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WOODMASTER OUTDOOR FURNACES • OWNER'S MANUAL

Existing Hot Water Heat

A Water-to-Water Heat Transfer Unit (0020-052) is used to connect to an

existing hot water boiler system.

NOTE: Any changes that are made to an existing boiler should be done by a qualified

plumber and follow all state and local codes .

Cold Water Return to

Outdoor Furnace

Existing Heat Zone

Return

Existing Hot Water

Boiler

Hot Water Supply from

Outdoor Furnace

Water-to-Water Heat

Transfer Unit

Circulating Pump for

Existing Hot Water

Heating System

Existing Forced Air

A water-to-air heat exchanger is inserted in the existing plenum. In most

cases the heat exchanger is placed in a horizontal position, keeping all

four sides level. The air must be forced through the finned area of the heat

exchanger evenly. The hot water line coming from the hot water tube enters

the bottom fitting of the heat exchanger and exits the top fitting, which

returns to the furnace. If the plenum is too large or too small, it must be

altered to fit the heat exchanger properly.

NOTE: The water-to-air heat exchanger must be installed below any existing off-peak

electric coils already in the plenum .

After the installation of the add-on water to air exchanger, the air flow may

need to be increased to fuel furnaces, electric furnaces, and electric/gas

furnaces. Methods of doing this are:

Belt Drive System - Blower pulleys and motor pulleys may be changed

but the electric current flowing through the motor shall not exceed the

nameplate rating. A blower motor or larger power may be used.

Direct Drive System - The motor shall not be changed, however the speed of

the motor may be increased.

CAUTION

All wiring must follow state and local codes and should be done by a qualified

electrician . Wire thermostats according to directions provided by the manufacturer .

Cold Water Return

to Outdoor Furnace

Hot Water Supply from

Outdoor Furnace

(always put supply in

lower port)

The heat exchanger works on

the same principal as your car

heater. Air blows through the heat

exchanger, taking the heat from

the water and blowing it into your

existing duct work.

Summary of Contents for 3300

Page 1: ...TDOOR WOOD FURNACE 3300 4400 HEAVY DUTY 5500 HEAVY DUTY 6500 HEAVY DUTY Retain this manual Conserver ce manuel WoodMaster com IN THE U S THIS APPLIANCE IS FOR NON RESIDENTIAL APPLICATIONS ONLY p n 9000804 REV A AUG 2020 ...

Page 2: ...our authorized WoodMaster dealer or heating contractor Record the information below for future reference Model Serial Number Installation Date Dealership Name Phone Number Owner Name WoodMaster Inc 600 Polk Ave SW Red Lake Falls MN 56750 WoodMaster com ...

Page 3: ...ng 11 Inline Filter and Fill Valve Assembly 11 Furnace Installation Connecting to Your Existing System 11 Domestic Hot Water 11 Existing Hot Water Heat 12 Existing Forced Air 12 Optional Auger Assembly 13 Water Quality And Maintenance 14 Test Supply Water 14 Adding Initial Water Treatment 14 Filling with Water 15 Bleeding the System 15 Immediately Heat the System Water to 170 F 76 C 15 Test the Tr...

Page 4: ...ehold garbage material treated with petroleum products particle board railroad ties and pressure treated wood leaves and cardboard Paper products should only be used when firing your furnace 3 LOADING FUEL For a more efficient burn pay careful attention to loading times and amounts Follow the manufacturer s written instructions for recommended loading times and amounts 4 STARTERS Do not use lighte...

Page 5: ...ndicate the presence of a hazard which can cause severe personal injury or death to an operator or bystander or substantial property damage if ignored CAUTION This symbol and text indicate the presence of a hazard which can cause minor personal injury or property damage if ignored NOTE Indicates supplementary information worthy of particular attention relating to installation operation or maintena...

Page 6: ...ectly behind the chimney on top of the furnace CAUTION The WoodMaster is designed for outdoor use We do not recommend installing in a building CAUTION Manufacturer recommends a minimum 25 foot clearance from buildings or fire hazards If placed near a fire hazard area an approved spark arrester should be used CAUTION Only responsible adults should operate your furnace If furnace is not fired proper...

Page 7: ...la cheminée en haut de foyer PRECAUTIONS A PRENDRE Le WoodMaster a été concue pour être utilisé a l extérieure Nous ne recommandons pas qu il soit installé a l intérieure d un batiment PRECAUTIONS A PRENDRE Il est recommandé par le fabricant qu une distance minimal de 25 piéds entre le foyer et tout batiments ou zone inflammable Si placé à proximité d une zone inflammable une barièrre anti étincel...

Page 8: ... Utility Light Baffle Bypass ETC System Electronic Temperature Control Draft Fan Assembly Inside Shroud Heat Baffle Instructions Optional Ash Auger Port Operating Instructions Rear Panel 4400 Shown Cold Water Return Valve Cold Water Return Valve Hot Water Supply Valve Hot Water Supply Valve Main Power Junction Box Furnace Drain ...

Page 9: ...ted the lower the cost will be for the installation of the hot supply and return water lines and ThermoPEX insulation Be sure to maintain the required clearances to combustibles and recommended maintenance clearances ThermoPEX pre insulated piping is recommended for all installations Other types of insulated pipe configurations may result in high heat loss and increased wood consumption If the gro...

Page 10: ...e that may be caused by an occurrence outside the outdoor furnace enclosure Foundations may consist of concrete crushed rock or patio blocks Do not use any combustible materials for the foundation CAUTION Outdoor furnace must be installed on a noncombustible surface or foundation that incorporates an enclosure that will prevent supply and return lines from possible exposure to sunlight fire or phy...

Page 11: ... that the incoming fuse or circuit breaker not exceed 15 amps ThermoPEX Advantage ThermoPEX is flexible pre insulated piping that is ideal for use with outdoor wood furnaces ThermoPEX consists of two 1 inch oxygen barrier PEX lines two 1 1 4 inch oxygen barrier PEX lines or two 25mm oxygen barrier PEX lines a supply and a return line The lines are insulated with high density urethane insulation an...

Page 12: ...on NOTE If it is unavoidable that the trench will run through an area of ponding water use ThermoPEX instead of other materials ThermoPEX should also be used for above ground or winter installations and if the area is likely to be affected by compaction Temporary Above Ground or Winter Installations For temporary above ground or winter installations in which the supply and return lines can not imm...

Page 13: ...en bolt the pump to the flange Make sure the arrow on the pump indicating direction of water flow points down 3 Bolt the remaining Flange and Gasket to the bottom of the Pump NOTE Make sure that the pump is attached to the supply line not the return CAUTION The pump must run continuously whenever the WoodMaster furnace is in use It cannot be wired to thermostats that only run the pump when the bui...

Page 14: ...A 1 male Sharkbite Adapter 0020 510 may be substituted for the 1324 and 1335 fittings Wiring the Pump 1 Remove the cover on the pump 2 Using an approved wire connect the ground wire to the green ground screw on the pump 3 Connect the black wire to the yellow wire on the pump 4 Connect the remaining two white wires together and replace the pump cover 5 Locate junction box on back of furnace and rem...

Page 15: ...ed so that a garden hose can be connected between a domestic water supply and the fill valve Cold Water Return from Heat Exchanger Cold Water Return to Outdoor Furnace Domestic Water Supply for Filling Boiler Furnace Installation Connecting to Your Existing System A common installation is to connect the outdoor furnace to an existing water heater and then to an existing forced air system NOTE Ther...

Page 16: ...num is too large or too small it must be altered to fit the heat exchanger properly NOTE The water to air heat exchanger must be installed below any existing off peak electric coils already in the plenum After the installation of the add on water to air exchanger the air flow may need to be increased to fuel furnaces electric furnaces and electric gas furnaces Methods of doing this are Belt Drive ...

Page 17: ... and align the center auger shaft with the hole in the auger cap The auger cap should completely slide on the tube If this does not happen the center auger is not all the way on the stub shaft Rotate auger while pushing in to ensure the cap and auger are installed properly Tighten the auger cap 3 Insert the grate and place over the top of the auger carriage NOTE The ash auger and grate must be rem...

Page 18: ...d there are no other known water quality problems then the outdoor furnace may be filled with this water 4 Water that has a pH level of less than 6 5 or greater than 8 0 or that has other known water quality problems should not be used to fill the furnace Instead water should be supplied from a different source Adding Initial Water Treatment CAUTION Avoid damaging your furnace and voiding your war...

Page 19: ...eezing and breaking If furnace is powered the water level light on the controller can be used to aid with filling Routinely pay attention to the water level light If the light is not lit this indicates that the water level is low and the furnace may need to have water added Add water until it flows out of the vent pipe CAUTION Air in the water lines can cause damage to the pump Bleeding the System...

Page 20: ...of the furnace Before collecting the sample open the valve and drain about a quart of water then carefully fill the sample container without contaminating the sample Be sure to properly close the valve when finished 2 Dip a pH test strip from the test kit in the water sample Shake excess water off the test strip Compare the color of the test strip to the chart provided to determine pH level The pH...

Page 21: ...xed with inhibitors MolyArmor 350 is compatible with raw propylene glycol It is important to use MolyArmor 350 with straight propylene glycol for corrosion protection If adding antifreeze to the system it is imperative that the entire system contain at least 30 antifreeze concentration mixed with softened reverse osmosis or deionized water to prevent bacterial growth and minimize minerals in the s...

Page 22: ... are too large can reduce output capacity because they burn slower Seasoned wood burns more efficiently minimizes the amount of creosote formation and reduces emissions Maintain a quantity of smaller drier pieces of wood for relighting the fire if the wood load is burned very low or becomes completely empty Green wood contains about 50 moisture by weight Energy is required to heat the wood and eva...

Page 23: ...degrees the furnace is ready to be filled to capacity to operate for a 12 hour period Load wood towards the back of the furnace for improved efficiency WoodMaster recommends burning cut split and seasoned wood Do not overfill so that hot coals fall out of the furnace when opening the fuel door During periods of warmer weather you may find it to have creosote inside the firebox It is important to f...

Page 24: ... This will allow air from the draft fan to circulate properly creating the optimum burn environment Keep your face away and stay as far away as possible from the firebox door area when opening the door Load the back of the furnace first stacking the wood lengthwise in the fire box After the rear is loaded fill the front of the furnace in the same fashion Be mindful of the latch on the door when yo...

Page 25: ...l y S e m i A n n u a l l y P o s t S e a s o n M 2 M 2 M 5 M 4 M 3 M 1 M 1 Refer to Water Quality and Maintenance A A A A C B Check pH and moly levels of water Check water level Completely remove ash Remove ash Inspect chimney door vent seals Inspect chimney and chimney connector for creosote Clean out Baffle Bypass Stir ash and pull hot coals to front of firebox Scrape bottom of firebox B C C ...

Page 26: ...firebox maintenance is essential to the longevity of the outdoor furnace CAUTION Do not burn plastic garbage treated wood or fuels not listed for this outdoor furnace NOTE Chloride or sulfurous gases can be generated if plastic or rubber is burned and will mix with the moisture from the wood to form hydrochloric or sulfuric acids in the firebox creating corrosion MAINTENANCE SECTIONS M 1 Ash Rotat...

Page 27: ... rake to pull the ashes from the rear of the furnace to create a level bed of hot coals The ashes should be placed in a metal container with a tight fitting lid The closed container of ashes should be placed on a noncombustible floor or on the ground and well away from all combustible materials pending final disposal Ashes should be retained in the closed container until all of the cinders have th...

Page 28: ... metal in a very short time CAUTION Corrosion in the firebox is not a workmanship defect Warranty does not cover firebox corrosion Neglecting to clean your furnace or cover the chimney when not in use will void your warranty When the furnace is in use be sure that you maintain a good ash rotation This should be done weekly If you are using a spark arrester or a chimney cap you will need to provide...

Page 29: ... the firebox door slightly ajar If smoke seems very restricted remove the firewood and hot coals then check the chimney top and bottom and behind the baffle for obstructions 7 Building s poorly insulated or uninsulated Poorly insulated or uninsulated buildings buildings with uninsulated or poorly insulated ceilings or a lack of proper insulation under radiant flooring can cause excessive fuel cons...

Page 30: ...aterleveltoensurethatyourfurnace is full 3 Water is not circulating The pump should run continuously and water needs to circulate continuously through the supply and return lines to keep water temperature uniform in the outdoor furnace 4 Circulation valve s closed Be sure the proper valves in the system are open to allow circulation 5 In extremely warm weather a smaller amount of wood should be us...

Page 31: ...tall extension is added to the chimney the increased draw through the draft may cause excessive wood consumption Decreasing the draft opening may increase efficiency and reduce wood consumption 5 Supply and return line heat loss If supply and return lines are buried in a wet low lying area there may be a large heat loss which would greatly increase wood consumption 5 High heat demand Concrete slab...

Page 32: ...the weekend wood firing furnace runs out of wood and back up system takes over To restart the WoodMaster simply push the Set Button Start Up Reset The first time the WoodMaster is powered up or when it has shutdown the controller display will flash LA Low Alarm two times and then display the water temperature for two seconds and then start over This is normal and indicates the system has shut down...

Page 33: ...y or ALL push the set key once value of parameter should be displayed use arrows to change value and push the set key value should flash a few times After 10 15 seconds the display will change back to water temperature Green Float Light Green light ON Water level OK Green light OFF Water level low add water through vent pipe or follow fill valve instructions if system is installed with an indoor f...

Page 34: ...loads and the power supply are separated and far enough from each other without crossing or intertwining 2 GENERAL DESCRIPTION The ETC is designed to control the furnace temperatures between the parameters that are selected by the operator 3 CONTROLLING LOADS 3 1THE REGULATION OUTPUT The regulation is performed according to the temperature measured by the probe When the appropriate temperature SP ...

Page 35: ...browses the parameter codes or increases the displayed value DOWN To see the last temperature alarm that occurred in programming mode it browses the parameter codes or decreases the displayed value KEY COMBINATIONS UP DOWN To lock unlock the keyboard SET DOWN To enter in programming mode SET UP To return to the temperature display 4 1 USE OF LEDS Each LED function is described in the following tab...

Page 36: ...n h mm 3 Then the instrument displays the temperature once again NOTE1 if an alarm is still occurring the tim shows the partial duration NOTE2 the alarm is recorded when the temperature comes back to normal values 5 2 HOWTO RESET A RECORDED ALARM OR ONETHAT IS STILL OCCURRING 1 Hold the SET key pressed for more than 3s while the recorded alarm is displayed the rSt message will be displayed 2 To co...

Page 37: ...Press SET to store the new value and move to the following parameter To exit Press SET UP or wait 15s without pressing a key NOTE the set value is stored even when the procedure is exited by waiting for the time out to expire 6 4 HOWTO LOCKTHE KEYBOARD 1 Keep pressed for more than 3s the UP and DOWN keys 2 The POF message will be displayed and the keyboard will be locked At this point it will be p...

Page 38: ... 8 ALARM SIGNALS Message Cause Outputs LA Minimum temperature alarm Outputs unchanged 8 1 ALARM RECOVERY Probe alarm P1 starts some seconds after the fault in the related probe it automatically stops some seconds after the probe restarts normal operation Check connections before replacing the probe Temperature alarms HA and LA automatically stop as soon as the thermostat temperature returns to nor...

Page 39: ...LL from the previous step press the set button The number that appears is the Low Alarm temperature 2 To adjust the number press the up or down arrow 3 Press the Set button to lock in the setting Definitions Set Point The temperature at which the fan will shut down until hysteresis is achieved Hy aka Differential The amount in degrees the temperature has to drop in order to start the fan ALL aka L...

Page 40: ... BLACK BLACK BLACK BLACK 14 SENSOR BROWN 15 SENSOR BLUE 2 BLOWER ORG 12 SNAP DISC JUMPER ORG 1 HOT BLK 8 FLOAT HOT BLK 4 NEUTRAL WHT 5 JUMPER WHT 6 JUMPER WHT 9 FLOAT PNK 3 LIGHT RED 11 SNAP DISC ORG PINK BROWN BLUE BROWN BLUE PINK WHITE WHITE WHITE WHITE WHITE WIRE GROUND WIRE ATTACH TO BOX MAIN POWER SUPPLY INLET ENCLOSED IN JUNCTION BOX JUNCTION BOX FLOAT THERMISTOR PROBE WIRE SAME AS BLOWER 1 ...

Page 41: ... 2 000 sq ft 5 000 sq ft 10 000 sq ft 20 000 sq ft Firebox Dimensions 24 x 32 38 x 44 50 x 56 60 x 58 Weight filled with water 2 292 lbs 2 784 lbs 4 450 lbs 7 789 lbs Loading Door Opening Outside Dimensions 20 x 21 24 x 24 27 x 27 44 x 31 Amp draw may vary depending on the revision of your furnace and external devices attached to your furnace Maximum Amp Draw can only occur when all devices are op...

Page 42: ...38 WOODMASTER OUTDOOR FURNACES OWNER S MANUAL Notes ...

Page 43: ...is installed and operated as defined in the Owner s Manual Your dealer may charge you for a service call to do warranty work Parts will be replaced on an even exchange basis WoodMaster furnaces are not intended to be the only source of heat therefore a backup system should be in place to prevent any damage caused by lack of heat Damage caused by abuse accidents improper installation overheating co...

Page 44: ...Printed in U S A 2020 WoodMaster p n 9000804 REV A AUG 2020 ...

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