Meyer 4000, 2900, 526 User Manual
INSTRUCTION AND PARTS BOOK
FOR
MODELS 526, 2900, & 4000
Installation must be made in accordance with local and state codes which
may differ from manual. Save these instructions.
WOOD/COAL FURNACES
07/97
Phone 715/654-5132
Fax 715/654-5513
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
neering have made your Woodchuck the finest heating appliance available to
day.
Solid fuels are abundant and inexpensive. Wood is our only renewable
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 furnace.
For a lifetime of satisfaction, thank you for not compromising with quality.
Sincerely,
Donald A. Meyer
President
MEYER MANUFACTURING CORP.
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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.
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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.
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TABLE OF CONTENTS
Page
Introduction..........................................................................................................................................................2
Table of Contents ................................................................................................................................................3
Furnace Safety ....................................................................................................................................................4
Specifications ......................................................................................................................................................5
General Information.............................................................................................................................................6
High Quality Construction ................................................................................................................................6
Efficiency .........................................................................................................................................................6
Comfort ............................................................................................................................................................6
Additional Comfort And Saving........................................................................................................................7
Operation.............................................................................................................................................................8
Common Sense ...............................................................................................................................................8
! If You Have Chimney Fire !............................................................................................................................8
! Important ! Operation Procedure In The Event of Power Failure ..................................................................8
Operating Your Woodchuck Furnace ..............................................................................................................9
Startup..........................................................................................................................................................9
Burning Wood In Your Woodchuck..................................................................................................................9
Helpful Hints...............................................................................................................................................10
Ash Removal..............................................................................................................................................10
Burning Coal In Your Woodchuck..................................................................................................................11
Starting A Coal Fire....................................................................................................................................11
Recharging.................................................................................................................................................11
Banking ......................................................................................................................................................11
Bituminous Recharging ..............................................................................................................................11
Helpful Hints...............................................................................................................................................11
Ash Removal..............................................................................................................................................12
Maintenance......................................................................................................................................................12
Trouble Shooting ...............................................................................................................................................13
Installation .........................................................................................................................................................15
General Requirements...................................................................................................................................15
Placement And Minimum Clearances............................................................................................................15
Chimney Installation ......................................................................................................................................17
Installing Your Woodchuck ............................................................................................................................18
Stove Pipe Installation ...................................................................................................................................18
Installation Of A Barometric Draft ..................................................................................................................18
Air Duct Installation........................................................................................................................................19
Woodchuck Final Assembly...........................................................................................................................20
Optional Shaker Grate Installation-Model 526 ...........................................................................................20
Install Shaker Grate Handle, Model 2900 Only..........................................................................................21
Install Firebrick ...........................................................................................................................................22
Install Optional Catalytic Combustor ..........................................................................................................22
Assemble Manual Draft-Model 526 Only ...................................................................................................23
Install Comfort Control Center And Forced Draft Blower ...........................................................................23
Install Circulating Blower............................................................................................................................24
Assemble Filter Box ...................................................................................................................................24
Electrical Hookup .......................................................................................................................................25
Repair Parts ......................................................................................................................................................27
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FURNACE 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 HEED 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.
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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.
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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:
WARNING:
DISCONNECT APPLIANCE FROM ELECTRICAL SUPPLY BEFORE SERVICING UNIT. FAILURE TO HEED MAY
RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
CAUTION:
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Equipment Must Be Installed By A Qualified Heating Person.
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Only “class A” All-fuel Or Solid Fuel Chimneys Intended Foe Use With Your Woodchuck Should Be Used.
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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.
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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 lbs.
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
Height 48.5"
Width 26"
Depth 28"
Blower 850 to 1850 CFM
Max. BTU Capacity 150,000
Log Size 22"
Loading Door Size 15"x13"
Weight, Approx. 700 lbs.
Warm Air Plenum 20"x23"
Flue Outlet 8" Dia.
Flue Collar Height 47" Overall Height
Secondary Heat Exchange YES
Listings UL391, CSA B366,
1-M ETLM
Firebox Chamber 7.70 cu. ft.
Height 51.5"
Width 26"
Depth 33"
Blower 850 to 1850 CFM
Max. BTU Capacity 180,000
Log Size 24"
Loading Door Size 15"x13"
Weight, Approx. 815 lbs.
Warm Air Plenum 20"x23"
Flue Outlet 8" Dia.
Flue Collar Height 50" Overall Height
Secondary Heat Exchange YES
Listings UL391, CSA B366,
Firebox Chamber 9.10 cu. ft.
MODEL 4000
1-M ETLM
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.
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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 means that you can better avoid overheating
the unit and developing excessive and unsafe temperatures.
Woodchuck furnaces are subjected to the most stringent test criteria applicable by an independent third
party testing laboratory and listed/labeled as having
met or exceeded those standards. Finally, any machine, 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 features 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. The large surface area of
the firebox and secondary heat exchanger provide for
efficient transfer.
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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
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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 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.
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
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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
WASTED HEAT
ZONE
82°
THERMOSTAT
COMFORT ZONE
74°
DISCOMFORT ZONE
60°
FIGURE 1
Options are available for your Woodchuck furnace, and
one of these deserve special mention. The Aqua-Si
phon is capable of pre-heating your domestic water
free of charge during the heating season for additional
saving to you.
UNCOMFORTABLY HOT
UNCOMFORTABLY COLD
FIGURE 3
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75°
THERMOSTAT
74°
73°
FIGURE 2
FIGURE 4
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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.
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.
! 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.
3. Call the fire department.
NOTE: Emptying a 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.
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MANUAL DRAFT
! 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 every Woodchuck.
The following steps should be taken in the event of an
electrical power failure:
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DANGER:
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.
CAUTION:
·
RISK OF FIRE
·
DO NOT OPERATE WITH FUEL LOADING OR
ASH REMOVAL DOORS OPEN.
·
DO NOT STORE FUEL OR OTHER COMBUSTI
BLE MATERIAL WITHIN MARKED INSTALLATION
CLEARANCES.
·
INSPECT AND CLEAN FLUES AND CHIMNEY
REGULARLY.
·
UNDER CERTAIN CONDITIONS OF USE, CREO
SOTE BUILDUP MAY OCCUR RAPIDLY.
·
WAIT 10 SEC. ON FIRST LATCH BEFORE RE
FUELING.
·
LOAD FUEL CAREFULLY OR DAMAGE MAY RE
SULT.
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1. Locate all heating duct dampers
damper), if any, to open position.
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 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.
(not smoke pipe
CLOSED
MANUAL DRAFT
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SHAKER
GRATE
DOUBLE LATCH
LOADING DOOR
COMFORT
CONTROL CENTER
FAN/LIMIT
HEAT EXCHANGER
CONTROL ROD
DOUBLE LATCH
LOADING DOOR
COMFORT
CONTROL CENTER
FAN/LIMIT
DRAFT CHANNEL
SELECTOR - 80/20
COMBUSTION AIR
RATIO CONTROL
MODELS
ASH DOOR
2900/4000
FORCED DRAFT
BLOWER
FIGURE 5 WOODCHUCK CONTROLS
(OPTIONAL)
TEMPERATUR
E GAUGE
CIRCULATING
BLOWER
DRAFT BLOWER
LO-LIMIT BYPASS
DRAFT BLOWER
MANUAL SWITCH
FIGURE 6 COMFORT CONTROL CENTER
OPERATING YOUR WOODCHUCK
FURNACE
MANUAL DRAFT
(Forced Draft Is
Optional)
ASH DOOR
SHAKER GRATE CRANK.
SHAKER GRATES ARE OPTIONAL
MODEL 526
NOTE: All models are equipped with a “low limit” which
will not allow the auto draft to operate when the unit is
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 WOODCHUCK
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.
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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.
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.
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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 treat 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.
CAUTION:
WAIT 10 SECONDS ON FIRST LATCH BEFORE REFUELING. OPENING LOADING DOOR RAPIDLY CAN
CAUSE A FLAME TO FLASH OUT THE DOOR. THIS
OCCURS WHEN THERE IS UNBURNT FUEL AND A
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
fora6to8hour burn.
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.
CAUTION
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, particularly because
of its potassium content. Ashes will also decrease the
acidity of garden soil.
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KEEP ASH PAN OUT OF UNIT DURING OPERA
TION. 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.
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PROVEN FACT- SMALL RED EMBERS BURIED
IN ASH CANS STAY RED HOT FOR DAYS.
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ASHES ARE A GOOD THERMAL INSULATOR
AND KEEP ENOUGH OXYGEN AWAY SO THE
EMBERS DO NOT BURN OUT.
CAUTION
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In the spring and 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
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