Congratulations On Your Investment

Transcript

CONGRATULATIONS ON YOUR INVESTMENT You have selected one of the simplest yet durably advanced outdoor furnaces on the market today! The Spirit S4868P has been designed and built to old fashion quality standards that have resulted in outstanding operating principals and longevity To ensure that you get the maximum benefits and initiate safe operating principals, we suggest you get to know your Spirit and read this manual from cover to cover before operation. Although we have strived to include all possible scenarios for safe operation and troubleshooting of your furnace , there may arise a circumstance that is not covered in this manual. NEVER attempt to make changes to the operating system without authorization if it is not covered in this manual. Doing so could result in death or injury to yourself or others. Thank you for choosing The Spirit S4868P Outdoor Wood Burning Furnace. We Hope you enjoy both the new comfort and savings created by your new Spirit Outdoor Wood Burning Furnace. Model S4868P Outdoor Furnace Guru, 511 Pine Street, Sparta, WI 54656 Tel. (608) 487-2013 Fax. (608) 487-9136 www.outdoor-furnace-guru.com 1 SOLID (WOOD) FUEL BOILER TESTED TO CSA B366.1-1991, UL 726-06 CHAUDIERE COMBUSTIBLE À (BOIS) SOLIDE TESTÉ CSA B366.1-1991, UL 726-06 Although tested at one time, these units will not come with a UL certification sticker! 2 SAVE THESE INSTRUCTIONS Table of Contents Congratulations CSA label Table of contents Safety Specifications Component Locations Base Requirements Installation Requirements & Cautions Operation Procedures Cautions A overview to burning the Spirit way Filling the furnace with water Starting a fire in the furnace Loading the furnace with fuel The burning cycle Ash removal Resetting the computer Shutting down for the season Maintenance Cleaning the blower damper Troubleshooting chart Wiring diagrams 3 Page 1 2 3 4 5 6,7 8 9 10 11 11,12 13,14 15 16 17 18 19 20 21-24 25 26-28 !!CAUTION!! ! The Spirit Outdoor Wood Furnace should not be used as a stand alone unit. A backup system should be in place in case of failure. Burn seasoned firewood only. Green wood does not burn hotter and will cause inefficiency and problems. NEVER burn other materials such as garbage, tires, engine oil, solvents, gasoline or any other flammable liquids. ! ! Start your fire with paper and kindling only! NEVER use gasoline, kerosene, charcoal lighter fluid or any other similar liquid to start or freshen up a fire. ! Operate your Spirit Outdoor Wood Burning Furnace at atmospheric pressure only! DO NOT seal, clamp or tape any caps in place. ! NEVER install the Spirit Outdoor Furnace inside another building! The Spirit is designed for outdoor use only! ! Do Not operate the furnace during power failure. ! Do Not allow the furnace breath by providing combustion air through an open fire door. ! Crack open the fire door slowly when opening to allow combustible gases to escape. Unburned gases can ignite and cause serious burns if the door is opened to quickly. ! Keep the area 10 feet around your furnace clear of wood, paper and other combustible materials at all times. ! Locate your Spirit Outdoor Wood Burning Furnace at least 50 feet from any buildings or structure. Check with your insurance company for additional requirements regarding the installation of your Spirit Outdoor Wood Burning Furnace to safe guard your coverage. ! Use of a rain cap with spark arrestor is recommended. ! Installation is to be done by a qualified installer only. For additional information on safe burning4procedures, request the NATIONAL FIRE PROTECTION ( Using Coal and Wood Stoves Safely), NFPA No. HS-10-1978. Address is NFPA, 470 Atlantic Ave., Boston, MA 02210. Elite Heat 4868P Specifications Total Width 50 Base Width 48 Total Length 82 Base Length 68 Height 90 Firebox Length 54 Firebox width 38 Chimney size 8 Wood Length 42 Water Capacity (US gal) 320 Door Size 20 x 20 Weight 2790 Heating Capacity* 1200—7000 Sq. Ft. All measurements are expressed in inches. Weights and measures may vary slightly. *May vary according to home and climate conditions. 5 Furnace component name and locations 1 2 3 4 5 6 7 8 10 9 14 15 11 16 17 13 12 1-Float and vent tube 2-Float cap assembly 3-Water level indicator washers 4-Lifting eye 5-Rain cap/spark arrestor (Not sold with furnace) 6-Insulated stove pipe (Not sold with furnace) 7-Stove pipe adapter (Not sold with furnace) 8-8” flue pipe 9-Upper level temperature gauge 10-Blower shut off switch 11-Door hinges 12-Base lifting and tie down tubes 13-Base 14-Fire door safety latch 15-Fire door handle 16- Fire door latch 17-Fire door shield 6 Furnace component name and locations 23 18 22 19 24 20 26 21 27 25 28 26 Rear Access Area (Shown with 2 pumps installed) 18– Computer controller 19– Mini fuse & main shut off switch 20– Blower 21– Blower mounting plate 22– Secondary return 23– pump receptacle box 24– primary return 25– secondary return 26– reservoir drain 27– temperature control probe 28– field wiring junction box Component location and materials may vary by revision. 7 Base Requirements Minimum Slab Dimensions 80.00" 15" 6" B Rear 30.00" SECONDARY LINES 6" 60" 15" A Front PRIMARY LINES Represents furnace base 14" NOTE: When installing one set of lines for service to a single area, the lines must come in to the unit on the primary side marked A for the furnace to sense and operate properly. Secondary sets of line must come into the access area in the area marked B. ! When electing to use blocking instead of a cement slab, support the furnace by the lift tubes both front and back on either side. USE SOLID BLOCKING ONLY! DO NOT USE CINDER BLOCK! 8 Installation Requirements & Cautions ! SAVE THESE INSTRUCTIONS Use only chimneys suitable for solid fuel. Contact your dealer for instructions if additional chimney is needed . Do not connect to a chimney flue serving another appliance. Use only non-combustible materials with adequate support for a base. Maintain the following clearance to combustibles. Sides=36” Front=48” Top=12” Chimney connection=18” Adhere to minimal clearances or fire may result! Installation with existing boiler This unit may not be connected to an existing boiler system unless a suitable water to water exchanger is used. This unit shall be installed without interfering with the normal delivery of heated water from the original boiler. This unit shall be installed without affecting the operation of electrical and mechanical safety controls of the original boiler. Installation of this unit shall provide for a change over from one fuel to another without requiring manual adjustment of any controls or components other than the thermostats. Maintain adequate water capacity in this unit to prevent damage in the advent of a power failure. Do not change the function of any controls or rewire the original boiler. A wiring interconnection is permitted. The electrical system of both boilers must be powered from a singe branch circuit without exception. The operation of a gas boiler must be verified for acceptable operation before and after installation of this unit by a gas fitter who is recognized by the regulatory authority. Installation should comply with requirements of CAN/CSA-B365, and changes to the installation should comply with CSA B139 (for oil-fired), C22.1 (for electric) or CAN/CGA-B149.1 or CAN/CGA-B149.2 (for gasfired) 9 Operational Procedures SAVE THESE INSTRUCTIONS Burn wood only! WARNING! Risk of Fire Do not operate with fueling door open! Keeping the door closed tightly and seals in good condition is a must for proper operation. Inspect and clean the flue regularly! Use only CSA and UL approved double wall, insulated, stainless steel chimney pipe when additional chimney height is required. Additional chimney should be braced. Do not operate during a power failure. Keep doors closed until power is restored. Do not store fuel or other combustibles within clearances! Sides=36” Front=48” Top=12” Chimney connection=18” Adhere to minimal clearances or fire may result! OPERATE THE (GAS, OIL, ELECTRIC) BOILER PERIODICALLY TO ENSURE THAT IT WILL OPERATE SATISFACTORILY WHEN NEEDED. DO NOT CONNECT TO ANY CHIMNEY OR VENT SERVING A GAS APPLIANCE. 10 Operational Procedures A overview to burning the Spirit way At fist glance, you will notice that the S4868P firebox is very simple and similar to other outdoor wood furnace fireboxes on the market. However, that is where the similarities stop. The S4868P combustion area has been designed to accept large wood loads without flooding the combustion chamber with to much fuel release or to much combustion air. The S4868P regulates the air/fuel ratio to burn a hotter more efficient fire. We call our burning method the wick-burn/air-shear design. The result of burning with this method allows the S4868P to burn cleaner, hotter and more efficient than other more common designs while maintaining a large firebox size. Large firebox designs are appealing due to ones ability to cut wood larger, saving valuable time preparing the winters fuel supply. Even though you may be a veteran wood burner, we recommend that you study the following operational methods and adhere to them closely. Following the set operational procedures will ensure that your furnace can do the greatest amount of heating on the least amount of wood, and do it cleanly. Filling the furnace with water The Model S4868P furnace has a water capacity of approximately 320 gallons. It is recommended that you estimate the filling time before starting in order to prevent overflow. This can be done by timing how long it takes to fill a 1 gallon pail. Example: 1 gallon in 15 seconds 15 seconds x 320 = 4800 seconds 4800 seconds / 60 = 80 minutes IMPORTANT: It is recommended that a flushing is performed before filling the unit to remove any foreign materials that may have found their way into the water reservoir. 11 Operational Procedures Filling the furnace with water STEP 1 : Remove float cap assembly to one side of the float and vent tube. STEP 2 : Insert a garden hose into the float and vent tube. Be sure that the hose is not kinked or water flow will be affected, changing the calculated fill time. STEP 3 : When the furnace is approximately 1/2 full, add the approved Outdoor Wood Furnace water treatment. STEP 4 : Continue to fill until the water level is approximately 1 inch below the bottom of the vent tube. This will allow for expansion of the warming water to the proper water level when the furnace is fired. NOTE: If overflow occurs, drain excess water from rear at the reservoir drain STEP 5 : Open any valves and check all installed plumbing for leaks. STEP 6 : Apply power to the pumps and allow circulation and mixing to occur of the treated water Proper water level is 3-1/2” out of the Top of the float cap assembly These Measurements are at operational temperatures(160-180 deg.) Water should not be allowed to drop below 2” from the top of float cap assembly. 12 Operational Procedures Starting a fire in the furnace LOAD FUEL CAREFULLY OR DAMAGE MAY RESULT STEP 1 : Perform the following pre-firing checks.  Does the firebox door move freely and seal?  Does the combustion fan operate?  Is the furnace water level correct ?  Is the flue free from obstructions?  Are there any leaks?  Is the blower damper flap able to move freely?  Is the pump circulating properly? STEP 2 : Place paper or cardboard in firebox approximately 3/4 the way back. CAUTION! Hot surfaces. Keep children away. Do not touch during operation. Always open door slowly! STEP 3 : Place approximately 1 bushel of dry kindling on the front side of the paper in a loose random fashion as shown. NOTE: Establish a routine for firing techniques. Check daily for creosote build up until experience shows how often cleaning is necessary. Have a clearly understood plan to handle a runaway fire. 13 Operational Procedures Starting a fire in the furnace (continued) STEP 4 : Make sure the blower switch is in the off position. Light a piece of paper on fire and throw it to the back of the furnace. Immediately turn the fan switch to the on position for 3 seconds and then turn off. This ensures that the fire will make contact with your starter fuel. Once the starter fuel has begun to burn, close the door and immediately turn on the blower switch. Lighting fire Starter fuel igniting Fan pushing fire into kindling (Shown with the door open for instructional purposes only!) Always open door slowly! Burn dry seasoned wood only. Store wood in dry covered area outside of the require clearances and out of the way of cleaning and fueling the furnace. Establish a safe routine for fuel storage and loading. ! ! Never lean or reach into the firebox for any reason! Start your fire with paper and kindling only! NEVER use gasoline, kerosene, charcoal lighter fluid or any other similar liquid to start or freshen up a fire! 14 Operational Procedures Loading the furnace with fuel STEP 5 : Allow the kindling to burn down to a coal bed. Turn the blower switch off and open door slowly. Push the coal bed to the rear 25% of the firebox with a long handled shovel. Always open door slowly! STEP 6 : Load fire wood just in side the door and rank as tightly as possible. Cut wood no longer than 36 inches. Longer cut wood will temporarily obstruct air flow and cost efficiency. Do not fill the firebox above the indicated maximum load line. NOTE: If firebox becomes overfilled, turn the blower switch off and allow the fire to die down before removing any fuel. Remove fuel to proper containment for hot fuel. Maximum load line STEP 7 : Shut the furnace door and turn the blower switch to the on position. 15 Operational Procedures The burning cycle Please learn and follow the cycle of combustion and re-fueling in the S4868P furnace. Doing so will increase the life of your unit by reduced emissions, increase efficiency and decrease the amount of ash removal. The S4868P furnace burns its fuel charge in a wick form. This effectively controls the amount of air and fuel that are allowed to mix, thereby creating a cleaner burn with hotter firebox temperatures. The greater the difference between the water temperature and the firebox temperature, the more heat transfer power is available. This equates to quicker recovery times and shorter burn cycles. Notice to the left how the wood charge has been consumed from the back to the front. This is an appropriate amount of coal bed to start up the next fuel charge. Carefully push the remaining coal bed from the previous fuel charge to the rear 1/3 of the firebox with a long handled shovel. NOTE: Be aware that the hotter the fire, the less creosote that is deposited and that weekly cleanings may be necessary during mild weather, even though monthly cleaning may be enough in the coldest months. A Small intense is preferable to a small smoldering fire to reduce the amount of creosote deposition. Load the new fuel charge to the front of the firebox no higher than 3/4 up in the door frame. A partial fuel charge is shown in the picture to the left for educational purposes. Once you get to know your furnaces demands, it would be good practice to only load as much fuel as would be needed to get you to the next convenient fueling time. 16 Operational Procedures Ash removal Ash removal, when used at maximum capacity, will be at 7 to 10 day intervals, depending on ash content of the fuel being burned. For most, ash removal will be at 21 to 30 day intervals. Ash is removed when it builds up in the rear of the furnace enough that it noticeably affects air flow. This will be noticed in more emissions (smoke) and longer cycling times. When the furnace is used at 50% capacity or less, some ash should be left in the firebox rear to protect your unit from going out on an extended period of cycling time. The extra ash helps to hold the coals while combustion air is not present. The following is the suggested method for ash removal. ! Always use a metal container with a lid to hold ash. STEP 1 : Pull or keep a small bed of coals to the front of the firebox. STEP 2 : Remove remaining ash using the rear of the furnace as a back stop. STEP 3 : Push the coal bed to the rear of the firebox and reload with fuel. 17 Operational Procedures Resetting the computer Your S4868P furnace is equipped with a fail safe in the event that it should drop below normal operating temperatures for a period of time. This would signify that there is no heat being created in the firebox. The fail safe prevents the cold outside air from blowing threw the firebox, helping to prevent a possible freeze up or wasting heat. Follow these steps to reset the computer. NOTE: All the required operating parameters are pre-set at the factory. Do Not try to alter these settings. Doing so may cause operating problems and will not be covered as a warranty item. Press and hold these two buttons (Down arrow and SET) at the same time for 1 second to reset the computer from a low alarm (LA flashes intermittently with the current water temperature). The blower will start within 7 seconds. OR Disconnecting the power for a couple of seconds and turning it back on will also reset the computer. Power failures will not change the settings within or harm the computer. 18 Operational Procedures Shutting down for the season The following procedures should be taken to protect your investment when not in operation for extended periods of time. A. Scrape the inside of the firebox and flue clean of creosote and ash build up and remove. B. Spray down the inside of the firebox and flue with vegetable oil. Do not use motor oil. C. Cap the top of any chimney or the flue to prevent moisture from entering the firebox. D. Disconnect the power to the unit. E. Check all caulk seam and gasket and repair as needed. F. Make sure the water reservoir is full to prevent corrosion. G. Draw a cool water sample before shutting down the pumps and forward to the testing lab in the sample bottle provided with the approved treatment. Follow the recommendations of the lab for corrections, if any. NOTE: Running your pumps during the off season for a period of 24 hours every other week will help keep pump seals from drying out. Cleaning of the flue pipe, chimney and draft inducer is especially important at the end of the heating season to minimize corrosion during the summer months from accumulated creosote and ash. Water conditioning Use only Wood Burning Furnace Water Treatment Part # WT072 from your dealer. Product of: CERTIFIED LABORATORIES A division of NCH Corporation P.O. Box 2493 Fort Worth, Texas 76113-2493 19 Maintenance 1. Periodically inspect vent and float tube for freeness. 3. Coat the inside of the firebox and flue with vegetable oil when clean and dry. Do not use motor oil! 2. Remove ash and scrape firebox free of build up as needed. 4. Be sure the furnace reservoir is to the maximum fill point. 3. Check water level daily. 5. Periodically circulate water during the off-season to keep the treatment mixed thoroughly and lubricate pumps. Circulate for 24 hours once every other week. While in use 4. Check door for air tightness. The door gasket may display dark hard areas where leaks are present. 6. Cap chimney or flue to prevent moisture from entering the firebox. 5. Ensure shields and access panels are in place at all times. 6. Watch for damp areas inside the firebox. This could signify a leak. Condensation during the first fire or while burning unseasoned wood during warmer weather may also be present. Only burn seasoned wood and clean out damp ashes immediately. 7. If needed, thoroughly clean the blower and flapper assembly. Use the following procedure outlined on page to check for correct operation of the flapper assembly. After use (seasonal) 1. Thoroughly clean the furnace of any creosote and ash. This is the easiest to do when the furnace is still warm. 2. Check all parts of the furnace for any standing moisture. 20 Maintenance Cleaning the blower damper The S4868P uses an air delivery system that draws unburned gases in with the fresh air stream and pushes it back into the hot coals of the burning fire. Time, burning green wood or overloading your furnace so that it is in the off cycle for long periods of time, may cause the blower flapper to become dirty and hang up or stick closed. Use the following tools and process for cleaning the blower flapper. Tools Required Disconnect Power 5/16” socket or nut driver Utility knife Wire brush High temperature caulk WD-40 or equivalent High temperature grease Carefully remove 3-5/16” self tapping screws that retain the blower to the blower plate. Position blower to the side. Using a utility or putty knife, remove the caulk surrounding the blower plate. Blower Plate Flapper Plate screws Carefully remove 2-5/16” self tapping screws that retain the blower plate to the blower tube. Notice: A new blower plate revision has significantly reduced cleaning maintenance to seasonal in most instances. 21 Maintenance Cleaning the blower damper (continued) Inside the blower tube STEP 4 : Scrape and clean all creosote and deposits from the blower plate, flapper and blower tube. Firebox side of blower plate and flapper Penetrating fluid works well for cleaning between and in the hinge area. Be sure that the hinge swings freely when finished. 22 Maintenance Cleaning the blower damper (continued) Apply high temperature grease (500 Degree or higher) within the pivoting parts of the hinge. The grease acts as a barrier to the stickiness of the creosote and helps keep it out of the hinged area. Replace the blower plate to the blower tube. Be sure that the flapper seats well against the blower pate and swings freely. If not, the hinge may have been bent during the cleaning process. Remove and carefully adjust the hinge. Apply high temperature caulk around the blower plate, (500 Degree or higher). 23 Maintenance Cleaning the blower damper (continued) Reinstall the blower. Be sure not to over-tighten any screws during the complete reassembly process. Checking the flapper for correct operation Disconnect power To check the flapper for correct operation, insert a small diameter stiff wire through the squirrel cage until the flapper can be felt. Gently push the flapper open and closed. You should feel the free movement of the flapper and hear the tick of it shutting against the blower plate. 24 Troubleshooting Guide Problem Boiling or higher than normal temperature Low water temperature Moisture present in firebox Possible cause Solution Water not circulating Check pump operation Flapper sticking open Clean flapper Pg. 20 Leaking door gasket Replace door gasket Door left open Close door Flapper not opening Clean flapper Pg. 20 Blower not operating Reset computer Computer low alarm Reset computer Poor quality wood Burn good seasoned wood Green or poor quality wood Burn good seasoned wood Extreme low water tempera- Build up temperature tures Leak present Contact dealer Water down the flue Use a rain cap Excessive smoke and creo- Green or poor quality wood sote Flapper not opening properly Fan not operating Burn good seasoned wood Clean flapper Pg. 20 Check low alarm Improper burning procedure Follow burning procedure Excessive sparks or fire out Wrong fuel type the flue Use proper fuel, fuel length and loading recommendations Improper burning procedure Follow burning procedure Use spark arrestor 25 Wiring Diagram 26 Wiring Diagram Digital controller probe connects digital controller power supply outlet draft blower outlet power supply power from high limit switch Grounded 14 gage pig tail plug 27 S4868P Wiring Map Blower outlet Wiring Wire 1 - (BLACK) Distribution block (A,1) to blower switch 9’ 14 Ga. solid Wire 2 - (RED) Blower outlet switch to limit switch 8’ 14 Ga. solid Wire 3 - (RED) Limit switch to #4 on CPU 18” 14 Ga. stranded Wire 4 - (BLACK) #5 on CPU to blower outlet 20” 14 Ga. stranded Wire 5 - (White) Blower outlet white to distribution block (C,1) 20” 14 Ga. solid Wire 6 - (Green) Ground on blower switch to frame 18” 14 Ga. solid Wire 7 - (Green) Ground on blower outlet to distribution block (B,1) 18” 14 Ga. solid Light Wiring Wire 8 - (Blue) Distribution block (A,2) to light switch 9’ 14 Ga. solid Wire 9 - (Black) Light switch to light black Wire 10 - (White) Light white to orange wire nut in light switch box Wire 11 - (White) Orange wire nut in switch box to distribution block (C,2) 9’ 14 Ga. solid Wire 12 - (Green) Ground from light switch to frame 18” 14 Ga. solid Wire 13 - (Green) Frame ground in rear to distribution block (B,2) 3’ 14 Ga. solid Outlet Wiring Wire 14 - (Black) Distribution block (A,3) to outlet 12” 14 Ga. solid Wire 15 - (White) Outlet to distribution block (C,3) 12” 14 Ga. solid Wire 16 - (Green) Outlet ground to distribution block (B,3) 12” 14 Ga. solid CPU Wiring Wire 17 - (Black) Distribution block (A,4) to #7 on CPU 12” 14 Ga. stranded Wire 18 - (Blue) #8 on CPU to distribution block (C,4) 12” 14 Ga. stranded Wire 19 - (White thermo wire) #1 on CPU to #9 on CPU Wire 20 - (White thermo wire) #2 on CPU to #11 on CPU Wire 21 - (White thermo wire) #11 on CPU to thermo-coupler Wire 22 - (White thermo wire) #12 on CPU to thermo-coupler Source Wiring Wire 23 - Black from field wiring connection to A on distribution block Wire 24 - White from field wiring connection to C on distribution block Wire 25 - Green from field wiring connection to B on distribution block 28