- DL manuals
- Wood Master
- Heater
- Flex Fuel
- Owner's Manual
Wood Master Flex Fuel Owner's Manual
Summary of 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
2 flex fuel owner’s manual march 2011 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. May quality, workmanship and on going pro...
Page 3: 1: Table of Contents
3 march 2011 flex fuel owner’s manual 1. Contents ....................................................................................................................... 3 2. Terms...........................................................................................................................
Page 4: 1: Table of Contents
4 flex fuel owner’s manual march 2011 1: table of contents 11. Bulk materials mode ............................................................................................... 37 11.1 general information ................................................................................................
Page 5: 2: Terms
5 march 2011 flex fuel owner’s manual 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 drie...
Page 6: 2: Terms
6 flex fuel owner’s manual march 2011 2: terms air ratio - see air factor esc - function on display controlled by the operator to move back fire irons - metal pokers and scrapers used for ash/wood cleaning & maintenance fault - an error that causes an alarm hopper - storage container used to hold pe...
Page 7: 3: Safety
7 march 2011 flex fuel owner’s manual 3: safety • all installation and operations must follow state and local codes for wiring, plumbing, and firing of this unit. These codes may differ from this manual. Installation must be performed by a qualified installer. • all flex fuel models operate at atmos...
Page 8: 3: Safety
8 flex fuel owner’s manual march 2011 3: safety ul certification.
Page 9: 4: Features
9 march 2011 flex fuel owner’s manual 4: features 1. Ash door - a large opening to make cleaning the ash chamber simple and easy. 2. Firebox door - a large opening to make filling and cleaning the firebox simple and easy 3. Display for controller - designed for easy operation. 4. I/o board - an inpu...
Page 10: 5: Installation
10 flex fuel owner’s manual march 2011 5: installation your flex fuel must be installed by a professional and should follow all local, state and federal laws and regulations. Any use of an unapproved installation may result in a voided warranty. It is recommended to have your installation approved b...
Page 11: 5: Installation
11 march 2011 flex fuel owner’s manual 5: installation 5.4 water connections the following layouts are basic configuration for the furnace water connections. Contact your woodmaster flex fuel dealer for additional layouts. Insulate the lines if desired to prevent heat loss. 1” line is recommended fo...
Page 12: 5: Installation
12 flex fuel owner’s manual march 2011 5: installation furnace and buffer in separate buildings running with a plate pump. Furnace and buffer in separate buildings running without a plate pump. Pump plate pump diverting valve 10 gal expansion tank 20 gal expansion tank temp probe temp probe furnace ...
Page 13: 5: Installation
13 march 2011 flex fuel owner’s manual 5: installation 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. All plumbing sho...
Page 14: 5: Installation
14 flex fuel owner’s manual march 2011 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 ...
Page 15: 5: Installation
15 march 2011 flex fuel owner’s manual 5: installation expansion tank (20 gallon shown) 0020-247 1” blk st 90 0020-247 1” blk st 90 0020-250 1” x 2” blk nipple 0020-273 vent cap 0020-140 1” pex x 1” mpt 0020-140 1” pex x 1” mpt 1” pex line 1” pex line 1” pex line 0020-142 1” x 1” pex crimp 90 0020-1...
Page 16: 5: Installation
16 flex fuel owner’s manual march 2011 5: installation buffer tank kit (020-0009) part no. Description 0020-140 1” pex x 1” mpt (2) 0020-145 1” pex crimp ring (2) 0020-189 1 1/4” x 1”reducer (4) 0020-195 3/4” f hose x 1/2” part no. Description 0020-197 1” fpt ball valve (6) 0020-247 1” blk st 90 002...
Page 17: 5: Installation
17 march 2011 flex fuel owner’s manual 5.5 electrical connections note: be sure to follow all local, state and federal guidelines. Wiring installation should be preformed by a qualified electrician. Main power connection your flex fuel needs a 120 v connection with a 20 amp circuit for the basic uni...
Page 18: 5: Installation
18 flex fuel owner’s manual march 2011 5: installation 5.6 i/o board pellet auger room feed auger vibrator lambda circ temp stack temp stove temp supply temp return temp intake auger temp display triac fuse 10a draft inducer solar pump n l spare fuse 10a secondary air primary air main circulating pu...
Page 19: 5: Installation
19 march 2011 flex fuel owner’s manual 5: installation fle x fuel 60 kw fle x fuel 30 kw # 4 m ain c ircula ting p ump connections.
Page 20: 5: Installation
20 flex fuel owner’s manual march 2011 5: installation 5.7 connecting to 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 thro...
Page 21: 6: Fuels
21 march 2011 flex fuel owner’s manual 6: fuels all fuels must conform to certain quality standards to ensure trouble free operation of the furnace. Use of unapproved fuels may result in faulty operation and a voided warranty. Never use the follow- ing: trash, plastics, gasoline, rubber, or naphtha....
Page 22
22 flex fuel owner’s manual march 2011 it is only possible to switch the furnace on and off from the start screen. The currently selected operating mode is indicated on the line “selected furnace mode” (in this example “bulk materials”). The status line “boiler is switched off!“ indicates that the f...
Page 23
23 march 2011 flex fuel owner’s manual the furnace is then switched on and you are returned to the start screen. The status line indicates the current operational status of the furnace. The significance of the status lines are best described in sections • section 11.6: status lines during furnace op...
Page 24: 8: Display
24 flex fuel owner’s manual march 2011 8: display overview: all settings are changed using the control knob in the center of the operating unit. Turn the wheel to scroll through the various menus, move the cursor to the settings or increase/decrease the values. Press the control knob to access the m...
Page 25: 8: Display
25 march 2011 flex fuel owner’s manual 8: display 8.1 the starting screen the displayed values are current actual values. The boiler temperature, the flue gas temperature and the air factor are displayed. The lowest line(s) of the starting screen is/are the status line(s). The status line shows the ...
Page 26: 8: Display
26 flex fuel owner’s manual march 2011 8.2 menu navigation scrolling through the system components on the starting screen, turn the control knob to the right or left; the actual values and conditions of the existing system components are displayed by this method. By pressing the control knob you wil...
Page 27: 8: Display
27 march 2011 flex fuel owner’s manual changing/viewing individual settings by turning the control knob, you can: • navigate between various main menu levels, • navigate within a menu, • view or change individual settings. A symbol appears in the upper right hand corner of the screen, which will sho...
Page 28: 9: Basic Furnace Settings
28 flex fuel owner’s manual march 2011 if you press the control knob on the starting screen, the menu “basic boiler settings” will appear (shown below). Press the control knob again and the cursor moves to the first menu item. By turning the control knob to the right, the cursor moves to the availab...
Page 29: 9: Basic Furnace Settings
29 march 2011 flex fuel owner’s manual 9.5 setting the clock/date note: there is no automatic conversion for daylight saving time. Note: this furnace runs on dd/mm/yy date format and on military time format. Once you have selected this menu item, the clock stops and the following figure appears on t...
Page 30: 9: Basic Furnace Settings
30 flex fuel owner’s manual march 2011 9.8 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 perform...
Page 31: 9: Basic Furnace Settings
31 march 2011 flex fuel owner’s manual move the curser by turning the control knob to the output test – boiler line and press the control knob. The menu “outputs 1” appears on the screen. You can now press the control knob to scroll through the items to select one to change. If the control knob is t...
Page 32: 9: Basic Furnace Settings
32 flex fuel owner’s manual march 2011 9.11 hour meter t he following operating hours are also logged: • feed runtime (in hours) • lambda sensor heating time (in hours) • induced draft fan runtime, during which the furnace operating mode was set to pellets (in hours) • induced draft fan runtime, dur...
Page 33: 10: Operating Modes
33 march 2011 flex fuel owner’s manual 10.1 view of the selected operating mode when booting up the display, the set operating mode is automatically displayed for approximately 3 seconds. All flex fuel systems contain "bulk materials" operating mode. The following modes are possible: operating mode ...
Page 34: 10: Operating Modes
34 flex fuel owner’s manual march 2011 depending on the installed options, up to three furnace operating modes are available: • bulk materials the furnace is operated using bulk material fuel. This must be manually ignited. • bulk materials auto control the furnace is operated using bulk material fu...
Page 35: 10: Operating Modes
35 march 2011 flex fuel owner’s manual 10: operating modes flex fuel v 10.060 tu, 12.09.10 bulk materials boiler temperature: flue gas temperature: air factor: boiler is switched off! Xxxºf 13:44 xxxºf x.Xx once you have verified that a change-over is possible, press the con- trol knob when the star...
Page 36: 10: Operating Modes
36 flex fuel owner’s manual march 2011 turn the control knob to move the cursor to the line of the desired operating mode. For example, the following picture illustrates the selection of operating mode “pellets auto control” . Boiler operating mode bulk materials bulk materials auto control pellets ...
Page 37: 11: Bulk Materials Mode
37 march 2011 flex fuel owner’s manual note: always ensure that the insert corresponding to the furnace operating mode is fitted and the pellet slide and flap (if installed, section 13.3) are in the correct position for the selected mode. If the furnace operating mode is changed from “pellets auto c...
Page 38: 11: Bulk Materials Mode
38 flex fuel owner’s manual march 2011 check the insert check that the correct insert is installed in the firebox, and that the insert is free from any buildup that may block air flow. Remove and clean the insert if needed. Below is the correct insert for this operating mode. 11.3 firing general ins...
Page 39: 11: Bulk Materials Mode
39 march 2011 flex fuel owner’s manual firing first take the dry, small-sized and easily combustible material and arrange it parallel to the firebox side wall up to the height of the air deflectors, making sure to fully cover the bottom of the chamber. 11: bulk materials mode then spread your firing...
Page 40: 11: Bulk Materials Mode
40 flex fuel owner’s manual march 2011 now close the firebox door and wait unit the status line changes from “please ignite” to “bulk materials”. This changeover indicates that the kindling has ignited across its surface and there is sufficient flame to add wood. The change from “please ignite” to “...
Page 41: 11: Bulk Materials Mode
41 march 2011 flex fuel owner’s manual now you can completely fill the firebox right to the top with bulk material for a full burn, or a part load, depending on demand for heat. 11: bulk materials mode flex fuel v 10.060 tu, 12.09.10 bulk materials boiler temperature: flue gas temperature: air facto...
Page 42: 11: Bulk Materials Mode
42 flex fuel owner’s manual march 2011 11.6 status lines during furnace operating mode “bulk materials” boiler is switched off! The furnace is switched off. Press and hold the control knob for 3 - 4 seconds if you now want to start the furnace using bulk materials. Stop system! The furnace has just ...
Page 43: 11: Bulk Materials Mode
43 march 2011 flex fuel owner’s manual smoldering gas extraction! Please add more! Smoldering gas extraction is activated. You can now add more bulk material. Press the esc button for 3 – 4 seconds to deactivate smoldering gas extraction. Smoldering gas extraction is automatically deactivated after ...
Page 44: 11: Bulk Materials Mode
44 flex fuel owner’s manual march 2011 before filling, it is recommended that the buffer temperatures are checked. If the existing temperature is already sufficient, furnace filling is not recommended, rather the furnace should be allowed to burn out. When filling is not necessary (smoldering gas ex...
Page 45: 12: Bulk Materials Auto Mode
45 march 2011 flex fuel owner’s manual note: always ensure that the insert corresponding to the furnace operating mode is fitted and the pellet slide and flap (if installed, section 13.3) are in the correct position for the selected mode. If the furnace operating mode is changed from “pellets auto c...
Page 46: 12: Bulk Materials Auto Mode
46 flex fuel owner’s manual march 2011 12: bulk materials auto mode check the status line(s) always monitor the current operating status which is displayed on the status line. It is only possible to start the furnace in operating mode “bulk materials auto control” when the operational status is “boi...
Page 47: 12: Bulk Materials Auto Mode
47 march 2011 flex fuel owner’s manual next cover the small pieces with a layer of paper. Covered the paper with another small layer of bulk materials. Ensure that there is paper close to the igniter tube. 12: bulk materials auto mode then begin to cover with a layer of paper, making sure that the p...
Page 48: 12: Bulk Materials Auto Mode
48 flex fuel owner’s manual march 2011 cover the cardboard with a layer of small bulk materi- als that covers the entire bottom of the firebox. 12: bulk materials auto mode 12.4 setting the release period note: it is particularly important that you determine whether sufficient power demand is availa...
Page 49: 12: Bulk Materials Auto Mode
49 march 2011 flex fuel owner’s manual then turn the control knob to scroll to the screen “bulk materials auto control“. The release mode currently set and current time release status (on/off) can now be seen. Press the control knob to change the release mode. The screen “bm auto control – release” ...
Page 50: 12: Bulk Materials Auto Mode
50 flex fuel owner’s manual march 2011 you can now enter up to three release periods for the weekdays monday to friday. If furnace operating mode “bulk materials auto control” is set, the furnace will only start on weekdays if a heating circuit demand is present and a time release is given. Once you...
Page 51: 12: Bulk Materials Auto Mode
51 march 2011 flex fuel owner’s manual release mode “acc. To date” select release mode “acc. To date” if the furnace should be started on a particular day. The screen “bm auto control – acc. To date” is shown on the display: one can now set the exact date and time on which the ignition process shoul...
Page 52: 13: Pellets Auto Control
52 flex fuel owner’s manual march 2011 note: always ensure that the insert corresponding to the furnace operating mode is fitted and the pellet slide and flap (sections 13.3) are in the correct position for the selected mode. Ensure that the diverting valve has been properly set. (section 5.4) 13.1 ...
Page 53: 13: Pellets Auto Control
53 march 2011 flex fuel owner’s manual check status line(s) before starting the furnace in “pellets auto control” the furnace should be switched off. Check pellet supply your furnace operating mode is “pellets - manual filling” meaning the operator must fill the hopper manually. Open the cover of th...
Page 54: 13: Pellets Auto Control
54 flex fuel owner’s manual march 2011 13: pellets auto control adjustment bolt (fig. 1) correct burn: no further adjustments needed (fig. 2) incorrect burn: bolt is too far in. (fig. 4) incorrect burn: bolt is too far out. (fig. 3) allow the furnace to burn for another 45 minutes and check the pile...
Page 55: 13: Pellets Auto Control
55 march 2011 flex fuel owner’s manual 13: pellets auto control 13.4 starting the furnace in operating mode “pellets auto control” setting the furnace operating mode verify that the furnace operating mode is currently set to “pellets auto control” . The operating mode line must read “pellets“. If it...
Page 56: 13: Pellets Auto Control
56 flex fuel owner’s manual march 2011 13.6 status lines for operating mode “pellets auto control” boiler is switched off! The furnace is switched off. If you want to start the furnace, switch it on as described in section 7. Availability! The furnace is in standby mode. All calls for heat have been...
Page 57: 13: Pellets Auto Control
57 march 2011 flex fuel owner’s manual 13: pellets auto control pellets mode! The furnace regulates in “pellets mode!” as long as there is a call for heat and the furnace temperature is lower than the set “boiler target temperature“. The speed of the induced draft fan and the pellets fill level in t...
Page 58: 13: Pellets Auto Control
58 flex fuel owner’s manual march 2011 fgt-drop or ar too high! Fan lag! The flue gas temperature during the “start phase!” or in “pellets mode!” has noticeably dropped or the measured air factor was noticeably high. Possible reasons for these noticeable effects could be: • the firebox door or ash d...
Page 59: 13: Pellets Auto Control
59 march 2011 flex fuel owner’s manual 13: pellets auto control feeder temperature too high! Fan lag! The temperature monitor in the feeder has measured an over temperature. Fan lag is activated and the feeder is emptied. The fan lag cycle (duration 10 – 30 minutes) is completed even if the feeder t...
Page 60: 13: Pellets Auto Control
60 flex fuel owner’s manual march 2011 possible reasons why an ignition fault may be caused: • the ash chamber or flue pipe is covered in ash. • the ash door and/or firebox door are not fully closed. • the pellets insert is contaminated with dirt and should be cleaned. • the igniter is defective. • ...
Page 61: 14: Buffer/thermal Storage
61 march 2011 flex fuel owner’s manual if a buffer is available, the following figure appears on the screen of the actual values of individual system components. To access the buffer settings turn the control knob while on the start screen until the following screen appears. If you would like to che...
Page 62: 14: Buffer/thermal Storage
62 flex fuel owner’s manual march 2011 release method you may select 3 different types of releases for the buffer. Likewise, the release type only has an affect in the furnace operating modes "pellets automatic", and "bulk materials-automatic". Always off if you select always off, the buffer is not ...
Page 63: 15: Maintenance
63 march 2011 flex fuel owner’s manual 15: maintenance 15.1 general information note: the owner/operator must follow any local and state codes/laws concerning the operation of a wood fired furnace. The operator must follow the guidelines for furnace operation as stated in this owners manual. The cor...
Page 64: 15: Maintenance
64 flex fuel owner’s manual march 2011 15: maintenance cleaning the ash chamber • check that the furnace is not operational and is cool • open the outer enclosure door • open the ash chamber door • push the ash tray onto the bottom door frame • use the ash scraper to carefully pull the ash onto the ...
Page 65: 15: Maintenance
65 march 2011 flex fuel owner’s manual 15: maintenance notes:.
Page 66: 16: Error Messages
66 flex fuel owner’s manual march 2011 if a malfunction occurs, the error message is directly displayed on the screen. The red led of the esc key is switched on. The following error messages can appear: main fuse faulty! The i/o board is fitted with a fuse (10a slow-blow) to protect the controller. ...
Page 67: 16: Error Messages
67 march 2011 flex fuel owner’s manual safety temperature limiter has tripped! The furnace temperature can rise above 194 °f if there is a sudden reduction in heat demand. In this case the built-in safety temperature limiter will trigger a fast shutdown of the furnace. Fault rectification 1. Wait un...
Page 68: 16: Error Messages
68 flex fuel owner’s manual march 2011 burn back damper blocked! The burn back damper could not be fully opened during pellets start. Possible causes of this error message: • functional fault of the burn back damper (mechanical or electrical) • blockage near the burn back damper if it was possible t...
Page 69: 17: Troubleshooting
69 march 2011 flex fuel owner’s manual 17: troubleshooting problem cause/solution heating system is not working furnace is producing excessive smoke check power connection furnace emergency switch is deactivated refer to section 23 activate furnace furnace is in part load mode. Do not add more wood ...
Page 70: 18: Specifications
70 flex fuel owner’s manual march 2011 18: specifications flex fuel 30 kw flex fuel 60 kw maximum current draw average daily power consumption max heat capacities hopper capacity (optional) firebox dimensions firebox door frame core furnace material thickness draft control water temperature control ...
Page 71
Customer’s name ________________________________ dealer’s name _____________________________ customer’s signature _____________________________ dealer’s signature __________________________ woodmaster flex fuel warranty northwest manufacturing, inc. 600 polk ave. Sw – red lake falls, mn 56750 toll f...
Page 72
Installed by: dealer customer if customer, was installation explained to you? Yes no type of installation: house/garage shop/shed greenhouse kiln other ____________________________ purchased: with pellet arm without pellet arm northwest manufacturing inc. 600 polk ave. Sw red lake falls, mn 56750 no...
Page 73
Customer’s name ________________________________ dealer’s name _____________________________ customer’s signature _____________________________ dealer’s signature __________________________ woodmaster flex fuel warranty northwest manufacturing, inc. 600 polk ave. Sw – red lake falls, mn 56750 toll f...
Page 74
Installed by: dealer customer if customer, was installation explained to you? Yes no type of installation: house/garage shop/shed greenhouse kiln other ____________________________ purchased: with pellet arm without pellet arm northwest manufacturing inc. 600 polk ave. Sw red lake falls, mn 56750 no...
Page 75: 19: Warranty
75 march 2011 flex fuel owner’s manual woodmaster flex fuel warranty northwest manufacturing, inc. 600 polk ave. Sw – red lake falls, mn 56750 toll free (800) 932-3629 or (218) 253-4328 ten-year warranty on firebox and water jacket northwest manufacturing, inc. Of red lake falls, mn 56750 warrants m...
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..