Daka Corporation 521FB User manual

DAKA 521FB Manual Page 1 of 31 January 2009
Rev. 1, June 2011
MODEL 521FB
WOOD-BURNING FURNACE MANUAL
Manufactured in the U.S.A. by
DAKA CORPORATION
955 Industrial Street NE
Pine City, Minnesota 55063
Phone: [phone] x
x
Fax: [phone]
www.dakacorp.com

DAKA 521FB Manual Page 2 of 31 January 2009
Rev. 1, June 2011
I. LIMITED WARRANTY
This model has been tested and listed in accordance with
Underwriters Laboratories Standard UL 391-2010
for Solid Fuel Central and Supplementary Furnace by
Intertek Testing Services/Warnock Hersey Inc.
International Conference of Building Officials (ICBO) Report No. TL116
Council of American Building Officials (CABO) Report No. NER QA219
Purchase Date:
Purchased From:
Model #:
Serial #:
DAKA Corporation warrants the combustion chambers of its supplementary and central furnaces to be free of
defects in material or workmanship for five years (non-prorated) from date of sale. All other components, including
electronics, gaskets and grates, are covered in the same manner for a period of one year.
DAKA Corporation will repair or replace defective components, at our option, at no charge for parts and labor,
and will pay freight charge for one-way shipment for warranty claims during the first year. In second and
subsequent years, only parts and labor will be provided at no charge. DAKA Corporation is not responsible for
installation or dismantling costs.
The warranty is void if unit is not used in a residential service connected to conventional basement-type upflow
central heating system, if non-approved fuels are used in firing of units, or if unit is damaged due to accident,
improper installation or negligence.
For service under this warranty, contact selling dealer or DAKA Corporation, Customer Service Dept.,
955 Industrial St. NE, Pine City, MN 55063; telephone [phone] or email [e-mail].
Implied warranties including that of merchantability are expressly limited in duration to the duration of this
warranty. DAKA Corporation disclaims any responsibility for consequential damages. Some states do not allow
limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential
damages, so this limitation and exclusion may not apply to you.
This warranty gives you specific legal rights and you also may have other rights that vary from state to state.
This is our exclusive written warranty.
SAVE
THESE
INSTRUCTIONS.
This furnace meets
U.S. Test Standard: UL 391-2010

DAKA 521FB Manual Page 3 of 31 January 2009
Rev. 1, June 2011
II. TABLE OF CONTENTS
DAKA 521FB
WOOD-BURNING FURNACE MANUAL
I. LIMITED WARRANTY.................................................................................................. 2
II. TABLE OF CONTENTS ............................................................................................... 3
III. FEATURES .................................................................................................................. 4
IV. SPECIFICATIONS........................................................................................................ 5
V. OPTIONAL FURNACE ACCESSORIES ...................................................................... 6
VI. GENERAL WOOD-BURNING SAFETY ................................................................... 7, 8
VII. CHECKING SHIPMENT ............................................................................................... 9
VIII. PLANNING YOUR INSTALLATION ...................................................................... 10-14
A. General
B. Clearances
C. Chimney
D. Supplementary Add-on
E. Central
IX. ASSEMBLY INSTRUCTIONS ............................................................................... 15-20
A. Components (Main)
B. Electrical components (Fan Control, Wiring)
C. Cold Air Return Filter Box
X. INSTALLATION ..................................................................................................... 21-25
A. Connecting to Ductwork
1. Supplemental Add-On
2. Central
3. Alternative Connection Options
B. Connecting to Chimney
XI. OPERATING INSTRUCTIONS............................................................................. 26, 27
A. General
B. Operating Controls: Snap Disc Fan Control & Automatic Damper Control
C. Emergency
XII. MAINTENANCE INSTRUCTIONS.............................................................................. 28
XIII. TROUBLESHOOTING ............................................................................................... 29
XIV. PARTS LIST & EXPLODED VIEW ............................................................................. 30

DAKA 521FB Manual Page 4 of 31 January 2009
Rev. 1, June 2011
III. FEATURES
5
-Year Warranty –
5
-year non-prorated warranty on
firebox; 1 year on all other materials.
See
Written Warranty for details.
Snap Disc Thermostat
–A
highly reliable independent
snap disc thermostat controls
blower.
Heavy Duty Cast Iron Grates –
High heat resistance provides
longer life.
2
Sides and
Back Fire Brick
Lining
–
Durable
construction for
long life and
consistent heat.
UL Tested by WHI –
Tested to UL Standard
391
-
2010. Ensures
safety and efficiency.
42,000 to
105,000 BTU’s –
Offers wide range
of heat output.
8 Hour Burn
Time –
For average heating
output, up to 12 hours
of “overnight” heating
needs.
Complete 7
gauge (3/16”)
steel throughout
Firebox –Most
competitors offer
only a 10-gauge
firebox; approx.
half the strength of
a DAKA Furnace.
Heats Homes up
to 2,6
00 sq. ft.
–
Largest heating
capacity for the
price available in
the market.
USE AS AN ADD-ON or CENTRAL FURNACE
–Add-on utilizes existing central ductwork and distribution system
–Central application has its own ductwork.
NOTE: Return Cold Air Filter Box included but not
shown. The filter box improves indoor air quality.
Large Fire Box
holds 90 lbs
.
of
22” logs
–
Allows
for maximum burn
time.
Automatic Damper Control –For
maintenance free, consistent heat;
automatically adjusts air supply to fire.
Backdraft Damper
–
Factory
-
installed warm air
back draft damper is
included with every
521FB furnace.
Full Length Ash Pan
–
Makes ash handling
more convenient and reduces spillage; no
back on ash pan for ease of dumping.
2
-
8” Warm Air Outlets
–
for secure connection
of 8” round duct pipe.
Heavy Duty Cast Iron
Door
–
Prevents warping
and maximizes efficiency.
Blower, 550 CFM –
1/10 HP helps maintain
CFM at higher static
pressures. Totally
enclosed, permanently
lubricated ball-bearings.

DAKA 521FB Manual Page 5 of 31 January 2009
Rev. 1, June 2011
IV. SPECIFICATIONS
DAKA MODEL 521FB WOOD-BURNING FURNACE SPECIFICATIONS
Manufacturer:
DAKA Corporation
Model:
521FB
U.L. Approval:
Tested to U.L. Standard 391–2010 by WHI
Fuel Type:
Wood / Coal
Dimensions:
44” Height x 24” Width x 25-½” Depth
BTU Output:
42,000 –105,000 per hour
Fuel Capacity:
22” Log Length / 90 lb.
Air Outlet Size:
2 –8” round
Flue Outlet Size:
6” round
Weight:
432 lbs.

DAKA 521FB Manual Page 6 of 31 January 2009
Rev. 1, June 2011
V. OPTIONAL FURNACE ACCESSORIES
DAKA CORPORATION
955 Industrial St NE, Pine City MN 55063
Telephone: [phone] Fax: [phone]
Email: [e-mail] Website: www.dakacorp.com
Visit our website or call 1-800-884-3252
for pricing and shipping information.
273
- TWIN 550-CFM BLOWER KIT
For installations requiring additional air pressure, such as
for use as a central furnace. Kit includes one 550
-
cfm split-
capacitor blower, wiring
and instructions. For use with
models 521FB/621/622, many earlier deluxe models.
258 – DUAL BLOWER RETURN COLD AIR FILTER BOX
With No. 273 twin blower kit installed, this galvanized filter
box covers both blowers. Takes one 14" x 25 x 1” paper
furnace filter (not included.).
218
-LARGE BLOWER & FILTER BOX KIT
Mounts on side of furnace to provide increased air delivery
for higher static pressure central furnace applications. Kit
includes a 1580
-cfm blower with 1/4-HP belt-
drive motor,
galvanized steel return
cold air filter box. 115V AC.
223
- HOT-TUBE™ DOMESTIC HOT WATER PREHEATER
Connects to present domestic hot water tank to provide
gallons of piping hot water. Weldless boiler pipe has working
pressure of 1200lbs./sq. in. Kit includes pre
-heater pipe,
hardware,
gaskets and instructions.
238D - SOFT COAL SHAKER GRATE KIT
Replaces wood-burning grate to permit burning of
bituminous and sub-bituminous coal in Deluxe models
311/411/521FB/621/622 above, many earlier models.
Includes extra -thick 3-section shaker grates and shaker rod
assembly & fire door with spinner knob.
`
253 - FORCED DRAFT CONVERSION KIT
Adds convenience of living area control of heat output of
Deluxe models 521FB and 621, many earlier models. Kit
includes 35-cfm draft blower, wall thermostat,
transformer/relay, controls, wiring and instructions.
283
- BAROMETRIC DRAFT REGULATOR
Installs in chimney connector to help provide constant draft
control, extend burn times, save fuel, avoid
over-
firing, and
reduce creosote formation. Adjustable from .02" to .08"
updraft. For 6" pipe. U.L. Listed.

DAKA 521FB Manual Page 7 of 31 January 2009
Rev. 1, June 2011
VI. GENERAL WOOD--BURNING SAFETY
STOP FOR SAFETY!
Safe assembly, operating and maintenance practices should
always be followed whenever using any equipment.
READ THROUGH THE ENTIRE MANUAL BEFORE BEGINNING
YOUR INSTALLATION OR OPERATING YOUR FURNACE.
FOLLOW ALL STEPS EXACTLY!
WARNING: Disconnect all power before making
electrical connection. For power supply connections,
use No. 14 AWG or larger wires acceptable for at
least 105qC. Check local codes for acceptable
components.
WARNING: Do not over fire the furnace. Over firing
will happen if the fire door or ash door is left open
during operation. Such actions can result in very
dangerous operating conditions.
WARNING –Risk of fire! Do not operate with flue
draft exceeding .06” WC. (measured in water
column). Use of a draft gauge is highly
recommended. Follow gauge manufacturer’s
instructions. Gauges to measure chimney draft are
readily available at furnace shops and are
economical to purchase or rent. If a draft gauge is
not available, with the draft regulator fully installed
and a good fire burning, adjust the counterbalance
weight closer to the gate for as low a draft setting as
possible, without the fire dying or getting smoke-
back with the stove door slightly open. To obtain
higher heat levels, move the weight away from the
gate to increase the setting.
WARNING: 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.
WARNING: Do not operate furnace while under the
influence of drugs or alcohol.
WARNING: For further information on using your
furnace safely, contact the National Fire Protection
Association (NFPA) at www.nfpa.org.
WARNING: To prevent burns, always wear
protective clothing, leather hearth gloves and eye
protection, while tending the fire.
WARNING: While in operation, keep the fire door
and ash door closed at all times except while
tending the fire.
WARNING: Burn wood only or burn coal only.
CAUTION: Hot Surfaces! Keep children away. Do
not touch during operation. Maintain clearance to
combustibles as listed on nameplate. Refer to
product nameplate and manual for additional
information.
CAUTION: During a power failure, set auto damper
no higher than EPF setting. Remove furnace air
filter. Air jacket top and sides may be removed to
keep the firebox from overheating. DO NOT expect
the furnace to keep the house as warm as when
power is on. Do not attempt to increase heat output
by opening ash door or fire door.
CAUTION: Turn off all power to furnace
before cleaning.

DAKA 521FB Manual Page 8 of 31 January 2009
Rev. 1, June 2011
VI. GENERAL WOOD--BURNING SAFETY
Building Codes: Check local building and mechanical codes prior to installation to ensure
conformance with all requirements.
Home Insurance: Review home insurance policy for coverage.
Paint Odor: During initial start-up, the unit may omit fumes as the paint outside shell cures. Please
provide outside ventilation throughout the home to help clear the odor.
Ash Disposal: 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. The ashes may be disposed of by burial in the soil or
otherwise locally dispersed. They should be retained in the closed container until all cinders have
thoroughly cooled.
Creosote: Formation & Need for Removal
When wood is burned slowly, it produces tar and other organic vapors that combine with expelled
moisture to form creosote. The creosote vapors condense in the relatively cool chimney flue of a slow-
burning fire. As a result, creosote residue accumulates on the flue lining. When ignited, this creosote
makes an extremely hot fire.
The chimney connector and chimney should be inspected at least twice monthly during the heating
season to determine if a creosote buildup has occurred. If creosote has accumulated, it should be
removed to reduce the risk of a chimney fire.
SAFETY NOTICE
IF THIS FURNACE IS NOT PROPERLY
INSTALLED, A HOUSE/BUILDING FIRE
MAY RESULT. FOR YOUR SAFETY,
CONTACT LOCAL BUILDING OR FIRE
OFFICIALS ABOUT PERMITS,
RESTRICTIONS AND INSTALLATION
REQUIREMENTS FOR YOUR AREA.
REFER TO MARKING ON APPLIANCE
FOR ADDITIONAL INFORMATION.

DAKA 521FB Manual Page 9 of 31 January 2009
Rev. 1, June 2011
VII. CHECKING SHIPMENT
UNPACKING
DO NOT LIFT FULL CARTON THAT
CONTAINS FIREBRICK AND BLOWER FROM
INSIDE THE FIREBOX.
Open box and remove individual firebricks and
blower first.
Check piece count against parts list in back of
manual.
MISSING OR DAMAGED PARTS
PLEASE DO NOT RETURN THE PRODUCT
TO THE STORE WHERE PURCHASED.
CALL DAKA CORPORATION DIRECTLY.
1-800-884-3252 Monday through Friday
8:00 AM to 4:30 PM Central Time
It is our goal to send replacement parts to you
immediately after we receive your order.
In order to assist our Customer Service
Representative, please have the following
information available.
xFurnace Model Number
xProduct Part Number
xDescription
xFurnace Serial Number
We are committed to customer satisfaction and
are dedicating our efforts to earn your
continued support.
FIG. 2
FIG. 1

DAKA 521FB Manual Page 10 of 31 January 2009
Rev. 1, June 2011
VIII. PLANNING YOUR INSTALLATION
PLANNING YOUR INSTALLATION
Read through the entire manual before
beginning your installation. Follow all steps
exactly. Your Model 521FB Furnace can be
installed as a supplementary Add-on Furnace
or as a free-standing central furnace with its
own plenum and ductwork.
Review the location options below and
determine how you are going to install your
system.
A. GENERAL
1. The DAKA 521FB wood-burning furnace is
designed for use only in conventional up
flow systems. It must deliver heated air to a
supply (warm air) plenum –never to
ductwork. When installed as an Add-On
furnace, the warm air supply from this
furnace must never be connected to the
cold-air return inlet of the primary furnace;
components of the primary furnace may
overheat causing damage to the primary
furnace.
2. Check local building and mechanical codes
prior to installation to insure conformance
with all requirements. Review home
insurance policy for coverage.
3. A qualified individual familiar with solid-fuel
systems must install this furnace.
4. Installation of this furnace in mobile homes
is prohibited.
5. For garage installation, check your local
building code ordinance.
6. Do not operate as a room heater.
DANGER –Risk of fire or
explosion –Do not burn garbage,
gasoline, drain oil or other
flammable liquids.
B. CLEARANCES
1) FLOOR PROTECTION
1. This furnace must be installed on a non-
combustible floor surface such as solid
concrete or 3/8” non-combustible floor protector
board. This surface must extend at least 16” in
front and 8” to both sides of the furnace and
also extend at least 2” out from the sides of the
chimney connector. See FIG. 3 for details.
FIG. 3
Dimensions shown are minimum
clear distances for floor protector or
non-combustible floor.