1. Woodmaster Wood Burner

. WOODMASTER ULTRA SERIES Retain this manual Pellet Furnace Powered by the Renovator Pellet Burner www.woodmaster.com / 800-932-3629 / Manual PN: 7994-875 Northwest Manufacturing, Inc / 600 Polk Ave SW / Red Lake Falls, MN 56750 Rev:5.1/Software V22. 37-40 Specifications.41 Notes.42-43 Thank you for purchasing a qual- ity Ultra Series Pellet Furnace from WoodMaster. This product was de- signed to deliver easy, trouble free operation for years to come.

WoodMaster heating system. It is our goal to build the highest quality product at a competitive price, and maintain total customer satisfaction. This manual is a. Please read this entire manual before you install and use your new heater. Instructions may result in property damage, personal injury, and even death.

Check out other WoodMaster heating products at www.woodmaster.com. Terms Renovator AKA Burner or Pellet Gun - Combustion chamber that burns pellets Air Compressor - On board air cleaning agent PLC - Programmable Logic Control - Controls the burner Start Dose - Amount of fuel need to initiate ignition (approx. 5.25 oz, 150 grams, and 8.5 oz in volume) Photo Sensor - Read the photo resistance value to control the flame from ignition to combustion Auger Spiral - Feed auger screw Pellets - Wood sawdust compressed into small cylinders to be used as fuel. Safety.

Read and follow these directions carefully. Retain this manual for as long as you own your furnace. All installation and operations must follow STATE and LOCAL CODES for wiring, and firing of this unit.

These CODES may differ from this manual. Installation must be performed by a qualified installer. Safety. The water pump must run continuously whenever the WoodMaster Furnace is being used. The water pump must be installed on the supply line on the furnace. Take the proper precautions to ensure that the modifications made to an existing heating system does not interfere with existing safety controls.

Central electrical location for ease of wiring. Safety tested by Guardian to meet or exceed their standards for product quality & safety.

Benefits of the Ultra Series 1. High efficiency Renovator burner with automatic ignition. Easy access ash door in front for quick and easy ash maintenance. Fuels All wood pellets must conform to certain quality standards to ensure trouble free operation of the burner. Use of unapproved fuels will result in faulty operation and a voided warranty. Never use the following: trash, household garbage, plastics, gasoline, rubber, naphtha, leaves and materials treated with petroleum products (ie: particleboard, railroad ties &. Installation Unpacking Before you start installing your Ultra Furnace, remove the ash shovel and auger pipe from the furnace.

Woodmaster Wood Burner

These are lo- cated inside the back access door along the left hand side. The fire box contains the remainder of the system compo- nents. Note: Use only approved water line insulation sold through your WoodMaster Dealer.

Poor insulation will cause your Wood Master furnace to burn large amounts of fuel, and hurt the efficiency of the system. For best results use high quality insulation. Installation Mounting the Pump Cold Water Return Valve Note: The pump must be located on the furnace. The pump flange valve comes pre installed on the supply line. Locate one of the black rubber gaskets, and place it be- Hot Water tween the pump and the mounted flange valve, bolt the Supply Valve pump to the flange.

Installation Entering the building with water lines can be done underground or over the sill plate. Once inside the building the typical hookup would run first to the Domestic Hot Water Supply and next to an existing heating system such as a forced air furnace or a hot water heating system. Finally, before leaving the building, a fill valve must be installed near a water supply for filling and flushing the boiler in the WoodMaster Furnace. Installation Existing Hot Water Heat A Water to Water Heat Transfer Unit (0020-052) is used to connect to an existing hot water boiler system. Note: Any changes that are made to an existing boiler should be done by a qualified plumber and follow all state and local codes.

Installation Bleeding The System While filling the boiler, close the cold water return valve on the furnace for two or three minutes, and then open the valve. This will force trapped air out of the hot water supply line. Repeat this process with the hot water supply valve on the furnace to force air out of the cold water return line. Installation Locate the flame deflector that fits over the burner to prevent excess heat from contacting the door. Slide the ring of the flame deflector over the burner until it contacts the rear door of the firebox.

Ultra Owners Manual 2015. Installation Feed Auger Installation The angle of the auger should be between 43 and 45 degrees. The auger is to be hung from the roof of the boiler housing on the motor mount stud. The feed auger location is positioned so that it does not sit right above the tipping chute on the burner. Installation 5. Side the assembly through the hole in the side of the furnace until the T-pipe contacts the siding. Hang the motor on the hook that is located under the roof of the furnace using the hanger on the motor that is by the T-pipe set screw.

Put the top on the hopper by securing the hopper top to the side hopper with the screws (6) provided. Place the hopper in its location next to your Ultra Series furnace. 2015 Ultra Owners Manual.

Installation 5. Secure the boot to the intake auger tube with the clamps provided. Apply the bottom boot to the end of the intake auger tube and secure it with the clamp. Tighten the clamp on the boot to secure it to the side hopper. Installation Unpack the air compressor. Connect the air hose to the air compressor via the quick connect. Make sure the air compressors power switch is left in the “on” position.

NOTE: Do not modify the length of the air hose. Place the air compressor on the shelf that is next to the burner Plug the supplied air compressor power cord adaptor. Installation Flue Gas Analysis NOTE: THE FURNACE AND CHIMNEY WILL BE HOT DURING THIS TEST! Once the furnace is installed, it must be adjusted to proper burn settings. A flue gas instrument needs to be used that can read the following values: Draft, O2%, CO2%, PPM CO and stack temp. The sample is to be taken directly above the tube access box, in the port provided on the exhaust outlet.

Operation The burner is not adjusted from the factory. The burner has to be adjusted with a flue gas instrument the first time the burner is fired and after a change in fuel brand/quality. Remove the blue hose from the burner prior to priming the feed auger. Connect cable of the auger with the power cable for the burner and run it manually until pellets have been fed out from the auger for about 15 minutes using a bucket or pail to catch the pellets. Operation In phase two, the soft start level, the auger feeds the burner 5 times with three second operation intervals on the SOFT START auger before it goes over completely to full burn mode.

The SCREW ON +03.5 three values in this menu can be changed. SCREW OFF +15.0 NO OF CYCLES+05.0.

Operation The PLC also keeps track of some faults that could be use- ful to in the event of a problem occurring. This history shows HISTORY OF FAULTS how many ignition errors, fuel errors and if the burner has IGNITION +00000 overheated via the temperature sensor that is placed on the FUEL FAULT +00000. Operation Error on the ignition element. This may be caused by an incorrect start dose, a dirty burner or a failed igniter.

Turn off the burner and restart. Check to make sure you have the cor- IGNITION FAULT rect start dose settings, or check the connection for the feed auger. Maintenance WARNING: Before performing any of the following tasks, ensure that the power is disconnected from the furnace and the burner, and that all components of the system have had ample time to cool. Removal and Cleaning of the Burner - 30 kW Disconnect the cables on the side of the burner. Maintenance Lifting Up on the combustion fan, carefully lift the burner assembly off of the fire pot. Carefully remove the gasket.

Slide the burn pot out of the boiler. Ultra Owners Manual 2015. Maintenance Inspect the inner burner sleeve for warping or other damage. Replace if necessary.

Clean any buildup out of the burn pot, and clean all debris out of the air holes. Once clean, insert the inner part of the burn pot into the outer sleeve. Maintenance When reassembling the burner, line up the four align- ment screws that align the sections together with the gasket in place.

Then latch the quick latches. Repeat the reset of the removal process in reverse to reassemble the burner. To remove the outer sleeve Remove the burner for cleaning as stated in the previ- ous process.

Maintenance Cleaning of the Swirlies, Tube Box and Firebox Remove the pellet tube from the chute. Remove the two screws that hold the pellet chute in place. Lay the pellet chute across the top of the burner, being careful not to damage the wires. Release the two quick latches on the tube access box and open the door. Maintenance Brush out each of the heat transfer tubes. Vacuum all ash from the tube box, including the door and any remaining ash in the heat transfer tubes. Remove all ash from the firebox.

This includes any ash that is on the top of the burner, and the walls of the firebox. Maintenance Clean all ash from the firebox door. Reinstall the swirlies into the heat transfer tubes. Close and latch the tube box. Reinstall the pellet chute and tube.

Dispose of all ash properly. 2015 Ultra Owners Manual. Maintenance WARNING: Before performing any of the following tasks, ensure that the power is disconnected from the burner by switching the circuit breaker to the off position, and that all components of the system have had ample time to cool. Replacing the Igniter Location of the screw. Maintenance Note: You should clean the furnace on an “as needed” basis, typically once a week.

Not all wood pellets burn the same, some may require you to clean the furnace more frequently. Your warranty does not cover ash corrosion. The furnace must be completely cleaned of ash and creosote at least twice a year, including at the end of the heating season. Troubleshooting Error Cause Solution The burner has stopped. The pellet hopper is empty. Fill the pellet hopper with pellets. Fault” is on the display.

Restart the furnace. An air pocket has developed in the inlet of the feed auger. Wiring From Prev Page To Next Page Pressure Switch 2015 Ultra Owners Manual. Wiring From Previous Page BLACK GREEN WHITE To Next Page Ultra Owners Manual 2015. This Warranty is provided by Northwest Manufacturing, Inc. Only for the bene t of the initial purchaser (Original Owner) of the Northwest Manufacturing, Inc. Ultra Series Pellet Furnace (the “Furnace”) on the original site of installation (the “Site of Original Installation”).

Warranty VI. Any costs for labor for the examination, removal or reinstallation of allegedly defective parts, transportation of the parts to and from Northwest Manufacturing, Inc. Facilities will not be covered and will be the responsibility of the Original Owner. This includes any other labor and costs for any material necessary for the said examination, removal or re-installation. Northwest Manufacturing Inc. PLACE POSTAGE 600 Polk Ave. SW HERE Red Lake Falls, MN 56750 Northwest Manufacturing Inc.

600 Polk Ave. SW Red Lake Falls, MN 56750.

WoodMaster Ultra Series Warranty Registration Card Please fill out the warranty registration card below and mail it back to us. Failure to register may delay warranty claims. Serial Numbers Burner Heat Exhanger Owners Name Address City State Fold Fold Fold.

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Specifications Power Connection. Single Phase, 120v, 60 Hz Maximum Current Draw. Notes Ultra Owners Manual 2015. Notes 2015 Ultra Owners Manual. www.woodmaster.com / 800-932-3629 / Manual PN: 7994-875 Northwest Manufacturing, Inc / 600 Polk Ave SW / Red Lake Falls, MN 56750.

This is another episode on how to set up the control panel of your wood burning stove. On this topic, we have already discussed the settings we use during the, but this time we’re going to talk about two of the most frequent errors the WoodMaster ETC panel shows. Today we’re going to talk about the WoodMaster product. I have been selling WoodMasters for a long time and before I got into selling parts I used to be a dealer for.

I still carry most of their parts and I am still a dealer. However, one of the things that I get a lot of questions on is related to a couple of issues that WoodMaster runs into, here and there, and it’s usually one of these simple errors, with a very common and simple fix. P1 Error on the ETC Panel.

First, it’s the P1 error, which comes up on the ETC panel. So when people turn on the unit for the season, or whatever, it will come up and read “P1”. So I’ll go over on how to fix that, and the other one is that there is a fan indicator on the panel, and the temperature will be below what is set to, and the fans are not turned on. So I’m also going to talk about that. The Temperature Probe WoodMaster Installation Now, what a lot of people do is that they think they have to unthread it, but no! It slides out!

WoodMaster uses a sealant in there to ensure it doesn’t come out, and also to make sure you get a correct reading, so it’s kind of like an electric grease that ensures a good reading of your control panel. The wire is long and it goes all the way to the E.T.C. Panel, all around the side, but here’s the nice thing about it: the things that make this wire go bad is the heat, first of all, because it’s a very sensitive little temperature probe.

So when the wires touch and shorted out, which gives you the P1 error, or when a mouse or something got in there and chewed the wires. So what I recommend you to do is to take out the old one. But, just so you know, getting the old one out is sometimes very difficult, because that is why everybody assumes that it’s screwed into the back of the WoodMaster.

So you’re going to take a pair of needlenose pliers and you’re going to pull it out and sometimes it comes out really nice and easy, but sometimes it doesn’t. Some people have actually had to start drilling it and it pulls right out, but anyway, this is what you have to do to get it out. ETC Panel So once it is out you take the new one, and you are going to basically find the old wire and just splice it in and put it back into the thermal well, and see if you get a reading on your E.T.C. If you do, that’s great! But if you still get the P1, then most likely the damaged wire is between the temperature probe and the E.T.C. Panel, so here’s a simple solution to that. Take off the E.T.C.

Panel, there’s a black box behind it, and there is a quick connect and behind that quick connect is another quick connect and basically you’re going to tie the new wire to the old one in the back of the furnace, and you should be able to shake it all the way back and then splice it in. And this is the fix to the P1 Error Code on the WoodMasters E.T.C. 9 / 10 times, people put in the new one, splice in three of four feet of it and the problem is solved! Stay tuned for part 2 on how to and, also, check out our stove maintenance blog post on and, don't forget, i f you have any questions, This entry was posted in on August 9, 2017 by Jeff.

Jamie Love your tutorial videos. They are very helpful.

I have a woodmaster 4400 and have it for about 6yrs now. Absolutely love it! Wish i would have installed one many years ago. I have a question my green light doesnt go out when i drain my system. I've been told that my float needs to be cleaned because i have high iron in my water. Is the float located at the back or front of the woodstove?

I see it in the owners manual schematic but it doesnt say anything for location. Thanks in advance. Admin the fire rope and fan cover should be done every year, that is important. If those two item's are new there is two possible things. First being the fan cover is getting stuck in the up position, this doesn't happen all the time but once in a while it does.

The fix is turning the loop on the back of the fan cover to take the stress off the spring. The second thing is where the optional auger goes thru the hole there might be a leak there. There is a round plate on the inside of the stove stopping the air from getting in, sometimes it shifts and lets air in. The bolt on the outside will loosen. It and hold in place and re tighten. I hope this helps, Jeff.