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
Phone 715/654-5132
Fax 715/654-5513
07/97
INTRODUCTION
Dear Woodchuck Owner,
Congratulations on your purchase of a Woodchuck heating appliance. Undoubtedly you have given much consideration to your purchase and we’re proud that you have selected a Woodchuck. Pride in craftsmanship and engineering have made your Woodchuck the finest heating appliance available today.
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 convenience 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.
We are constantly improving and updating our product in order to provide the highest quality and value possible. Consequently pictures might sometimes differ 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.
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TABLE OF CONTENTS |
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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.
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 Embers Do Not Burn Out.
THERE ARE ADDITIONAL HAZARDS ASSOCIATED WITH IMPROPER INSTALLATION OF WOOD/COAL FURNACES 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:
Equipment Must Be Installed By A Qualified Heating Person.
Only “class A” All-fuel Or Solid Fuel Chimneys Intended Foe Use With Your Woodchuck Should Be Used.
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, |
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1-M ETLM |
Firebox Chamber |
6.10 cu. ft. |
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MODEL 2900 |
MODEL 4000 |
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, |
|
1-M ETLM |
Firebox Chamber |
9.10 cu. ft. |
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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 setting, 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 massive 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 provide for durability and help promote efficient combustion 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 follow all instructions.
EFFICIENCY
The total efficiency of a unit is broken down into combustion efficiency and transfer efficiency. We know that when woodburning, 20% of it burns as fixed carbon. 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 reverse the ratio depending on the fuel being used. Combustion air must be warm when it enters the firebox 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 firebox 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 combustion air. A lever on the front of Models 2900/4000 allows 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 turbulence and causes the oxygen to mix thoroughly with the gases for complete combustion.
Finally, Woodchuck Model 2900/4000 furnaces are designed to accept a catalytic combustor. This device will cause the small amount of unburned fuel to ignite before entering the secondary heat exchanger. The benefits 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.
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 efficiency of your home.
On a furnace with a conventional single speed blower, the speed of the blower is a compromise between comfort and efficiency. If the blower has a large enough capacity to heat the home in the coldest 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
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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 comfortable. 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 installation. In addition, when the weather is mild and the furnace 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.
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
more comfortable and lose less heat through your ceilings 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 stratify; warm air rising to the upper levels and cool air collecting 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 your domestic water free of charge during the heating season for additional saving to you.
WASTED HEAT
ZONE
82° THERMOSTAT
COMFORT ZONE
74°
DISCOMFORT ZONE
60°
FIGURE 1
75° THERMOSTAT
74°
73°
FIGURE 2
UNCOMFORTABLY HOT
UNCOMFORTABLY COLD
FIGURE 3
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 guarantee 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 damaged 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.
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 RESULT 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 COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES.
INSPECT AND CLEAN FLUES AND CHIMNEY REGULARLY.
UNDER CERTAIN CONDITIONS OF USE, CREOSOTE BUILDUP MAY OCCUR RAPIDLY.
WAIT 10 SEC. ON FIRST LATCH BEFORE REFUELING.
LOAD FUEL CAREFULLY OR DAMAGE MAY RESULT.
! IF YOU HAVE CHIMNEY FIRE !
Meyer Mfg. Corp. recommends the following actions:
1. Shut any doors and air inlet dampers and draft control. This should take no longer than a few seconds.
CLOSED
2. Alert everyone in the house.
3. Call the fire department.
MANUAL DRAFT
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.
! 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:
1. Locate all heating duct dampers (not smoke pipe damper), if any, to open position. CLOSED
2. Turn manual draft controls to this position.
Ash door should never be used |
MANUAL DRAFT |
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in power failure. |
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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 preset.
In the event of a runaway fire, close all drafts. Close smoke damper halfway.
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DOUBLE LATCH |
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COMFORT |
LOADING DOOR |
COMFORT |
HEAT EXCHANGER |
CONTROL CENTER |
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CONTROL ROD |
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CONTROL CENTER |
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SHAKER |
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GRATE |
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FAN/LIMIT |
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FAN/LIMIT |
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DOUBLE LATCH |
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LOADING DOOR |
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DRAFT CHANNEL |
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MANUAL DRAFT |
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SELECTOR - 80/20 |
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(Forced Draft Is |
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COMBUSTION AIR |
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Optional) |
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RATIO CONTROL |
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MODEL 526 |
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MODELS |
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2900/4000 |
ASH DOOR |
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ASH DOOR |
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FORCED DRAFT |
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SHAKER GRATE CRANK. |
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BLOWER |
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SHAKER GRATES ARE OPTIONAL |
FIGURE 5 WOODCHUCK CONTROLS
CIRCULATING
BLOWER
DRAFT BLOWER |
DRAFT BLOWER |
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MANUAL SWITCH |
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LO-LIMIT BYPASS |
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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 automatic 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 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 paper 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 according to your needs also.
NOTE: On airtight units, the burning time is controlled mostly by the draft controls on the furnace, contrary to
9
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 furnace or open all drafts fully until you have become thoroughly 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 FIREBOX. WHEN THE DOOR IS OPEN, OXYGEN IS COMBINED 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 efficiency when you add only the amount of wood needed for a 6 to 8 hour burn.
In the spring and fall, the weather is mild, which will allow you to burn very large loads of wood for long periods 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 temperature thermometer (Woodchuck part #08-0084) is included 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.
CAUTION
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.
PROVEN FACTSMALL 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.
10
BURNING COAL IN YOUR WOODCHUCK
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.
CAUTION:
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 ignited, adjust the drafts accordingly. Check the fire periodically to 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 recharging, fresh coal tends to give off large quantities of volatile gas. This gas may accumulate and possibly ignite 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 supply 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. Approximately 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 should be removed with gloves or tongs, and as always, put into a metallic air-tight container.
BITUMINOUS RECHARGING
Because bituminous coal has a higher percent of sulphur 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 operation 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 air needed.
5.Coal not sized to furnace. We recommend 1" to 3" diameter 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.
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