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Summary of Contents for Weld Rite Shaver Pro 140
- Page 1 INSTALLATION AND OPERATING INSTRUCTIONS THE SHAVER OUTDOOR WOOD and COAL BURNING FURNACE Manufactured by Weld Rite Inc. 328 Hwy 62 West Salem, Arkansas 72576 870-895-3104 or 3111 http://www.outdoor-wood-furnaces.com The BEST Outdoor Wood Furnaces On the Market! Revised 1/10/2009...
- Page 2 (2) Warranty & Return Warranty Card (pages 6 – 8, 49) (3) A large specially designed poker FREE - as a bonus! (Often shipped above the boiler in the back of the furnace.) Weld Rite Inc. 328 Hwy 62 West Salem, Arkansas 72576...
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Page 3: Table Of Contents
Table of Contents General Information – Specifications ….……………..……...……….…………..………………… SAFETY PRECAUTIONS ….………...……………………………………………………………… 20-Year Limited Warranty ..………….………………………..……………………………………… Warranty Card ………………………………………..……………………..………………………… Outdoor Wood Furnace Best Burn Practices ………….………………………..………………….. Where should an Outside Wood Burning Furnace be located? ……….………………………… 9/13 Wood Recommendations and Burning Coal ...………….………………………..………………… How does an outside furnace heat my home? …………….……………………..……………..…... -
Page 4: General Information - Specifications
GENERAL INFORMATION Specifications Type of fuel – Wood and coal only For outdoor use only Electrical Rating 115 VAC/ 60 HZ / 1PH 15 AMP Breaker Clearance to Combustibles Top, Rear, Sides: 18” Chimney Connector: 18” Always use a double or triple-wall pipe when going through any kind of roof with at least 6”... -
Page 5: Safety Precautions
• Do not modify the furnace. Do not substitute repairs that can be provided by your dealer, distributor, or Manufacturing Company (Weld Rite, Inc). • Failure to heed these warning or any additional warnings on the furnace may result in an accident causing personal injury and damage. - Page 6 Shaver Outdoor Wood Furnace Lifetime Limited Warranty 5 Year 100% On-Site Warranty! plus a Lifetime and 30 Year Warranty on roof and siding! We have a 5-YEAR ON-SITE warranty against leaks on the furnace - NOT prorated. Plus we have a 20-YEAR ON-SITE warranty against leaks on the furnace - Parts AND Labor.
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Page 7: 20-Year Limited Warranty
• transport and installation. 2. Transport and packaging cost. 3. All costs not previously accepted by Weld Rite, Inc. 4. Costs and deterioration due to the non-use of the equipment. 5. The cost of any incidentals or consequential damage, including the loss of anti-freeze and/or water treatment. - Page 8 All warnings in this manual on Page 5 and elsewhere and all maintenance items on Page 42 constitute part of this warranty.
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Page 9: Warranty Card
Serial Number: (Only applicable only if financed) ___________________________ Date of Installation and who installed (Proper self-installation, following the instructions. will not void the warranty): ___________________________ Dealer Purchased from (if purchased from the factory, put Weld Rite, Inc.): _________________________________________________________ Dealer Address: ________________________________________________________________ ________________________________________________________________ Dealer Phone Number: ___________________________ Please keep this manual with all other important papers. -
Page 10: Outdoor Wood Furnace Best Burn Practices
O UTDO O R FURNA C E BEST BURN PRA C TIC ES 1. Read and follow all operating instructions supplied by the manufacturer. FUEL USED: You may burn any hardwood (or softwood), as well as pallets that have been split up and coal but NEVER burn driftwood, painted, stained or pressure or/and chemically treated wood. -
Page 11: Wood Recommendations And Burning Coal
Wood Recommendations Burn only cordwood that has been seasoned for 12-18 months. Burning unseasoned wood is wasteful and inefficient, using much of the combustion energy to boil off the excess moisture. It also puts a lot of moisture into the ash “pan” which makes it corrosive. The wood can be split to aid in seasoning if it’s real wet and should be approx. -
Page 12: How Does An Outside Furnace Heat My Home
THE SHAVER OUTDOOR WOODBURNING FURNACE How does an outdoor furnace heat my home? The Shaver outdoor wood furnace is designed to save the most energy and provide the most comfortable heating available. It heats your home by heating a firebox surrounded by a steel tank filled with water. -
Page 13: Insulated Pex Pipe & Insulating Yourself
your house turns on. See your controller manual or consult an expert in this area. You can also leave the outdoor pump on 24/7, since it only uses 80 watts of power – less than a 100W bulb. The outside furnace has a hot water thermostat that senses the water temperature of the unit. If the water is not as hot as the thermostat setting, the combustion air blower is automatically turned on (building a hotter fire by feeding oxygen to the base of the fire) and remains on until the desired (set) temperature is attained. -
Page 14: Pex Pipe Connections - Back Of Furnace
Pex Pipe Routing Single zone setup with one pump 1. Goes to house heat exchanger 2. Return from house heat exchanger 3. Power to pump, thermostat and blower 4. Inlet to potable water coil (not seen - inside of furnace, in water jacket) 5. -
Page 15: Concrete Pad
still heat your house and hot water easily. The chimney should extend at least 2 feet higher than any portion of a building within a horizontal distance of 100 feet. (See page 9) If the furnace is located more than 100 feet away, you may experience some heat loss in the water going to your heat exchanger (and water heater) –... - Page 16 the ground. We put a large full-size door on the back that will allow you easy access for the connection of the plumbing and electrical lines. We recommend the pad to be 48” wide and 82” long, minimum. If you add extra length, it will allow ample concrete in front of the furnace to stand, for loading wood and removing ashes.
- Page 17 Have insulation ready to put UNDER the furnace on the pad, before delivery. After placing your new Shaver Furnace on the concrete pad (we normally put it on the pad for you if we deliver it), you are ready to continue the installation process. The piping can go in any direction.
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Page 18: Preparing Your Furnace
PREPARING YOUR FURNACE 1. Simply open the large rear door to gain access to the rear of the furnace, to make plumbing and electrical connections. 2. Open the protective cover on the side of the blower. Simply swing it open so the inlet is exposed ¼... -
Page 19: Filling Furnace With Water And Chemicals
The listing below describes each water line and their function. 1. One water supply line to heat exchanger - placed into existing heating system. This one is attached at the circulating pump. All of these must be 1” pipe. 2. One water return line from heat exchanger. This line is attached at the nipple at the bottom of the furnace, to carry cool water back into the water jacket. - Page 20 Plate ^ You can also use an elbow and extension at the 2 outlet (if not being used) to fill using a funnel. Keep it capped when not using for chemicals. Alternatively, you can use a funnel and hose on the overflow tube. DO NOT block off the overflow tube permanently!
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Page 21: Plumbing Parts Needed
Plumbing Parts Needed You can get a complete install kit with all the fittings and three shut-off valves. A. The pump needs a 1” quest-fitting adapter or SharkBite® fitting, to screw into a flange that is supplied and already mounted to the pump. The flange has a female NPT thread. - Page 22 C. The pump comes already mounted directly to the furnace without a shut-off valve. However, it is a good idea to install a shut-off valve above the pump (as pictured below) so that if the pump ever has to be changed, the water supply can be shut off so water doesn’t flow out of the furnace during the repair or pump replacement.
- Page 23 Adding Shut-off Valves for Testing a New furnace & for Trouble-shooting down the road (Note PVC Pipe at bottom right (above), is installed in the concrete for future addition of heat to the garage, shop or other building) Adding two shut-off valves on the return lines is done so that if there is a potential problem with a stopped up heat exchanger or bad pump, it can be diagnosed easily by the owner, without the need for a service call.
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Page 24: Installing The Heat Exchanger In The Plenum Or Ductwork
Installing the Heat Exchanger in the Plenum or Ductwork If you have Air Conditioning, the heat exchanger must be installed between the furnace and the evaporator coil. Failure to do so may result in freezing of the heat exchanger. If you can’t place the heat exchanger between the furnace and the evaporator coil, you must drain the heat exchanger annually before using the A/C. - Page 25 Slide the heat exchanger into the hole for a test fit. Ideally the tubes (D and E) should stick out of the plenum [see diagram on previous page]. The header and tubes (F) can stick out of the plenum as well, if necessary. As long as the whole coil surface (B) is in the plenum, you should be good even if a little more of the header (F and even G) sticks out.
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Page 26: Installing A Heat Exchanger That Is Longer Than The Plenum
Install the braces as shown above. Simply put them in place, the proper width apart (Dimension C). Drill through the duct work and your newly made ‘L’ pieces and pop rivet or screw them into place. You will need four pieces, two each on the top and bottom. Slide the heat exchanger carefully into the plenum to check the fit again. - Page 27 Slide the heat exchanger through the front hole to the back hole. So that it protrudes front and back. Ideally the core of the heat exchanger will be entirely within the plenum. (Item B) Crimp the sheet metal to the edge of the heat exchanger. This is item G in the diagram above (Page 23).
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Page 28: Heat Exchanger And Transition Pictures
A transition was built here so that a larger heat exchanger could be used with smaller ductwork. A customer’s photo of his heat exchanger installation. -
Page 29: Bleeding A Heat Exchanger
Bleeding a Heat Exchanger With the pump running (turn the thermostat up to 90 F so that the pump comes on), simply close the brass valve on the return line quickly, holding it for 3-4 seconds. Then open the valve. Repeat the procedure at least 4 times. If you’re unsure if all the air is getting out, you can separate the 2 valves (shown on previous page) at the Pex Pipe between them, after turning off both valves so that water won’t drain out. -
Page 30: Connection Of Power To Furnace
Connection of Power to Furnace WARNING! Do not touch the terminals or wires on the thermostat – THEY ARE HOT AND DANGEROUS!! ALWAYS cover the thermostat with a solid receptacle/box cover (Not shown here) or a piece of Plexiglas, as shown below. - Page 31 There are three insulated wires in a 12/3 wire; red, black and white plus an uninsulated ground wire. Either terminal on the pump can be connected to the black or white wire. White is common and also goes to fan/blower Black wire from the pump runs to house, to fan inside existing furnace.
- Page 32 To add a switch for the pump, so that it will run constantly when you are away, simply wire a switch from the red (hot) wire to the same terminal that the black wire goes to on the pump. IMPORTANT! You will also need to put a switch on the black wire going to...
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Page 33: Wiring Your Home Thermostat
Wiring up your house thermostat These instructions are for a forced air furnace, with a single-speed fan. If you have other than a single-speed fan, a boiler or are unsure about anything, you will need to consult an HVAC technician. Most existing thermostats have a fan switch that you can set to ON or AUTO. - Page 34 Mercury Switch Top and Bottom wires in the switch are typically used. 2-wire bi-metal thermostat The two wires you need to connect are at 3 and 5 in this example of a 2-wire bi-metal thermostat. They are wired to the G Terminal on the existing thermostat and to the wire that went to the G terminal, that you removed.
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Page 35: Hooking Up The Hot Water Heater
Hooking up the Hot Water Heater With an electric hot water heater, we recommend that you unscrew the pop-up valve and replace it with a ‘T’ fitting (using Teflon or plumbers tape). Screw the pop-up valve back on one side of the T and mount the circulating pump on the other side of the T. - Page 36 Alternatively, you can run the incoming (hot) Pex pipe to a brazed plate heat exchanger for your hot water heater – before running to your heat exchanger for your furnace. It is usually about $175. In this case, you would only need 3 Pex lines running to your house, which may save a little, if the furnace is going to be a long distance away.
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Page 37: Hot Water Heater Pump Pictures
Customer supplied photograph: Make sure using a single wire is to code in your area. -
Page 38: Heat A Pool Or Spa
Hooking up a Pool or Spa A heat exchanger should be used to transfer heat from the outdoor wood furnace to the pool or spa. You don’t want old dirty furnace water mixing with nice clean pool water! Never use a brazed plate heat exchanger for a pool as the chlorine will destroy it in short order. -
Page 39: Hooking Up The Outdoor Furnace To An Existing Boiler
Hooking up the Outdoor Furnace to an Existing Boiler Again, we need to use a heat exchanger to transfer heat from the outdoor furnace to the boiler or hydronic system so that the two systems remain isolated from each other. A water-to-water plate heat exchanger is used in this type of system. -
Page 40: Boiler And Pool Heat Exchanger Pictures
Set the existing boiler water thermostat lower than the temperature of the outdoor boiler. Plate exchanger Stainless Steel Shell and Tube Heat Exchanger for pool or spa... -
Page 41: Starting A Fire
Starting a Fire Use small pieces of split kindling together with crumbled newspaper or cardboard, adding larger pieces as the flame grows. Remember: The smaller the better; the drier the better. If it is difficult to start the fire the reasons could be: Not enough air: Make sure that fan is on or open the ash door (approx. -
Page 42: Testing A New Furnace
Quickly crack open the firebox door to see what the fire is doing. (Leaving the door open any length of time will give you a blazing fire.) If you have too hot a fire with the fan off, close the cover on the side of the fan a little more. -
Page 43: Maintenance
Maintenance Clean out ash!! Moisture combined with ash will eat through a furnace in short order and ash or/and coal corrosion IS NOT COVERED under warranty. Green wood can also cause a lot of water to get into the ash area as well, so keep a sharp eye on that. -
Page 44: Replacing A Hot Water Coil (In Furnace)
Replacing the hot water coil in the furnace In areas where there is a lot of lime or other minerals (or hard water), it may be necessary to clean out or replace the hot water coil in the furnace. Thankfully, this is an easy job. - Page 45 Simply cut through the silicone seal and lift it off. Place safely out of the way. You can see the water coil now. This is where you add your chemicals! Simply loosen and remove the compression fittings and slide the coil out the top. A 50-foot copper coil is readily available at most hardware and home improvement stores, already coiled up! Simply straighten the ends and reattach the Pex pipe.
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Page 46: Trouble-Shooting
Trouble-shooting: Poor Water Flow or little or No Heat 1. Check to make sure that the furnace is full of water. Simply open the valve on the front until water flows out of the overflow tube. DO NOT block off the overflow tube! 2. -
Page 47: Excessive Water Usage
11. Remove the pump and open the valve above it. If water flows freely, you know that there is no blockage there. If good, proceed with next step. 12. Next, disconnect the Pex line at the pump output. Install a short piece of hose or Pex pipe, about 4-6 feet long and insert the pipe into a bucket. -
Page 48: Heat Exchanger Cleaning Procedure
Heat Exchanger Cleaning Procedure If you use the proper chemical additives from Wood Boiler Solutions LLC you should never have to clean your heat exchanger. This is a wise idea and keeps your warranty valid. A specialist experienced in chemical cleaning should perform this procedure. The easy way out –... -
Page 49: Disclaimer
Disclaimer All installation, wiring and operation must follow Federal, Provincial, State and local codes, ordinances and laws. Do Not consider outdoor wood furnaces for built up urban areas. The Shaver furnace is not intended to be the only source of heat. Therefore a backup system should always be in place and be ready for use. -
Page 50: Extra Warranty Card To Be Mailed Back To Us
Serial Number: (Only applicable only if financed) ___________________________ Date of Installation and who installed (Proper self-installation, following the instructions. will not void the warranty): ___________________________ Dealer Purchased from (if purchased from the factory, put Weld Rite, Inc.): _________________________________________________________ Dealer Address: ________________________________________________________________ ________________________________________________________________ Dealer Phone Number: ___________________________ Please keep this manual with all other important papers.
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