Ozark BioMass Renewable Energy Outdoor Furnace Owner’s Manual Ozark BioMass Renewable Energy Outdoor Furnace 11136 Highway AD | PO Box 50 Falcon, Missouri 65470 Phone 417-453-6751 Fax 417-453-6082 http://ozarkbiomassfurnace.com email: firstname.lastname@example.org TABLE OF CONTENTS Very Important …………………………….………. Set-Up ……………………………………….....…… The back of the unit ………………………………… Operation of domestic water ………………………… Firing Directions …………..…………………..…….. Installation of thermostat ……….…………….……… Wiring on the Outside Unit ………………….………. Maintenance …………………………………….…… Parts on the front ……………...…………………….. Trouble Shooting ……………………………………. Basic Installation Diagram……………………………. Warranty Papers ……………………………………… Registration Papers …………………………………… 2 4 4 5 6 7 8 9 10 11 12 & 13 14 15 16 VERY IMPORTANT SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE 1. This product should be installed in accordance to local electrical and building codes. Authority having jurisdiction should be consulted before installation. 2. Sizes & Ratings: Ozark BioMass Renewable Energy Furnaces are manufactured in the following sizes and BTU/hr ratings. Voltage rating on all models is 120 V one phase, 60 Hz. Meramec BTU 150,000 Gasconade BTU 225,000 3. The following precautions must be adhered to for the safe operation of this product: a. No makeshift compromises during installation b. Do not use chemicals or fluids to start fire c. Do not burn flammable fluids such as gasoline, naphtha, engine oil or garbage d. Keep children away from this product while it is in operation e. Do not store solid fuel within clearance to combustible materials shown on label within the space required for charging and ash removal f. Ensure that the vent pipe is kept open at all times to insure the stove does not become pressurized and that the condensation tank is placed on vent pipe to help prevent water loss. g. When unit is not in use drain the system of all water to prevent freezing in cold weather h. Make sure sufficient amount of water treatment is kept in unit at all times while unit is filled with water i. Unit must be filled with at all times to insure safer operation otherwise unit will be damaged SET UP Your OZARK BIOMASS RENEWABLE ENERGY Outdoor Furnace should be set on a cement pad. The area around your OZARK BIOMASS RENEWABLE ENERGY unit should be covered with noncombustible material (gravel, concrete, patio stones) at least one foot on either side and back and front. 3 ON THE BACK OF THE OZARK BIOMASS RENEWABLE ENERGY FURNACE Domestic Water Coil Extra Zone Clean Out Door Inlet to furnace Pump Extra Domestic coil bung Extra Zones Cold water fill-up valve Cleanout Bung for tank Extra Return Return Electrical Supply While furnace is in use valve above pump should be opened, valve on return line should be opened. The cold water fill up valve should be shut except while filling up furnace tank. 4 When side valves are opened and middle valve is shut your outside furnace will heat your water. Reverse for water heater only. 5 FIRING DIRECTIONS Start your fire just as you would for any other wood burner. Stack your wood at the front of the firebox, laying it lengthwise in the firebox. See Figure 30. When you go to add wood to your OZARK BIOMASS RENEWABLE ENERGY Furnace you should always rake the coals to the front of the firebox and stack you wood at the front also. The blower on the OZARK BIOMASS RENEWABLE ENERGY will make it easier to start your fire. Note: When you first fire the furnace up the cold water in the tank will cause a tremendous amount of condensation inside the firebox and flues. It should stop in a few hours. After starting fire shut the fire box door turn fan switch on. If it is dark outside you can turn on your outside light to assist you in loading. BLEEDING THE SYSTEM Turn off the ball valve on Heat Inlet and turn on the ball valve on Heat Outlet. If you have cut off flanges on your pump, make sure that they are open. Take the pex pipe loose from Heat Inlet. Leave it loose until you get a good flow of water, then turn on the pump. A steady flow with no gurgles, burps, or spruts signals that no air is coming through the line. Cut off the pump, hook the pipe back up and open the ball valve. If the coil is mounted at a point as high or higher than the water level in the heater, it may be necessary to bleed the system in sections. Take the pex pipe loose from the outlet side of the pump and make sure that you have water through the pump. Hook that pipe back up at the pump and go to the top (highest) outlet on the coil and loosen that fitting. Turn on the pump and let it run until you stop getting air out of that fitting. Turn off the pump and open the ball valve on Fitting (make sure that the pex pipe has been re-attached). You may get some more air out of the top fitting on the coil at this point. When all air is out, tighten your fittings. The system should now be bled. 6 INSTALLATION OF THERMOSTAT The basic concept is to start your circulating pump and air handler simultaneously as there is not time delay for heat strips to warm. Your existing thermostat may be utilized or an additional unit may be installed to exclusively control your new OZARK BIOMASS RENEWABLE ENERGY Furnace. Service Tip: Ozark BioMass Renewable Energy Manufacturing recommends installing an electrical receptacle near the wire controlling the circulating pump which is controlled by the thermostat. This will enable a service technician to check the circulating pump without necessitating access to the thermostat. If you have any questions please contact your Ozark BioMass Renewable Energy Dealer. 7 Wiring On The Outside Unit Power Supply G W Light B W B G Aquastat Light Switch Fan Switch Fan B MAINTENANCE 8 W G Your Ozark BioMass Renewable Energy Furnace requires maintenance regularly to allow proper performance and efficiency. Requirements include checking all flue pipes, ensuring there is no internal creosote build up. When build up occurs, the scrapers and flue brush in you clean out kit will allow you to remove the burnt materials from the flue pipes here also. Your Ozark BioMass Renewable Energy furnace tank should be flushed annually and Ozark BioMass Renewable Energy Chemical replaced after the tank is cleaned. We recommend checking the pipes at least once a month and more often if the wood is of high sap content. After the first full year of operation you OZARK BIOMASS RENEWABLE ENERGY furnace should be drained and inspected for sediment deposits. Ozark BioMass Renewable Energy Chemical should always be used when refilling the tank after it has been drained. Flush with clean water to wash out all of the sediment deposits. The furnace should be drained and flushed with clean water and the Ozark BioMass Renewable Energy Chemical replaced every year or as needed. You will need to caulk around the base of the condensation tank and flue once a year with high temperature caulk. Cleaning Out Flues 1. To clean out open doors front and back. 2. The upper return flue will normally require the most attention because when wood is burned slowly, or when the wood smoke is cooled sufficiently it produces tar and other organic vapors, which combine with expelled moisture to form creosote. The creosote vapors condense in the relatively cool chimney flue of a slow-burning fire. As a result, creosote residue accumulates on the flue lining. When ignited this creosote makes an extremely hot fire. If creosote has accumulated, it should be removed to reduce the risk of chimney fire. The unit is not to be connected to a chimney flue serving another appliance. IMPORTANT It is important to keep the flues free of a creosote build up to avoid a creosote flue fire. Should a creosote flue fire develop it is best to let the fire burn itself out. Even though the creosote fire is very undesirable because of excessive smoke it is much safer to let the flue fire burn itself out. Do not open doors or remove flue covers during a creosote fire because there is a danger of flames leaping out at the newly exposed opening causing severe burns. Remember, the best way to handle a creosote flue fire is prevention. Inspect your flues once a month and keep them clean. ASH REMOVAL You do not have to take the fire out of the unit to remove the ashes. Here are two ways this can be accomplished. 1. The fire in you Ozark BioMass Renewable Energy furnace burns from front to back. If you like, you may periodically remove ashes from the front of the firebox before you put wood in it. 2. When you put wood in your unit and the fire burned down to just a bed of coals, you can take your flatnosed shovel and rake the coals to one half of the firebox. Repeat this process for the other side of the firebox. ***CAUTION*** Dispose of the ashes away from other combustible material. For safety, the ashes can be disposed of in a steel container. Parts on the front of your furnace. 9 10 Trouble Shooting Guide PROBLEM POSSIBLE CAUSE HOW TO CHECK PROBABLE SOLUTION House too warm Stove will not heat up properly Thermostat May be defective Replace thermostat Relay may be defective Replace relay Improper Wiring Check all Wiring Pump not shutting off properly No wood in unit Check the wiring in particular where it connects to the relay Fill stove with wood Flues on stove pipe clogged or obstructed Examine Clean flues and or stove pipe Aquastat not working Examine Replace aquastat Draft fan not working ** Draft damper is hung Not enough heat in house Burn too much wood No domestic hot water check to see if it's getting current if yes fan is bad Check to see if solenoid is getting current if yes solenoid is bad Replace fan Replace solenoid Aquastat set too low Draft fan will turn off before 180 Turn up aquastat Pump on but not circulating Pipe is hot to pump & cold leaving pump or pipe is hot to coil and cold leaving coil Bleed air out of system Pump will not turn on Bad thermostat Bad Relay Improper wiring bad pump call an electrician replace thermostat replace relay check wiring replace pump Flues Clogged Examine Clean flues and or stove pipe Aquastat is operating on too large of differential Return duct on a forced air system is sucking cold air Check adjustments Reset A close inspection of system Seal ductwork Stove is not hot Check temp gauge see above ** Aquastat is set too low Draft fan may be cutting off before 180 is reached Turn Aquastat up Stove too far away Aquastat set too high Stove too hot Examine add a pump draft fan not shutting off at 180 Turn down Aquastat Weather is too hot turn off draft fan with switch and use more hot water. As long as the stove is full of water you can't hurt it. Weather is too hot Use less wood 11 12 WHO GETS THE WARRANTY? The Ozark BioMass Renewable Energy Outdoor Furnace limited warranty is extended to the original purchaser only. This limited warranty is only extended on furnaces purchased new from a certified Ozark BioMass Renewable Energy Outdoor Furnace dealer or direct from factory. This warranty is not transferable. Requirements for warranty: 1. Installation must be inspected and signed by a certified Ozark BioMass Renewable Energy Outdoor Furnace dealer. 2. Customer must complete, sign, and return warranty to Ozark BioMass Renewable Energy Outdoor Furnace, PO Box 50, Falcon, Mo 65470 within 30 day of purchase to be valid. Return registration along with the purchase agreement from the dealer. WARRANTY Meramec and Gasconade Units have a 10 year limited warranty. The warranty does not cover accessories or components on your Ozark BioMass Renewable Energy Outdoor Furnace. Those components have their own manufacturer’s warranty. Warranty does not cover the domestic hot water coil stopping up with lime. If you have hard water you will need a softener, have your water checked. Front door and door gasket has 1 (one) year warranty. If your Ozark BioMass Renewable Energy Outdoor Furnace fails while in normal use and operated while maintaining strict factory standards of routine service, care, and cleaning due to a manufacturing defect in materials and or workmanship within warranty period from the date of delivery, Ozark BioMass Renewable Energy Outdoor Furnace will repair the product. The repaired product will be warranted under the terms of this limited warranty for the remainder of the warranty period mentioned above. You should understand that company representatives may include replacement of the product part or components with functionally equivalent reconditioned products parts or components. All warranty work is done at factory in Lebanon, Missouri, USA. It is the responsibility of customer to unhook, for freight to and from manufacturing facility and reinstalling of the unit. Ozark BioMass Renewable Energy Outdoor Furnace is also not responsible for loss of use while repairs are being made. Ozark BioMass Renewable Energy Outdoor Furnace is also not responsible for labor costs. Your Responsibilities: Your Ozark BioMass Renewable Energy Outdoor Furnace must have adequate water-treatment at all times. Every 6 (six) months Ozark BioMass Renewable Energy Outdoor Furnace needs a sample of water to verify sufficient water-treatment is in unit at all times. You must buy Ozark BioMass Renewable Energy Outdoor Furnace water treatment or Control 200 from your authorized dealer or directly from Ozark BioMass Renewable Energy Outdoor Furnace. You must keep flues and firebox clean. Don’t let ash, soot, and creosote build up in unit. Keep clean all the time. You must clean furnace out annually flushing all water out of tank, replace with fresh Ozark BioMass Renewable Energy Outdoor Furnace water-treatment or Control 200 water treatment. You must caulk around the base of the condensation tank and flue once a year with high temperature caulk. Use of other products voids warranty. Do not use other chemicals. Do not mix chemicals. Negligence, modifications, abuse, or unauthorized repairs are not covered under warranty. All Ozark BioMass Renewable Energy Outdoor Furnace units must be maintained properly. What is NOT covered: This warranty does not cover unhooking, reinstalling, freight to and from Ozark BioMass Renewable Energy Outdoor Furnace nor loss of use while repairs are being made. Ozark BioMass Renewable Energy Outdoor Furnace is not responsible for loss due to water leakage or failure of any part of the system. Hot water burns are not a liability of Ozark BioMass Renewable Energy Outdoor Furnace. Ozark BioMass Renewable Energy Outdoor Furnace does not warranty parts of tank from freezing, overheating, pressurization or the use of unauthorized fuels. DO NOT PRESSUREIZE your Ozark BioMass Renewable Energy Outdoor Furnace or it will explode. DO NOT LET YOUR Ozark BioMass Renewable Energy Outdoor Furnace run out of water, that will damage unit; Ozark BioMass Renewable Energy Outdoor Furnace is not responsible for falling into or on your Ozark BioMass Renewable Energy Outdoor Furnace, back problems or any injuries associated with lifting wood and domestic disputes are not the responsibility of Ozark BioMass Renewable Energy Outdoor Furnace and not covered by warranty. Nor is Ozark BioMass Renewable Energy Outdoor Furnace responsible for fires from sparks or hot ashes. Hot ashes must be put in proper and safe places, in a metal can or put out and cooled off by water Ozark BioMass Renewable Energy Outdoor Furnace specifically disavows any other representation, warranty, or liability related to the condition or use of this product. These units are built to burn wood, hay, stubble or coal only. The burning of petroleum based products, tires, roofing materials, paints, solvents, naphtha, and other fuels is dangerous and in most instances illegal and could damage your unit your property, not to mention cause serious injury or death to yourself or others, and void your warranty. Do not burn aerosol cans, old cigarettes lighters, propane or map gas bottles, gun powder, black powder, ammunition, fireworks, light bulbs, batteries, or anything that can be explosive. Ozark BioMass renewable Energy Furnace is not labial for property damage, personal injury or death, fires, explosions, civil suits, domestic disputes, back or head injuries from fueling stoves or for any fines for illegal burning of domestic waste or other. The unit’s door could get hot enough to burn and should be approached with caution, but normally does not. The handle should be safe to touch, gloves are recommended when fueling. There is a shut off switch which should be shut off during fueling and be sure to turn it back on after the door is shut. Children should never fire this unit. The flue on the back of the stove also gets very hot when fired and will burn if touched and should be approached with caution. Ozark BioMass Renewable Energy Outdoor Furnace is not labial for any person or persons getting burned while touching the flues or hot doors, or the fire box, or the fire in the fire box, or falling into the fire box. Your Ozark BioMass Renewable Energy Outdoor Furnace should be set at least 25 feet from any structure. It can also be as far as 400 feet. But up to 100 feet you will experience the least amount of heat loss. It should be placed in your yard where it is convenient for you and for fueling; in an area where wind is less likely to blow into your house or neighbors homes. The flue can be extended above the roof lines and a cap can also be used to prevent sparks in cases where dry wood and trash is frequently burned or in areas where a lot of dry grass and leaves exist. These areas should be cleaned to prevent brush fires. 13 Ozark BioMass Renewable Energy Outdoor Furnace Warranty Registration To validate this warranty, your registration must be completed within 30 (thirty) days of purchase date and sent by certified mail. To: Ozark BioMass Renewable Energy Outdoor Furnace PO Box 50 Falcon Missouri 65470 Registration Please Print Purchaser’s Name__________________________________________________________ Address___________________________________________________________________ City_______________________________State__________Zip_______________________ Model #________________________________ Serial #_____________________________ Date of Purchase_____________________________________________________________ Dealer Name________________________________________________________________ Dealer Signature_____________________________________________________________ Copy of Dealer Invoice attach I have read and understand the terms of this warranty and will retain possession of and will abide by them and the accompanying maintenance guide. Purchaser’s Signature___________________________________________Date__________ You will receive an acknowledgement from Ozark BioMass Renewable Energy Outdoor Furnace regarding the receipt of your warranty and registration forms. Please retain the acknowledgement in your records.