Wood master CleanFire 400 User manual
2CleanFire Owners Manual 2016
Safety.....................................................................................2-7
Fuel ........................................................................................... 8
Features .................................................................................... 9
Installaon ......................................................................... 10-16
Operaon........................................................................... 17-22
Maintenance ...................................................................... 23-34
Wiring Diagram ....................................................................... 35
Troubleshoong ................................................................. 36-38
Warranty ............................................................................ 39-42
Specicaons .......................................................................... 43
Thank you for purchasing a quality wood boiler from WoodMaster. This
product was designed to deliver easy, trouble free operaon for years
to come. Check out other WoodMaster heang products at
www.woodmaster.com, or our line of quality pellet grills at
www.woodmasterpelletgrills.com.
Table of
Contents
• Read and follow these direcons carefully. Retain this manual for as long as you own your CleanFire.
• All installaon and operaons must follow STATE and LOCAL CODES for wiring, and ring of this
unit. These CODES may dier from this manual. Installaon must be performed by a qualied installer.
• Follow the manual carefully. Follow the recommended cleaning and maintenance.
• The WoodMaster CleanFire is designed to be operated in a pressurized system. Make sure all necessary
safety components are installed and funconing properly.
• Freeze protecon must be guaranteed in all water-bearing parts in the event of extensive idle
periods of the system. Note: Your WoodMaster CleanFire is not intended to be your only heat source.
• Boiler water treatment must be used to ensure proper water quality.
Safety
3
CleanFire Owners Manual
2016
• The chimney height may need to be adjusted depending on the installaon and local codes. Do not connect
this unit to a chimney ue serving another appliance. Follow all state/local codes.
• Never open the tube access door or lower access door during operaon!
• All cover plates, enclosures and guards must be properly maintained and in place at all mes except during
maintenance and servicing. Never operate any part of the system with covers, shields or panels removed.
• Anyone who is not familiar with and/or has not been trained to operate the CleanFire may not
operate the system. Only responsible adults should operate your CleanFire. If the CleanFire is not red
properly, damage could result and the warranty may be voided.
• Never allow children to play near or tamper with the Boiler, fuels or any other part of the system.
• Always keep the area around, and in front of the system clean and free from combusble materials.
• Keep animals away from the system.
• The operaon may not be connued or restarted in the event of visible damages (for example,
thermal distoron, traces of smoke or re, mechanical damages, etc.). Any damages must be repaired.
In the event of any doubts, please contact your authorized WoodMaster dealer.
• The system must not be exposed to external mechanical stress (for example, as storage, climbing
support, brace, or similar). This also applies for single parts (doors, covers, etc.).
• Only touch the Fire Controller and door handle during the operaon. Temperatures at other points
(for example, chimney, tube access box & door, water lines…) can be very high.
• The WoodMaster CleanFire must be operated exclusively according to the guidelines for planning,
assembly, regulaons, statutes and product related instrucons. The manufacturer is not liable for
damages and their results, if they occurred due to improper assembly, operaon, applicaon and also
inadequate maintenance and cleaning.
• Disconnect all electrical power to the CleanFire before performing any service.
• The water pump must run connuously whenever the WoodMaster CleanFire is being used.
• Do not aempt to re the CleanFire during a power outage.
• In the event of a power outage, the air ow to the re will be stopped and the re will go out. When power is
restored, the CleanFire must be relit.
• Never shut power o to the CleanFire if there is a re and fuel in the re chamber unless there is an emergency.
• Take the proper precauons to ensure that the modicaons made to an exisng heang system does not
interfere with exisng safety controls.
• Never use the following: trash, plascs, gasoline, rubber, or naphtha in your WoodMaster CleanFire.
• The WoodMaster CleanFire operates as a negave pressure combuson chamber, always open the re
chamber door with cauon.
• Read and follow these direcons carefully. Retain this manual for as long as you own your CleanFire.
• For either indoor or outdoor installaon.
• This wood heater contains a catalyc combustor, which needs periodic inspecon and replacement for proper
operaon. It is against federal regulaons to operate this wood heater in a manner inconsistent with operaon
Safety
4CleanFire Owners Manual 2016
Safety
instrucons in this manual, or if the catalyc element is deacvated or removed.
• The WoodMaster CleanFire will not funcon properly with the catalyc combustor removed.
• This wood heater needs periodic inspecon and repair for proper operaon. It is against federal regulaons to
operate this wood heater in a manner inconsistent with operang instrucons in this manual.
• This wood heater has a manufacturer-set minimum low burn rate that must not be altered. it is against federal
regulaons to alter this seng or otherwise operate this wood heater in a manner inconsistent with operang
instrucons in this manual.
Boilers intended to be connected to an exisng boiler or boiler system shall:
1. Be capable of being installed without interfering with the normal delivery of heated water from the original boiler to
mechanical safety controls of the original boiler.
manual adjustment of any controls or components other than the thermostats.
Warning!
parts and install them.
Emission Standards
ing values:
5
CleanFire Owners Manual
2016
Safety
Northwest Manufacturing, Inc.
600 Polk Ave SW
Red Lake Falls, MN 56750
800-932-3629 / www.woodmaster.com
US ENVIRONMENTAL PROTECTION AGENCY
Certied to comply with 2020 particulate
emission standards using cord wood.
Date Code:_____________________
CleanFire 400
.07 Lb/MMBTU emissions tested to
EPA Method 28 WHH 2016 Crib Wood
Serial #_____________
This Wood heater needs peri-
odic inspection and repair for
proper operation. Consult the
owner’s manual for further
information. It is against
federal regulations to operate
this wood heater in a manner
inconsistent with the opera-
tion instruction in the owner’s
manual.
Northwest Manufacturing, Inc.
600 Polk Ave SW
Red Lake Falls, MN 56750
6CleanFire Owners Manual 2016
Safety
Cerfied by
Northwest
Manufacturing
Inc.
MAWP. Water _________
Maximum Water Temp. _________
Heang Surface _________boiler Sq Ft
Heang Surface _________Sq Ft water wall
Heang Surface _________extended
Ext HS generang cap _______
Minimum relief valve capacity _______
Mfg. Serial No. ____________
Year built_______
30 psi
250
20XX
XXXXXX
100 LB HR
31
Cerfied by
Northwest
Manufacturing
Inc.
MAWP. Water _________
Maximum Water Temp. _________
Heang Surface _________boiler
Heang Surface _________Sq Ft water wall
Heang Surface _________extended
Ext HS generang cap _______
Minimum relief valve capacity _______
Mfg. Serial No. ____________
Year built_______
30 psi
250
20XX
XXXXXX
100 LB HR
16
Safety Standards
7
CleanFire Owners Manual
2016
Safety
Northwest Manufacturing Inc.
600 Polk Ave SW Red Lake Falls, MN 56750 / 800-932-3629 / www.woodmaster.com
Model: CleanFire 400 Voltage: 120 VAC AMPS: 10 Frequency: 60 Hz
Minimum Ampactity (MCA): 10 Maximum Over Current Protective Device: 10
REFER TO OWNERS MANUAL for basic operating and maintenance instructions For Supply Connections Use 14 AWG Acceptable for at least 105˚C
Replaceable circuit breaker markings are provided in the control box for each circuit breaker.
All Flue connections must be installed with: A UL 103 listed double wall chimney rated for solid fuel in compliance with NFPA 211.
For use on non-combustible flooring. For Either Indoor or Outdoor Installation. Unit will not operate without electrical power.
Minimum Installation clearance: TOP: 18” (45.7 cm), FRONT: 48”(121.9 cm), SIDES: 6”(15.2 cm), REAR: 36”(91.4 cm), BOTTOM: Non-Combustible: 0” (0 cm)
See owner’s manual for ventilation requirements of the heating room.
Only use cord wood as fuel as described in the owners manual. Load fuel carefully or damage may result.
DANGER-RISK OF FIRE OR EXPLOSION
DO NOT burn garbage, gasoline, drain oil or other flammable liquids.
WARNING-RISK OF FIRE
DO NOT operate with flue draft exceeding -0.05 inch w.c. DO NOT operate with fuel loading or ash removal doors open.
DO NOT burn garbage, gasoline, fuel oils, or other flammable liquids or materials. DO NOT use chemicals or fluids to start unit firing.
DO NOT store fuel or other combustible materials within marked installation clearances.
DO NOT connect this unit to a chimney or flue serving another appliance. Inspect and clean flues and chimney regularly.
For safety leave fuel door and ash removal doors tightly closed during operation.
In the event of a runaway fire disconnect the power supply. Allow the pump to continue circulation.
The heat exchanger pipes, flue pipe, and chimney must be cleaned regularly to remove accumulated creosote and ash. Ensure that the heat exchanger pipes, flue
pipe, and chimney are cleaned at the end of the heating season to minimize corrosion during the summer months. The appliance, flue pipe and chimney must be
in good condition.
CAUTION HOT SURFACES
KEEP CHILDREN AWAY! - DO NOT TOUCH DURING OPERATION MAXIMUM DRAFT MARKED ON NAMEPLATE
In the event of power loss, do not attempt to restart the fire without first checking for fire in the fire chamber, and for any damage to the unit. Check the display
for errors. If errors are present, consult with the owners manual for course of action. If no fire is present, restart according to the owners manual.
PRODUCTION DATE CODE
MH29131
UL 2523 STANDARD FOR SOLID FUEL-FIRED HYDRONIC HEATING APPLIANCES,
WATER HEATERS, AND BOILERS - Edition 1 - Revision Date 2013/02/08
CSA B366.1-11 SOLID-FUEL-FIRED CENTRAL HEATING APPLIANCES - Edition 4 -
Revision Date 2014/01/01
8CleanFire Owners Manual 2016
Fuel
All fuels must conform to certain quality standards to ensure trouble free operaon of the boiler. Use of
unapproved fuels may result in faulty operaon and a voided warranty. DANGER: Risk of Fire for Explosion;
NEVER use the following: trash, household garbage, plascs, gasoline, rubber, naphtha, leaves, and materi-
als treated with petroleum products (ie: parcleboard, railroad es & pressure treated wood). Newspaper
and plain, unprinted cardboard should only be used as kindling, not as fuel. Other paper products should
not be used. Please contact your WoodMaster dealer for any quesons on fuel use.
Water Content
Bark Content
boiler clearances.
Note: The amount of wood needed to heat your system will vary depending on a lot of
dierent factors. System design, insulaon values and type of wood are a few of the con-
tribung factors that will determine how much wood is needed.
9
CleanFire Owners Manual
2016
Features
1. Fire Door
2. Dry Fire Chamber
5. Negative Pressure Suction Fan
6. Isolators
7. Dampers - primary and secondary
8. Oxygen Injection Tube
9. Catalyst location
8
9
3
1
2
4
6
7
5
FEATURES
• ASME certied pressurized vessel
• Dry re chamber
• Minimal maintenance
• Non-cycling, modulates for heat load
FUEL DOOR
• Large fuel door for ease of lling.
• Spring loaded door latch maintains pressure and
ensures a tight seal.
• Two part door, very insulated. Greatly reduces heat
transfer to the outside.
DRY FIRE CHAMBER
• Patent pending design
• A dry re chamber means no creosote build-up, no ash
corrosion, and no need for ceramics.
• Pre-heated combustion air.
• Made from 8 gauge steel.
• Very long lasting due to no creosote.
• Extremely easy maintenance, can be cleaned in a
few minutes
COMBUSTION PROCESS
• Primary and secondary air ducts equipped with 2
dampers to allow for optimal burn.
• The remaining gasses leaving the combustion chamber
are mixed with oxygen in the injection tube ensuring a
complete combustion through the catalyst.
• The catalyst temperatures are controlled to ensure
clean combustion and longevity.
• The heat is recovered in the heat exchanger, then exits
the chimney.
• The stack averages an optimal temperature to remain
efficient, yet not condense. (approx. 240 degrees)
• The CleanFire is equipped with a lambda sensor which
monitors the oxygen levels and adjusts the boiler to
maintain the optimal burn.
10 CleanFire Owners Manual 2016
Choosing Locaon
Clearances
For Outdoor Installaon
For Indoor Installaon
Installation
Forkli
Overhead Liing
Forks
Residence not
served by furnace
2 feet
Residence
served by furnace Minimum of 100 feet
Chimney height
should be 2 feet above roof line
11
CleanFire Owners Manual
2016
Installation
manual.
Chimney Specicaons
ney must be 6” in diameter and cannot be reduced or enlarged.
boiler as possible.
himeny that is sized for your measuring device. Properly plug the hole when completed.
Note: Remove the chimney cap prior to lighng
the boiler.
CAUTION: Using a non-insulated chimney or
failure to use a Class A Insulated Chimney WILL
result in a voided Warranty. When using more
than four feet of chimney extension external
support is needed.
Pad Supports
of the boiler and at least one foot clearance on
74.5”
64”7”
55.049”
55.985”
.467” 47.25”
67”
8”
Boiler Feet
Plumbing &
Electrical Cutout
TOP VIEW
Front
12 CleanFire Owners Manual 2016
Trench
Wiring
conductors only.
Water Lines
NOTE:
Note: Leave a minimum of three feet of water line exposed above ground at the boiler to
insure adequate length for connecon.
Note: Before insulang and burying the water lines, label the hot water supply line at both ends. Once the
lines are covered you will be able to easily determine which line is connected to the pump.
Note: Use only approved water line insulaon sold through your WoodMaster Dealer. Poor insulaon will cause
your Wood Master boiler to burn large amounts of fuel, and hurt the eciency of the system. For best results
use high quality insulaon.
Note: Remove the chimney cap before ring your WoodMaster. Replace the chimney cap when the boiler is o
for extended periods.
Note: Check the re chamber and remove any accessories that are included before starng the boiler.
Note: DO NOT seal or insulate any of the seams on the exterior panels of the CleanFire. The gaps in the seams
are necessary to supply combuson air to the boiler.
An annual blow down of the pressure vessels is recommended to remove any sediment.
Installation
13
CleanFire Owners Manual
2016
Installing the Water Pump
wires together and replace the pump cover.
stalled on the boiler.
WARNING: Do Not install close o valves on the boiler, closing of the loop while in operaon can create danger-
ous condions. Follow all state and local codes for installing a pressurized system.
Note: The wires from the pump will have to connect with the main power wires in a juncon box.
Note: The pump must run connuously whenever the WoodMaster Boiler is in use. DO NOT run the
pump dry.
Note: All wiring must follow state and local codes and should be done by a qualied electrician. Disconnect
power before servicing any electrical components.
All water lines on the boiler loop must be 1” in size and the boiler loop must be installed in a way that will not
allow excessive pressure to develop in the system.
Installation
Water Flow
Air Bleeder
Expansion Tank
Pump Suppy To Heat Zone
Return To WoodMaster
Fill
Building Being Heated
14 CleanFire Owners Manual 2016
Installation
Plumbing
Pressure Relief ValvesPressure Relief Valves
Hot Supply
Hot Supply
Cold Return
Cold Return
Drains
Drains
LWCO Location
LWCO Location
15
CleanFire Owners Manual
2016
Domesc Hot Water
VERTICALLY
Exisng Forced Air
Note: The water to air heat exchanger must be in-
stalled below any exisng o-peak electric coils
already in the plenum.
Belt Drive System
Blower pulleys and motor pulleys may be changed but
Direct Drive System
the motor may be increased.
water in
WoodMaster
water out
Domestic Cold
Water in
Domestic Hot
Water out
WoodMaster
The heat exchanger works on the same princi-
pal as your car heater. Air blows through the
heat exchanger
, taking the heat from the water
and blowing it into your existing duct work.
Hot Water Supply from WoodMaster
(Always put supply in lower port.)
Cold Water Return to
WoodMaster
Installation
The following examples are as a secondary
heat source.
16 CleanFire Owners Manual 2016
Installation
Hot Water Supply from
WoodMaster
Cold Water Return to
WoodMaster
Existing Heat
Zone Return
WoodMaster Water to
Water Heat Transfer Unit
Circulating Pump
for Existing Hot
Water Heating
System
Existing Hot
Water Boiler
Cold Water Return from
Heat Exchanger
Domestic Water
Supply for fi lling
boiler
Cold Water
Return to
WoodMaster
Exisng Hot Water Heat
Note: Any changes that are made to an exisng boiler should be done by a qualied
plumber and follow all state and local codes.
In Line Filter and Fill Valve Assembly
Hot Water Supply from
WoodMaster
Cold Water Return to
WoodMaster
Existing Heat
Zone Return
WoodMaster Water to
Water Heat Transfer Unit
Circulating Pump
for Existing Hot
Water Heating
System
Existing Hot
Water Boiler
Cold Water Return from
Heat Exchanger
Domestic Water
Supply for fi lling
boiler
Cold Water
Return to
WoodMaster
Filling With Water
system is purged.
17
CleanFire Owners Manual
2016
Operation
Understanding the Boiler Controller
Note: Do not use your ngernails or sharp objects to press the buons as this will cause damage to the membrane.
Switching the Boiler On
Controller Navigaon
the controller.
will adjust its burn to maintain the water set point.
Running
Catalyst ºF
Water ºF
185 1800
Menu Reload
Time and Date
Set Point
Standby
Pressure
Main Menu
Time: 04:15 PM
Date: 05/25/16
Cancel ModifyNext
Set Point: 185˚F
Modify Save
18 CleanFire Owners Manual 2016
Operation
Accessing the Diagnoscs Menu
properly.
changes can be made on this screen.
Light Timer
Exit
Main Menu
Sensor mV: 131.1
Sensor O2: 1.94
(Hold 3s) Cal 21% Exit
Pressure: 13.1 PSI
Exit
O2 Calibrate
TC Calibrate
Exit
Main Menu
Cold Junction: 97
TC Values: 1085 173 97 97
(Hold 3s) Calibrate Exit
Light Timer: 5 Minutes
Modify Save
Controller Navigaon
19
CleanFire Owners Manual
2016
Operation
Firing
Note: A cardboard and newspaper combinaon works
best at starng the re.
Cauon: DO NOT use laminated or coated paper or
cardboard in your CleanFire. Using laminated or coated
products WILL damage the boiler and void your warran-
ty. Only use plain, unprinted cardboard and news paper
to re your boiler.
Cauon: Load your boiler carefully and avoid any hard
contact between the fuel and the re chamber, the re
chamber throat, and the re chamber door.
NEVER use uids or chemicals to start the re.
needed.
20 CleanFire Owners Manual 2016
Operation
door opening.
boiler should enter burn mode. more fuel can be added
energy by volume.
1”
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