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Summary of Contents for Wood master Flex Fuel
- Page 1 Northwest Manufacturing, Inc 600 Polk Ave SW Red Lake Falls, MN 56750 www.woodmaster.com Retain this manual Owners Manual Manual PN: 7994-300...
- Page 2 Congratulations on your decision to purchase the WoodMaster Flex fuel. You will be extremely pleased with this product, which stands out from the competition in terms of ease of use, furnace efficiency and low emissions. Burning Wood Burning Pellets May quality, workmanship and on going product enhancement never be just a passing thought, but rath- er an everyday tangible aspect, that improves the lives of our employees, dealers, and customers alike.
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Page 3: Table Of Contents
9.11 Hour Meter ..........................32 10. Operating Modes ....................33 10.1 View of the Selected Operating Mode ................33 10.2 Setting the Furnace Operating Mode ................33 10.3 Changing the Furnace Operating Mode ................34 March 2011 Flex Fuel Owner’s Manual... - Page 4 14.1 Buffer Settings .......................... 61 15. Maintenance ......................63 15.1 General Information ........................ 63 15.2 Cleaning the Furnace ......................63 16. Error Messages ......................66 17. Troubleshooting ..................... 69 18. Specifications ......................70 19. Warranty ........................71 Flex Fuel Owner’s Manual March 2011...
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Page 5: Terms
2: Terms Flex fuel - Hydronic heater designed to burn multiple wood fuel types Furnace/Boiler AKA appliance, stove - An apparatus in which heat may be generated, as for heating homes, buildings, pools and radiant heat via water Seasoned Wood - Wood that has dried to an internal moisture content of 25% or less Cord Wood - Lengths of wood that are typically 8’... - Page 6 Blow Down - The process of removing sediment deposits from the furnace/buffer tank(s) by draining water from the bottom of the unit(s) until the water runs clean Lambda - AKA Oxygen Sensor - A sensor that measures the amount of oxygen in the flue gas Flex Fuel Owner’s Manual March 2011...
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Page 7: Safety
WoodMaster Flex fuel Dealer. • Freeze protection must be guaranteed in all water-bearing parts in the event of extensive idle periods of the system. Note: Your Flex fuel is not intended to be your only heat source. In the event that your existing heat source will not back up your Flex fuel antifreeze must be used. - Page 8 3: Safety UL Certification Flex Fuel Owner’s Manual March 2011...
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Page 9: Features
11. Smoldering Gas Duct - Prevents any exhaust from exiting the furnace when the firebox door is open. 12. STL (Safety Temp Limiter) - Safety switch that shuts down the furnace in the even of it overheating. All photos in this manual represent the Flex fuel 30 kW unless otherwise noted March 2011... -
Page 10: Installation
Your Flex fuel can only be installed indoors where the temperature will not fall below 50°F. The furnace may be installed inside the building that it serves or in an out building. Your Flex fuel must not be allowed to freeze. Your Flex fuel does not need to be installed in the same structure that it serves. -
Page 11: Display
WoodMaster Flex fuel Dealer for additional layouts. Insulate the lines if desired to prevent heat loss. 1” line is recommended for the Flex fuel 30 kW and 1.25” line is recommended for the Flex fuel 60 kW. Furnace and Buffer in Vent Cap the same building. - Page 12 This is a SUGGESTED layout only. User must determine if system layout will work for their particular application. Return to Furnace Tank User should check and follow all state and local codes. Drain Furnace Flex Fuel Owner’s Manual March 2011...
- Page 13 Plumbing the Rear of the Furnace The images below show how to connect the pump to the back of your Flex fuel furnace using the installation kit. Please note that the circulation pump and copper lines are not included in the kit.
- Page 14 5: Installation Expansion Tank Since the Flex fuel is a non pressurized system, an expansion tank is needed to allow the water to expand when heated. The Expansion tank should be connected to the furnace through 1” line and should be placed higher than the top of the furnace.
- Page 15 The size of the buffer tank is determined by the size of the furnace. Recommended buffer tank capacities are approximately 165 gallons for the Flex fuel 30 kW running only on pellets, and approximately 300 gallons if bulk materials are to be used. Approximately 285 gallons is recommended for the Flex fuel 60 kW running only on pellets and approximately 600 gallons if bulk materials are to be used.
- Page 16 Additional line may be required to extend the drain. Adapters may be purchased through your WoodMaster Flex fuel Dealer for using this buffer tank with 1” Pex line or 1” copper line. The tank should be installed by a qualified plumber. All Threaded fittings require the used of thread seal tape or pipe dope.
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Page 17: Electrical Connections
Secondary power connections include a pump, igniter (optional) and the pellet arm (optional). Main Circulating Pump Your Flex fuel comes with the proper wiring harness and connections to power a pump at the rear of the furnace. Pump wiring must be done by a qualified electrician. -
Page 18: I/O Board
POWER DI Temp. Draft Inducer Speed Bin Switch Reverse PE N L TK TK Ash Extraction Heat Exchanger Clean Igniter SPARE FUSE 10A Gate Motor BB Pro Main Circulating Pump Primary Air Secondary Air Flex Fuel Owner’s Manual March 2011... - Page 19 5: Installation Connections March 2011 Flex Fuel Owner’s Manual...
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Page 20: Connecting To Heating System
Hot Water Supply from Flex fuel (Always put supply in lower port.) After the installation of the WoodMaster add-on water to air exchanger, the air flow may need to be in- creased to fuel furnaces, electric furnaces, and electric/gas furnaces. Contact your dealer for assistance. -
Page 21: Fuels
Only cut, split, seasoned wood with a internal moisture content of 25% or less may be used. Wood can be cut to a maximum length of 21 inches for the Flex fuel 30 and a maximum of 26 inches for the Flex fuel 60. -
Page 22: Bulk Materials
To switch on the furnace, press and hold the control knob for 3 – 4 seconds. The following confirmation message appears on the display for several seconds: Your boiler is switched on! Boiler operating mode: Bulk materials Flex Fuel Owner’s Manual March 2011... -
Page 23: Switching The Furnace Off
The status line then indicates “Boiler is switched off!” If the furnace is running in Bulk materials or Bulk materials auto control mode, it is only possible to switch off the furnace when the following conditions are met: • Low flue gas temperature (Below factory default) • Air factor is above 2.50 • Lambda sensor pre-heat time has elapsed (duration 150 seconds) March 2011 Flex Fuel Owner’s Manual... -
Page 24: Display
Smoldering gas extraction can also be deactivated by pressing the ESC button for 3 seconds. When making changes in a screen, pressing the ESC button will NOT save the changes. Flex Fuel Owner’s Manual March 2011... -
Page 25: The Start Screen
The currently selected furnace operating mode is displayed. Depending on the furnace model, the following furnace operating modes are available: • Bulk materials • Bulk materials auto control • Pellets auto control Read further in this section to gain a better understanding of menu navigation, otherwise proceed to the next section. March 2011 Flex Fuel Owner’s Manual... -
Page 26: Menu Navigation
Output test - boiler Operating hour counter Language selection & Unit Screen 7 Screen 6 Screen 5 Set CLOCK/DATE Set CLOCK/DATE Set CLOCK/DATE Date: 10.09.10 Date: 10.09.10 Date: 10.09.10 Time: 17:05 Time: 17:05 Time: 17:05 Flex Fuel Owner’s Manual March 2011... - Page 27 Note: By pressing the ESC key, you will always move back one level, no matter where you are. You will always return to the starting screen. Data WILL NOT be changed by using the ESC key. March 2011 Flex Fuel Owner’s Manual...
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Page 28: Basic Furnace Settings
It is recommended that a continuous release period is specified (00:00 – 24.00), otherwise a situation may occur where the furnace is not released to start even though there is a call for heat (status line “Heat exchanger cleaning waiting to be released!”). Flex Fuel Owner’s Manual March 2011... -
Page 29: Setting The Clock/Date
The service menu includes factory settings designed to provide ideal combustion characteristics. These settings have already been optimized in the factory. Access to these settings can only be obtained by your dealer. Please contact your WoodMaster Flex fuel Dealer for assistance. 9.7 Alarm Protocol All malfunctions are chronologically listed in the alarm protocol. -
Page 30: Output Test - Heating Cycle
Note: Output tests may be preformed by the owner, however, damage can occur if preformed incorrectly. Please contact your WoodMaster Flex fuel dealer for assistance. An output test of all connected pumps and mixers can be performed in this menu, in order to be able to test the correct operating method. -
Page 31: Language Selection/Temperature Scale Selection
ESC key. All activated components are automatically switched off. 9.10 Language Selection/Temperature Scale Selection LANGUAGE SELECTION Please select your language! German Italian French English Spanish Temperature unit: °F -> °C In this menu you can select your desired language and temperature scale. March 2011 Flex Fuel Owner’s Manual... -
Page 32: Hour Meter
• Secondary air motor runtime (in hours) • Igniter runtime (in hours) • Heat exchanger cleaning runtime (in hours) • Furnace runtime during which the Operating status was "Bulk materials!" (in hours) • Furnace runtime during which the Operating status was "Bulk materials! Part load mode!" (in hours) • Furnace runtime during which the Operating status was "Pellets mode!" (in hours) • Number of furnace starts (applies to furnace operating modes "Bulk materials" or "Bulk materials - automatic") The counter always increases by 1 if the operating status changes either from “Please ignite!” to “Bulk materials!” (for furnace operating mode “Bulk materials” or from “Automatic ignition!” to “Bulk materials!” (for furnace operating mode “Bulk materials - automatic”) • Number of furnace starts (applies to furnace operating mode “Pellets” ”) The counter is always increased by 1, if the operating status changes from “Ignition phase!” to “Start phase” Flex Fuel Owner’s Manual March 2011... -
Page 33: Operating Modes
Note: Your Flex fuel furnace may not have the igniter or pellet option installed. If this is the case the system will not let you select “ Bulk materials - auto control” or “Pellets - Manual Filling”. -
Page 34: Changing The Furnace Operating Mode
“Furnace is “Heat exchanger cleaning is “Heat exchanger cleaning waiting Bulk materials switched o !” active!” to be released!“ auto control Bulk materials auto control to Change-over possible for any operational status! Bulk materials Flex Fuel Owner’s Manual March 2011... - Page 35 The actual display image depicts a combination furnace for bulk mate- rial/pellets. The current furnace operating mode is “Bulk materials“. Bulk materials Bulk materials auto control Pellets auto control selected boiler mode: Bulk materials March 2011 Flex Fuel Owner’s Manual...
- Page 36 The line displaying the current furnace operating mode will also indicate the successful change to operating mode “Pellets” . If the furnace indicates the status “Boiler switched off!” and you wish to start the furnace with the selected furnace operating mode, switch on the furnace by pressing the control knob for three seconds, as described in section 7. Flex Fuel Owner’s Manual March 2011...
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Page 37: Bulk Materials Mode
Check the Primary Air Feed To guarantee that your Flex fuel receives the oxygen feed necessary for ensuring clean burning, the two air deflectors which are located on the right and left furnace side walls in the firebox must be checked or cleaned with the fire irons. -
Page 38: Firing
It is necessary to configure the firing process so that a full-area fire bed can form. The purpose of this section is to clarify bulk material heating with the Flex fuel in a visual manner. In general your bulk material should correspond to the specification described in section 6.2. It is particularly important that you determine whether sufficient power demand is available prior to the firing process. -
Page 39: March 2011 Flex Fuel Owner's Manual
Note: A cardboard and paper combination works best at starting the fire. Now ignite the material making sure that it is ignited in several positions. March 2011 Flex Fuel Owner’s Manual... - Page 40 Now wait 1 to 2 minutes until a clean, full-area fire bed has formed. Flex Fuel Owner’s Manual March 2011...
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Page 41: Smoldering Gas Extraction And Adding Fuel
ESC button for 3 - 4 seconds. A deactivation message briefly appears and the furnace switches back to regulated operation. Smoldering gas extraction is automatically deactivated after several minutes. 11.5 Combustion Completed Furnace combustion is completed when: • the flue gas temperature drops below the factory default flue gas switch-off temperature and; • the air factor is above 2.50 for a longer period of time (10 - 20 minutes). The message “Stop system!” appears on the status line. Note: The furnace may reignite if conditions permit. March 2011 Flex Fuel Owner’s Manual... - Page 42 • a time release is set (section 9) • the furnace is cooled (below factory default) • the flue gas temperature is low Heat exchanger cleaning is active! The furnace immediately carries out its heat exchanger cleaning. The duration of the cleaning impulse is system specific and can vary between 3 and 20 minutes. Flex Fuel Owner’s Manual March 2011...
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Page 43: Status Lines During Furnace Operating Mode "Bulk Materials
You cannot abort Fan Lag. 11.7 Indications Your WoodMaster dealer can undertake pre settings so that the system operator receives various instructions at the display. These instructions are not to be understood as a furnace malfunction or fault. - Page 44 This instruction provides information to the system operator. At the end of the last burn-off the furnace had little demand and had to be operated with reduced power. Ensure that at the next firing there is sufficient demand. Flex Fuel Owner’s Manual March 2011...
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Page 45: Bulk Materials Auto Mode
Check the Primary Air Feed To guarantee that your Flex fuel receives the oxygen feed necessary for ensuring clean burning, the two air deflectors which are located on the right and left furnace side walls in the firebox must be checked or cleaned with the fire irons. -
Page 46: Filling The Furnace
Note: Ensure that the igniter tube is not blocked by kindling. The igniter tube is located in the bot- tom of the firebox right next to the insert on the right side. Flex Fuel Owner’s Manual March 2011... - Page 47 Cover the layer of paper with a layer of cardboard, again making sure to cover the entire bottom of the firebox. March 2011 Flex Fuel Owner’s Manual...
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Page 48: Setting The Release Period
If the start screen is not displayed, press the ESC button until it appears. FLEX FUEL V 10.060 Tu, 12.09.10 13:44 Bulk materials Boiler temperature: XXXºF Flue gas temperature: XXXºF Air factor: X.XX Stop system! Flex Fuel Owner’s Manual March 2011... - Page 49 “Saturday to Sunday…“. For example, select “Monday to Friday” and the screen “BM AUTO CONTROL – Mo-Fr” is shown on the display. BM-AUTO CTRL - Mon-Fr Release period 1: 07:00-09:00 Release period 2: 11:00-14:00 Release period 3: 17:00-22:00 March 2011 Flex Fuel Owner’s Manual...
- Page 50 One should therefore ensure that there is sufficient demand. The only condition for ignition is that the current furnace temperature is lower than the set “boiler target temperature” less the set “starting difference”. Flex Fuel Owner’s Manual March 2011...
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Page 51: Activating "Bulk Materials Auto Control
Combustion has been completed when the flue gas temperature falls below the factory default switch-off temperature and the air factor value is above the factory default setting over a long period (factory default setting 10 minutes). The status then switches to “Stop system!”. March 2011 Flex Fuel Owner’s Manual... -
Page 52: Pellets Auto Control
Check the Primary Air Feed To guarantee that your Flex fuel receives the oxygen feed necessary for ensuring clean burning, the two air deflectors which are located on the right and left furnace side walls in the firebox must be checked or cleaned with the fire irons. -
Page 53: Adjusting The Pellet Slide
3 and 4 as references. Note: Monitoring can be activated and deactivated the same way Smoldering Gas Extraction (section 11.4) is activated to prevent the furnace from shutting down and to vent the furnace. March 2011 Flex Fuel Owner’s Manual... - Page 54 Check the slide adjustment once a month to ensure a proper burn. Note: Adjusting the slide is a time consuming process. Allow yourself at least 2.5 hours to correctly adjust the slide. Flex Fuel Owner’s Manual March 2011...
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Page 55: Starting The Furnace In Operating Mode "Pellets Auto Control
5 minutes. The following message appears on the display for several seconds: Flue gas and air monitoring has been re-activated! The monitoring function has now been reactivated; do not re-open the doors during operation (otherwise “FGT-drop or air factor too high! Fan lag!”). March 2011 Flex Fuel Owner’s Manual... -
Page 56: Status Lines For Operating Mode "Pellets Auto Control
When all the ignition conditions have been fulfilled (flue gas has risen, low air factor), the furnace switches to the “Start phase!“. The duration of the “Start phase!” is limited to 10 - 20 minutes. The speed of the induced draft fan increases during the start phase and the pellet fill level in the firebox is regulated depending on the measured air factor. Once the “Start phase!” has finished, the operating status switches to “Pellets mode!”. Flex Fuel Owner’s Manual March 2011... - Page 57 The furnace is carrying out its heat exchanger cleaning. The duration of the cleaning impulse is system specific and can vary between 3 and 20 minutes. After the end of cleaning, the furnace starts automatically once a heating circuit demand exists. March 2011 Flex Fuel Owner’s Manual...
- Page 58 The most probable cause of this error message may be a faulty air supply. Wait until the furnace has cooled down and is switched off. Then clean the firebox, primary air deflectors, insert, ash chamber and the flue pipe. Press the control knob to restart the furnace. Flex Fuel Owner’s Manual March 2011...
- Page 59 IGNITION NOT POSSIBLE! Press START to start up the boiler and STOP to Switch off the boiler! Boiler temperature: XXºF Flue gas temperature: XXºF Air factor X.XX March 2011 Flex Fuel Owner’s Manual...
- Page 60 Your furnace is fitted with a safety chain that is currently open. This safety chain is attached to sensor input “Circulation sensor” on the I/O Board (section 5.6). Close the safety chain and the furnace will automatically start. Flex Fuel Owner’s Manual March 2011...
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Page 61: Buffer/Thermal Storage
The buffer difference temperature is the temperature by which the buffer temperature, top may be less than the required flow temperature before the furnace is started (with furnace operating modes “Pellets- auto control” and “bulk material auto control”). March 2011 Flex Fuel Owner’s Manual... - Page 62 You can set 3 different release periods for the buffer from 0:00 to 24:00 hours. If you do not require all release period, set the starting and ending value to the same setting value in order to deactivate this release period. Flex Fuel Owner’s Manual March 2011...
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Page 63: Maintenance
The Correct function of the safety devices should be checked before every heating period and after a system fault. Your Flex fuel should be serviced by your dealer once every three years or following any faults. The water in your furnace must be tested every year, and treated or replaced if necessary Weekly visual inspections for any leaks, corrosion or ash build up should be preformed. - Page 64 After the Blow Down procedure is preformed on the furnace, a sample of water is to be taken from the bottom of the furnace. A water testing kit and mailing instructions is available at your dealer. Failure to preform this test annually will result in a voided warranty. Flex Fuel Owner’s Manual March 2011...
- Page 65 15: Maintenance Notes: March 2011 Flex Fuel Owner’s Manual...
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Page 66: Error Messages
I/O Board (section 5.6). Additional replacement fuses can be obtained at your Woodmaster Flex Fuel Dealer. Disconnect the furnace from the main power supply before replacing the main fuse (unplug the main connector or switch off the main circuit breaker for the heating system). - Page 67 After the control knob is pressed, the furnace starts as soon as a system component makes a request. If the error message occurs again upon the next start attempt, then press the ESC key and inform an authorized WoodMaster Flex fuel Dealer. March 2011...
- Page 68 The furnace operating mode is automatically reset to “Bulk materials”. Check whether the feed sensor is correctly connected to the I/O Board (section 5.6) of the Flex fuel. If you have checked that the cabling is correct, please contact your WoodMaster Flex fuel Dealer.
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Page 69: Troubleshooting
If the furnace is being operated on pellets, di erent grades and brands of pellets will produce more/less heat. Please contact your WoodMaster Flex fuel Dealer for di erent pellet options. -
Page 70: Specifications
18: Specifications Flex fuel 30 kW Maximum Current Draw 15 Amps @ 120v 60hz. Note: only happens when all components are running, which rarely occurs Average Daily Power Consumption 2.8 kilowatts per day = less than 1 amp Max Heat Capacities... -
Page 71: Warranty
(10) years from the purchase date to the original owner only. If there is a leak in your properly delivered and installed WoodMaster Flex Fuel furnace in the first year, WoodMaster will replace the furnace at no cost to the original owner. - Page 72 OWNER’S REGISTRATION CARD Name _________________________________________ Installed by: Dealer Customer Address _______________________________________ If customer, was installation explained to you? _______________________________________________ Phone ________________________________________ Type of Installation: Date of Purchase ________________________________ House/Garage Shop/Shed Greenhouse Kiln Model No. ______________________________________ Other ____________________________ Serial No. ______________________________________ Purchased: (Model and serial numbers are located on the decal on furnace.) With Pellet Arm...
- Page 73 (10) years from the purchase date to the original owner only. If there is a leak in your properly delivered and installed WoodMaster Flex Fuel furnace in the first year, WoodMaster will replace the furnace at no cost to the original owner.
- Page 74 OWNER’S REGISTRATION CARD Name _________________________________________ Installed by: Dealer Customer Address _______________________________________ If customer, was installation explained to you? _______________________________________________ Phone ________________________________________ Type of Installation: Date of Purchase ________________________________ House/Garage Shop/Shed Greenhouse Kiln Model No. ______________________________________ Other ____________________________ Serial No. ______________________________________ Purchased: (Model and serial numbers are located on the decal on furnace.) With Pellet Arm...
- Page 75 (10) years from the purchase date to the original owner only. If there is a leak in your properly delivered and installed WoodMaster Flex Fuel furnace in the first year, WoodMaster will replace the furnace at no cost to the original owner.
- Page 76 May quality, workmanship and on going product enhancement never be just a passing thought, but rather an everyday tangible aspect, that improves the lives of our employees, dealers, and customers alike.
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