Ignite Tech™ | HD80 Operator Manual

IGNITECH HD80

INDUSTRIAL COAL AND WOOD INDOOR FURNACE MODEL: HD80

Manufactured B y: IGNITECH Industries 10950 Linpage Place Saint Louis, MO 63132 1-800-875-4788 MADE IN USA

Contains Proper Burn Practices!

Certified to UL391

APRIL 20 21

PROPER BURN PRACTICES FOR MAXIMUM EFFICIENCY AND SAFETY!

• The chimney is one of the most important elements of the furnace. If the chimney is not connected properly and installed according to manufacturer’s specification and national and local codes, the unit is not safe and will not burn efficiently. Lack of proper chimney installation will cause unit to produce more smoke and less heat output. See Pages 7-9 of this manual to ensure proper installation. • Proper use of all electrical components is essential: For instance, the wall thermostat must be hooked up to the furnace and the front draft blower must be in operation at all times. This will increase furnace efficiency and produce more heat output. See Page 13 of this owner’s manual for more information. • Wood that is properly cut and stored to dry will produce more BTUs and higher heat output than wood that has a higher moisture content. Wood with higher moisture content will create creosote in the chimney and cause flue fires. See Pages 10 and 14 for proper wood handling practices. • There should be no alteration of the IGNITECH Furnace in any way, as this will void the UL391 listing and affect the operation of the furnace. This will also void the warranty of the unit. • IGNITECH Furnace makes two types of units, indoor as well as outdoor furnaces. The indoor units are manufactured and tested for indoor applications only. They are not meant to go outside of the building but must be placed indoors in a basement or utility room. Any indoor unit placed outside of the building , will void the warranty, violate the safety listing, and will not produce the maximum efficiency possible with this unit. For outdoor applications please use unit HD90X .

• FOR COMMERCIAL USE ONLY.

IGNITECH INDOOR FURNACE MANUAL MODEL: HD80

SAVE THESE INSTRUCTIONS

Congratulations! You have selected the finest quality wood and coal burning indoor furnace, manufactured with pride in the USA. Please take a few moments to carefully read the owner’s manual. By taking the time to familiarize yourself with your new IGNITECH Furnace, you will be able to look forward to years of trouble-free, dependable service.

Installation: First: Check local codes. The installation must comply with all local rules and requirements.

Furnace installation is to be performed by a qualified installer. This furnace must not be installed in trailers, modular or mobile buildings . Always have a properly installed and functioning smoke detector in your building . To prevent accidental injury, do not allow anyone who is unfamiliar with the furnace to operate it. Spend time familiarizing yourself with your IGNITECH Furnace, especially the different settings and the effects they have on burn patterns. It is impossible to predict how each setting will affect your furnace due to variations in conditions, fuels and temperatures. Transportation Damage: Every effort has been made to ensure that your IGNITECH Furnace will arrive in perfect condition. Any visible damage should be noted on the freight bill at the time of delivery. If upon unpacking your IGNITECH Furnace you find damage has occurred during transit, notify your supplier immediately. Your supplier will advise you what actions must be taken to address the problem. Disclaimer Notice: The listed BTU rating for your new IGNITECH Furnace was obtained using laboratory calculations. The actual BTU output you experience may vary somewhat depending on the type, condition and moisture content of the fuel used, damper adjustment, chimney type and other factors. Therefore, the manufacturer disclaims any guarantee as to the BTU output or capacity. IGNITECH Industries disclaims any responsibility for the following: installation of a furnace that has been altered or modified in any way; installation of the furnace other than as instructed in this manual; installation and/or use of any component or part not approved by IGNITECH Industries for use with this furnace. Be sure to complete and return your warranty card within 30 days of purchase in order to activate warranty coverage on your furnace. Manufacturer’s Notice: Please be advised that we periodically make changes to improve our products, therefore the information in this manual may not be completely applicable to your IGNITECH Furnace. Please refer to markings on the appliance for additional information. THIS IS A WOOD AND COAL BURNING FURNACE ONLY AND SHOULD NOT BE ALTERED IN ANY WAY. FOR COMMERCIAL USE ONLY.

TABLE OF CONTENTS

General Information

3 3 4 4 5 6 6 7 9

Location and Installation

Assembly of Unit

Blower and Housing

Filter Box

Draft Blower

Fan Limit / Electrical Control Center

Chimney Types and Recommendations

Duct Runs

General Operation

10 10 11 12 12 13 13 13 13 14 14 15 17 17 18 19 24

TYPES OF WOOD TO USE

FIRST WOOD FIRE LOADING WOOD FIRST COAL FIRE Disposal of Ashes

Draft Blower

CREOSOTE FORMATION CREOSOTE PREVENTION

Chimney Fire Warning

Power Failure

DOUBLE CHECK TO MAKE SURE YOU HAVE RECEIVED ALL OF THE REQUIRED COMPONENTS. IF YOU FIND THAT THERE IS A PART MISSING, CALL 1-800-875-4788 FOR FASTEST SERVICE, PLEASE DO NOT GO BACK TO THE DEALER. DEALER DOES NOT HAVE REPLACEMENT PARTS.

General Information The IGNITECH Furnace has been engineered to accommodate the heating requirements of the average sized building , even during winter’s coldest months. It is constructed with high grade, heavy gauge steel and is continuously welded to assure the highest structural strength. In addition, the firebox is lined with firebrick to ensure many years of energy efficient service. The design of the secondary combustion chamber increases fuel efficiency by creating a “secondary burn” of smoke and wood gases before they are vented up the chimney. The cast iron doors are custom fitted to provide an airtight seal, greatly extending the burn time and ensuring maximum efficiency in fuel consumption. The heavy-gauge cast iron grate, designed for maximum heat transfer, allows for convenient ash removal and reduced maintenance. For total comfort and convenience, a thermostatically controlled draft and circulation blower system is included. These fully automatic components furnish rapid heat disbursement throughout your building , minimizing recovery time when the wall thermostat demands heat. All of these features are standard, offering you the most efficient, durable and affordable indoor wood and coal burning furnace. Your IGNITECH Furnace is designed to be either a supplemental or central heating source for your building . This wood and coal burning furnace may be installed in parallel with a properly operating electric, gas or oil-fired central furnace, listed or certified in accordance with a nationally recognized safety standard, and within clearances specified on the nameplate. When in a parallel installation the static pressure of the central furnace plenum may not exceed 0.15 water column inches and the maximum setting on central furnace limit switch is 182°F. With the IGNITECH Furnace in an “Interconnection Arrangement” your furnace should be upstream of the central furnace. The IGNITECH Furnace warm air supply should never be connected to return air for the central furnace. A qualified installer should perform the installation. IMPORTANT: FOR TECHNICAL SUPPORT OR CUSTOMER SERVICE ISSUES, DO NOT RETURN TO THE DEALER (THE DEALER DOES NOT HAVE REPLACEMENT PARTS), CALL 1-800-875-4788. Forced Hot Air Circulation: The plenum size of your IGNITECH Furnace must not be reduced to less than 12 inches in diameter or 113 square inches, and must provide a minimum of 18 inches between the top of your IGNITECH Furnace and the main trunk connection. The plenum attached to the furnace must be constructed of metal. The warm air supply duct system should be constructed of materials with a minimum temperature rating of 250° Fahrenheit. Clearances: Unit must be placed on a non-combustible floor. This floor must extend at least 16 inches in front, 8 inches on either side of fuel loading and ash removal doors, underneath the chimney connector and must extend 2 inches on either side of the chimney connector. The furnace must maintain the following clearances to combustibles: • Heat plenum = 2 inches • Chimney connector = 18 inches • Front = 48 inches • Rear = 31 inches • Sides = 12 inches • Main furnace = 12 inches These are minimum clearances and should be strictly followed. In the case of a power outage, a dangerous level of heat accumulation may develop. Do not store fuel or other combustible materials within installation clearances. Location and Installation NOTE: Before beginning installation, consult proper local authorities regarding local codes governing all such applications and installations. DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE. Your furnace must be placed on a non-

combustible floor. Position the furnace as close to the chimney as possible. Air for combustion must be provided into the room where the furnace is located. Allow air free access to the furnace for combustion and ventilation. RECOMMENDATION: Purchase Chimfex™ Dry Chemical Chimney Fire Extinguisher. These are readily available at most stove shops and hardware stores. Smoke detectors should be installed on all levels of your building . Having a fire extinguisher in the furnace room or area is strongly recommended.

OPEN/CLOSE RETURN DAMPERS 3 PLACES

RETURN AIR DUCT

SUPPLY DUCT

BACK DRAFT DAMPERS

Assembly of Unit Please review the parts list and diagrams contained on pages 15 - 17 of this manual.

DOUBLE CHECK TO MAKE SURE YOU HAVE RECEIVED ALL THE REQUIRED COMPONENTS. IF YOU FIND THAT THERE IS A PART MISSING, CALL 1-800-875-4788 FOR FASTEST SERVICE, PLEASE DO NOT GO BACK TO THE DEALER. DEALER DOES NOT CARRY REPLACEMENT PARTS. NOTE: For your convenience your IGNITECH Furnace has been factory assembled and the electrical control assembly pre-wired.

1. Fasten the right and left side angle brackets to the circulation blower using (4) ¼ - 20 bolts and nuts. Line up the blower with the pre-drilled holes on the backside of the furnace, firmly attach with the screws provided.

2. Attach blower to the left and right mounting brackets.

1/4-20 Bolt Four Places 1/4 - 20 Bolt

Angle Bracket Angle Bracket

1/4-20 Nut 1/4 - 20 Nut

Blower Assembly Blower Assembly Blower Assembly

Mounting Screw Mou ting Screw Mounting Screw

3. Assemble the following parts using 6 #10 sheet metal screws. Both “B” and “C” panels should fit inside of “D” and “A” panel flanges. Attach “D” (bottom panel) to “B” (side panel with electric) and “C” (side panel). After the top and sides are assembled, attach ”A” (top panel) using 6 #10 sheet metal screws provided.

Top Panel (A) p n l (A)

Top Panel (A)

#10 Sheet Metal Screw Twelve Places 10 Sheet Metal Screw h t Metal Screw

Side Panel (C) Side Panel

Side Panel (C)

Side Panel With Electric (B) Side Panel with Electric (B) i e Panel with Electric (B)

Bottom Panel (D) Bottom Pan l

Bottom Panel (D)

4. Position the assembled filter box on rear of furnace, supporting it approximately 4 inches from the floor, covering the rear distribution blower. Make sure the filter box is tightly pressed to the back of the furnace. Use 8 #10 self-tapping screws (included) to firmly attach the filter box to the sides of the furnace.

Filter Box Filter Box Filter Box

#10 Screw #10 Screw #10 Screw

5. Mount the forced draft blower with 3 ¼-20 x 3/4 inch bolts (provided).

1/4-20 Screw /4 - 0 Bolt

6. Attach Fan limit with 3 #10 screws in pre-drilled holes. 7. Mount the electrical control center with 4 #10 screws (provided).

Fan Limit thermostat To install, remove thermostat cover, attached with three #10 sheet metal screws and replace thermostat cover Fan Limit Control: install, remov c ver, attach with three #10 sheet metal screws and replace cover. THERMOSTAT TERMINALS THERMOSTAT TERMINALS

DETAIL B SCALE 1

ATTACH THE TWO WALL THERMOSTAT WIRES TO THE TERMINALS SHOWN ttach the two wall thermostat wires to the terminals shown

8. Secure the flex conduit to the side of the furnace using the bracket with 1 screw (provided). 9. Plug motor into the back of the electrical control center.

10. Connect the thermostat wire (not included) to the 2 posts located on the side of the control center. For convenience, you might consider locating the wall thermostat next to your existing thermostat in your home. The thermostat MUST be installed for the furnace to operate. (See diagram for step 7) 11. Plug the 3 pronged grounded plug into a grounded electrical outlet. The filter box requires one 20” x 25” x 1” filter (not included, but available at most hardware and home centers). See diagram for proper installation of electrical assembly and filter box. The bracket must be attached to the side of the furnace to secure the conduit. With the connection of the thermostat, chimney pipe and ductwork, your furnace installation is complete. Inspect your filter regularly and replace the filter every 30 days during heating season for maximum efficiency.

Chimney Types and Recommendations See Diagram on page 8. Safety requirements demand that your IGNITECH Furnace be connected to “Class A” HT2100 All Fuel, or stainless-lined masonry chimney ONLY. By definition, “Class A” refers to either a lined masonry chimney or all fuel factory-built chimney. Although experts have expressed differing opinions as to which system is the best, it is a matter of what you find most suitable. Regardless of your choice of chimney type, for the HD80 , a minimum 6 -inch diameter chimney is needed . In order to create the most effective draft, the chimney size should not exceed 12 inches, with a maximum .08 water column inches of draft. The flue draft can be measured with the use of a draft gage or manometer. If there is more than .08 water column inches of draft, it can be adjusted with the installation of a flue damper. The stovepipe required to connect the furnace to the chimney should be a minimum of 24 gauge black or stainless steel. NEVER USE GALVANIZED PIPE. Horizontal run should not exceed 5 feet and should have a minimum rise of 2 inches per foot. No installation should have more than 2 elbows, a 45° elbow is recommended over a 90° elbow. As a safety precaution, all pipe selections should be fastened together with a minimum of 3 sheet metal screws. For your convenience, the crimped male ends of the pipe should point toward the furnace to form drip-free connections, thereby reducing the possibility of creosote leakage from the joints. Installing a non-UL-listed heat reclaimer in the pipe is not recommended because it reduces the stack temperature thus causing creosote formation. Installing a manually operated cast iron damper in the stovepipe between the furnace and the chimney pipe is recommended. The addition of a damper will greatly assist in regulating the fire and achieving optimum results. Always install a tee with clean-out cap to the chimney outlet on the back of the furnace. This allows for easier cleaning of the chimney system. Never use a 90° elbow off the back of the furnace. When using a masonry chimney, you must line the chimney with a stainless steel liner. The stainless steel liner will keep the chimney temperature hotter for better draw and significantly reduce the creosote formation in the chimney. If using this method, a 6-inch stainless liner should be used for the HD80 .

The termination cap should be designed to inhibit down-drafting without restricting the exhaust discharge.

For the best draw the chimney termination should be at least 2 feet above the highest point of the roof that is within a 10 foot radius of the chimney.

When using a brick chimney, you must line the entire chimney with stainless steel liner. The liner must be the correct size for the furnace.

The diameter of the chimney stack should be consistent throughout the length of the chimney.

The chimney size should be at least as large as the exhaust stack on the furnace , but not more than twice its size.

The chimney stack should have a built-in airtight clean out. WARNING: Do not operate with clean out uncapped.

WARNING- RISK OF FIRE:

• Do not operate with flue draft exceeding .08 water column inches (19.9 Pa). • Do not operate with fuel loading or ash removal doors open. • Do not store fuel or other combustible materials within marked installation clearances. • Inspect and clean flues and chimney regularly. DANGER: Risk of Fire and Explosion. Do not burn garbage, gasoline, naphtha, engine oil, or other flammable liquids/inappropriate materials. WARNING: • NEVER use galvanized pipe in your chimney connection, it produces poisonous gases when subjected to extreme temperatures. • USE only lined masonry or manufactured Class “A” HT2100 All Fuel Chimney for your furnace. • INSPECT chimney system periodically for structural integrity. • CLEAN the chimney system regularly to prevent creosote accumulation. • NEVER leave the ash pan in your furnace during operation. • DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE. Duct Runs Ductwork should be designed so the external static pressure on high speed does not exceed .02 water column inches while developing air velocities of 450 - 600 feet per minute at the registers. The heat outlet area should never be less than 12 inches round or 113 square inches. The furnace can be installed with a cold air return system, or the return air can be drawn from the basement. If the return air is drawn from the basement, you will have to install 3 “open and close” air register vents in the return air duct connected to your existing furnace; the air will take the path of least resistance without using ductwork to connect the two together. The return air system should be a minimum of 10% larger than the heat outlet to readily transfer the cold air back to the furnace. Avoid using 90° elbows in duct runs; 45° elbows provide better airflow and less resistance. CAUTION: The warm air supply outlet of the supplementary furnace should not be connected to the cold air return inlet of the central furnace, because a possibility exists for components to overheat and cause the central furnace to operate other than intended. Canadian Requirements for Supplemental/Add-On Furnaces • DO NOT USE DUCT ELBOWS HAVING AN INSIDE RADIUS OF LESS THAN 6 inches (150mm) ON OIL, ELECTRIC, OR GAS FURNACES. • DO NOT CONNECT TO A DOWNFLOW FURNACE. • DO NOT CONNECT DUCTWORK SO THAT A REVERSE FLOW IS POSSIBLE. • OPERATE THE GAS/OIL/ELECTRIC/ FURNACE PERIODICALLY TO ENSURE THAT IT WILL OPERATE SATISFACTORILY WHEN NEEDED. • CERTIFIED FOR INSTALLATION WITH APPROPRIATE DUCTWORK CONFIGURATIONS ONLY. • DO NOT RELOCATE OR BYPASS ANY OF THE SAFETY CONTROLS IN THE ORIGINAL GAS/OIL/ELECTRIC FURNACE INSTALLATION. • DO NOT CONNECT TO ANY GAS FURNACE THAT HAS NOT BEEN CERTIFIED INITIALLY AS COMPLYING WITH CAN/CGA-2.3. • THE OPERATION OF THE GAS FURNACE MUST BE VERIFIED FOR ACCEPTABLE OPERATION BEFORE AND AFTER INSTALLATION OF THE ADD-ON APPLIANCE BY A GAS FITTER WHO IS RECOGNIZED BY THE REGULATORY AUTHORITY. • DO NOT CONNECT TO ANY GAS FURNACE THAT IS NOT EQUIPPED WITH AN AIR-CIRCULATION BLOWER, OR TO A CHIMNEY OR VENT SERVICING A GAS FURNACE OR GAS APPLIANCE. The add-on unit should only be installed on a furnace duct system and chimney that are in good operating condition. On a belt-driven system, blower and motor pulleys may be changed but the electrical current flowing through the motor cannot exceed the nameplate rating. On a direct-drive system, the motor should not be changed, however, the speed of the motor may be increased. The

blower cannot be changed. This equipment should be installed, acceptable to regulatory authority, by experienced licensed personnel. The 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 gas-fired). IMPORTANT: FOR TECHNICAL SUPPORT OR CUSTOMER SERVICE ISSUES, DO NOT RETURN TO THE DEALER (THE DEALER DOES NOT HAVE REPLACEMENT PARTS), CALL 1-800-875-4788.

BURN WOOD AND COAL ONLY!

General Operation NOTE: Always pull the bypass rod all the way out before opening the fuel door. Types of Wood to Use:

We advise using only dry, seasoned hardwoods in your IGNITECH Furnace rather than high resin woods such as pine. Firewood should be cut at least one full season prior to the time of its intended use, for optimum heat output. Firewood should be stacked to provide a free flow of air between the logs, thus allowing more rapid seasoning of the wood. If wood is stored outdoors, it should be completely covered year round to protect it from moisture and exposure to the elements. FUEL RECOMMENDATIONS: (Log size by model) • HD80 – 22 inch maximum log length Use extreme caution when opening the door during operation, temperatures can exceed 300°F. Always pull the bypass rod all the way out before opening the fuel door. Wait at least 10 seconds after releasing the latch, and then proceed to the fully open position. Opening the door in this manner is designed to eliminate the possibility of gaseous ignition. Heat resistant gloves are recommended when opening the fuel door, regulating the spin draft, or emptying the ash pan. CAUTION: HOT SURFACES. KEEP CHILDREN AWAY. DO NOT TOUCH DURING OPERATION. CAUTION: • INSPECT FLUE PIPES, JOINTS AND SEALS REGULARLY TO ENSURE THAT SMOKE AND FLUE GASES ARE NOT DRAWING INTO, AND ARE NOT BEING CIRCULATED BY THE AIR-CIRCULATION SYSTEM. • CLEANING OF THE HEAT EXCHANGER, FLUE PIPE, CHIMNEY AND DRAFT INDUCER (IF USED), IS ESPECIALLY IMPORTANT AT THE END OF THE HEATING SEASON TO MINIMIZE CORROSION DURING THE SUMMER MONTHS CAUSED BY THE ACCUMULATED ASH. • Never use chemicals or gasoline to start or maintain your fire. • Do not burn oil, garbage, trash, plastic, or any fuel other than wood or coal in your furnace. Doing so will void the warranty. • DO NOT operate your furnace with the fuel bypass rod open; the handle must be pushed all the way in (except when refueling). • DO NOT leave the ash pan inside your furnace during operation. WARNING: – RISK OF FIRE • DO NOT operate with flue draft exceeding .08 water column inches (19.9 Pa). • DO NOT store fuel or other combustible materials within marked installation clearances. • Inspect and clean flues and chimney regularly. • DO NOT operate your furnace with the fuel or ash doors open. WARNING: NEVER fuel your furnace with wet, unseasoned wood or wood that has been exposed to a recent rainfall. Burning wood with high moisture content will cause a rapid accumulation of hazardous creosote, which has been proven to be the

most common cause of flue fires. NEVER burn plastics, any wood product containing glue, or wood treated with chemical preservatives in your furnace. The combustion of these substances may release harmful, toxic gases. DANGER: RISK OF FIRE OR EXPLOSION – do not burn garbage, gasoline, naphtha, engine oil, or other flammable liquids/inappropriate materials. Supplemental Outside Combustion air may be necessary if: • The solid-fuel-fired appliance does not draw steadily, smells, experiences smoke rollout, burns poorly, or back-drafts whether or not there is combustion present. Opening a window slightly on a calm day may alleviate these symptoms. • The building is equipped with a well-sealed vapor barrier and tight fitting windows, and/or has any powered devices which exhaust building air. • If fans are installed in the storage area they should not create negative pressures in the room where the solid fuel-burning appliance is located. • There is excessive condensation on windows in the winter. • A ventilation system is installed in the building . BURN WOOD AND COAL ONLY! First Wood Fire: Set the wall thermostat to 90°F. Check to make sure the spin draft is wide open to allow oxygen into the firebox. Make sure the switch for the draft blower is in the ON position. Adjust slide cover on draft blower to an opening of approximately ⅜ inch.

slide cover to make adjustment

OPEN

Place several crumpled newspapers on the grate with some dry kindling layered on top of the papers, then ignite the newspaper. When the kindling is burning, add several small pieces of wood, allow wood to fully ignite. After about 20 minutes the fire should be established, allowing you to add more wood – do not overload which would smother the fire. Add more wood slowly, so the flames have time to engulf the fresh wood. Once the fire is burning and there is a glowing ember bed, adjust the draft to achieve desired burn pattern. Learning how to adjust the draft to maintain the desired temperature for your building may take several days. After a short time you will know which settings and adjustments work best for your building . Set the wall thermostat to the desired building temperature. Do not over-fire the furnace. Over-firing by overloading/over fueling the furnace causes the metal to superheat and expand, then cool rapidly, which causes cracking, therefore voiding the warranty. Over-firing or abuse can easily be determined upon inspection. It will take about 40 minutes to establish a bed of hot embers. Once you have achieved the hot ember bed, add larger pieces of firewood and push the bypass rod in all the way. Within 30 to 40 minutes, adjust the spin draft and the damper to obtain optimum performance. Finally adjust the wall thermostat and draft blower cover to a comfortable setting. Ash pan must remain out of furnace during operation. NOTE: Your new IGNITECH Furnace is capable of producing a very high BTU output. Do not fuel your furnace to capacity upon initial firing. It’s recommended that you become thoroughly familiar with your IGNITECH Furnace before operating at full capacity.

The new steel and metal components of the furnace have a protective coating or paint on the surface which could produce an odor during the break in period. Adequate ventilation within the building and furnace room or area is recommended during the initial firing and break in period to accommodate this possibility. Your new IGNITECH Furnace is classified as having airtight construction. This type of design should enable you to experience an average burn time between 6 and 12 hours per full load of fuel (dry, seasoned hardwood). However, abnormally cold weather may reduce the burn time somewhat, but if your burn cycle is significantly less, for instance, 2 to 4 hours, you are over-firing your furnace. This type of occurrence is usually symptomatic of heat demands in excess of furnace capacity. Contact an authorized professional to determine if your IGNITECH Furnace has been improperly sized for your building . Loading Wood: When opening the fuel door during operation, always pull the bypass rod all the way out before opening the fuel door, wait 10 seconds after releasing the first latch, then open the door the rest of the way. The dual latch system has been incorporated as a safety feature, designed to eliminate the possibility of gaseous ignition. Laboratory testing has determined that when incomplete combustion occurs the partially spent fuel sometimes concentrates large amounts of potentially hazardous gases within the fire chamber. If the door is opened suddenly under these conditions, the oxygen may combine with these gases and cause ignition referred to as “back flash.” Use EXTREME CAUTION when opening the fuel door. When reloading the furnace, spread embers evenly over the grate. Place smaller pieces of wood or coal on the hot embers and layer larger pieces on top of them. Finally, due to the wide variety of temperature ranges during the winter, you may experience periods when it is not necessary to fully load the fire chamber in order to maintain an overnight burn. Your IGNITECH Furnace will operate at the highest efficiency by adding fuel in amounts needed to maintain comfortable temperatures in your building . Starting the First Coal Fire: Burning coal is much harder than burning wood. There is more care and work in building and maintaining a coal fire than a wood fire. Anthracite is the best coal to burn, due to its long even burn with higher heat output and clean burn quality but is more difficult to manage than Bituminous coal. The size of coal is important. “Nut” coal sizes of 4 inches for Bituminous and 2¾ to 4½ inches for Anthracite coal are recommended. Never use coal other than the sizes recommended. If the coal is too small it will smother the fire and if it is too large the coal will not burn well. When burning Bituminous coal, start the fire with wood (as described above). Always use dry kindling, as this will provide a hotter fire and add small pieces of wood until you get a good hot ember bed. At this point add a small amount of coal. When the coal is hot enough to ignite, add small amounts at a time, so as not to smother the fire. Keep in mind that Bituminous coal will require more maintenance as this type of coal will produce more soot, requiring more frequent cleaning to prevent buildup. Also make sure that the spin draft is wide open to establish the correct burn pattern. When adding coal to Bituminous fires always add coal to the center of the bed creating the cone effect. Bituminous coal is more volatile and adding coal to the center of the bed causes the flames to drive off the volatile gases. Remember that no two installations and chimney set-ups are the same, so be prepared to experiment until you achieve the desired results. Always allow enough air to the firebox and keep the damper open so that volatile gases are properly burned. When adding fuel, remember to break up the cone with a poker if it has formed a crust, but be careful to avoid mixing the coal as this can form clinkers. Rotate the grates slightly so as not to disturb the fire. Excessive movement wastes fuel and exposes the grate to extreme heat, which will cause warping or burnout. For overnight burn operations, follow the above instructions and adjust the chimney damper and set the thermostat. When burning Anthracite coal, start the fire with wood (as described above). Add layers of coal making sure not to smother the fire, the third layer should be a little heavier, but should not to extend above 2 inches below the top of the brick in the firebox . Before adding more fuel, be sure to leave a red spot in the center of the bed. This hot spot will help ignite the gases given off the new charge. A deep charge will give a more even heat and a longer fire. It may take up to a couple hours before the whole bed is fully ignited. When the fire is established and the building is becoming warm, you may adjust the damper. It may still take some experimenting with the wall thermostat to ensure proper operation, as no two installations are the same. Once the coal bed has reduced to half its original depth it is time to add fuel to the furnace. At this point pull out the bypass rod and turn up the wall thermostat. This will allow the fire to burn off the accumulated gases. Open the fuel door, using a small rake or hoe pull the coals towards the front of the bed, trying not to disturb the fire too much. Next, add coal to the back, being careful not to seal off the top. Only rotate the grates a couple times a day to allow the ash to fall into the ash pan. Keep the ash pan cleaned out to ensure good airflow. You may want to start this banking process early in the evening before retiring or before leaving the building so that you may make proper adjustments after the fire is well established.

WARNING: It is unsafe to load any type of coal within 2 inches of the top of the firebrick. Load fuel carefully or damage may result. NOTE: Do not burn coke, charcoal, highly volatile Bituminous coal, sub Bituminous, lignite or cannel coal (sometimes called channel coal or candle coal. Never burn chemically processed logs, such as fire logs, as their use is intended for fireplaces only. Please follow all guidelines in this manual concerning wood and coal burning applications due to safety concerns and to maintain warranty coverage.

BURN WOOD AND COAL ONLY!

Disposal of Ashes: Heat resistant gloves are recommended. In order to remove ashes from your IGNITECH Furnace, open the ash door and slide the ash pan to the rear of the furnace. Remove the ash pan from the furnace and dump the ashes into a metal container with a tight fitting lid. The closed container of ashes should be placed on a non-combustible floor or on the ground, well away from all combustible materials, pending final disposal. If the ashes are disposed of by burial in soil or otherwise locally dispersed, they should be retained in the closed metal container until all cinders have thoroughly cooled. The ash pan must be removed from your IGNITECH Furnace during operation. This precautionary measure is recommended because if the ash pan is allowed to remain inside the furnace during operation, it will become dangerously hot to touch, block the flow of air under the grates and reduce the efficiency of the furnace. Remove the ashes from your IGNITECH Furnace at least once a day, or as often as necessary to ensure the ashes do not accumulate to the height of the grates. If ash build-up occurs at grate level, it will cause premature failure of the grate system, voiding the warranty on the grates. Unacceptably high temperatures will result because the ashes have restricted the flow of cooling air beneath the grates. This flow of air was designed to not only cool the grates, but to also provide warmed air for better combustion. If the ash level is improperly maintained the firebox will be starved of combustion air, greatly reducing the efficiency and heat output of your IGNITECH Furnace. CAUTION: HOT SURFACES. KEEP CHILDREN AWAY. DO NOT TOUCH DURING OPERATION. IMPORTANT: FOR TECHNICAL SUPPORT OR CUSTOMER SERVICE ISSUES, DO NOT RETURN TO THE DEALER (THE DEALER DOES NOT HAVE REPLACEMENT PARTS), CALL 1-800-875-4788. Draft Blower: The front draft blower plays an important role in the operation of your IGNITECH Furnace. When the wall thermostat calls for heat, the draft motor turns on and supplies fresh air into the firebox producing a hotter fire, which in turns provides more heat in the heat chamber. The heat is then sent through the duct system throughout your building . When the wall thermostat temperature is met, the draft blower shuts off until the thermostat calls for heat, beginning the cycle again. The draft blower has a slide cover located on the side of the motor that is factory preset, with an opening of approximately 3/8”. The cover should be fully closed only when there is a power failure and electricity is lost. With the cover closed, no air is introduced into the firebox, then the fire dies, preventing the furnace from possible overheating and damage. The manual combustion air spin damper control on the ash door should be set with a 1/8 inch gap to start. Adjust slowly by making 1 rotation at a time to find the correct air setting. Important: Blower Speed Changes: Your HD80 furnace is equipped with a 3 speed high efficiency bearing shaft motor (started with a capacitor) that draws a maximum of 5 amps when set at high speed. The 3 speed switch on your electrical control center allows you to manually adjust speeds to your desired setting. If you are unable to detect or hear the speed change when you move the switch selector to a different setting it doesn’t mean the blower motor didn’t change speeds. Most blower motors that are manufactured today are sleeve shaft motors that don’t have any bearings so the motor creates more variation in sound. Your motor has bearings so it runs very smoothly and quietly. The furnace needs to be connected to ductwork to have significant resistance (static pressure against the blower so it will operate at full power. If you are running the blower without a fire in the furnace, the speeds will be different than when you have a fire burning. Hot air

flows through the ductwork with less resistance than cold air. Creosote Formation and Need for Removal:

When wood is burned slowly, it produces compounds in exhaust smoke which combine with expelled moisture to form creosote. The creosote vapors condense in the relatively cooled chimney flue of a slow burning fire. As a result, creosote residue accumulates on the flue lining. When ignited, this creosote makes an extremely dangerous fire in the chimney. The chimney connector and the chimney should be inspected at least twice monthly during the heating season to determine if a creosote build-up has occurred. If creosote has accumulated it should be removed to reduce risk of a chimney fire. Creosote Prevention: To help reduce the formation of creosote within the flue, ALWAYS BURN DRY, SEASONED WOOD. Dry wood burns hotter, allowing flue gases to maintain temperatures above 212°F which should reduce the quantity of creosote in the chimney. If the flue gas temperature falls below 212°F, condensation occurs causing creosote formation and accumulation within the chimney. As an added precaution, periodic chimney inspections are recommended during the heating season to determine if creosote formation has occurred. For safety and efficiency, it is recommended that the chimney system be inspected and cleaned prior to each heating season. Chimney Fire Warning: In the event of a chimney fire, take the following actions immediately: • Activate and toss a Chimfex™ Dry Chemical Chimney Fire Extinguisher into the firebox. • Close the ash door, fuel door, spin draft and slide cover on the draft motor. • Alert entire building and prepare to evacuate if necessary. • Call your local fire department. Power Failure: In case of power failure, to prevent your IGNITECH Furnace from over-heating and causing damage to the electrical components, follow these steps: • Ensure that the bypass rod is pulled out, allowing heat to go up the chimney. • Close the spin damper control on the ash door. • Close the slide cover on the side of the draft motor. • Do NOT add more fuel (coal or wood) to the firebox. There is no warranty on electrical components damaged due to power failure. NOTE: OVER-FIRING OR DELIBERATE ABUSE CAN EASILY BE DETERMINED UPON INSPECTION AND WILL VOID THE WARRANTY. Always keep your wood covered year round. Dry wood will produce a higher BTU output and a longer burn time. Refer to the nameplate on furnace for additional information. WARNING: RISK OF FIRE • Do not operate with the flue draft exceeding .08 water column inches (19.9 Pa). • Do not operate with fuel loading or ash removal doors open. • Do not store fuel or other combustible material within marked installation clearances. • Inspect and clean flues and chimney regularly. THIS IS A WOOD AND COAL BURNING FURNACE ONLY AND SHOULD NOT BE ALTERED IN ANY WAY. FOR COMMERCIAL USE ONLY.

Furnace Diagram

PARTS LIST

ITEM

QTY

DESCRIPTION

ASH DOOR ASSEMBLY

ASH PAN TRAY

DRAFT BLOWER

FURNACE SHELL

RIGHT SIDE PANEL

ELECTRICAL CONTROL CENTER FAN LIMIT CONTROL

7 8

1 1

FILTER BOX

SMOKE SLIDE DAMPER

BLOWER ASSEMBLY

TOP PANEL

SMOKE DAMPER ROD

LEFT SIDE PANEL

14 15

4 1

DOOR HINGE PIN

FUEL DOOR ASSEMBLY

AIR CONTROL DAMPER KNOB

PARTS LIST

TOTAL QUANTITY

COMMON ITEM NUMBERS

FC500E ITEM NUMBERS

FC700E ITEM NUMBERS

FC1100E ITEM NUMBERS

ITEM

ITEM DESCRIPTION

1 2 3 4 5 6 7 8 9

1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1

Ash Door Assemply

SFFDA

Ash Pan Tray Draft Blower Furnace Shell

FC5AP

FC7AP

FC11AP

FCDB

- -

FC5SHELL FC7SHELL FC11SHELL

Right Side Panel with Insulation

FC5RA

FC7RA

FC11RA

Electrical Control Center

ECC

- - - - -

Fan Limit Control

FCFLC

Filter Box

FCFB

Smoke Slide Damper

FC000-15

10 11 12 13 14 15 16

Blower Assembly

FC3SPMOTOR

Top Panel

- - -

FC5TOP FC7TOP FC11TOP FC5DR FC7DR FC11DR

Smoke Bypass Rod

Left Side Panel with Insulation

FC5LA

FC7LA

FC11LA

Door Hinge Pin

FCDP

- - -

Fuel Door Assembly

FCFDA

Spin Draft

FCSD

THIS PAGE LEFT BLANK INTENTIONALLY

HD80 PARTS LIST

ITEM

QTY

PART DESCRIPTION

1 2 3

1 1 1 1 1 2 1 1 1 1

FC000 ROLLER GRATE HANDLE

FRONT PLATE

ROLLER GRATE BASE

3b 3c

ROLLER GRATE EXTENSION BASE ROLLER GRATE EXTENSION BASE - SHORT

4 5

ROLLER GRATE SUPPORT

BACK PLATE

FC000 ROLLER GRATE EXTENSION - SHORT FC000 ROLLER GRATE EXTENSION

6 7

FC000 ROLLER GRATE

FIRE BRICK

Blower Motor Assembly Diagram

PARTS LIST

ITEM

QTY

DESCRIPTION

1 2 3 4

1 1 1 1

BLOWER WHEEL BLOWER HOUSING MOTOR CAPACITOR BLOWER MOTOR

HD80 PARTS LIST

ITEM

QTY

DESCRIPTION

1 2 3 4

1 1 1 1

BLOWER WHEEL BLOWER HOUSING MOTOR CAPACITOR BLOWER MOTOR

WIRING DIAGRAM INDOOR FURNACE

Wiring Diagram

FAN LIMIT CONTROL

ORANGE

YELLOW

WALL THERMOSTAT

BLACK

YELLOW

RED

RELAY

3 SPEED SWITCH

120V AC/24V AC TRANSFORMER

BLUE (MED) RED (LOW) BLACK (HI)

DRAFT MOTOR ON/OFF SWITCH

120V AC POWER SUPPLY WHITE

BLACK GREEN

WHITE

BLACK

3 SPEED BLOWER MOTOR

DRAFT BLOWER MOTOR

Troubleshooting

Problem: Circulation blower runs constantly. NOTE: Make sure the white button on fan limit control is pulled out and in the “auto” position.

Remedies:

Possible Causes:

• “Off”setting on fan limit control is low.

• Remove cover on fan limit control and check for the proper setting. The point indicators should be set at 100° “Off” and 150° “On.” Do NOT attempt to adjust the fan limit by manually adjusting the temperature indicators on the dial.

• Pull white button out and the blower should stop.

• White button on fan limit control is pushed in.

• Check by moving “ON” and “OFF” point indicator to a temperature position where blower should turn off. If the blower continues to run, replace the fan limit. • Review wiring diagram. If unit is wired correctly, seek professional assistance.

• Defective fan limit.

• Improper wiring.

• Backdraft damper is in the “closed” position.

• Open backdraft damper.

Problem: Circulation blower vibrates during operation.

Possible Causes:

Remedies:

• Screw on squirrel cage is not tight.

• Check squirrel cage alignment and position so that it does not drag on the housing during rotation, then tighten the screw sufficiently to fasten the squirrel cage securely to the shaft. • You may attempt to adjust the weights yourself to obtain an acceptable balance. If you are unsuccessful, contact your supplier. • Return the blower to your supplier for replacement.

• Balance weights on squirrel cage have become dislocated.

• Defective main bearings.

Problem: Flames discharging from fuel door during reloading.

Remedies:

Possible Causes:

• Opening the door has provided additional oxygen which has ignited the accumulated gases from partially spent fuel. • Bypass rod is in the “CLOSED” position.

• Always open the door cautiously and allow the safety latch system to perform its designed function, containing gases within the fire chamber.

• Pull out bypass rod.

• Cast iron damper in the “CLOSED” position.

• Open damper.

• Insufficient natural draft or an obstruction in the flue system. • Fire chamber filled to capacity with unburned fuel.

• See #6 and #9.

• Do not attempt to overload the furnace.

Problem: Draft blower will not run. NOTE: Verify that the wall thermostat is in the “HEAT” position, and make sure batteries are installed.

Remedies:

• Defective rocker switch on control center. Possible Causes:

• Replace rocker switch.

• This can be checked by turning the thermostat to a temperature setting that is higher than the temperature in your building . If the draft blower does not operate, the thermostat may be defective. Replace if necessary. • Move switch on wall thermostat to the “HEAT” position.

• Defective wall thermostat.

• Wall thermostat is in the wrong position. • Defective relay in transformer.

• Replace relay.

• Replace draft motor. • Review wiring diagram. If unit is wired correctly, seek professional assistance.

• Defective draft motor.

• Improper wiring.

Problem: Excessive dirt accumulation surrounding air registers in the building .

Possible Causes:

Remedies:

• Smoke discharge from loading door while refueling. • Furnace is not connected to return air duct and is drawing dirt from furnace room floor and disbursing it throughout building . • Filter box not installed, or no filter in filter box.

• Always pull exhaust bypass rod completely forward before opening fuel door.

• Connect to return air duct system.

• Install filter box on furnace. Install filter in filter box.

Problem: Smoke from the fire chamber is puffing back through the forced draft motor.

Remedies:

Possible Causes:

• Furnace is not connected to

• Connect to return air duct system. Or room may be too airtight, refer to “Location and Installation” section on page 3.

return air and is drawing smoke fumes from the flue.

• Excessively long run of stove pipe from furnace to flue.

• Relocate the furnace so the horizontal run does not exceed 5 feet and has a 2 inch rise per foot. • The run should not contain more than 2 elbows. • Replace with a larger flue providing a minimum of 50 square inches but not more than 100 square inches of draft area. If the flue is within these specifications, check the draft with a draft gage (manometer). Your flue should provide a minimum of .04 water column inches and a maximum of .08 water column inches.

• Too many elbows.

• Insufficient flue size.

Problem: Draft blower runs constantly.

Remedies: • This can be checked by turning the thermostat to a lower setting than the temperature in your building . If the draft blower continues to run, the thermostat may be defective. Replace if necessary. • Replace transformer and relay. • Have a professional determine the proper size furnace and insulation factor of your building .

• Defective wall thermostat. Possible Causes:

• Defective relay in transformer. • Building is not being supplied with a sufficient amount of heat to satisfy the wall thermostat.

Problem: Rapid accumulation of creosote in furnace and flue .

• Use of high resin wood, such as pine. Possible Causes:

Remedies:

• Completely avoid using if at all possible. If hardwoods are not available, fuel the furnace with smaller loads. This will cause the thermostat to call for more heat more often, which will initiate the running of the draft blower. Consequently, the fires will be hotter, thereby reducing the accumulation of creosote. • Install flue gas thermometer and maintain stack temperatures between 300° and 400° F. • See #9. • DANGER: Never use uninsulated stove pipe as chimney. It must not be used on the inside of your building due to high stack temperatures, which create an extreme fire hazard. Uninsulated pipe cannot be used as an outside flue because it causes rapid cooling of the stack gases, which causes them to condense as creosote on the inside of the flue. • Inspect entire flue run, from the exhaust stack of the furnace to the termination cap. Repair as necessary. • Furnace room may be too airtight to supply sufficient amount of oxygen for combustion. Install an aperture to the outside consisting of a minimum of 12 square inches or 4 inches round. • Install stainless steel liner in masonry chimney to reduce creosote formation and improve draw. Use appropriate size stainless liner for the furnace.

• Under-firing the furnace has

caused low flue gas temperature.

• Insufficient chimney draft. • Using uninsulated stove pipe for the chimney, especially if the construction is on the exterior of the building . • Improper connection in stove pipe causing air leakage or a structural defect in the chimney itself. • Fire box not receiving adequate amount of oxygen.

• Use of an unlined masonry chimney with a large clay tile opening.

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