-On furnace, confirm that your primary furnace is capable
of running at an external static pressure greater than 0.2” W.C. This information should be found on
the primary furnace nameplate.

It can be connected in parallel to a conventional primary furnace system. Using present ductwork, the
DAKA supplementary furnace system & blower lifts the warm air from the wood-burning furnace into the
plenum of the primary furnace for distribution by the primary furnace blower. The heat produced by the
wood-burning furnace should be able to keep the room temperature above that of the setting of the
primary furnace wall thermostat. This will keep the primary furnace from burning any gas, oil, or
electricity beyond what is required to run the primary distribution blower. Should the wood fire fail to
provide sufficient heat, the primary furnace will begin operating as usual.

When used as a supplementary Add-On furnace, a fixed back-draft damper may be required in the 8”
warm duct pipes from the DAKA furnace. They also may be needed in the plenum of the existing
primary furnace. Installation of these back-draft dampers is to prevent overheating. We recommend
that once the units are operating that both units be monitored to make sure that neither is overheating.

DAKA 521FB Manual Page 13 of 31 January 2009
Rev. 1, June 2011

VIII. PLANNING YOUR INSTALLATION

FIG. 8

E. CENTRAL FURNACE APPLICATION

When installed with its own plenum and ductwork, the furnace will operate as a freestanding Central
furnace. See FIG. 8.

The 550-cfm blower provided is often sufficient to provide air distribution for smaller homes with short
duct runs. A second optional 550-cfm blower, or a single 1580-cfm side mounted blower, may be
required for larger homes with longer ductwork (available online at www.dakacorp.com).

CAUTIONARY NOTE:

DO NOT USE AS A FREE-STANDING RADIANT HEATER.

DAKA 521FB Manual Page 14 of 31 January 2009
Rev. 1, June 2011

IX. ASSEMBLY INSTRUCTIONS

FIG. 9

Fire door 

Fire Door

FIG. 10

Ash Pan

FIG. 11

INSTALL FIRE DOOR

1. Attach fire door hinge to front of furnace.
See FIG. 9. Position hinge against furnace
with hinge pinhole closest to door opening.
When viewing hinge bracket from top, make
sure that the notched corner is facing away
from door opening.

2. Insert two ¼” hex bolts through hinge
bracket and holes located just to the right of
the door opening. Place washer and nut on
bolt from INSIDE furnace. NOTE: ¼” nut
that is used is a lock-nut and will require
that you use an open-end wrench to hold
the nut while turning the bolt with socket
driver on exterior. Center bolts in slotted
holes to start with. Tighten bolts enough to
hold bracket in place with fire door installed.

3. Install fire door onto hinge bracket. See
FIG. 10. Insert hinge pin from top down.
NOTE: Rotate door handle
counterclockwise to secure door in the
closed position.

4. With fire door installed, check fire door for
proper fit – doorframe should hit center of

rope gasket. If door doesn’t fit properly

(e.g., cast iron door hits door frame rather
than gasket), note location of problem and
then remove fire door. With fire door
removed, adjust hinge bracket location.
The holes in the hinge bracket are slotted
vertically for up and down adjustment. The
holes in the furnace are slotted horizontally
for left to right adjustment. Once the

proper placement has been found,
tighten bolts securely to prevent hinge
from moving.

INSTALL ASH PAN & ASH DOOR

1. Insert thermal gasket between ash door and
ash pan front, making sure that silver foil
side of gasket is facing INWARD toward ash
pan.

2. Securely attach ash door to ash pan using

two (2) ¼” bolts and nuts provided. See

FIG. 11.

NOTE: Ash pan is open-ended scoop design
for easy emptying of ash pan.

DAKA 521FB Manual Page 15 of 31 January 2009
Rev. 1, June 2011

IX. ASSEMBLY INSTRUCTIONS

Cast Iron Grate 

FIG. 12

Grate 

FIG. 13

Auto Damper
Control 



INSTALL FIRE BRICK

With everything removed from inside firebox,
install firebrick.

1. To install firebrick, hold firebrick in standing
position and angle top of firebrick toward
outside wall. Slip top edge of firebrick under
retaining angle. Stand firebrick up so bottom of
brick sits evenly on support rail.

2. Center rear firebrick (3) across back of
firebox. Insert sidewall firebrick (5 ea) at front
of furnace. As more are inserted, push brick as
far back as possible towards rear of furnace.

NOTE: There will be a small gap in each back
corner. This is normal and will not adversely
affect operation.

INSTALL CAST IRON GRATE

With reinforcement ribs facing down, insert
grate through fire door opening. Grate must be
held at a 45° degree angle as shown in FIG. 12.
Place one side edge down on support rail.
Drop other side down. Grate should lie flat on
both side support rails.

INSTALL AUTOMATIC DAMPER CONTROL

Remove Automatic Damper Control from

protective wrapping. Remove ¼” bolt and ¼”

nut that were installed in one corner of damper
control for shipping purposes only.

Attach Automatic Damper Control assembly to
front of furnace below the fire door opening with

six (6) No. 12 x ½” screws. Install top corner

screws first. Do not completely tighten until all
six screws have been inserted into holes.

NOTE: To ease installation of screws, use one
drop of motor oil on each screw before

installing. Use a 3/8” nut driver equipped with a
3/8” socket to install screws. TIGHTEN

FIRMLY. See FIG. 13.

Auto Damper

DAKA 521FB Manual Page 16 of 31 January 2009
Rev. 1, June 2011

IX. ASSEMBLY INSTRUCTIONS

FIG. 14

Blower 

INSTALL BLOWER

NOTE: For Add-On furnace installation, do

NOT remove the back-draft damper plate.
For Central Furnace installation, back-draft
damper plate may be removed. (It is located
inside the blower inlet on the right hand side of
back of furnace. Break wire nut to remove).

Install 550-cfm blower over inlet on right hand
side of back of furnace using four (4) No. 12 x
½” screws. See FIG. 14.

CAUTION: Handle blower by the housing unit.
DO NOT REACH INSIDE IMPELLER CAVITY.

INSTALL AIR JACKET PANELS

Furnace is shipped with air jacket panels
installed. If loose or removed during
installation, re-install as follows:

1. Install bottom edge of side panel into
channel on bottom support rail. Working
from the bottom up, press side panel tightly
against firebox. See FIG. 15.

2. Install top air jacket from back to front
making sure air jacket lip goes OVER the
outside of side panels (shoebox style fit).
NOTE: To ease top over sides, insert a
putty knife under top lip and pry lip outward
over side panel. See FIG. 17.

INSTALL SWING PLATE

Open fire door and carefully feel for two (2)
steel hooks above door opening. With bent
edge facing inward, hang swing plate from
hooks. See FIG. 15.

DAKA 521FB Manual Page 17 of 31 January 2009
Rev. 1, June 2011

IX. ASSEMBLY INSTRUCTIONS

FIG. 16

Junction Box &



Cover

FIG. 17

 Outside Wiring

MOUNT JUNCTION BOX, INSTALL FAN CONTROL,

INSTALL CONDUIT WITH PRE-RUN WIRES, & WIRING

INSTALL FAN CONTROL ASSEMBLY

Junction Box and Conduit (FIG. 16):

1. Remove cover plate from junction box.

2. Mount junction box using two (2) No. 12 x
½” screws onto left side of furnace in outer
pre-punched holes.
NOTE: Screws go in upper left and bottom
right slotted corners.

3. Remove one knockout plug from bottom
and one knockout plug from top or from
whichever side your power supply will be
entering.

4. Place a conduit connector on each end of
the flexible conduit.

5. Insert one connector in the bottom hole of
the junction box located on side of furnace.

6. Attach the other connector to the junction
box on blower motor.

Snap Disc Fan Control: (FIG. 17)

1. Mount Snap Disc Fan Control using two
(2) No. 12 x ½” screws onto left side of
furnace in inner pre-punched holes
located within the junction box.

NOTE: Make sure Fan Control is flush
against furnace air jacket panel.

DAKA 521FB Manual Page 18 of 31 January 2009
Rev. 1, June 2011

IX. ASSEMBLY INSTRUCTIONS

FIG. 18

WIRING INSTRUCTIONS

WARNING: Disconnect all power before

making electrical connection.

Power Supply Connections

1. Using an approved conduit and connector,
bring a 3-wire 120V AC 15-amp minimum
electrical service to the Junction Box.

2. Use minimum No. 14 AWG or larger wires,
rated for at least 105qC (not provided).

NOTE: Power connections should be made by
a qualified installer to comply with The National
Fire Protection Association (NFPA) Standard
No. 70 (National Electric Code) and all local
codes and regulations.

Blower Junction Box Wiring:

1. Inside the blower junction box, connect
wires with two blue wire nuts as follows: a)
Black wire to one blue wire; b) White wire to
other blue wire. Blower motor operates in
one direction only & is not reversible.

2. Tuck the wires into blower junction box.

3. Replace blower junction box cover.

Fan Control Wiring:

1. Attach one of the crimp terminals to black
(hot) power supply wire.

2. Attach the other crimp terminal to one end
of one blue wire coming from blower.

3. Attach the two crimp terminals to each side
of the Snap Disc Fan Control.

4. Connect other blue wire to white wire
supplying power to the unit.

5. Connect green ground wires together.

6. Check all connections for tightness and
electrical safety.

7. Coil all wires within junction box.

8. Install 4” square Junction box cover plate.

DAKA 521FB Manual Page 19 of 31 January 2009
Rev. 1, June 2011

IX. ASSEMBLY INSTRUCTIONS

COLD AIR RETURN FILTER BOX

ASSEMBLY & INSTALLATION

1. Using the sheet metal screws provided (Key 6) first attach the bottom panel (Key 2) to side
panel A (Key 3)

2. Next, attach side panel B (Key 4) and side panel C (Key 5) to bottom panel (Key 2).

3. With blower and wiring already installed on DAKA furnace, the next step is to loosen, but not
remove, all four screws holding the fan hole cover plate. (See FIG. 2).

4. Remove air jacket top and right side air jacket panel from DAKA furnace.

5. Take the partially assembled filter box and slide it into position. Once in position, slide outer
flange on panel A (Key 3) under the fan hole cover plate. Retighten the four screws holding
the fan hole cover plate. Once these screws are tightened, they will hold the left side of the
filter box in position.

6. Install top panel of filter box to all side panels.

7. Reinstall right air jacket side panel, making sure back edge of air jacket panel overlaps outer
flange on panel C. Once air jacket side panel is in position, it will hold the right side of the
filter box in position.

8. Place air jacket top back onto DAKA furnace.

9. If a cold air return line is to be installed, a minimum of a 13 ¼” x 13 3/8” must be used.

10. Furnace Filter: Use size 14 x 20 x 1 paper filter (side may be cut to fit width of filter box).

DAKA 521FB Manual Page 20 of 31 January 2009
Rev. 1, June 2011

X. INSTALLATION

EXAMPLE

FIG. 19

FIG. 20

(See other options on page 23)

A. CONNECTING TO DUCTWORK (SUPPLEMENTAL ADD-ON)

NOTE: Supply plenum must be metal.

IMPORTANT: The plenums installed to the furnaces must be of metal construction.

Verify beforehand that sufficient clearance is available above air conditioner coil, etc. If sufficient
clearance is not available, air conditioner coil may have to be moved to a second plenum with diversion
baffles for summer use.

The 90° degree elbow within the supply plenum forms a venturi. This is used to extract air from the
DAKA furnace when the primary furnace blower comes on. The absence of this elbow will cause back
pressure down the warm air pipe to the DAKA furnace. This will adversely affect the heat distribution
and possibly damage the DAKA furnace. If space prohibits installation of 90° degree elbow as
recommended, look for alternate designs shown in FIG. 20 or on Page 23.

DAKA 521FB Manual Page 21 of 31 January 2009
Rev. 1, June 2011

X. INSTALLATION

IMPORTANT: In a Supplementary Add-on installation, the blower on the DAKA furnace is not used as
a circulation blower for heating the house, but as a lift blower to get the heat into the supply plenum.
From there, the primary blower will turn on as heat is received from the DAKA furnace. A fan control
will have to be installed, wiring it in parallel with the primary blower fan control at the heat exchanger
level. See next page for necessary position of this fan control.

NOTE: After attaching warm and cold air supply and return pipes to the primary furnace, check the
entire system to insure that static pressure remains unaffected. Verify horizontal duct clearances.

A. CONNECTING TO DUCTWORK (WHEN USED AS CENTRAL FURNACE)

1. Install a minimum 16” x 16” plenum on air jacket top. You may want to cut top with tin snips or saber

saw to help free up the air flow out of the DAKA furnace.

2. Install ductwork with proper clearances to combustibles in accordance with local building codes.

3. Connect cold air return to No. 260 filter box provided. A twin blower conversion kit No. 273 is
available to increase airflow to 1100-cfm where necessary. This will provide for better heat distribution.

NOTE: The No. 273 twin blower conversion kit requires a No. 258 dual blower cold air return filter box.

IMPORTANT: The plenums installed to the furnaces must be of metal construction.

DAKA 521FB Manual Page 22 of 31 January 2009
Rev. 1, June 2011

X. INSTALLATION

ALTERNATIVE
CONNECTION OPTIONS

DAKA 521FB Manual Page 23 of 31 January 2009
Rev. 1, June 2011

X. INSTALLATION

FIG. 21

Chimney

Barometric
Regulator

Smoke Pipe

B. CONNECTING TO CHIMNEY

Mount and secure 6” non-galvanized smoke
pipe, 24-ga. or heavier, to rear smoke outlet
collar on DAKA furnace. The collar is sized so
that the crimped end of a standard 6” stove pipe
will fit inside collar. Continue same gauge
single-wall pipe to chimney connection. At
chimney connection, use a double-crimped end
stove pipe adapter to connect to chimney.
Smoke pipe should normally be installed with
crimped ends leading from chimney to furnace.
Should runny creosote be formed in chimney
connector, it will then return through pipe to
furnace without dripping out of joints.

INSTALL BAROMETRIC REGULATOR

A barometric regulator should be installed in

smoke pipe at least 18” from furnace. This will

permit adjustment of chimney draft to a

maximum of .06’ water column draft.

Barometric Regulator No. 283 with adjustable
draft setting is available through DAKA dealers
or direct from the factory for this purpose. See
FIG. 21.

Single wall smoke pipe must maintain a

minimum 18” clearance to all combustibles and

must never pass through walls or ceilings. Use
proper thimbles for those passages.

All joints of chimney connector pipe should be
secured with a minimum of three No. 7 sheet
metal screws and further sealed with furnace
cement to maintain good draft.

Maintain a minimum of ¼” per foot of pipe rise

to chimney connection. The steeper the rise,
the more easily draft will be maintained,
generally.

Limit the use of 90°elbows in any chimney
connector as they adversely affect draft.

If 90° elbows must be used, do not install more
than two in any chimney connector.

NOTE: During initial start-up, the unit may omit
fumes as the paint on the outside shell cures.
Please provide outside ventilation through the
home to help clear the odor.

Heat reclaimers, fins or the like should not be
used on smoke pipe as they tend to cool flue
gases and add to creosote formation on stoves
and furnaces of advanced airtight design.

Adequate combustion air must be provided in
furnace area to prevent poor firing and poor
draft. Keep a window cracked open in furnace
area or install dryer-type 4” vent to bring in
outside fresh air.

DAKA 521FB Manual Page 24 of 31 January 2009
Rev. 1, June 2011

X. INSTALLATION

B. CONNECTING TO CHIMNEY

DAKA 521FB Manual Page 25 of 31 January 2009
Rev. 1, June 2011

XI. OPERATING INSTRUCTIONS

FUEL TYPES

Burn wood only or burn coal only. Do not burn
garbage, flammable fluids, drain oil, wood chips
or any other non-approved items. Wood should
be cut & split and seasoned for at least 6
months.

FUELING PROCEDURE

Start fires by first taking single sheets of
newspaper and rolling them tight. Lay them on
the grate. Place finely-split kindling on top of
newspaper.

Open ash door about 1” and turn auto damper
to “High.” Place one more sheet of paper on

top of shelf baffle inside furnace. Light this
sheet first and let it burn completely out before
lighting paper underneath kindling. NOTE:
Burning the newspaper on top of baffle first
helps pre-heat the flue and gets the draft
working.

With the kindling burning, proceed to add
several larger pieces of cord wood. DO NOT
FILL ABOVE THE TOP OF THE FIREBRICK.

With the fire now burning, make sure to close
the ash door tightly and turn the auto damper to
appropriate setting for your heating needs.
Attend to fire as often as possible and add
wood as needed.

FIRE CHAMBER AND ASH PAN

Check ash pan every few days and safely
dispose of ashes. Keep ashes from building up
on grate and interfering with combustion airflow
from below.

AIR FILTER (14 x 20 x 1)

Check weekly and change as necessary.

FLUE PIPE AND CHIMNEY

A visual inspection of the flue pipe and chimney
is recommended once a week for the first
month and once a month thereafter.

Most problems associated with creosote are
seen in the fall and spring times of the year. It
is at this time when most people do not need

much heat to keep the house warm.
Remember to build fires using less wood and
continue to run the damper at a higher setting
vs. over-filling the firebox and turning the
damper down. This may require more frequent
tending of the fire, but will result in a cleaner
and safer fire.

If running the furnace at higher setting results in
too much heat generation, i.e., “over-heating
the house,” the best thing to do is reduce the
amount of wood used.

An inexpensive magnetic thermostat located on
the flue pipe is a great way to tell what
temperature you are burning at. Flue pipe
temperatures in the range of 300°-600° are

DAKA 521FB Manual Page 26 of 31 January 2009
Rev. 1, June 2011