Charmaster Wood Furnace Manual

The Charmaster Wood Furnace is a high-efficiency heating system designed for residential and commercial use, featuring durable steel construction, advanced combustion technology, heat exchanger system, thermostatic controls, ash removal system, and safety features including overheat protection and door interlocks. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation Requirements 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting to Ductwork 7. Operating Procedures 8. Safety Features 9. Maintenance & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Steel firebox, Heat exchanger, Thermostat control, Ash pan, Door safety interlock, Flue collar, Air intake controls.

Feature	Description
Firebox	Heavy-duty steel construction for durability
Heat exchanger	Maximizes heat transfer efficiency
Thermostat control	Automatically regulates temperature
Ash pan	Removable for easy ash disposal
Door safety interlock	Prevents operation when door is open
Flue collar	Standard 6-inch connection for chimney
Air intake controls	Primary and secondary air adjustment
Overheat protection	Safety switch activates at high temperatures
Blower system	Forced air distribution
Firebrick lining	Insulates and protects firebox

Installation Requirements

Proper installation is critical for safety and performance.

Location: Install on non-combustible surface with proper clearances to walls (minimum 36 inches).
Chimney: Connect to approved masonry or UL-listed chimney with proper height above roof.
Ductwork: Connect to existing forced-air system or install new ductwork as needed.
Electrical: Connect to 120V AC power for blower operation.
Venting: Ensure proper draft and install draft inducer if required.

WARNING! Installation must comply with local building codes and NFPA standards. Professional installation recommended.

First-Time Setup

Complete initial setup before first use.

Inspect unit: Check for shipping damage and remove all packaging materials.
Install firebrick: Position firebrick according to diagram in firebox.
Connect chimney: Attach flue pipe to collar with proper clearance to combustibles.
Test controls: Verify thermostat and blower operation without fire.
Seasonal preparation: Remove any manufacturing oils by burning small, hot fires initially.

CAUTION! Never use gasoline or other flammable liquids to start fire. Use only approved fire starters.

Specifications

Heating Capacity: Up to 2,500 square feet
Firebox Size: 24 x 18 x 16 inches
Maximum Log Length: 18 inches
Heat Output: 85,000 BTU/hour
Efficiency: 78% overall efficiency rating
Flue Size: 6-inch diameter
Blower: 120V AC, 2.5 amps
Weight: 285 pounds
Warranty: 10-year limited warranty
Fuel Type: Seasoned hardwood only

Controls and Settings

Primary controls located on front panel and thermostat.

Front Panel: Door latch, Air intake controls, Ash door, Blower switch.

Thermostat: Set desired temperature range (typically 65°F-75°F). Air Controls: Primary air for startup, secondary air for clean burn. Blower Control: Manual or automatic operation. Safety Controls: Overheat switch, door interlock, high-limit protection.

Connecting to Ductwork

Integration with existing heating system.

Turn off power to existing furnace before making connections.
Install plenum adapter between wood furnace and existing ductwork.
Install backdraft damper to prevent heat loss when wood furnace is not operating.
Connect cold air return to maintain proper air circulation.
Verify all connections are sealed with approved duct tape or mastic.

Tip: Consider installing a heat-powered fan for improved heat distribution without electricity.

Operating Procedures

Proper operation ensures efficiency and safety.

Starting fire: Use kindling and small splits; open air controls fully.
Loading: Place wood toward back of firebox; avoid overloading.
Air adjustment: Reduce primary air once fire is established; use secondary air for clean burn.
Refueling: Open door slowly; wear heat-resistant gloves.
Ash removal: Remove ashes regularly but maintain 1-inch ash bed for insulation.
Overnight burning: Load fully and reduce air supply for extended burn times.

WARNING! Never burn trash, plastic, or treated wood. These materials release toxic fumes and damage the furnace.

Safety Features

Multiple safety systems protect against hazards. Overheat Protection: Automatic shutdown at 200°F. Door Interlock: Prevents operation when loading door is open. High-Limit Switch: Cuts blower if temperatures exceed safe limits. Flue Damper: Optional for draft control. Clearance Indicators: Mark minimum safe distances to combustibles.

Maintenance & Cleaning

Regular maintenance ensures optimal performance and safety.

Daily: Remove ashes when ash pan is 2/3 full.
Weekly: Inspect door gaskets and replace if damaged.
Monthly: Clean heat exchanger tubes with brush.
Seasonally: Inspect and clean chimney; check all electrical connections.
Annually: Professional inspection recommended before heating season.

CAUTION! Always allow furnace to cool completely before performing maintenance. Wear protective gloves and eyewear.

Regulatory Information

UL 391 certified for solid fuel burning stoves. EPA Phase II qualified for emissions standards. Complies with ASTM E2558 standards. Installation must meet NFPA 211 requirements for chimneys and solid fuel burning appliances. For technical support, contact Charmaster Products at 1-800-772-0466 or visit www.charmaster.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Poor draft	Cold chimney/blockage	Warm chimney with newspaper; inspect and clean flue.
Excessive smoke	Wet wood/air restriction	Use seasoned wood; check air controls and chimney.
Insufficient heat	Wet wood/poor draft	Use dry hardwood; improve chimney draft.
Blower not working	Power/overheat switch	Check power supply; reset overheat protection switch.
Door leaks smoke	Worn gasket	Replace door gasket; ensure proper latch adjustment.
Rapid wood consumption	Excessive air	Reduce air supply; use larger wood pieces.

Emergency: In case of chimney fire, close all air controls and call fire department immediately.

Service: 1-800-772-0466; www.charmaster.com