Johnson Energy Systems Wood Furnace Manual

The Johnson Energy Systems Wood Furnace is a high-efficiency heating system designed for residential and commercial use, featuring advanced combustion technology, durable steel construction, automatic draft control, integrated heat exchanger, ash removal system, safety shut-off mechanisms, and compatibility with existing ductwork. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation 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: Heavy-duty steel firebox, Automatic draft control, Heat exchanger system, Ash pan, Temperature gauge, Safety shut-off switch.

Feature	Description
Firebox	Heavy-duty steel construction for durability
Draft control	Automatic adjustment for optimal combustion
Heat exchanger	Efficient heat transfer to ductwork
Ash pan	Removable for easy ash disposal
Temperature gauge	Monitors furnace operating temperature
Safety shut-off	Automatic shut-off in case of overheating
Door latch	Secure closure for firebox access
Air intake	Adjustable for combustion air control
Blower motor	Forced air distribution
Thermostat connection	Compatible with standard thermostats

Installation

Unpack and inspect all components. Ensure proper clearances to combustible materials.

Position furnace: Place on non-combustible surface with proper clearances.
Connect to chimney: Install proper flue pipe with required clearances.
Connect ductwork: Attach to existing heating ducts using proper fittings.
Electrical connection: Wire to power supply and thermostat.
Test operation: Verify all systems function properly before regular use.

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

First-Time Setup

Complete installation verification and initial startup procedure.

Check all connections: Verify flue, ductwork, and electrical connections.
Set draft control: Adjust to recommended setting for your installation.
Test safety features: Verify shut-off mechanisms function properly.
Initial firing: Start with small fire to cure new components.
Adjust thermostat: Set desired temperature range.

CAUTION! Never use flammable liquids to start fire. Keep combustible materials away from furnace.

Specifications

Heating Capacity: Up to 2,500 square feet
Firebox Size: 3.5 cubic feet
Efficiency: 78% AFUE rating
Maximum Log Length: 24 inches
Flue Size: 8 inches diameter
Blower CFM: 1,200 cubic feet per minute
Electrical Requirements: 120V AC, 15 amp circuit
Weight: 450 pounds
Warranty: 10 years on heat exchanger

Controls and Settings

Primary controls located on front panel and integrated thermostat.

Front Panel: Door latch, Draft control knob, Temperature gauge, Reset button.

Operation: Adjust draft control for burn rate (HIGH/MEDIUM/LOW). Monitor temperature gauge for optimal operation (300-600°F). Use thermostat to set desired room temperature. Safety reset button for blower overload protection.

Connecting to Ductwork

Compatible with standard forced-air heating systems.

Turn off power to existing furnace before connections.
Measure and cut duct openings to match furnace outlets.
Install proper dampers for air flow control.
Seal all connections with high-temperature duct tape.
Verify air flow through all registers.

Tip: Balance air flow by adjusting dampers for even heat distribution.

Operating Procedures

Proper wood loading and fire management techniques.

Loading: Place seasoned hardwood with proper air space between logs.
Starting: Use kindling and newspaper; avoid accelerants.
Adjustment: Set draft control for desired heat output.
Monitoring: Watch temperature gauge; maintain 400-500°F for efficiency.
Reloading: Add wood when bed is reduced to hot coals.
Shutdown: Allow fire to burn out completely; close draft control.

WARNING! Never overload firebox. Use only seasoned firewood.

Safety Features

Automatic high-limit switch, Door safety latch, Overheat protection, Blower delay timer.

Maintenance & Cleaning

Regular maintenance ensures optimal performance and safety.

Daily: Remove ashes when ash pan is 2/3 full.
Weekly: Clean glass door with approved cleaner.
Monthly: Inspect and clean flue pipe.
Seasonally: Professional inspection of entire system.
Annually: Replace gaskets and inspect heat exchanger.

CAUTION! Always allow furnace to cool completely before cleaning. Wear protective gloves.

Regulatory Information

UL certified to UL 391 standards. EPA Phase II qualified for emissions. Complies with local building codes for solid fuel heating appliances. Copyright © Johnson Energy Systems. For technical support, visit www.johnsonenergy.com or contact 1-800-555-HEAT.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Poor draft	Clogged flue/cold chimney	Clean flue pipe; warm chimney with small fire first
Insufficient heat	Wet wood/improper draft	Use seasoned wood; adjust draft control
Blower not working	Power/overload	Check power supply; reset overload protection
Smoke in room	Negative pressure/downdraft	Open window slightly; check chimney height
Rapid wood consumption	Draft too high	Reduce draft setting; use larger logs

Reset: Press reset button on control panel if blower stops.

Service: 1-800-555-HEAT; www.johnsonenergy.com