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Summary of Contents for Wood master Ultra Series
- Page 1 WOODMASTER ULTRA SERIES Retain this manual Pellet Furnace Powered by the Renovator Pellet Burner www.woodmaster.com / 800-932-3629 / Manual PN: 7994-875 Northwest Manufacturing, Inc / 600 Polk Ave SW / Red Lake Falls, MN 56750 Rev:5.1/Software V22...
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Page 2: Table Of Contents
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,... -
Page 3: Terms
Terms Renovator AKA Burner or Pellet Gun - Combustion chamber that burns pellets Air Compressor - On board air cleaning agent PLC - Programmable Logic Control - Controls the burner Start Dose - Amount of fuel need to initiate ignition (approx. 5.25 oz, 150 grams, and 8.5 oz in volume) Photo Sensor - Read the photo resistance value to control the flame from ignition to combustion Auger Spiral - Feed auger screw Pellets - Wood sawdust compressed into small cylinders to be used as fuel... -
Page 4: Safety
Safety • Read and follow these directions carefully. Retain this manual for as long as you own your furnace. • All installation and operations must follow STATE and LOCAL CODES for wiring, and firing of this unit. These CODES may differ from this manual. Installation must be performed by a qualified installer. •... -
Page 5: Safety
Safety • The water pump must run continuously whenever the WoodMaster Furnace is being used. • The water pump must be installed on the supply line on the furnace. • Take the proper precautions to ensure that the modifications made to an existing heating system does not interfere with existing safety controls. -
Page 6: Technical Features
- Central electrical location 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. -
Page 7: Fuels
Fuels All wood pellets must conform to certain quality standards to ensure trouble free operation of the burner. Use of unapproved fuels will result in faulty operation and a voided warranty. Never use the following: trash, household garbage, plastics, gasoline, rubber, naphtha, leaves and materials treated with petroleum products (ie: particleboard, railroad ties &... -
Page 8: Installation
Installation Unpacking Before you start installing your Ultra Furnace, remove the ash shovel and auger pipe from the 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;... - Page 9 Note: Use only approved water line insulation sold through your WoodMaster Dealer. Poor insulation will cause your Wood Master furnace to burn large amounts of fuel, and hurt the efficiency of the system. For best results use high quality insulation.
- Page 10 Installation Mounting the Pump Cold Water Return Valve Note: The pump must be located on the furnace. The pump flange valve comes pre installed on the supply line. Locate one of the black rubber gaskets, and place it be- Hot Water tween the pump and the mounted flange valve, bolt the Supply Valve pump to the flange.
- Page 11 Installation Entering the building with water lines can be done underground or over the sill plate. Once inside the building the typical hookup would run first to the Domestic Hot Water Supply and next to an existing heating system such as a forced air furnace or a hot water heating system. Finally, before leaving the building, a fill valve must be installed near a water supply for filling and flushing the boiler in the WoodMaster Furnace.
- Page 12 Installation 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.
- Page 13 Installation Bleeding The System While filling the boiler, close the cold water return valve on the furnace for two or three minutes, and then open the valve. This will force trapped air out of the hot water supply line. Repeat this process with the hot water supply valve on the furnace to force air out of the cold water return line.
- Page 14 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. Ultra Owners Manual 2015...
- Page 15 Installation Feed Auger Installation The angle of the auger should be between 43 and 45 degrees. The auger is to be hung from the roof of the boiler housing on the motor mount stud. The feed auger location is positioned so that it does not sit right above the tipping chute on the burner.
- Page 16 Installation 5. Side the assembly through the hole in the side of the furnace until the T-pipe contacts the siding. 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 the T-pipe set screw.
- Page 17 4. Put the top on the hopper by securing the hopper top to the side hopper with the screws (6) provided. Place the hopper in its location next to your Ultra Series furnace. 2015 Ultra Owners Manual...
- Page 18 Installation 5. Secure the boot to the intake auger tube with the clamps provided. Apply the bottom boot to the end of the intake auger tube and secure it with the clamp. Tighten the clamp on the boot to secure it to the side hopper.
- Page 19 Installation Unpack the air compressor. Connect the air hose to the air compressor via the quick connect. Make sure the air compressors power switch is left in the “on” position. NOTE: Do not modify the length of the air hose. Place the air compressor on the shelf that is next to the burner Plug the supplied air compressor power cord adaptor...
- Page 20 Installation Flue Gas Analysis NOTE: THE FURNACE AND CHIMNEY WILL BE HOT DURING THIS TEST! Once the furnace is installed, it must be adjusted to proper burn settings. A flue gas instrument needs to be used that can read the following values: Draft, O2%, CO2%, PPM CO and stack temp. The sample is to be taken directly above the tube access box, in the port provided on the exhaust outlet.
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Page 21: Operation
Operation The burner is not adjusted from the factory. The burner has to be adjusted with a flue gas instrument the first time the burner is fired and after a change in fuel brand/quality. 1. Remove the blue hose from the burner prior to priming the feed auger. Connect cable of the auger with the power cable for the burner and run it manually until pellets have been fed out from the auger for about 15 minutes using a bucket or pail to catch the pellets. - Page 22 Operation In phase two, the soft start level, the auger feeds the burner 5 times with three second operation intervals on the SOFT START auger before it goes over completely to full burn mode. The SCREW ON +03.5 three values in this menu can be changed. SCREW OFF +15.0 NO OF CYCLES+05.0...
- Page 23 Operation The PLC also keeps track of some faults that could be use- ful to in the event of a problem occurring. This history shows HISTORY OF FAULTS how many ignition errors, fuel errors and if the burner has IGNITION +00000 overheated via the temperature sensor that is placed on the FUEL FAULT +00000...
- Page 24 Operation Error on the ignition element. This may be caused by an incorrect start dose, a dirty burner or a failed igniter. Turn off the burner and restart. Check to make sure you have the cor- IGNITION FAULT rect start dose settings, or check the connection for the feed auger.
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Page 25: Maintenance
Maintenance WARNING: Before performing any of the following tasks, ensure that the power is disconnected from the furnace and the burner, and that all components of the system have had ample time to cool. Removal and Cleaning of the Burner - 30 kW Disconnect the cables on the side of the burner. - Page 26 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. Ultra Owners Manual 2015...
- Page 27 Maintenance Inspect the inner burner sleeve for warping or other damage. Replace if necessary. Clean any buildup 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.
- Page 28 Maintenance 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. To remove the outer sleeve Remove the burner for cleaning as stated in the previ- ous process.
- Page 29 Maintenance Cleaning of the Swirlies, Tube Box and Firebox Remove the 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.
- Page 30 Maintenance Brush out each of the heat transfer tubes. Vacuum all ash from the tube box, including the door and any remaining ash in the heat transfer tubes. Remove all ash from the firebox. this includes any ash that is on the top of the burner, and the walls of the firebox.
- Page 31 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. 2015 Ultra Owners Manual...
- Page 32 Maintenance WARNING: Before performing any of the following tasks, ensure that the power is disconnected from the burner by switching the circuit breaker to the off position, and that all components of the system have had ample time to cool. Replacing the Igniter Location of the screw.
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Page 33: Maintenance
Maintenance Note: You should clean the furnace on an “as needed” basis, typically once a week. Not all wood pellets burn the same, some may require you to clean the furnace more frequently. Your warranty does not cover ash corrosion. The furnace must be completely cleaned of ash and creosote at least twice a year, including at the end of the heating season. -
Page 34: Troubleshooting
Troubleshooting Error Cause Solution The burner has stopped. “Fuel 1. The pellet hopper is empty. 1. Fill the pellet hopper with pellets. fault” is on the display. Restart the furnace. 2. An air pocket has developed in the inlet of the feed auger. 2. -
Page 35: Wiring Diagram
Wiring From Prev Page To Next Page Pressure Switch 2015 Ultra Owners Manual... - Page 36 Wiring From Previous Page BLACK GREEN WHITE To Next Page Ultra Owners Manual 2015...
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Page 37: Warranty
This Warranty is provided by Northwest Manufacturing, Inc. only for the bene t of the initial purchaser (Original Owner) of the Northwest Manufacturing, Inc. Ultra Series Pellet Furnace (the “Furnace”) on the original site of installation (the “Site of Original Installation”). - Page 38 Warranty VI. Any costs for labor for the examination, removal or reinstallation of allegedly defective parts, transportation of the parts to and from Northwest Manufacturing, Inc. facilities will not be covered and will be the responsibility of the Original Owner. This includes any other labor and costs for any material necessary for the said examination, removal or re-installation.
- Page 39 Northwest Manufacturing Inc. PLACE POSTAGE 600 Polk Ave. SW HERE Red Lake Falls, MN 56750 Northwest Manufacturing Inc. 600 Polk Ave. SW Red Lake Falls, MN 56750...
- Page 40 WoodMaster Ultra Series Warranty Registration Card Please fill out the warranty registration card below and mail it back to us. Failure to register may delay warranty claims. Serial Numbers Burner Heat Exhanger Owners Name Address City State Fold Fold Fold...
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Page 41: Specifications
Specifications Power Connection ......... Single Phase, 120v, 60 Hz Maximum Current Draw . -
Page 42: Notes
Notes Ultra Owners Manual 2015... - Page 43 Notes 2015 Ultra Owners Manual...
- Page 44 www.woodmaster.com / 800-932-3629 / Manual PN: 7994-875 Northwest Manufacturing, Inc / 600 Polk Ave SW / Red Lake Falls, MN 56750...
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