A-Maize-Ing Heat LDJ991 Installation instructions

Boiler Installation and Owners Manual
Model LDJ991 Boiler
Model LDJ991-10 Boiler
Model 14 Bin
LDJ991_E01_R03_2006.03

This manual explains the proper installation,
operation, and maintenance of your A-MAIZE-ING
HEAT®boiler. Study and understand these
instructions thoroughly before installing,
operating, or maintaining the boiler. Failure to do
so could result in serious injury or death and/or
equipment damage. Consult your A-MAIZE-ING
HEAT®dealer or LDJ Manufacturing, Inc. if you do
not understand the instructions in this manual or
need additional information.
LDJ Manufacturing, Inc. recommends that you
retain this manual for future reference of
operation, maintenance, and parts information.
The instructions, illustrations, and specificationsin
this manual are based on the latest information
available at the time of publication. Your boiler
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, electronic or
mechanical, including photocopying, recording, or by any information storage and
retrieval systems, without the express written consent of LDJ Manufacturing, Inc.
Copyright © 2006
All rights reserved.
LDJ Manufacturing, Inc.
1833 Highway 163
Pella, Iowa 50219, USA
A-MAIZE-ING HEAT®, and A-MAIZE-ING HEAT® Logo are
registered trademarks of LDJ Manufacturing, Inc.
in the U.S. and/or other countries.
Boiler tested and certified by
Underwriters Laboratories

Boiler Installation and Owners Manual 1
2005.08.29 PTC Models LDJ991 and LDJ991-10
TABLE OF CONTENTS
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Disclaimer of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Welcome to the A-MAIZING-HEAT® Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Installation and Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Boiler Clearances and Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Important Installation Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Masonry Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Listed Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Barometric Draft Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Unpacking and Setup - Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Unpacking and Setup - Storage Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Chimney Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Barometric Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Draft Guage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Low-Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Burner Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Draft Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Boiler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Typical Operation Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Clinker Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Power Failure Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Summary of Settings and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
HIGH FIRE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
LOW FIRE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Variable BTU Timer (LDJ991-10 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

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2005.08.29 PTC
Models LDJ991 and LDJ991-10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Tips for Good Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Initial Setup Quick Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Operation Quick Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Poor Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Inefficient Operation and/or Operating Too Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Mechanical / Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Wiring Diagram: LDJ991 100,000 BTU Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Wiring Diagram: LDJ991-10 165,000 BTU Variable Rate Boiler . . . . . . . . . . . . . . . . . . . .24
Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Burn Pot Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Hopper Bin Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Storage Bin - Model 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Boiler Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Addendum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Venting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Barometric Draft Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

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WARRANTY
LDJ Manufacturing, Inc. warrants the A-MAIZE-ING HEAT®boiler against any defects in workmanship
and materials for a period of one (1) year after the date of purchase. LDJ Manufacturing, Inc. will repair
or replace as necessary any defective parts within the warranty period.
LDJ Manufacturing, Inc. warrants the boiler and burner only, for a period of five (5) years after the date of
purchase. LDJ Manufacturing, Inc. will replace any defective boiler or burner parts free of charge within
the five (5) year period. All boiler and burner claims will be limited to parts only, labor is not provided.
This warranty does not take effect until the warranty registration card is sent in. If the card is not filled out
and returned to LDJ Manufacturing, Inc. within 30 days of date of purchase, warranty claims on your unit
may be denied. All warranty claims must be reported to the nearest A-MAIZE-ING HEAT®dealer.
DISCLAIMER OF LIABILITY
The foregoing warranty constitutes the only warranty made by LDJ Manufacturing, Inc. regarding the
A-MAIZE-ING HEAT®boiler. LDJ Manufacturing, Inc. makes no warranty as to the merchantability or as
to the fitness of this product for any particular purpose. LDJ Manufacturing, Inc. disclaims any and all
liability for damages, consequential or otherwise, cost or expense of any sort or nature arising out of the
use of the A-MAIZE-ING HEAT® boiler or any alleged defect in design, manufacture, assembly,
instructions, or labeling thereof.
WELCOME TO THE A-MAIZING-HEAT®BOILER
Congratulations on your purchase of the A-MAIZE-ING HEAT®biomass fueled boiler. We are honored
that you selected the A-MAIZE-ING HEAT®boiler. The A-MAIZE-ING HEAT®boiler is the first biomass
fired boiler to be listed by Underwriters Laboratories. The UL listing is your assurance of a safe and
quality product.
As convenience fuels become more expensive and less abundant, corn and pellets as fuel are becoming
very attractive and viable as alternative heat sources. With high energy costs it makes sense to use a
heat source that utilizes a resource that is readily available and cost effective.
LDJ Manufacturing, Inc. believes that there is no substitute for safety and quality. You can have
confidence that your A-MAIZE-ING HEAT®boiler will serve your heating needs now, and for years to
come. We emphasize that you follow our policy of SAFETY FIRST when installing and using your
A-MAIZE-ING HEAT®boiler. The installation and owners manual must be read before installing and
operating your A-MAIZE-ING HEAT®boiler.
Your A-MAIZE-ING HEAT®boiler is a practical alternative heat source specifically designed for
residential use. Proper care of this appliance should result in many years of service and comfort. An
annual checkup by a certified HVAC service person is recommended.
If you have any problems, questions, or concerns, please contact your nearest A-MAIZE-ING HEAT®
dealer, or contact LDJ Manufacturing, Inc. at 866-535-7667 for information on the dealer nearest you.

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LDJ991_E01_R03_2006.03
Models LDJ991 and LDJ991-10
SAFETY INSTRUCTIONS
Failure to follow these safety instructions may result in serious injury
or death and/or property damage.
• Do not install or use this product unless the instructions within this manual have been carefully read
and understood.
• This heating appliance must be installed in accordance with local codes.
• Installation is to be performed by a qualified installer, according to state and local codes.
• Maintain adequate minimum clearances to combustible materials (refer to “Boiler Clearances and
Accessibility” on page 5).
• Install in an area with adequate air for combustion and ventilation: a minimum of 60 cubic feet per
minute.
• Do not connect this heating appliance to a chimney flue serving any other heating device.
• Disconnect all power to the unit before performing routine maintenance or service. Before servicing,
allow the unit to cool.
• Establish a regular service and maintenance schedule for efficiency and safe operation (refer to page
page 17). 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
their inhalation can result in serious health problems or death.
• Do not place clothing or other flammable materials on or near this appliance.
• 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 disposal. If the ashes are disposed of by burying in soil or otherwise
dispensed, they should be retained in the closed container until all clinkers have thoroughly cooled.
CONTACT INFORMATION
If you have any questions about this product or its installation, please contact us:
Address LDJ Manufacturing, Inc.
1833 Hwy 163
Pella, Iowa 50219
Phone 641 • 620 • 9412
866 • 535 • 7667
Fax 641 • 620 • 8302
Website www.cornheat.com
Email inf[email protected]

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LDJ991_E01_R03_2006.03 Models LDJ991 and LDJ991-10
INSTALLATION AND LOCATION CONSIDERATIONS
Failure to install the A-MAIZE-ING HEAT®boiler according to the
guidelines and instructions contained within this manual may result in
serious injury or death, property damage, or voiding of the warranty.
Boiler Clearances and Accessibility
The following are the minimum distances the
boiler may be to a combustable surface:
top.........................................................................32"
either side ...............................................................6"
front.......................................................................30"
back cabinet surface...............................................6"
flue connector on back..........................................18"
For ease of service, the following minimum
distances are recommended:
top.........................................................................32"
side opposite bin...................................................24"
front.......................................................................36"
rear-most surface on back (boiler or flue).............18"
The overall dimensions of the A-MAIZE-ING
HEAT®boiler are as follows:
boiler cabinet width...............................................22"
boiler cabinet depth (with door).............................36"
boiler cabinet height..............................................59"
storage bin width...................................................35"
storage bin depth..................................................51"
storage bin height .................................................47"
overall width when assembled
(as configured above) ...........................................67"
12"
18" (**)
36" (*) 24" (*) 22" 35"
51"
*Minimum service distance
**Minimum combustable clearance

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LDJ991_E01_R03_2006.03
Models LDJ991 and LDJ991-10
Combustion Air Requirements
Failure to provide adequate combustion air can lead to increased
carbon monoxide production and increased emissions of combustion
gases into the building, which may cause death or serious injury.
The boiler must have a minumum supply of
60 cubic feet of air per minute. Consult a
qualified boiler installer to analyze if the air
supply is adequate. In newer air-tight homes,
the combustion air may need to be brought in
from the outside.
Venting
Failure to provide correct chimney venting can lead to increased
carbon monoxide production and increased emissions of combustion
gases into the building, which may cause death or serious injury.
Do not connect this heating appliance to a
chimney 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 boiler. This provides a
continous supply of fresh air into the appliance so
that proper combustion is possible.
Important Installation Points
• The connection from the heating appliance to
the chimney must be made using 6" black
pipe.
• Avoid using more than two elbows in
connecting the boiler to the chimney.
• Any horizontal runs of connector pipe should
have a minimum rise of 1/4" per foot of run to
allow condensation to flow back to the
firebox.
• A minimum distance of 18" must be
maintained between the connection pipe and
combustible wall surfaces.
• A minimum distance of 32" must be
maintained between the connection pipe and
combustable ceiling surfaces.
Masonry Chimney
An existing lined masonry chimney must be
cleaned and inspected. All connections made to
the chimney must comply with NFPA Standard
211 and all applicable building codes. Consult a
qualified boiler installer and/or local building
inspector to make sure the chimney and
connections comply and are safe.
Listed Chimney
A listed chimney must be rated for a solid-fuel
burning appliance and must comply with NFPA
Standard 211 and all applicable building codes.
Consult a qualified boiler installer and/or local
building inspector to make sure the chimney and
connections comply.
For more information on venting with listed
chimneys, refer to “Venting Information” on
page 29.

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Barometric Draft Controls
IMPORTANT: In order for the boiler to operate
correctly, 0.04" to 0.06" water column of draft
during low-fire operation must be established
and maintained. Low-fire operation is when the
thermostat is satisfied and no fuel is being
augered into the burner. If the chimney draft is
too high, the fire will go out. If the draft is too
low, smoke may back up into the boiler and
storage bin, creating a possible 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 31.
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 Setup - Boiler
IMPORTANT: Before unpacking and
assembling the A-MAIZE-ING HEAT®boiler,
review the “Installation and Location
Considerations” section starting on page 5 for
the proper placement of the boiler and storage
bin.
Step 1: Remove all shipping materials and
remove boiler from pallet.
Step 2: Place boiler at desired location.
Step 3: Remove auger motor assembly and
hardware package from ash pan drawer.

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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 top of base (5) .
Make sure it is level and fitted against base at all
corners.
Step 4: Slide auger boot (6) with clamp (7) over
bin outlet. Tighten clamp securely.
Step 5: Install two sheet metals screws through
clamp, auger boot, and into the bin outlet for a
permanent connection.
Step 6: Install coupler (8) between bin auger
tube and boiler fuel inlet. Secure with two hose
clamps (9).
Step 7: Attach flexible conduit (10) from bin
auger to boiler auger motor housing (11) with a
conduit locknut.
Step 8: 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.
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2
3
4
5
6
7
8
9
9
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11