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Ultra Owners Manual

2015

Table of

Contents

Terms ....................................................................................

3

Safety .................................................................................

4-5

Technical Features .................................................................

6

Fuels .....................................................................................

7

Installation .......................................................................8-20
Operation ....................................................................... 21-24
Maintenance .................................................................. 25-33
Troubleshooting ..................................................................

34

Wiring Diagram ..............................................................

35-36

Warranty ........................................................................ 37-40
Specifications ......................................................................

41

Notes ............................................................................. 42-43

Thank you for purchasing a qual-

ity Ultra Series Pellet Furnace from

WoodMaster. This product was de-

signed to deliver easy, trouble free

operation for years to come. Check

out other WoodMaster heating

products at www.woodmaster.com,

or our line of quality pellet grills at

www.woodmasterpelletgrills.com.

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Summary of Contents for Ultra Series

Page 1: ...novator Pellet Burner Pellet Furnace WOODMASTER ULTRA SERIES Retain this manual Northwest Manufacturing Inc 600 Polk Ave SW Red Lake Falls MN 56750 www woodmaster com 800 932 3629 Manual PN 7994 875 Rev 5 1 Software V22 ...

Page 2: ...Wiring Diagram 35 36 Warranty 37 40 Specifications 41 Notes 42 43 Thank you for purchasing a qual ity Ultra Series Pellet Furnace from WoodMaster This product was de signed to deliver easy trouble free operation for years to come Check out other WoodMaster heating products at www woodmaster com or our line of quality pellet grills at www woodmasterpelletgrills com ...

Page 3: ...rner Testo 327 310 or 320 End Stop Replaceable plate at the end of the burn pot that prevents the pellets from falling off the burn pot Flame Guard A guard that prevents the flame from going up the intake chute Igniter A heating element that automatically ignites the pellets Tipping Chute The fuel inlet pipe on the Renovator Combustion Fan The fan that controls the air flow for combustion Temp Sen...

Page 4: ... children to play near or tamper with the burner fuels fuel tank or any other part of the system Always keep the area around and in front of the system clean and free from combustible materials Keep animals away from the system The operation may not be continued or restarted in the event of visible damages for example thermal distortion traces of smoke or fire mechanical damages etc Any damages mu...

Page 5: ...arts and install them They can then reevaluate the system and provide a flue gas analy sis Failure to perform a flue gas analysis may void your warranty Emission Standards Visit the EPA Burnwise website http www epa gov burnwise index html for information on wood fuel fired appliances as well as a list of approved appliances Safety Standards Guardian info Solid Fuel Burner System Listed by Guardia...

Page 6: ...ation for ease of wiring Safety tested by Guardian to meet or exceed their standards for product quality safety Benefits of the Ultra Series 1 High eﬃciency Renovator burner with automatic ignition 2 Easy access ash door in front for quick and easy ash maintenance 3 Large ash box for longer intervals between cleaning 4 Eﬃcent heat transfer tubes 5 Rear access door that the burner mounts to 6 Easy ...

Page 7: ...aster for any questions on fuel use Pellet Specifications Only premium wood pellets certified by the Pellet Fuels Institute may be used and must follow these guidelines Bulk density per cubic foot must be a minimum of 40 pounds The diameter is between 1 4 inch to 5 16 inch Maximum length is 1 5 inches Fines dust of not more than 0 5 by weight Sodium content shall be less than 300 parts per million...

Page 8: ...e furnace These are lo cated inside the back access door along the left hand side The fire box contains the remainder of the system compo nents the auger spiral air compressor and hose kit tube brush wringing a box containing the auger motor and fit tings the flame deflector and a box containing boiler treat ment and a steam saver cap make sure all components are removed before beginning installat...

Page 9: ...inches of open trench is where the water lines are placed Use only water line approved by Northwest Manufacturing through your Woodmaster Dealer NOTE If lines travel under a driveway or where heavy equipment travels the line should be buried two to three feet deep If lines travel through a low or wet area they should be insulated and installed in a water tight piping PVC Note The water temp gauge ...

Page 10: ... Rubber Gasket Supplied with pump Hot Water Supply Valve Black Rubber Gasket Supplied with pump Hot Water Supply On back of furnace Direction of Flow Indicator Arrow 1 Pex Crimp x 1 MIP 0020 140 1 Pex Water Line 0020 130 1 Pex Crimp Ring 0020 145 Hot Water Supply Valve Cold Water Return Valve Drain Hot W Wiring The Pump Remove the cover on the pump Then using an approved wire connect the ground wi...

Page 11: ...ube 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 in stalled below any existing off peak electric coils already in the plenum After the installation of the WoodMaster add on water to air exchanger the air...

Page 12: ...r Supply from WoodMaster Cold Water Return to WoodMaster Existing Heat Zone Return WoodMaster Water to Water Heat Transfer Unit Circulating Pump for Existing Hot Water Heating System Existing Hot Water Boiler Cold Water Return from Heat Exchanger Domestic Water Supply for filling boiler Cold Water Return to WoodMaster Filling With Water Connect a garden hose between a domestic water supply and the...

Page 13: ...come pre installed in its mounting location on the furnace ter temp probe must be installed in the well on the line of the furnace Install the probe in the well on the supply line Make sure the probe set screw contacts the metal of the probe DO NOT clamp the probe by the wire this will damage the probe Contact paste can be used to increase the accuracy of the probe Connect the wires to the burner ...

Page 14: ...al 2015 Installation Locate the flame deflector that fits over the burner to prevent excess heat from contacting the door Slide the ring of the flame deflector over the burner until it contacts the rear door of the firebox ...

Page 15: ...s to the length of the components can be made 1 Attach the auger spiral to the motors output shaft Push the spiral as far as it can go onto the shaft then pull it back approx 3 8 to prevent binding Clamp the spiral in place by tightening the two bolts that hold the clamp in place Note The auger head may have a slightly different ap pearance than the one shown in the pictures Assembly of the auger ...

Page 16: ...the inlet pipe over the auger tube The hole in the inlet pipe should be 180 degrees towards the out let on the T pipe Fasten the screw shown to lock the inlet pipe in place Apply a bead of caulking the joint of the inlet pipe and auger tube to prevent water from reaching the pellets 6 Hang the motor on the hook that is located under the roof of the furnace using the hanger on the motor that is by ...

Page 17: ...ct the pellets from the elements 2 Stand the side hopper upright Attach the leg sup ports ensuring that the longer of the three supports is on the side of the hopper that faces the furnace Note Install the supports on the inside of the legs securing the supports to the legs with the U bolts DO NOT TIGHTEN THE U BOLTS AT THIS TIME 3 Attach the boot to the bottom of the side hopper Do not tighten th...

Page 18: ...r ignition as well as lower maintenance Below is a brief explanation of the installation process NOTE Disconnect all power during installation 1 Disconnect the wiring and remove the plastic cover of the burner Note The burner does not need to be removed from the furnace boiler to perform this installation the burner is shown off the furnace for reference only The location of the air line connector...

Page 19: ...e air compressor power cord into the adaptor Replace the burner cover Place the air compressor next to the furnace making sure the air line and power cord are clear of the ash door and other heat sources If you do not wish to use the on board air cleaner you still need to supply compressed air to the burner for cleaning Northwest Manufacturing Inc offers an adapter Part Number 0020 213 that will a...

Page 20: ... 3 5 minutes between adjustments to give the burner time to react to the adjustments Shorter on off time intervals will result in a more even and efficient burn When adjusting to the oxygen level if the O2 level is below the target values less fuel is needed if it is above the target values more fuel is needed Note The boiler should be readjusted each time a new brand of pellets is used The target...

Page 21: ... catch the pellets Insert the tube adaptor into the tipping chute when complete 2 Setting of screw on the amount of pellets at ignition A good start dose is approx 150 grams 5 25 ounces We recommend manually measuring the start dose The start dose is approx equal to the volume of an 8 5 oz cup 3 To adjust amount of fuel for operation a flue gas instrument must be used The proper adjustment is need...

Page 22: ...adjustable between 100 and 400 grams and is the adjustment used when the burner is in Auto burning mode The MAX RUN TIME value is how long the burner will run before shutting down to self clean The default value shown is 3 hours If heat is still called for the burner will restart after the clean ing is completed You can also read the operation time of the burner and how many times it has started B...

Page 23: ...l only ap pear if you have set up a level sensor in the pellet hopper If you do not have a level senor in the pellet hopper then a FUEL FAULT will occur See the troubleshooting section for further assistance Menu Ok HISTORY OF FAULTS IGNITION 00000 FUEL FAULT 00000 OVERHEATED 00000 1 2 3 4 Menu Ok NO PELLETS 1 2 3 4 Menu Ok SENSOR FAULT 1 2 3 4 Alarm The display shows a message and the burner has ...

Page 24: ... the connection for the feed auger If the burner starts no further action is needed If not see the troubleshooting section for further assistance If the problem persists or if the igniter is bad contact your dealer or Northwest Manufacturing Inc Menu Ok FUEL FAULT V22 1 2 3 4 Menu Ok IGNITION FAULT V22 1 2 3 4 Operation 13 Shutting the Burner Off When shutting off the burner either for maintenance...

Page 25: ...Cleaning of the Burner 30 kW Disconnect the cables on the side of the burner Remove the auger tube from the burner chute Re move the four thumb screws that hold the cover on the burner Remove the cover Disconnect the air line from the air compressor by pushing in the blue collar on the fitting while pulling out on the hose Release the quick latches that hold the sections togeth er Be careful as to...

Page 26: ...26 Ultra Owners Manual 2015 Maintenance Lifting Up on the combustion fan carefully lift the burner assembly off of the fire pot Carefully remove the gasket Slide the burn pot out of the boiler ...

Page 27: ...ildup out of the burn pot and clean all debris out of the air holes Once clean insert the inner part of the burn pot into the outer sleeve Ensure the alignment pins line up Inspect the inner burner sleeve for warping or other damage Replace if necessary ...

Page 28: ...e the outer sleeve Remove the burner for cleaning as stated in the previ ous process Once the burner is removed slide the deflector off of the burner When reassembling the burner line up the four align ment screws that align the sections together with the gasket in place Then latch the quick latches Repeat the reset of the removal process in reverse to reassemble the burner ...

Page 29: ... pellet tube from the chute Remove the two screws that hold the pellet chute in place Lay the pellet chute across the top of the burner being careful not to damage the wires Release the two quick latches on the tube access box and open the door Maintenance Remove and clean each swirly ...

Page 30: ...the tube box including the door and any remaining ash in the heat transfer tubes Maintenance Remove all ash from the firebox this includes any ash that is on the top of the burner and the walls of the firebox Brush out each of the heat transfer tubes ...

Page 31: ...Owners Manual 2015 Maintenance Clean all ash from the firebox door Reinstall the swirlies into the heat transfer tubes Close and latch the tube box Reinstall the pellet chute and tube Dispose of all ash properly ...

Page 32: ...iter and place the new one in the mount Secure the screw and plug the igniter in Properly secure all wires Remount the burner Replacing the Flame Guard The flame guard is located inside the burn pot of the burner Remove the burner as shown on the prior page The flame guard is in the chute of the burn pot To remove the flame guard first locate the metal pin that holds the guard in place Bend one en...

Page 33: ...access box Replace the swirlies and close the door Replace the tipping chute and blue hose on the burner Annual Furnace Water Jacket Blow Down If antifreeze is being used water should be drained from the bottom of the furnace to remove any sediment buildup The water should drain until it runs clean approximately 2 gallons You can also completely drain and flush your furnace if needed Remember to r...

Page 34: ...1 Adjust the fuel feed rate 2 Clean or replace the flame guard The burner does not ignite Ignition fault is on the display 1 Incorrect start dose 2 Broken ignition element 3 Stop in tipping chute 1 Change the start dose 2 Replace the ignition element 3 Clean the tipping chute The burner stops without visible reason 1 Incorrectly adjusted burner 2 Too much back pressure in the chimney 3 Error in th...

Page 35: ...35 Ultra Owners Manual 2015 Wiring To Next Page From Prev Page GREEN BLACK WHITE 800 Watt Igniter Pressure Switch BROWN BROWN ...

Page 36: ...revious Page WHT BLK GRN 120VAC 60 HZ 15 AMP 192 SNAPDISC GREEN WHITE DRAFT INDUCER BLACK GREEN GREEN BLACK ACK WHITE WHITE LIGHT WHITE BLACK NO COM BLACK BLACK BLACK BLACK 4 BLACK WHITE 800 Watt Igniter 4X4 Box RESET OFF 1 2 3 WHITE GREEN BLACK e h BROWN ...

Page 37: ...ng Inc will determine whether to repair or replace the defective parts LIMITED ONE 1 YEAR WARRANTY ON ADDITIONAL COMPONENTS Northwest Manufacturing Inc warrants to the original owner only any additional components including but not limited to the outer shell paint insulation doors and latches during normal usage for a period of one 1 years from the date of installation START OF WARRANTY PERIODS Th...

Page 38: ...t be taken and immedi ately treat and refill the furnace Failure to send in a water sample annually will void the warranty III This Warranty is non transferable and only covers the Original Owner at the original site of installation IV Northwest Manufacturing Inc shall have the time needed and unobstructed access to the Furnace and Burner for the purpose of conducting tests of the Furnace and Burn...

Page 39: ...Northwest Manufacturing Inc 600 Polk Ave SW Red Lake Falls MN 56750 Northwest Manufacturing Inc 600 Polk Ave SW Red Lake Falls MN 56750 PLACE POSTAGE HERE Cut here and mail registration card ...

Page 40: ...Radio Newspaper Internet TV Print Other Would you like information on other products from Northwest Manufacturing Inc Yes No I have read the owners manual and understand the proper usage of my WoodMaster Ultra Signature Printed Name Fold Fold Fold Fold Fold Fold Fold Fold Fold Fold Fold Fold Fold Fold Fold Fold Fold Fold Measured start dose in grams Dosage time in seconds Setting of operation time...

Page 41: ...aw 1 Amp 120 v 60 Hz Combustion Fan Max Draw 0 34 Amps 120 v 60 Hz Draft Fan Max Draw 1 Amp 120 v 60 Hz Maximum Power Input 30 kW unit 102 000 BTU Weight 1000 Pounds approx Furnace Height 74 Furnace Width 46 Furnace Depth 48 Hopper Height 56 Hopper Width 28 Hopper Depth 40 System Height 74 System Width 90 System Depth 60 Hopper Capacity 280 Pounds Water Jacket Capacity 60 Gallons Door Size 16 x16 ...

Page 42: ...42 Ultra Owners Manual 2015 Notes ...

Page 43: ...43 Ultra Owners Manual 2015 Notes ...

Page 44: ...Northwest Manufacturing Inc 600 Polk Ave SW Red Lake Falls MN 56750 www woodmaster com 800 932 3629 Manual PN 7994 875 ...

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