A-Maize-Ing Heat LDJ620-9, Manual

Page 1: ...Furnace Installation and Owners Manual Model LDJ620 9 Furnace Model LDJ620 10 Furnace Model 14 Bin LDJ620_E01_R03_2006 03 ...

Page 2: ... the latest information available at the time of publication Your furnace may have product improvements and options not yet contained in this manual LDJ Manufacturing Inc reserves the right to make changes at any time without notice or obligation Additional copies of these instructions are available from LDJ Manufacturing Inc No part of this manual may be reproduced in any form or by any means ele...

Page 3: ...Chimney 6 Barometric Draft Controls 7 Installation 7 Required Tools 7 Unpacking and Setup Furnace 7 Unpacking and Setup Storage Bin 8 Ducting 9 Chimney Vent 10 Barometric Draft Control 10 Draft Guage 10 Electrical Connections 12 Electrical Supply 12 Thermostat 12 Operation 13 Burner Lighting 13 Draft Adjustment 15 Furnace Operation 15 Typical Operation Cycle 15 Clinker Buildup 16 Power Failure Ins...

Page 4: ...fficient Operation and or Operating Too Hot 22 Mechanical Electrical 23 Wiring Diagram LDJ620 9 100 000 BTU Furnace 24 Wiring Diagram LDJ620 10 165 000 BTU Variable Rate Furnace 25 Repair Parts 26 Burn Pot Auger 26 Hopper Bin Auger 27 Storage Bin Model 14 28 Heat Exchanger 29 Furnace Cabinet 30 Furnace Blower 32 Addendum 34 Venting Information 34 Barometric Draft Control Information 36 Ducting Inf...

Page 5: ...t of the use of the A MAIZE ING HEAT furnace or any alleged defect in design manufacture assembly instructions or labeling thereof WELCOME TO THE A MAIZING HEAT FURNACE Congratulations on your purchase of the A MAIZE ING HEAT biomass fueled furnace We are honored that you selected the A MAIZE ING HEAT furnace The A MAIZE ING HEAT furnace is the first biomass fired furnace to be listed by Underwrit...

Page 6: ...e for efficiency and safe operation refer to page page 18 Have a qualified service person perform tasks you are not familiar with Children and adults should be alerted to potential high service temperatures of the burner door KEEP CHILDREN AWAY Risk of fire or explosion Do not burn gasoline oil garbage or other flammable substances Do not burn treated corn Treatment chemicals can be unknown and th...

Page 7: ... duct work and its metal cold air joined to the return air system This unit is not intended to be an add on unit to another furnace If you intend to use the A MAIZE ING HEAT furnace in conjunction with another furnace air back feed prevention measures must be taken to prevent the overheating of either furnace Furnace Clearances and Accessibility The following are the minimum distances the furnace ...

Page 8: ...himney flue serving any other heating device Venting may be provided using a lined masonry chimney or a listed chimney class A The chimney has two functions 1 To exhaust smoke and flue gases that are the result of combustion 2 To provide draft to the furnace This provides a continous supply of fresh air into the appliance so that proper combustion is possible Important Installation Points The conn...

Page 9: ...le hazard The procedure for establishing the proper chimney draft will be discussed in the Installation section starting on page 7 For more information on the barometric draft regulator refer to Barometric Draft Control Information on page 36 INSTALLATION Required Tools Flat bit screwdrivers Phillips screwdriver 5 16 hex driver 3 8 hex driver 7 16 wrench 7 16 socket Drill and 1 4 bit Unpacking and...

Page 10: ...motor housing with conduit lock nut 6 Step 8 Install wooden handles onto door handle 8 and heat exchanger cleaner 9 by twisting them on Do not drive them on splitting may result Unpacking and Setup Storage Bin Step 1 Remove base parts and storage bin from shipping container Step 2 Assemble base rails 1 and legs 2 together with sixteen 1 4 20 x 1 2 bolts 3 and nuts Step 3 Position storage bin 4 on ...

Page 11: ...Connect one black bin auger motor wire to the two orange wires in the auger motor housing with a wire nut connector Step 9 Connect the other black bin auger motor wire to the two white wires in the auger motor housing with a wire nut connector Step 10 Install cover on auger motor housing Ducting IMPORTANT The hot and cold air furnace connections to the A MAIZE ING HEAT furnace must not be less tha...

Page 12: ...imney with 6 metal flue pipe using sheet metal screws to secure refer to Venting on page 6 Barometric Draft Control Install the baromatric draft control according to the directions beginning on page 36 It will be adjusted refer to Draft Adjustment on page 15 after the installation of the furnace is complete and a fire has been built Draft Guage The draft guage is installed to monitor the chimney d...

Page 13: ... to it Connect the all white hose to the port marked HIGH 6 Connect the white hose with the red line to the port marked LOW 7 Step 11 Turn the ZERO SET 8 knob counter clockwise 2 to 3 turns Step 12 Loosen and remove the FILL 9 plug Step 13 Open the bottle of red gage oil 10 and install nozzle top Step 14 Carefully pour oil into the FILL opening until the red gage oil reaches ZERO 11 Step 15 Re ins...

Page 14: ...th the National Electrical Code If unfamiliar with wiring and codes have a licensed electrician perform the electrical connection The electrical supply to the furnace should be from a 120V 15 amp protected circuit Make all connections inside box 1 Black wire to black wire White wire to white wire Ground wire green to ground terminal Thermostat A thermostat is not included with the A MAIZE ING HEAT...

Page 15: ... more time The powdered graphite will lubricate the storage bin auger until it begins to polish from the flow of corn pellets This operation should be repeated at the beginning of each heating season This operation should also be repeated if the hopper is allowed to run empty and a sticky smoke film coats the storage bin auger tube Powdered graphite may also be added about once a month at a time w...

Page 16: ...ch 4 to START This will start the burner blower only the auger motors will not turn until the furnace has reached operating temperature Keep the switch in the START position for 5 to 10 minutes or until you see a good even fire Step 7 With the fire 5 well started move the START OFF ON switch to ON Step 8 Set wall thermostat to desired temperature Step 9 If the corn pellets do not completely ignite...

Page 17: ...stat needs to be set to maintain the desired temperature The thermostat furnace temperature sensors and timers control the augers and blowers A typical furnace operation cycle is as follows Step 1 Thermostat activates fuel feed system The combustion fan starts and the augers feed fuel into the burner HIGH FIRE Step 2 Heat builds up in the furnace which activates the blower fan switch The blower fa...

Page 18: ...ned out of the burner pot and the fire restarted IMPORTANT When ashes are removed from the ash pan they should be placed in 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 burying in soil or otherwise dispensed they sh...

Page 19: ...are suggested timer settings to obtain various BTU outputs from the LDJ620 10 furnace when burning corn The actual BTU output may vary depending upon the characteristics of the fuel being burned Contact LDJ Manufacturing for settings for other fuels pellets etc The green arrow indicates the number of seconds the timer is OFF 1 5 15 seconds and the red arrow indicates the number of seconds the time...

Page 20: ...uel Supply Check level of corn pellets in storage bin 2 Refill as necessary to maintain an adequate supply Weekly Maintenance Check Ash Drawer Check ash drawer 3 and empty as needed Ashes should be placed in 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 dis...

Page 21: ... 5 on rear of furnace and inspect air filter Replace as necessary Monthly Maintenance Replace Air Filter Remove door 5 on rear of furnace and replace air filter Annual Maintenance Inspect Chimney Pipe Remove and inspect all chimney pipe connections Clean out ash buildup in pipes Replace any pipe showing any signs of burning through Inspect Motors Clean oil and inspect all blower and auger motors T...

Page 22: ...oubleshooting Initial Setup Quick Check Operation Quick Check Problem Possible Causes Fire won t start Initial startup may require use of kindling wood two or three times before the corn begins to burn completely Chimney draft too high On tall or large chimneys a second barometric regulator may be required or it may be necessary to reduce the outlet opening to approximately 28 square inches Furnac...

Page 23: ...n if chimney draft is sufficient 60 cubic feet per minute minimum of fresh air is required Clinker build up Burning the wrong type or quality of corn or pellets can cause excess clinker buildup due to extra materials and fire extinguish ing effect Improper installation causing the furnace to run on high fire for an extended period can also result in clinker formation Loosen clinkers manually with ...

Page 24: ...Chimney draft should never exceed 0 04 inches water column draft Verify correct installation install second barometric regulator if necessary refer to Barometric Draft Control Information on page 36 Furnace keeps open ing high limit switch and or is not blowing much heat through the vents Filter dirty and restricted Replace filter Not enough plenum or ductwork area the hot air or return air connec...

Page 25: ...t operate Variable input timer defective Check variable input timer Low limit switch defective Check low limit switch Defective heat relay or no HEAT signal from thermostat or defective 24V trans former Verify that transformer is okay Verify HEAT signal from thermostat Check heat relay The START OFF ON switch left in START position after starting fire in burn pot Change switch to ON Blower fan doe...

Page 26: ...former G W C Y R Fan Relay 87A 87 30 Thermostat connections Low Fire Timer Relay LF 7 2 timer M Combustion Blower Motor 3 Speed Fan Motor M BLK RED BLU High Low Med PUR 120V NEUTRAL 85 86 R 24V power supply to thermostat W Heat signal from thermostat Y A C signal from thermostat G Fan full time signal from thermostat C 24V Common 120V HOT Fuse 10A Disconnect 1 8 3 6 4 NC NO 1 8 3 6 OR M Furnace Au...

Page 27: ...stat connections Low Fire Timer Relay LF 7 2 timer High Fire Timer Relay HF 7 2 timer M Combustion Blower Motor OR M Furnace Auger Motor M Bin Auger Motor 3 Speed Fan Motor M BLK RED BLU High Low Med PUR 120V NEUTRAL 85 86 R 24V power supply to thermostat W Heat signal from thermostat Y A C signal from thermostat G Fan full time signal from thermostat C 24V Common 120V HOT Fuse 10A Disconnect 1 8 ...

Page 28: ...rt Number Part Description Quantity Used LDJ620 9 LDJ620 10 1 1900 Burn Pot Auger Motor 4 rpm 1 1 2000 Burn Pot Auger Motor 6 rpm 1 2 3180 Lock Collar 1 1 3 1980 Bolt 1 4 x 1 2 Self Tapping 1 1 4 3200 Burn Pot Auger Flighting 1 1 5 2070 Screw Sheet Metal 10 x 1 3 4 2 2 6 3000 Auger Support 1 1 7 1410 6 x 6 Box 1 1 1 2 3 4 5 6 7 5 ...

Page 29: ...ntity Used LDJ620 9 LDJ620 10 1 A 3220 Bin Auger Flighting 1 1 2 3180 Lock Collar 1 1 3 1880 Bin Auger Motor 2 rpm 1 3 1900 Bin Auger Motor 4 rpm 1 4 1410 6 x 6 Box 1 1 5 A 3070 Auger Support 1 1 6 5000 Lag Bolt 1 4 x 1 2 2 7 7530 Rubber Tee 1 1 8 A 7540 Bin Auger Tube 1 1 9 1480 Conduit Fitting 1 1 10 A 1550 Flex Conduit 1 1 1 2 3 4 5 6 7 8 9 10 6 ...

Page 30: ...l 28 LDJ620_E01_R03_2006 03 Models LDJ620 9 and LDJ620 10 Storage Bin Model 14 Ref Part Number Part Description Quantity Used LDJ620 9 LDJ620 10 1 7520 Bin Lid 1 1 2 7500 Bin Cavity 1 1 3 7510 Bin Base 1 1 4 7520 Shutoff Valve 1 1 1 2 3 4 ...

Page 31: ...anger Ref Part Number Part Description Quantity Used LDJ620 9 LDJ620 10 1 5700 Burner Heat Shield 1 1 2 5680 Heat Deflector 1 1 3 5660 Side Heat Shield 2 2 4 5640 Top Heat Shield 2 2 5 A 5720 Heat Exchanger 1 1 6 2200 Wooden Handle 1 1 7 2040 Bolt Shoulder 5 16 x 1 1 1 8 2020 Nut 1 4 1 1 1 2 3 4 5 6 7 8 4 ...

Page 32: ...Furnace Installation and Owners Manual 30 LDJ620_E01_R03_2006 03 Models LDJ620 9 and LDJ620 10 Furnace Cabinet 8 7 9 1 20 10 16 15 12 18 20 13 19 17 21 14 11 BACK FRONT 2 3 6 5 4 ...

Page 33: ...00 Washer Lock 5 16 1 1 6 2020 Nut 1 4 1 1 7 A 4180 Burner Door 1 1 8 6460 Door Trim 1 1 9 6440 Ash Drawer Trim 1 1 10 A 6040 Furnace Floor 1 1 11 6220 Front Panel 1 1 12 6200 Cold Air Wall 1 1 13 6280 Bank Side Panel 1 1 14 6240 Right Side Panel 1 1 6260 Left Side Panel 1 1 15 A 6180 Furnace Top 1 1 16 6400 Trim Ring 2 2 17 A 4260 Filter Rack 1 1 18 6300 Top Rear Panel 1 1 19 A 6340 Filter Access...

Page 34: ...y Used LDJ620 9 LDJ620 10 1 7F731 Blower Complete 1 1 2 4C710 Blower Wheel 1 1 3 A40152 Motor Mounting Brackets Complete 1 1 4 2C355 Housing Supports Both Sides 1 1 5 8122420 Vibration Pads 4 4 6 Screw Hex Head 10 24 x 7 8 6 6 7 Nut 10 24 6 6 8 Screw Hex Head 10 24 x 3 4 6 6 9 Screw Hex Head 1 4 20 x 1 2 3 3 10 4M098 Motor 1 1 1 2 3 1 4 5 6 9 7 10 8 ...

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Page 36: ...Furnace Installation and Owners Manual 34 LDJ620_E01_R03_2006 03 Models LDJ620 9 and LDJ620 10 ADDENDUM Venting Information ...

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Page 38: ...be less than indicated for proper operation See Figure 2 and Table 1 COLLAR INSTALLATION WHEN SHIPPED WITH A COLLAR To attach the collar to the flue see Figure 2 and follow the instructions as follows 1 Bend the two ears at the front corners of the collar outward Bend 90 behind the single hole on the straps 2 Insert clamping screw in ears on collar and bolt the remainder of the collar together 3 H...

Page 39: ...ts in flue adjacent to control NOT over fire drafts OIL BURNER COMBUSTION AIR AND OVERFIRE DRAFT SETTING INCHES OF W C After the burner has operated for at least 5 to 10 minutes take draft readings over the fire For a domestic oil burner the over fire draft should be approximately 02 to 03 although there are some makes of burners which require higher drafts Follow the burner manufacturer installat...

Page 40: ...Furnace Installation and Owners Manual 38 LDJ620_E01_R03_2006 03 Models LDJ620 9 and LDJ620 10 Ducting Information ...

Page 41: ...t significantly affect the energy efficiency of the heating and cooling system because the conditioned air will remain inside the house Also ducts located inside the house need minimal insulation in hot and humid climates if any at all Duct systems should be hard ducted as much as possible Duct system installations that use the house structure or building framing e g building cavities closets rais...

Page 42: ...xterior insulation DUCT BOARD BOOT AND DUCT CONNECTION HIGHLIGHTS FIBERGLASS DUCT BOARD DUCTS Fiberglass duct board is insulated and sealed as part of its construction It is usually used to form rectangular supply and return trunks branches and plenums although it can be used for runouts as well Fiberglass duct board provides excellent sound attenuation but its longevity is highly dependent on its...

Page 43: ...ucts should be sealed with mastic or approved pressure sensitive tapes It is sometimes easier to remove service panels and seal these areas from the inside using mastic PLENUMS Fiberglass duct board is often used to build supply and return plenums Mastics or approved tapes may be used to assemble butt joints on fiberglass duct board components such as plenum boxes Although it is not recommended cl...

Page 44: ...ure repair personnel Cloth backed rubber adhesive duct tapes should not be used because they deteriorate with time and exposure to heat Pressure sensitive metallic tape with butyl adhesive not meeting UL Standard 181 can be used to seal metal to metal connections Cork tape can be used to seal gaps where refrigerant lines penetrate the air handler unit cabinet I N S T A L L A T I O N M A T E R I A ...

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