Esse Ironheart EW User manual

Ironheart
Models EW & EWB
Wood Fired Cooking Stove
THIS APPLIANCE MUST BE COMMISSIONED BY A HETAS REGISTERED ENGINEER
THE WARRANTY CARD MUST BE RETURNED TO ENSURE GUARANTEE VALIDITY

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TableofContents
OPERATING INSTRUCTIONS ...............................................................................3
INTRODUCTION..............................................................................................3
BEFORE USING YOUR COOKING STOVE..........................................................3
YOUR COOKING STOVE ..................................................................................4
LIGHTING AND CONTROLLING THE FIRE.........................................................6
NOTES ON WOODBURNING.........................................................................10
LONG TERM SHUTDOWN.............................................................................11
FIREWOOD AND THE WOODBURNING PROCESS..........................................11
COOKING WITH THE COOK STOVE ...............................................................16
EXTENDED WOODBURNING.........................................................................18
CLEANING AND MAINTAINANCE..................................................................19
CONDITIONS OF GUARANTEE ......................................................................21
EXCLUSIONS.................................................................................................21
CUSTOMER CARE .........................................................................................22
SAFETY NOTES..............................................................................................22
INSTALLATION INSTRUCTIONS .........................................................................24
GENERAL SAFETY INFORMATION .................................................................24
THE CLEAN AIR ACT 1993 AND SMOKE CONTROLLED AREAS .......................25
DIMENSIONS AND CLEARANCES ..................................................................26
CHIMNEY AND FLUE INFORMATION ............................................................28
INSTALLING THE APPLIANCE ........................................................................31
HOT WATER SYSTEM (EWB MODELS ONLY) .................................................33
COMMISSIONING THE APPLIANCE ...............................................................35
REPLACEMENT PARTS ..................................................................................36
COMMISSIONING CHECKLIST .......................................................................38
TECHNICAL INFORMATION...........................................................................39

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Ironheart
OPERATING INSTRUCTIONS
INTRODUCTION
Thank you for choosing an ESSE cooking stove. Please read these instructions
carefully to ensure your safety and enjoyment whilst using this product.
Correctly installed and operated, your ESSE cooking stove will provide faithful
service indefinitely. We feel certain that like countless ESSE owners since 1854,
you will be truly satisfied by the warmth and comfort it will provide and the taste
of your food cooked within its oven.
BEFORE USING YOUR COOKING STOVE
Ensure that any protective packaging used to protect surfaces has been
removed. The hotplate has been oiled at the factory to prevent rusting and
therefore will require wiping with a damp cloth and drying with a tea towel or
kitchen roll.
During the first few operations of the cook stove there may be some ticking and
fumes emitted. This is normal and part of the initial expansion & material curing
process.

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YOUR COOKING STOVE
Figure 1 Ironheart Cooking Stove
Figure 1 show the cooking stove and it’s controls. The fire is loaded, refuelled,
and emptied through the large glass fire door.
A flue damper is fitted in the bottom of the flue box and is in the open position
when lever is pointing to rear of cooker. This is used on initial light up and also
gives a cooler oven temperature when open. It can also help to control excessive
flue draught. This is done by pointing the lever to the front of the cooker.
The controls are operated in the following ways:
Primary Air Control
Slide LEFT to open
Secondary Air Control
Slide LEFT to open
Oven Damper
Turn ANTI-CLOCKWISE to open
Flue Damper
PUSH back to open

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Included inside your cooking stove is a multi-purpose Operating Tool –for
adjusting the air supply and operating the door. A glove is also provided to
protect the user’s hand. (Figure 2)
WARNING
Do not place towels on the handrail, keep pets and children away and ensure
that any curtains near the appliance cannot ignite even when displaced.
Surfaces will be hot when in use.
An extractor fan MUST NOT be fitted in the same room as the appliance.
Figure 2 Operating Tool and Glove

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LIGHTING AND CONTROLLING THE FIRE
Figure 3 Multi-fuel Grate Firebox Parts
Figure 4 Wood Burning Firebox Parts

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Before lighting the fire ensure that all parts are in the correct position. For multi
fuel use see Figure 3.
The Ironheart may be configured to a wood burning only specification by
removing the grate and ashpan and substituting a steel wood burning box (see
Figure 4). This increases the firebox volume and by facilitating an ash bed can
extend reloading intervals.
Ensure both air controls are in the open position by moving the controls to the
LEFT, the oven damper is opened by rotating the control ANTI-CLOCKWISE, and
the flue damper opened by pushing the lever tot the REAR of the cooker.
Open the fire door and lay two logs along the base of the fire box forming a
space between them.
Figure 5 Logs Laid in Fire Box

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Place a firelighter in the space and surround with a small amount of kindling.
Figure 6 Fire Lighter and Kindling in Place
Lay a third log over the top of the space perpendicular to the other logs.
Figure 7 Final Log in Position
When you are ready to light the fire all that needs to be done is light the
firelighter.
Once the fire has been lit leave the door partially open to allow additional
airflow until the fire has become established. When the fire is established the
fire door can be fully closed. The air controls can be moved towards the closed
position once the sooting has burnt off the brickwork. To control the fire when
burning wood the secondary air control should be used, the primary air control
should be kept closed. The primary air control should be used when burning
smokeless fuels with the secondary control kept open where possible to prevent
the window sooting up.

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Figure 8 Oven Damper Controls
Once the fire has been established the oven damper control may be used to
regulate the oven temperatures along with the burning rate of the cookstove.
WARNING
When the cooking stove is running ALL HANDLES become hot and the
operating tool or glove provided should be used to open or close the doors
(Figure 2)
The burning rate of the stove can now be regulated by the rate at which fuel is
added and use of the air control. The maximum amount of fuel to be loaded
during normal operation is 2kg per hour in order to achieve nominal heat output.
NOTE
This appliance is not an incinerator and only dry well seasoned wood or
approved fuel should be used.
If the cook stove is being used primarily to heat the room it is recommended
that the bolster lid is kept in the raised position to allow heat from the hotplate
to radiate into the room.

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When refuelling the cook stove it is recommended that the logs are placed
running front to back as in Figure 5 as this leads to the cleanest combustion.
Before lighting a full fire in the cook stove for the first time it is recommended
that 3 smaller fires are lit first to ensure that any moisture is driven out.
WARNING
EWB MODEL ONLY: Do not light the cook stove if there is a possibility that
any part of the boiler loop is frozen.
NOTES ON WOODBURNING
Wood burns most efficiently when the air for combustion is supplied from above
the fire bed. This air supplies the oxygen necessary for the volatile gasses given
off by the wood as it is heated to combust which increases efficiency and
reduces heat being wasted up the chimney.
Running the cooking stove with the air control open will provide oxygen for the
wood to burn on the fire bed and should be used to control the fire when lighting
or refuelling. The cooking stove should ideally be run with the air control in the
closed position for the majority of the time in use. If the fire appears to die down
too low then opening the air control slightly for a short period can help revive it.
To get the best results from your cooking stove it is recommended that a wood
stove thermometer be fitted to the flue pipe above the cooking stove. This
allows you to monitor the temperature of the flue gasses leaving the cook stove.
Below 115oC
This is below the condensation point of wood gasses and may cause the build-
up of tar in the chimney, dirty the fire door glass and result in the inefficient
burning of fuel.
115oC –260oC
The flue gasses should be in this temperature band for the safest, most efficient
operation of your cooking stove.

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Above 260oC
Too hot. Heat will be wasted up the chimney. Excess heat may damage the
cooking stove or ignite an existing accumulation of tar resulting in a chimney
fire. In the event of a fire, close the air controls on the appliance and call the fire
brigade for assistance.
LONG TERM SHUTDOWN
If the cooking stove is to be shut down for long periods i.e. during summer
months or if the appliance is in a second home that is not used all the time,
precautions should be taken to avoid damage from condensation and corrosion.
First ensure that the cooking stove is fully cleaned and all ash removed. The
ovens and hotplate can then be treated with a light coating of flax oil to help
prevent moisture damaging the surfaces. The air control is to be left in the open
position (Error! Reference source not found.), the doors slightly ajar, and the
bolster lid left raised to allow for ventilation.
FIREWOOD AND THE WOODBURNING PROCESS
Seasoning and Storing Firewood
Wood, which has recently been cut and is still full of sap and water is known as
"green" wood.
Green wood will generally burn poorly and inefficiently, because it can have over
50% water in its cells. It may be hard to light, smoulder, not put out any heat
and cause more than the usual amount of creosote to build up in your chimney.
So your aim should be to dry the wood out to below 20% moisture content, this
process is called seasoning. As the name implies, you should store your wood
for a season or so, while it dries, but there are things you can do to speed up
seasoning by cutting the wood now rather than just before you use it.

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Wood is composed of bundles of microscopic tubes that were used to transport
water from the roots of the tree to the leaves. These tubes will stay full of water
for years even after a tree is dead. This is why it is so important to have your
firewood cut to length for 6 months or more before you burn it, it gives this
water a chance to evaporate since the tube ends are finally open and the water
only has to migrate a small distance to escape. Splitting the wood helps too by
exposing more surface area to the sun and wind, but cutting the wood to shorter
lengths is of primary importance.
Here’s how you can tell whether your wood is ready or not: Well seasoned
firewood generally has darkened ends with cracks or splits visible, it is relatively
lightweight, and makes a clear "clunk" when two pieces are struck together.
Green wood on the other hand is very heavy, the ends look fresher, and it tends
to make a dull "thud" when struck.
Another thing you can do to help is store your wood properly. Store it off the
ground by building the pile on some longer logs (or whatever method you can
devise). A shed or shelter with an open side makes an ideal storage place, as the
air can circulate around the logs and help to dry them out. Unventilated spaces
or plastic tarps, which never get taken off will prevent the drying and
evaporation process and cause moulds and rot. So, if a tarp is your only option,
take it off frequently to air the wood on fine days. And remember to put it back
on again. Seasoned firewood will reabsorb large amounts of water if exposed to
rain, snow and excessive dew, which is liable to make it rot and be unfit for
making a good fire.
When you build up a store of firewood, remember that the wood may start to
deteriorate after 4 to 5 years, although this is of course variable and depending
on storage conditions and species involved.
What Type of Wood is Best?
The difference between 'hard' and 'soft' woods is the density of their cells or
fibres.
As a general rule, the deciduous trees (those that loose their leaves in the
autumn) are usually thought of as hardwoods and the evergreen trees (such as
pines, firs and larches) as the softwoods. But generalisations are of course
always subject to many exceptions. Some evergreens may well be harder than

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some deciduous trees. Birch, for example, is not very hard at all. So we should
understand that there is a whole range of densities amongst our tree species,
including medium dense woods, which cannot be satisfactorily classed as hard
or soft.
Firewood tends to be sold by volume rather than weight. Assuming that the
wood is reasonably dry, the weight of a square metre of good hardwood may be
double of that of a square metre of softwood. This means that the same volume
of hardwood will provide you with more fuel to burn than an equal amount of
softwood, simply because it contains more substance.
(N.B. The price of hardwood will normally not be double that of softwood,
because it took the same amount of labour to prepare. So, if a trailer full of
hardwood costs more than the same size trailer full of softwood, the more
expensive option may well be the most economical.)
The other advantage of good hard firewoods are that the cooker does not need
to be fed as often and the charcoal-beds made by the glowing wood may burn
more easily overnight.
However, the ideal situation would be to have a store of both hard and soft
woods, because the softer woods also have distinct advantages. They light more
easily than the slower burning hardwoods and if the softwoods are dry, they
create a hotter, more intense fire. The draught created by the hotter fire moves
the air up the chimney faster.
After reading the notes opposite about the burning process, you will understand
that means less pollution in the form of smoke and less creosote condensation
in your chimney.
The denser hardwoods tend to smoulder more easily when the fire is first lit, so
their flue gas temperature will be much cooler.
Because softwoods like pine and larch contain a lot of resins and pitch, a popular
misconception is that they will fur up the chimney with creosote more easily
than a hardwood like oak. This is not necessarily true at all. It is not the pitch
that is the problem, it's the water IN the pitch. Once the water in the wood has
evaporated, that pitch becomes high octane fuel. When dry, softwoods burn
extremely hot.

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There is also the matter of seasoning to be considered. When you buy wood, it
will usually have been cut in the winter of the year you buy it. Hard woods tend
to take longer than softwoods to fully dry out.
Softwoods cut in the previous winter should, with proper storage, be ready to
burn the next autumn, whereas many hardwoods may take a bit longer than
that. Oak, for example, is very slow to dry out and ideally left for two years. It is
also possible to purchase pre seasoned wood or kiln dried wood.
Summarising we can say that it is always sensible to buy this year for next years
fuel supply and that it is very handy to have both soft and hardwoods. You can
use the softwoods to start a good fire and you will have additional control over
the fire (in addition to the cookers controls) by adding slower burning wood to
fast ones if you want to leave the cooker without tending it for a while.
Alternatively you can add some fast burning softwood logs to the slower
hardwood logs to instantly revive a fire, which has been neglected.
The Wood Burning Process
Understanding what happens when wood is burnt will enable you to burn wood
in a more environmentally friendly way, reduce the maintenance required for
your chimney and get more out of your wood. There are 3 stages in the wood-
burning process:
Evaporation
When you light the cooker a lot of energy will be needed at first to boil away any
moisture, which is left in the wood. Using energy to drive off excess water in
firewood robs the cooker of energy needed for an efficient and clean burn. Also,
much of the energy wasted in evaporating water is energy that could have
heated the hotplate and oven. This is a waste of wood, money and effort. The
presence of all that moisture tends to keep "putting out" the fire, and therefore
making it burn very poorly, which tends to produce a lot of creosote and
pollution.
Emissions
As the heat of the fire intensifies, waste-gases (smoke) are released from the
wood.
Unburned smoke is emitted into the air either as pollution, or condensed in the
chimney causing creosote build-up. It takes time for the air in your chimney to
heat up. When it is still cold you get an effect similar to the condensation of hot

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breath on a colder window or mirror. So when the by-products of combustion
(smoke in the form of gases) exit the cooker, and flow up into the relatively
cooler chimney, condensation occurs.
The resulting residue that sticks to the inner walls of the chimney is called
creosote. Creosote is formed by unburned, flammable particulates present in
the smoke. It is black or brown in appearance. It can be crusty and flaky, tar-like,
drippy and sticky or shiny and hardened. Quite often, all forms will occur in one
chimney system.
If the wood you are using is water logged, or green, the fire will tend to smoulder
and not warm the chimney sufficiently. Wet wood causes the whole system to
be cool, and inefficient. In contrast: dry wood means a hot fire, which results in
a hot flue, and a hot flue means much less creosote clogging up your chimney.
The cooker’s firebox is designed to operate at very high temperatures to burn
the gases and particles released from the wood, which means less air-pollution.
Charcoal
When most of the tar and gasses have burned the remaining substance is
charcoal (ash in it’s finer form). A hot bed of charcoals and ash can enhance the
combustion process when burning larger pieces of wood. Start with a small fire
to develop a bed of glowing embers. As the charcoal bed develops and the
cooker heats up, slowly add larger and larger pieces of wood. It takes time to
build a good charcoal bed, but it is well worth the effort. Only empty excess ash
periodically and always leave a bed of ash on which to light the next fire. When
wood burns it gives off volatile gases which contain calorific heat value.
Peat
Peat is a fuel conveniently available in some areas and should be burned in the
same manner as wood.
Ash Removal
Wood burns best on its own ash and a manageable layer of ash on the grate is a
benefit to the efficient running of your cooking stove. To empty the ashes from
the ash pan below the grate, open the door at the bottom left of the cooking
stove using the Operating Tool by connecting the tool to the door handle and
turning anti-clockwise. Insert the tool into the slot on the ash pan and pull
forwards and lift to remove. Care should be taken when disposing of ashes that

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are still warm. They should not be put into a plastic receptacle or anything that
might melt in contact with heat.
Always use the Operating Tool to open the ash door and remove the ash pan.
Use the Operating Tool to securely lock the door and ensure the door is closed
properly.
NOTE
The above text is a guide only. The ideal operation of your cooking stove
depends on a number of factors which vary with each installation. Gaining
experience on your cooking stove is the only way to learn its best operation.
COOKING WITH THE COOK STOVE
The oven and hotplate are heated directly by the fire. In order to heat up the
oven and hotplate, the fire should be lit as described on page 7.
The temperature of the hob is graduated from left to right. The left side is hotter
and so is used for boiling and the right side for simmering. The oven door and
the fire door are opened by lifting the handle either manually or using the
Operating Tool provided.
The oven and hob are heated directly by the fire. In order to heat up the oven
and hob the fire should be lit as described above. Once the fire is established
the oven damper should turned clockwise to close. This will allow the hot fumes
from the fire to circulate around the inner cavity between the cooking stove and
the oven thus heating up both the hob and the oven.
The hob lids can be left down when the hob is not being used in order to keep
the hotplates warm. In the up position they will allow more heat into the room.
To reduce the heat going to the oven when the cooking stove is up and
running, the oven damper knob can be turned anti clockwise. This will allow
the hot fumes to escape directly up the chimney via the boiling side of the
hotplate, thus reducing the heat to the oven but maintaining a hot hotplate.
To maintain a good cooking temperature in the oven the cooking stove requires
only a small amount of fuel. With the multi-fuel grate, to reduce the effective
size of the firebox, the fuel bar can be moved towards the back and thus used

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to hold a smaller amount of fuel at the rear of the firebox. This also has the
advantage of reducing the heat radiated through the window, making life easier
for the cook. Also the fire guard can be slid in front of the fire door in order to
reduce the heat through the glass and protect the operator whilst cooking.
The temperature gauge on the oven door provides an indication of the oven
temperature. It should be noted however that since the gauge is attached to
the door, the indicated temperature will drop if the door is left open for any
prolonged period, in which case, the oven may be hotter than it is indicated on
the dial. Once the door is closed again, the gauge will come back to
temperature.
Figure 9 Temperature Guage Temperature Guide
The oven is equipped with a wire shelf which can be set to the desired height.
The shelf has anti-pull out stops to prevent it from being pulled out
inadvertently; to remove a shelf, pull forward until the stop is reached, then lift
at the front and pull out of the oven. Use reverse procedure to refit. If the
shelves pull straight out then they are in back to front!
WARNING
If any part of the stove begins to glow it is being over fired. Stop use
immediately and allow to cool. If this occurs it is recommended that the
cooker is cleaned and inspected before further use and any warped baffles
straightened.

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EXTENDED WOODBURNING
This appliance has not been certified as a slow combustion stove. Loading a large
amount of wood into the cooking stove all at once will reduce the temperature
inside. If the temperature is too low, the gases given off from the wood will be
too low to combust, resulting in a lot of smoke which will cover the inside of the
cooking stove, including the glass, with soot.
In order to avoid adverse combustion conditions it is a good idea to increase the
temperature of the cooking stove before loading more wood by further opening
the air control. Load the wood and leave the air control open until the moisture
is driven out of the wood and the cooking stove is up to an efficient operating
temperature. The air control and the bolster lid can then be closed to hold the
temperature of the cooking stove.
The cooking stove can be set up to burn overnight if desired.

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CLEANING AND MAINTAINANCE
The successful operation of your cook stove is entirely dependent on the
adequate performance (pull) of the chimney or flue to which it is connected. The
following maintenance guidelines will be pointless unless the flue is also
maintained and cleaned regularly. How often it needs cleaning will depend on
the quality and moisture content of the wood you burn but an annual clean is
recommended. A partially blocked or dirty flue can have disastrous implications
for an otherwise perfectly installed cooker.
A healthy flue draught should read between 12 –25 pascals. A flue draught
reading below this value will result in poor smoky performance
Always carry out cleaning procedures when the cook stove is unlit and has been
allowed to cool sufficiently to avoid burns. With time and experience you will be
able to gauge the intervals between cleaning more accurately. It will vary
depending on the quality of your firewood and performance of your flue. Take
time to get to know your cooker and inspect it at regular intervals for the first 6
months.
As the cooking stove top is used for cooking, normal wear and tear will occur.
Spills should be mopped up immediately with a damp cloth, but oven cleaners
should not be used on the hob surface.
The oven and hotplate will rust if surface moisture is left on. Remember to
always light the cooker to warm and dry these after cleaning. To season the oven
or hotplate, we recommend a light vegetable oil spray is used. Remove any
stubborn stains with the wire brush.
To clean the glass of any built up residue, special cleaning solutions can be used,
or a ball of newspaper dampened and passed through the ash can be used. Do
not use abrasive or chemically aggressive cleaning products on the glass as this
can weaken or stain it.
If any of the chromed components become blue due to excess heat they can be
restored using a chrome cleaner.
The exterior of the cooking stove is painted with high temperature resistant
cooking stove paint and from time to time it may become necessary to renovate

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the exterior by repainting. The surface must be prepared by rubbing down with
a wire brush. The cooking stove paint will not key to the surface if there are fat
deposits or food particles on the area to be resprayed. High temperature
resistant cooking stove paints are available in aerosol form from your cooking
stove dealer, or from www.esse.com/spareparts/. Do not use this paint until the
cooking stove is completely cold and always follow the instructions on the
container before starting to paint. The usual precautions should be taken, such
as covering adjoining surfaces and protecting the hob lids.
The hob lids are made of chromed steel. The lids can be wiped clean with a damp
cloth and proprietary chrome cleaners may be used.
When de-ashing the cooking stove only remove small amounts of ash leaving
ideally 30mm depth of ash in the bottom for best performance.
To clean the flue way of the cook stove the hotplate must be removed. With the
hotplate removed the flue brush can be used to brush around the ovens and
beneath the top. Once the exterior of the ovens has been brushed the flue
access plate behind the lower right door can be removed and any loose debris
can be raked out using the flue rake. A vacuum can also be used for this process.
All panels should be replaced after cleaning.
Cleaning the Flue
It is recommended that the flue is cleaned at least every 12 months to maintain
a suitable flue draught and prevent poor performance of the cooking stove. It is
essential to maintain the integrity and cleanliness of the flue to ensure that your
cooker continues to perform at its best. When your cooker was installed the
main flue should have been equipped with an inspection hatch. These hatches
are designed to allow periodic access to the flue for inspection & cleaning.
If the chimney was previously used for an open fire, ensure any obstructions or
dampers are removed or locked open. The cooking stove operates at higher flue
gas temperatures, deposits of soot and debris that were firmly adhered to the
inside of the chimney, when it was used with an open fire, can loosen and cause
a blockage. We recommend that in such a situation a second sweeping of the
chimney should be carried out within one month of regular use of the cooking
stove after installation.