A-Maize-Ing Heat LDJ991 Installation And Owner'S Manual Download

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Boiler Installation and Owners Manual

LDJ991_E01_R03_2006.03

Models LDJ991 and LDJ991-10

I R I N G

I A G R A M

: L D J 9 9 1 1 0 0 , 0 0 0 B T U B

O I L E R

120V

24V

Transformer

Combustion

Blower Motor

120V

NEUTRAL

120V

HOT

Fuse

10A

Disconnect

(Installed By Others)

Toggle Switch

START

OFF

RUN

START

OFF

RUN

H-BK

Boiler Control Box

210°F

High Limit

Switch

Low Limit

Switch

Closes on
temp. rise

RED

Burner Relay (HR)

Relay

BLUE

Low Fire

Timer/Relay (LF)

timer

1,8

3,6

Thermostat

connections

Aquastat Relay

BLUE

Furnace Auger

Motor

Bin Auger

Motor

Summary of Contents for LDJ991

Page 1: ...Boiler Installation and Owners Manual Model LDJ991 Boiler Model LDJ991 10 Boiler Model 14 Bin LDJ991_E01_R03_2006 03 ...

Page 2: ... the latest information available at the time of publication Your boiler may have product improvements and options not yet contained in this manual LDJ Manufacturing Inc reserves the right to make changes at any time without notice or obligation Additional copies of these instructions are available from LDJ Manufacturing Inc No part of this manual may be reproduced in any form or by any means elec...

Page 3: ... Controls 7 Installation 7 Required Tools 7 Unpacking and Setup Boiler 7 Unpacking and Setup Storage Bin 8 Plumbing 9 Chimney Vent 9 Barometric Draft Control 9 Draft Guage 9 Electrical Connections 11 Electrical Supply 11 Thermostat 11 Low Limit Switch 11 Operation 12 Burner Lighting 12 Draft Adjustment 14 Boiler Operation 14 Typical Operation Cycle 14 Clinker Buildup 14 Power Failure Instructions ...

Page 4: ...eck 19 Poor Combustion 20 Inefficient Operation and or Operating Too Hot 21 Mechanical Electrical 22 Wiring Diagram LDJ991 100 000 BTU Boiler 23 Wiring Diagram LDJ991 10 165 000 BTU Variable Rate Boiler 24 Repair Parts 25 Burn Pot Auger 25 Hopper Bin Auger 26 Storage Bin Model 14 27 Boiler Electrical 28 Addendum 29 Venting Information 29 Barometric Draft Control Information 31 ...

Page 5: ...se of the A MAIZE ING HEAT boiler or any alleged defect in design manufacture assembly instructions or labeling thereof WELCOME TO THE A MAIZING HEAT BOILER Congratulations on your purchase of the A MAIZE ING HEAT biomass fueled boiler We are honored that you selected the A MAIZE ING HEAT boiler The A MAIZE ING HEAT boiler is the first biomass fired boiler to be listed by Underwriters Laboratories...

Page 6: ...for efficiency and safe operation refer to page page 17 Have a qualified service person perform tasks you are not familiar with Children and adults should be alerted to potential high service temperatures of the burner door KEEP CHILDREN AWAY Risk of fire or explosion Do not burn gasoline oil garbage or other flammable substances Do not burn treated corn Treatment chemicals can be unknown and thei...

Page 7: ...he boiler may be to a combustable surface top 32 either side 6 front 30 back cabinet surface 6 flue connector on back 18 For ease of service the following minimum distances are recommended top 32 side opposite bin 24 front 36 rear most surface on back boiler or flue 18 The overall dimensions of the A MAIZE ING HEAT boiler are as follows boiler cabinet width 22 boiler cabinet depth with door 36 boi...

Page 8: ...y of fresh air into the appliance so that proper combustion is possible Important Installation Points The connection from the heating appliance to the chimney must be made using 6 black pipe Avoid using more than two elbows in connecting the boiler to the chimney Any horizontal runs of connector pipe should have a minimum rise of 1 4 per foot of run to allow condensation to flow back to the firebo...

Page 9: ...e proper chimney draft will be discussed in the Installation section starting on page 7 For more information on the barometric draft regulator refer to Barometric Draft Control Information on page 31 INSTALLATION Required Tools Flat bit screwdrivers Phillips screwdriver 5 16 hex driver 3 8 hex driver 7 16 wrench 7 16 socket Drill and 1 4 bit Unpacking and Setup Boiler IMPORTANT Before unpacking an...

Page 10: ...amp securely Step 5 Install two sheet metals screws through clamp auger boot and into the bin outlet for a permanent connection Step 6 Install coupler 8 between bin auger tube and boiler fuel inlet Secure with two hose clamps 9 Step 7 Attach flexible conduit 10 from bin auger to boiler auger motor housing 11 with a conduit locknut Step 8 Connect one black bin auger motor wire to the two orange wir...

Page 11: ...nd Venting Information on page 29 for additional information Step 2 Make sure the boiler and storage bin are correctly placed Refer to Boiler Clearances and Accessibility on page 5 for proper clearance dimensions Step 3 Connect boiler to chimney with 6 metal flue pipe using sheet metal screws to secure refer to Venting on page 6 Barometric Draft Control Install the baromatric draft control accordi...

Page 12: ...onnected Step 9 At the opposite end of the double tubing split the two individual hoses apart for about 1 1 2 Step 10 At the top of the unit connect the hoses to it Connect the all white hose to the port marked HIGH 6 Connect the white hose with the red line to the port marked LOW 7 Step 11 Turn the ZERO SET 8 knob counter clockwise 2 to 3 turns Step 12 Loosen and remove the FILL 9 plug Step 13 Op...

Page 13: ...th the National Electrical Code If unfamiliar with wiring and codes have a licensed electrician perform the electrical connection The electrical supply to the boiler should be from a 120V 15 amp protected circuit Make all connections inside box 1 Black wire to black wire White wire to white wire Ground wire green to ground terminal Thermostat A thermostat is not included with the A MAIZE ING HEAT ...

Page 14: ...more time The powdered graphite will lubricate the storage bin auger until it begins to polish from the flow of corn pellets This operation should be repeated at the beginning of each heating season This operation should also be repeated if the hopper is allowed to run empty and a sticky smoke film coats the storage bin auger tube Powdered graphite may also be added about once a month at a time wh...

Page 15: ...h 4 to START This will start the burner blower only the auger motors will not turn until the boiler has reached operating temperature Keep the switch in the START position for 5 to 10 minutes or until you see a good even fire Step 7 With the fire 5 well started move the START OFF ON switch to ON Step 8 Set wall thermostat to desired temperature Step 9 If the corn pellets do not completely ignite i...

Page 16: ...ivates the Aquastat relay to turn on hot water circulation pump Step 2 If the water temperature is too cool the fuel feed system is activated The combustion fan starts and the augers feed fuel into the burner HIGH FIRE Step 3 The water heats up in the boiler until the Aquastat relay reaches set point the fuel feed system then stops Step 4 If the thermostat setting is satisfied the Aquastat relay w...

Page 17: ...of the combustion blower controls fuel air mixture during high fire only Only adjust this opening when the combustion blower is running Its adjustment should yield an intense fire that consumes the fuel at the same rate it is augered in LOW FIRE Adjustment The rate of burn during low fire operation is controlled by the amount of chimney draft Chimney draft must remain below 0 06 water column inche...

Page 18: ...Contact LDJ Manufacturing for settings for other fuels pellets etc The green arrow indicates the number of seconds the timer is OFF 1 5 15 seconds and the red arrow indicates the number of seconds the timer is ON IMPORTANT When adjusting the boiler always start with the settings for 100 000 BTU output and then make further adjustments after the boiler has run for thirty minutes 2 BTU Output Green ...

Page 19: ...l Supply Check level of corn pellets in storage bin 2 Refill as necessary to maintain an adequate supply Weekly Maintenance Check Ash Drawer Check ash drawer 3 and empty as needed 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 dispo...

Page 20: ...more easily performed through door 5 with heat plate 6 removed Use the flue cleaning brush supplied to clean out the 15 flue tubes Annual Maintenance Inspect Chimney Pipe Remove and inspect all chimney pipe connections Clean out ash buildup in pipes Replace any pipe showing any signs of burning through Inspect Motors Clean oil and inspect all blower auger and pump motors This includes the burner f...

Page 21: ...s supplied Refer to the tables below for detailed troubleshooting Initial Setup Quick Check Operation Quick Check Problem Possible Causes Fire won t start Initial startup may require use of kindling wood two or three times before the corn begins to burn completely Chimney draft too high On tall or large chimneys a second barometric regulator may be required or it may be necessary to reduce the out...

Page 22: ... if chimney draft is sufficient 60 cubic feet per minute minimum of fresh air is required Clinker build up Burning the wrong type or quality of corn or pellets can cause excess clinker buildup due to extra materials and fire extinguish ing effect Improper installation causing the boiler to run on high fire for an extended period can also result in clinker formation Loosen clinkers manually with a ...

Page 23: ...ster than the corn can be sup plied Chimney draft should never exceed 0 06 inches water column draft Verify correct installation install second barometric regulator if necessary refer to Barometric Draft Control Information on page 31 Boiler keeps opening high limit switch System not full of water and not at normal operating pressure Check for cause of water leakage and loss of operating pressure ...

Page 24: ...t Switch Verify power to high limit switch Verify high limit switch is closed when boiler is cool Combustion fan will operate but boiler auger and bin auger do not operate Variable input timer defective Check variable input timer Low limit switch defective Check low limit switch Defective heat relay or no HEAT signal from thermostat or defective 24V trans former Verify that transformer is okay Ver...

Page 25: ...20V HOT Fuse 10A Disconnect Installed By Others Toggle Switch START OFF RUN START OFF RUN BK H BK H BK WH WH Boiler Control Box 210 F High Limit Switch Low Limit Switch Closes on temp rise RED RED BK Burner Relay HR NO NC Relay BLUE OR 4 5 2 OR 1 3 Low Fire Timer Relay LF 7 2 timer NC NO 1 8 3 6 Thermostat connections T T Aquastat Relay L1 L2 B2 B1 BLUE OR M Furnace Auger Motor M Bin Auger Motor O...

Page 26: ...nnect Installed By Others Toggle Switch START OFF RUN START OFF RUN BK H BK H BK WH WH Boiler Control Box 210 F High Limit Switch Low Limit Switch Closes on temp rise RED RED BK Burner Relay HR NO NC Relay BLUE OR 4 5 2 OR 1 3 Low Fire Timer Relay LF 7 2 timer NC NO 1 8 3 6 High Fire Timer Relay HF 7 2 timer NC NO 1 8 3 6 OR M Furnace Auger Motor M Bin Auger Motor OR WH Thermostat connections T T ...

Page 27: ...rt Number Part Description Quantity Used LDJ991 LDJ991 10 1 1900 Burn Pot Auger Motor 4 rpm 1 1 2000 Burn Pot Auger Motor 6 rpm 1 2 3180 Lock Collar 1 1 3 1980 Bolt 1 4 x 1 2 Self Tapping 1 1 4 3200 Burn Pot Auger Flighting 1 1 5 2070 Screw Sheet Metal 10 x 1 3 4 2 2 6 3000 Auger Support 1 1 7 1410 6 x 6 Box 1 1 1 2 3 4 5 6 7 5 ...

Page 28: ...tity Used LDJ991 LDJ991 10 1 A 3220 Bin Auger Flighting 1 1 2 3180 Lock Collar 1 1 3 1880 Bin Auger Motor 2 rpm 1 3 1900 Bin Auger Motor 4 rpm 1 4 1410 6 x 6 Box 1 1 5 A 3070 Auger Support 1 1 6 5000 Lag Bolt 1 4 x 1 2 2 7 7530 Rubber Tee 1 1 8 A 7540 Bin Auger Tube 1 1 9 1480 Conduit Fitting 1 1 10 A 1550 Flex Conduit 1 1 1 2 3 4 5 6 7 8 9 10 6 ...

Page 29: ...al 27 LDJ991_E01_R03_2006 03 Models LDJ991 and LDJ991 10 Storage Bin Model 14 Ref Part Number Part Description Quantity Used LDJ620 9 LDJ620 10 1 7520 Bin Lid 1 1 2 7500 Bin Cavity 1 1 3 7510 Bin Base 1 1 4 7520 Shutoff Valve 1 1 1 2 3 4 ...

Page 30: ... LDJ991 LDJ991 10 1 1610 Varible BTU Timer inside box 1 2 1630 Aquastat Relay inside box 1 1 3 1642 Pressure Temperature Gauge 1 1 4 1645 Pressure Relief Valve 1 1 5 1660 Low Limit Switch chimney vent temperature 1 1 6 1636 High Limit Control 1 1 7 1680 START OFF ON Switch 1 1 8 1620 Low Fire Timer inside box 1 1 9 1860 Combustion Fan 1 1 1 2 3 4 5 6 7 8 9 ...

Page 31: ...Boiler Installation and Owners Manual 29 LDJ991_E01_R03_2006 03 Models LDJ991 and LDJ991 10 ADDENDUM Venting Information ...

Page 32: ...Boiler Installation and Owners Manual 30 LDJ991_E01_R03_2006 03 Models LDJ991 and LDJ991 10 ...

Page 33: ...e less than indicated for proper operation See Figure 2 and Table 1 COLLAR INSTALLATION WHEN SHIPPED WITH A COLLAR To attach the collar to the flue see Figure 2 and follow the instructions as follows 1 Bend the two ears at the front corners of the collar outward Bend 90 behind the single hole on the straps 2 Insert clamping screw in ears on collar and bolt the remainder of the collar together 3 Ho...

Page 34: ...s in flue adjacent to control NOT over fire drafts OIL BURNER COMBUSTION AIR AND OVERFIRE DRAFT SETTING INCHES OF W C After the burner has operated for at least 5 to 10 minutes take draft readings over the fire For a domestic oil burner the over fire draft should be approximately 02 to 03 although there are some makes of burners which require higher drafts Follow the burner manufacturer installati...

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