INSTRUCTION AND PARTS BOOK

FOR
MODELS 526, 2900, & 4000
Installation must be made in accordance with local and state codes which
may differ from manual. Save these instructions.

WOOD/COAL FURNACES

Phone 715/654-5132
Fax 715/654-5513
07/97
 INTRODUCTION

Dear Woodchuck Owner,

Congratulations on your purchase of a Woodchuck heating appliance. Un-

doubtedly you have given much consideration to your purchase and we’re
proud that you have selected a Woodchuck. Pride in craftsmanship and engi-
neering have made your Woodchuck the finest heating appliance available to-
day.

Solid fuels are abundant and inexpensive. Wood is our only renewable
source of fuel and conservative estimates put our coal reserves at 800 years.
Our dual fuel units provide the savings and comfort of solid fuels and the con-
venience of electric heat in one attractive package.

There is no substitute for quality. That is why thousands of people like you
have purchased a Woodchuck. They also felt it was the best equipment to
serve their heating needs, now and in years to come. We ask that you follow
our policy of “safety first” and we strongly suggest that you read through the
owner’s manual before installing and operating your furnace.

For a lifetime of satisfaction, thank you for not compromising with quality.

Sincerely,

Donald A. Meyer
President
MEYER MANUFACTURING CORP.

We are constantly improving and updating our product in order to provide the
highest quality and value possible. Consequently pictures might sometimes dif-
fer slightly from the actual product.

TRANSPORTATION DAMAGES

Before reading this manual and proceeding with the installation, inspect your new Woodchuck to make sure there
were no shipping damages. If you find there have been damages incurred, call your dealer immediately. He will
then take a course of action to correct the problem.

2
 TABLE OF CONTENTS
Page
Introduction..........................................................................................................................................................2
Table of Contents ................................................................................................................................................3
Furnace Safety ....................................................................................................................................................4
Specifications ......................................................................................................................................................5
General Information.............................................................................................................................................6
High Quality Construction ................................................................................................................................6
Efficiency .........................................................................................................................................................6
Comfort ............................................................................................................................................................6
Additional Comfort And Saving........................................................................................................................7
Operation.............................................................................................................................................................8
Common Sense ...............................................................................................................................................8
! If You Have Chimney Fire !............................................................................................................................8
! Important ! Operation Procedure In The Event of Power Failure ..................................................................8
Operating Your Woodchuck Furnace ..............................................................................................................9
Startup..........................................................................................................................................................9
Burning Wood In Your Woodchuck..................................................................................................................9
Helpful Hints...............................................................................................................................................10
Ash Removal..............................................................................................................................................10
Burning Coal In Your Woodchuck..................................................................................................................11
Starting A Coal Fire....................................................................................................................................11
Recharging.................................................................................................................................................11
Banking ......................................................................................................................................................11
Bituminous Recharging ..............................................................................................................................11
Helpful Hints...............................................................................................................................................11
Ash Removal..............................................................................................................................................12
Maintenance......................................................................................................................................................12
Trouble Shooting ...............................................................................................................................................13
Installation .........................................................................................................................................................15
General Requirements...................................................................................................................................15
Placement And Minimum Clearances............................................................................................................15
Chimney Installation ......................................................................................................................................17
Installing Your Woodchuck ............................................................................................................................18
Stove Pipe Installation ...................................................................................................................................18
Installation Of A Barometric Draft ..................................................................................................................18
Air Duct Installation........................................................................................................................................19
Woodchuck Final Assembly...........................................................................................................................20
Optional Shaker Grate Installation-Model 526 ...........................................................................................20
Install Shaker Grate Handle, Model 2900 Only..........................................................................................21
Install Firebrick ...........................................................................................................................................22
Install Optional Catalytic Combustor ..........................................................................................................22
Assemble Manual Draft-Model 526 Only ...................................................................................................23
Install Comfort Control Center And Forced Draft Blower ...........................................................................23
Install Circulating Blower............................................................................................................................24
Assemble Filter Box ...................................................................................................................................24
Electrical Hookup .......................................................................................................................................25
Repair Parts ......................................................................................................................................................27

3
 FURNACE SAFETY

THERE ARE INHERENT HAZARDS ASSOCIATED WITH THE OPERATION OF WOOD/COAL FURNACES. FOR
YOUR SAFETY READ, UNDERSTAND, AND HEED THE FOLLOWING:

DANGER:
RISK OF FIRE OR EXPLOSION. DO NOT BURN GARBAGE, GASOLINE, DRAIN OIL, OR OTHER FLAMMABLE
LIQUIDS. FAILURE TO HEED MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

DANGER:
NEVER USE CHEMICALS OR FLUIDS SUCH AS GASOLINE, CHARCOAL LIGHTER FLUID, DRAIN OIL, FUEL
OIL OR KEROSENE TO LIGHT A FIRE IN YOUR WOODCHUCK. FAILURE TO HEED MAY RESULT IN SERIOUS
PERSONAL INJURY OR DEATH.

DANGER:
DURING OPERATION, LOADING AND ASH DOORS, AND EXPOSED FIREBOX ARE EXTREMELY HOT. NEVER
TOUCH THESE PARTS WHEN HOT. FAILURE TO HEED MAY RESULT IN SERIOUS PERSONAL INJURY.

CAUTION:
· Risk Of Fire
· Do Not Operate With Fuel Loading Or Ash Removal Doors Open.
· Do Not Store Fuel Or Other Combustible Material Within Marked Installation Clearances.
· Under Certain Conditions Of Use, Creosote Buildup May Occur Rapidly. Inspect And Clean Flues And Chimney
Regularly.
· Wait 10 Seconds On First Latch Before Refueling. Opening Loading Door Rapidly Can Cause A Flame To Flash
Out The Door. Use Caution When Opening Loading Door.
· Unsafe To Load Coal Above Top Of Brick.
· Keep Ash Pan Out Of Unit During Operation. Ash Pan Can Get Very Hot.
· Ash Can Must Be Placed On A Noncombustible Surface.
· Never Use Anything But An Air Tight Metal Container To Dump Your Ashes In. Every Year Many Fires Are
Caused By Emptying Ashes Into Cardboard Boxes Or Paper Bags.
· Proven Fact - Small Red Embers Buried In Ash Cans Stay Red Hot For Days. Ashes Are A Good Thermal Insu-
lator And Keep Enough Oxygen Away So Embers Do Not Burn Out.

THERE ARE ADDITIONAL HAZARDS ASSOCIATED WITH IMPROPER INSTALLATION OF WOOD/COAL FUR-
NACES AND WITH SERVICE AND MAINTENANCE OF WOOD/COAL FURNACES. FOR YOUR SAFETY READ,
UNDERSTAND, AND HEED THE FOLLOWING:

WARNING:
DISCONNECT APPLIANCE FROM ELECTRICAL SUPPLY BEFORE SERVICING UNIT. FAILURE TO HEED MAY
RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

CAUTION:
· Equipment Must Be Installed By A Qualified Heating Person.
· Only “class A” All-fuel Or Solid Fuel Chimneys Intended Foe Use With Your Woodchuck Should Be Used.
· Furnace Must Be Installed On A Noncombustible Floor Or 3/8" Thick Fireproof Millboard Or Equivalent.

FAILURE TO HEED MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

4
 SPECIFICATIONS

MODEL 526
Height 42.5"
Width 24"
Depth 26"
Blower 850 to 1850 CFM
Max. BTU Capacity 120,000
Log Size 22"
Loading Door Size 14"x12"
Weight, Approx. 445 lbs.
Warm Air Plenum 20"x23"
Flue Outlet 6" Dia.
Flue Collar Height 41" Overall Height
Secondary Heat Exchange YES
Listings UL391, CSA B366,
1-M ETLM
Firebox Chamber 6.10 cu. ft.

MODEL 2900 MODEL 4000

Height 48.5" Height 51.5"
Width 26" Width 26"
Depth 28" Depth 33"
Blower 850 to 1850 CFM Blower 850 to 1850 CFM
Max. BTU Capacity 150,000 Max. BTU Capacity 180,000
Log Size 22" Log Size 24"
Loading Door Size 15"x13" Loading Door Size 15"x13"
Weight, Approx. 700 lbs. Weight, Approx. 815 lbs.
Warm Air Plenum 20"x23" Warm Air Plenum 20"x23"
Flue Outlet 8" Dia. Flue Outlet 8" Dia.
Flue Collar Height 47" Overall Height Flue Collar Height 50" Overall Height
Secondary Heat Exchange YES Secondary Heat Exchange YES
Listings UL391, CSA B366, Listings UL391, CSA B366,
1-M ETLM 1-M ETLM
Firebox Chamber 7.70 cu. ft. Firebox Chamber 9.10 cu. ft.

DISCLAIMER NOTICE

The heating capacity specifications are provided as guidelines only and in no way guarantee the output or capacity
of the units. The actual BTU output depends on the type of fuel being burned and its condition, the thermostat set-
ting, the draft adjustments and the chimney that the unit is installed into.

5
 GENERAL INFORMATION

Woodchuck furnaces represent the ultimate in solid fuel channel." Here it comes into contact with the hot fire-
and dual fuel heating appliances. From the massive box front and is warmed before entering the firebox.
model 4000 to the economy model 526, each unit is de- The draft channel is equipped with adjustable orifices
signed to be attractive, durable and efficient while pro- which provide for the 80/20 distribution of the com-
viding the safety and comfort you and your family bustion air. A lever on the front of Models 2900/4000
deserve. allows for quick and easy adjustment of these orifices
to correspond to the fuel being used. As the air enters
HIGH QUALITY CONSTRUCTION the firebox it strikes a deflector which creates a turbu-
lence and causes the oxygen to mix thoroughly with
Constructed of high grade, heavy gauge, hot rolled the gases for complete combustion.
steel plate, the firebox is continuously welded for an air-
tight seal and structural strength. The heavy duty cast Finally, Woodchuck Model 2900/4000 furnaces are
iron doors are equipped with a positive latching device designed to accept a catalytic combustor. This device
for your safety. The loading door has a two-step safety will cause the small amount of unburned fuel to ignite
latch. The large cast iron grates provide for durability before entering the secondary heat exchanger. The
and help promote efficient combustion of the fuel. The benefits of all this are threefold:
firebox is lined with heavy duty firebrick and is done so
without any retainers to warp or burn out. These fea- A.) You obtain very high combustion efficiencies,
tures together with high quality electrical components meaning you use less fuel.
provide the safety, efficiency and total control possible
only in a Woodchuck. Total control means that you can B.) You reduce the amount of unburned fuel that can
better avoid overheating the unit and developing exces- collect in your chimney as creosote and hence reduce
sive and unsafe temperatures. the hazard of a chimney fire.

Woodchuck furnaces are subjected to the most strin- C.) You virtually eliminate pollution of the air we all
gent test criteria applicable by an independent third breathe.
party testing laboratory and listed/labeled as having
met or exceeded those standards. Finally, any ma- Transfer efficiency refers to how effectively we trans-
chine, even this Woodchuck, is only as safe as the per- fer the heat generated inside the firebox to the rooms
son operating it. This is why we have compiled this we want to heat. Insufficient blower capacity will result
comprehensive manual to assist you in operating your in poor transfer allowing the unused heat to escape
Woodchuck properly and safely. Please read and follow up the chimney. This is why we utilize a blower with
all instructions. such large air handling capacity. The large surface
area of the firebox and secondary heat exchanger
EFFICIENCY provide for efficient transfer.

The total efficiency of a unit is broken down into com- COMFORT

bustion efficiency and transfer efficiency. We know that
when woodburning, 20% of it burns as fixed carbon. Comfort and efficiency are closely related. The more
The other 80% is in the gaseous state as it burns. efficient the heating system is, the more comfortable
Therefore, to obtain efficient combustion of the wood it you and your family are. Not only are the Woodchuck
is necessary to introduce 20% of the oxygen “under” furnaces efficient, they can actually increase the effi-
the fire to promote combustion of the solid material and ciency of your home.
80% “over” the fire where it can readily react with the
gaseous material. Coal burns just the opposite of wood. On a furnace with a conventional single speed
80% of it burns as fixed carbon and 20% burns in the blower, the speed of the blower is a compromise
gaseous state. Therefore, before a furnace can burn between comfort and efficiency. If the blower has a
coal or wood efficiently, it must provide the 80/20 ratio large enough capacity to heat the home in the cold-
of combustion air and allow the operator to reverse the est weather it will cycle rapidly in milder weather so
ratio depending on the fuel being used. Combustion air the system air is not as warm. If this air is moved
must be warm when it enters the firebox to further pro- too rapidly it can actually feel cool. Air that is mov-
mote complete combustion. Your Woodchuck furnace ing at 3 ft. per second will feel 4° cooler than sta-
provides all these features and more. Here is how: tionary air at the same temperature. If the blower
when combustion air enters a Woodchuck furnace it en- capacity is enough to operate properly in mild
ters into a “draft

6
weather, it will not be large enough to keep the more comfortable and lose less heat through your ceil-
house ings as illustrated in figure 2.
warm in cold weather. This could cause the furnace to This situation can be especially troublesome in
overheat and a loss of heat up the chimney. The result multi-level homes as illustrated in figure 3. As soon as
then is a compromise which is neither efficient or com- the blower shuts off, the air in the home begins to strat-
fortable. Woodchuck furnaces, however, have a three ify; warm air rising to the upper levels and cool air col-
speed circulation blower which can be adjusted via a lecting in the lower levels. The lower levels become
three position rotary switch on the Comfort Control increasingly uncomfortable until the blower turns on
Center. This allows the user to select the blower speed again. Unfortunately, the upper levels are still warm so
to meet the air movement requirements of the installa- they become uncomfortably warm before the blower
tion. In addition, when the weather is mild and the fur- turns off. By allowing for a steadier, more continuous
nace is operating at a lower output, the blower can be operation of the blower the entire house stays at a
set on low to gently move the air. Similarly, when it is more constant and comfortable level, figure 4.
cold and the furnace is operated at higher levels of
heat, output can be switched to higher speeds. ADDITION COMFORT AND SAVING
But how can all this improve the efficiency of your Options are available for your Woodchuck furnace, and
home? As figure 1 illustrates, heated air rises away one of these deserve special mention. The Aqua-Si-
from the living area and stratifies. This causes large phon is capable of pre-heating your domestic water
temperature differentials between the ceiling where free of charge during the heating season for additional
heat is lost rapidly through conduction and the floor saving to you.
where children often play. By allowing for continuous
air movement, even during periods of low heat output,
this stratification is not allowed to take place. You are

WASTED HEAT
ZONE

82° THERMOSTAT

COMFORT ZONE UNCOMFORTABLY HOT

74°
UNCOMFORTABLY COLD
DISCOMFORT ZONE

60°

FIGURE 1 FIGURE 3

75°

THERMOSTAT

74°

73°

FIGURE 2 FIGURE 4
7
 OPERATION

COMMON SENSE ! IF YOU HAVE CHIMNEY FIRE !

Please read the following before firing your furnace. It is Meyer Mfg. Corp. recommends the following actions:
most important that you follow these suggestions and
limitations in order to maintain your warranty and guar- 1. Shut any doors and air inlet dampers and draft con-
antee the long life of your furnace. trol. This should take no longer than a few seconds.
CLOSED
NOTE: Smoke detectors and fire extinguishers should 2. Alert everyone in the house.
always be a part of your equipment.
3. Call the fire department.
MANUAL DRAFT
This furnace is an airtight unit designed to burn 6-8
hours per load of wood or coal. If the furnace is being NOTE: Emptying a large box of baking soda will slow
fired hot constantly with full flames and operating at down the fire in your Woodchuck.
only 2-4 hour burn cycles, it may be over fired. Your
home heating needs may be too great for the size of Keeping your chimney and stove pipe clean is the best
furnace you have purchased. Your furnace can be dam- insurance against chimney fires.
aged if fired at extremely high temperatures.

Forced firing or abuse can be detected upon inspection ! IMPORTANT !

AND WILL VOID YOUR WARRANTY.
OPERATION PROCEDURE IN THE
EVENT OF POWER FAILURE:
DANGER:
RISK OF FIRE OR EXPLOSION. DO NOT BURN GAR- Your Woodchuck can operate and produce heat without
BAGE, GASOLINE, DRAIN OIL, OR OTHER FLAMMA- electric power. This is one of the features built into ev-
BLE LIQUIDS. FAILURE TO HEED MAY RESULT IN ery Woodchuck.
SERIOUS PERSONAL INJURY OR DEATH.
The following steps should be taken in the event of an
electrical power failure:

DANGER: 1. Locate all heating duct dampers (not smoke pipe

NEVER USE CHEMICALS OR FLUIDS SUCH AS damper), if any, to open position. CLOSED
GASOLINE, CHARCOAL LIGHTER FLUID, DRAIN
OIL, FUEL OIL OR KEROSINE TO LIGHT A FIRE IN 2. Turn manual draft controls to this position.
YOUR WOODCHUCK. FAILURE TO HEED MAY RE-
SULT IN SERIOUS PERSONAL INJURY OR DEATH. Ash door should never be used MANUAL DRAFT
in power failure.
CAUTION: 3. Remove filter box service access cover, allowing
· RISK OF FIRE cooler air to move hot air through the furnace, cooling
· DO NOT OPERATE WITH FUEL LOADING OR the plenum and the house hot air duct system.
ASH REMOVAL DOORS OPEN.
· DO NOT STORE FUEL OR OTHER COMBUSTI- If power fails, to avoid product damage, close manual
BLE MATERIAL WITHIN MARKED INSTALLATION draft completely. Forced draft and natural draft are pre-
CLEARANCES. set.
· INSPECT AND CLEAN FLUES AND CHIMNEY
REGULARLY. In the event of a runaway fire, close all drafts. Close
· UNDER CERTAIN CONDITIONS OF USE, CREO- smoke damper halfway.
SOTE BUILDUP MAY OCCUR RAPIDLY.
· WAIT 10 SEC. ON FIRST LATCH BEFORE RE-
FUELING.
· LOAD FUEL CAREFULLY OR DAMAGE MAY RE-
SULT.

8
 DOUBLE LATCH COMFORT
LOADING DOOR HEAT EXCHANGER CONTROL CENTER
COMFORT
CONTROL ROD
CONTROL CENTER
SHAKER
GRATE
FAN/LIMIT

FAN/LIMIT

DOUBLE LATCH
LOADING DOOR

DRAFT CHANNEL
SELECTOR - 80/20 MANUAL DRAFT
COMBUSTION AIR (Forced Draft Is
RATIO CONTROL Optional) MODEL 526
MODELS
2900/4000 ASH DOOR
ASH DOOR

FORCED DRAFT SHAKER GRATE CRANK.

BLOWER SHAKER GRATES ARE OPTIONAL

FIGURE 5 WOODCHUCK CONTROLS

NOTE: All models are equipped with a “low limit” which
will not allow the auto draft to operate when the unit is
not warm. To start auto draft, turn Lo-Limit toggle switch
on comfort control center to “On”, figure 6.

Now you are ready to light a fire.

CIRCULATING BURNING WOOD IN YOUR WOOD-

BLOWER
CHUCK
DRAFT BLOWER
DRAFT BLOWER MANUAL SWITCH 1. Adjust draft channel selector, figure 5, to appropriate
LO-LIMIT BYPASS fuel setting on model 2900/4000. On Model 526 with
manual draft, open it. Place several pieces of crumpled
paper in the center of your Woodchuck. Criss-cross a
couple of handfuls of dry kindling wood 3/4" thickness,
then several small dry pieces of firewood. Ignite the pa-
FIGURE 6 COMFORT CONTROL CENTER
per and close the door. Do not attempt to open the door
immediately after igniting the fire. There could be a
OPERATING YOUR WOODCHUCK flame flash out.
FURNACE 2. It will take 5-10 minutes for the fire to establish itself.
STARTUP Once you have some good red hot burning embers,
add larger pieces of wood. All chimneys and hookups
Never leave ash pan in unit. Use only when cleaning are different. After 3-4 fires, you’ll find out how your unit
out ashes. works for the best starting.

First thing is to check that your main blower and draft 3. After about 30-40 minutes you can adjust the draft
blower are in proper working order before lighting a fire. according to your needs. Adjust smoke pipe damper ac-
To check main blower, push button on fan/limit control cording to your needs also.
for manual override testing. When finished, reset to au-
tomatic position, figure 5. Next, turn thermostat upstairs NOTE: On airtight units, the burning time is controlled
to high temperature so draft blower turns on. mostly by the draft controls on the furnace, contrary to

9
the old type of pot belly stoves where the smoke pipe mometer at the rear of the furnace on the smoke pipe
damper controlled the burning time. where it connects to the collar on the back of the
Woodchuck. 300-400 degrees should be maintained
NOTE: With new steel, there is a small amount of oil or when the Woodchuck is operating in the burn cycle with
dirt on the metal and you may smell an odor. Provide the forced draft blower running to eliminate a creosote
adequate ventilating to home during the first operation. build up. (If the unit has a manual draft or a natural
Your new Woodchuck is capable of putting out many draft, monitor the flue temperature when the drafts are
BTU’s, so treat it with respect. Don’t fully load your fur- in the open position). Depending on the weather, you
nace or open all drafts fully until you have become thor- may not need a full load of wood for a good over night
oughly familiar with the operation of the furnace. burn. You will get best efficiency when you add only the
amount of wood needed until the next time you are
NOTE: A full load does not always give the best results available to load.
for your needs.
Always try to place the logs so air can flow between
4. When loading your Woodchuck with existing hot them -this will enhance combustion considerably.
coals, rake red hot embers over grates evenly. Put a
few small pieces of wood on the coals first, then ASH REMOVAL
load-up.
When burning wood, run your poker over top of the
5. If you have the automatic draft control, turn low limit grate to be sure grate slots are clear of burnt fuel. This
by-pass switch to “On”. Turn thermostat up to activate should be done every morning when there is just a bed
auto draft and proceed as with manual draft. Once the of hot coals.
unit is warmed up you can turn the low limit by-pass
switch to “OFF”. This will allow the auto draft to shut off
if the unit runs out of fuel while you are gone. CAUTION
NEVER LET ASHES BUILD-UP TO GRATE LEVEL.
THIS WILL GREATLY REDUCE THE LIFE SPAN OF
YOUR GRATE.
CAUTION:
WAIT 10 SECONDS ON FIRST LATCH BEFORE RE- Wood ash is useful as a fertilizer, particularly because
FUELING. OPENING LOADING DOOR RAPIDLY CAN of its potassium content. Ashes will also decrease the
CAUSE A FLAME TO FLASH OUT THE DOOR. THIS acidity of garden soil.
OCCURS WHEN THERE IS UNBURNT FUEL AND A
LARGE AMOUNT OF GASES ON TOP OF THE FIRE-
BOX. WHEN THE DOOR IS OPEN, OXYGEN IS COM- CAUTION
BINED WITH GASES AND IGNITES. USE CAUTION · KEEP ASH PAN OUT OF UNIT DURING OPERA-
WHEN OPENING LOADING DOOR. TION. ASH PAN CAN GET VERY HOT.
· ASH CAN MUST BE PLACED ON A
HELPFUL HINTS NONCOMBUSTIBLE SURFACE.
· NEVER USE ANYTHING BUT AN AIR TIGHT
Adjust the draft to the proper setting for your home METAL CONTAINER TO DUMP YOUR ASHES IN.
needs. The chimney, hookups, and kind of wood will EVERY YEAR MANY FIRES ARE CAUSED BY
also be a factor. EMPTYING ASHES INTO CARDBOARD BOXES
OR PAPER BAGS.
Your Woodchuck is capable of holding very large logs. · PROVEN FACT- SMALL RED EMBERS BURIED
DO NOT try to add a log that is larger than you can IN ASH CANS STAY RED HOT FOR DAYS.
easily place in the furnace. You will get the best effi- ASHES ARE A GOOD THERMAL INSULATOR
ciency when you add only the amount of wood needed AND KEEP ENOUGH OXYGEN AWAY SO THE
for a 6 to 8 hour burn. EMBERS DO NOT BURN OUT.

In the spring and fall, the weather is mild, which will al-
low you to burn very large loads of wood for long peri-
ods of time and hence accumulate very large amounts
of creosote. KEY: Stack temperature should be
300°F-400°F for good burning. An external flue temper-
ature thermometer (Woodchuck part #08-0084) is in-
cluded in the owner’s manual package for monitoring
stack temperature. Install the flue temperature ther-

10
BURNING COAL IN YOUR WOOD- A coal fire should not be poked or broken up as this
tends to bring ash to the surface of the coal bed where it
CHUCK may fuse. If the ash fuses, clinkers will form. It may be
necessary to remove all unburned material and ash from
Never attempt to burn coal without a shaker grate. the firebox to remove clinkers. These should be re-
Shaker grates are standard on Models 2900 and 4000 moved with gloves or tongs, and as always, put into a
but optional on Model 526. metallic air-tight container.
A barometric draft control in the smoke pipe must be
used when burning coal.
BITUMINOUS RECHARGING

Because bituminous coal has a higher percent of sul-

CAUTION: phur and lower percent of fixed carbon than anthracite,
UNSAFE TO LOAD COAL ABOVE TOP OF FIRE BRICK. recharging should be as follows:

Gently shake down grates, with drafts open and a good

STARTING A COAL FIRE
flow of primary air entering below the grates. Push the
hot coals to the rear of the fire box and position fresh
Open all draft controls on your Woodchuck.
coal on the grate in front of the banked coal. As the
fresh coal begins to burn, wood may be added to the top
Build a fire using dry wood kindling and establish a bed
of the coal.
of coals. Add several small shovels of coal over the
wood coals. After the coal fire is established and spread
NOTE: Woodchuck recommends coal 1 inch to 3 inches
throughout the firebox, add larger amounts of coal to
in diameter. Ashes may be sifted through a mesh screen
build up the coal bed. Gently shake the grate until live
to reclaim particles of unburned coal.
coals fall into the ash pan area. Allow your Woodchuck
to operate with drafts open for approximately 15 minutes
or until fresh coal ignites. When the coal is properly ig- HELPFUL HINTS
nited, adjust the drafts accordingly. Check the fire peri-
odically to be sure it is spreading through the coal bed. Burning coal will provide a lesson in patience. Take the
time necessary to experiment and understand the oper-
ation of your Woodchuck wood/coal furnace.
RECHARGING
Too much draft air will cause clinkering of coal and will
Gently shake grates down. Open drafts and establish a
waste heat up the chimney. Shut draft down to as low a
good flow of primary air below the grates. When re-
point as you can and still heat your home.
charging, fresh coal tends to give off large quantities of
volatile gas. This gas may accumulate and possibly ig-
1. NEVER stand in front of loading door when opening
nite causing a backpuff. To reduce back-puffing, open
it. Stand to the side.
the fire door to the first safety latch position for 15-20
seconds before opening fully. Spread fresh coal evenly
2. NEVER completely cover the live fire with fresh coal.
over existing coal, leaving some hot coals exposed in
Always leave a generous area of burning coal at the top
the center of the firebox. Be careful not to smother your
of the fire and at the rear.
existing coals. Never allow coal to build up above the
3. Always keep the ash pit clean.
top of the firebrick. When blue flame creeps up between
the coals, drafts may be adjusted to maintain burn level.
If the fire goes out or does not hold overnight look for:
If the coal fire dies down before recharging, a fresh sup-
1. Poor draft.
ply of kindling may have to be added.
2. Incorrect damper settings.
3. Improper firing methods for coal being used.
BANKING 4. More combustion air needed.
5. Coal not sized to furnace. We recommend 1" to 3" di-
Banking allows you to recharge in such a manner as to ameter pieces of coal.
retain a hot coal bed throughout the night. Approxi- 6. Ashes, if allowed to accumulate in the ash pit, will not
mately an hour before retiring for the night, push the allow the required air for combustion. Keep ash pit
coals to the rear of the firebox with the coal tapered clean.
down in the front. Add a new layer of coal. Always leave
some hot coals exposed in the front. This allows for
more coal to be added to the firebox.

11
ASH REMOVAL Coal firing produces much more ash than wood. These
ashes must be removed often (possibly daily) in order
Ash should always be put into an air-tight, metal con- to avoid piling up too closely to the grates. Removal of
tainer. the coal ash will prevent warpage and damage to
grates, and allow passage of primary air to the coal
bed.
CAUTION
· KEEP ASH PAN OUT OF UNIT DURING OPERA- Unlike wood ash, coal ash cannot be used as fertilizer.
TION. ASH PAN CAN GET VERY HOT. All coal contains small amounts of dangerous elements.
· ASH PAN MUST BE PLACED ON A It is therefore essential that your coal ash be disposed
NONCOMBUSTIBLE SURFACE. of in municipally designated areas.
· NEVER USE ANYTHING BUT AN AIR TIGHT
METAL CONTAINER TO DUMP YOUR ASHES IN.
EVERY YEAR MANY FIRES ARE CAUSED BY
EMPTYING ASHES INTO CARDBOARD BOXES
OR PAPER BAGS.
· PROVEN FACT- SMALL RED EMBERS BURIED
IN ASH CANS STAY RED HOT FOR DAYS.
ASHES ARE A GOOD THERMAL INSULATOR
AND KEEP ENOUGH OXYGEN AWAY SO THE
EMBERS DO NOT BURN OUT.

MAINTENANCE
OPTIONAL CATALYTIC COMBUSTOR
FOR MODELS 2900/4000
WARNING:
DISCONNECT APPLIANCE FROM ELECTRICAL NOTE: Optional catalyst not recommended for Model
SUPPLY BEFORE SERVICING UNIT. FAILURE TO 2900/4000 with 6" flue adapter. Smoke spillage may oc-
HEED MAY RESULT IN SERIOUS PERSONAL INJURY cur out of door when refueling.
OR DEATH.
Even with complete combustion there is a small amount
Keep chimney and smoke pipe clean by cleaning at least of residue. Eventually enough will collect on the
twice during a heating season. Keeping your chimney combustor to interfere with its operation. Therefore it is
and stove pipes clean is the best insurance against necessary to clean it periodically. To clean the
chimney fires. combustor simply remove from unit and run tap water
through it until no sign of residue remains. The
If you clean your own chimney and stovepipe, Meyer combustor simply slides up into the exhaust pipe stub
Manufacturing Corp. recommends purchasing the same which protrudes down into the firebox. There are three
equipment professionals use. Brushes are available in rods on the combustor which engage slots in the pipe
enough sizes and shapes to snuggly fit inside any com- and then turn slightly to lock in place. These rods are not
mon flue. symmetrical so observe their orientation when you re-
move it. Two rods are welded at 90° and they point to-
Replace any cracked or deteriorated firebrick. This will ward the rear of the firebox.
prolong the life expectancy of the firebox.
NOTCHES IN EXHAUST
Check door gasket and replace as needed. PIPE

Oil blowers every 6 months of use. (SAE 10 motor oil re-

quired.)

Keep ash pit clean especially when burning coal.

CATALYTIC ELEMENT
Turn on your regular furnace once every month to keep
it tuned up and limber.
RODS ON RETAINER

OPTIONAL CATALYTIC
COMBUSTOR

12
 TROUBLE SHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
1. Main blower vibrating Loose Allen screw on squirrel cage. Tighten Allen screw, be sure squirrel
when in use. cage did not move to one side or the
other.
Bad motor bearings. Return blower to your local dealer
for a replacement.
Weights on squirrel cage wheel moved in ship- Try to adjust it yourself or return
ment. blower for replacement.
2. Main blower continues to Manual control turned on (fan/limit control). Check fan/limit control switch. Push
run. for manual, pull for auto. If in auto
position, replace fan/limit control.
3. Main blower won’t turn Defective fan/limit control. Replace.
on. Defective 3-speed blower switch. Replace.
Defective circulation blower motor. Replace.
4. Draft blower staying on. Wall thermostat bad, check by turning temp. to Replace wall thermostat.
60° then check if draft blower is running.
Short in thermostat wire. Check all wiring again.
Home not getting heat needed to satisfy wall Check on spec’s chart to be sure
thermostat. your unit is large enough for your
home. Be sure installation is proper:
check with your local heating man.
5. Draft blower not turning Switch blower to the off position. Bad wall Ther- Replace thermostat.
on. NOTE: Be sure switch mostat; check by turning it up to 80° and if the
on blower is on. draft blower does not turn on, replace thermo-
stat.
Lo limit bypass on “off”. When starting up it is necessary to
turn toggle switch on front of comfort
control center to “on” until unit
warms up.
6. Smell an odor from the New steel, small amounts of residue on the This will disappear in a matter of
first fire in the furnace. steel. hours.
Bad weld, if smell continues for two weeks of Contact dealer immediately.
burning.
7. Not getting heat in the Unit may be too small for your home; check Replace with a larger unit or have
home. specification chart. regular furnace help.
Improper insulation in home allowing heat to Reinsulate!
escape.
Improper hookup to furnace. Check installation drawings and/or
Ducting not sized properly for unit. consult your local heating man.
8. Flames coming out the Excessive amount of gases on top of the fire
door when loading. box and igniting when given oxygen from open
door. NOTE: This is one of your Woodchuck
safety features built into every unit with a dou-
ble latch system.
Large amounts of unburned wood. Try to load when fire is at its lowest
point, but have enough embers left
for a good start again. NOTE: Only
you will know this time after some
experience with your unit and instal-
lation.

13
PROBLEM POSSIBLE CAUSE SOLUTION
9. Excessive amounts of Improper draft. Measure with draft gauge-should
smoke coming out loading have .04 to .06 water column.
door when loading. Chimney cap too close to top of chimney. Relocate.
Too long of run of smoke pipe from Woodchuck Relocate Woodchuck closer to
to chimney. chimney.
10. Puffing of smoke Improper draft. Check draft with gauge. Should be
through draft control. .04 to .06 water column.
Down draft on chimney. Check for cold spots on chimney
or obstruction outside chimney.
Trees or other buildings.
Plugged chimney. Check with mirror in clean-out
door or send cleaning brush down
chimney. Check stovepipe con-
nections.
11. Excessive dirt build-up Too much smoke escaping out of loading door Check problem No. 9.
around air vent in home. when loading.
Bad weld in fire box of unit. Call dealer immediately.
No return air ducting. Install return air duct.
12. Improper seal around Door rope not sealing on door frame. Check door rope so that all parts
door. of door frame are sealed, espe-
cially corners.
Loose door from shipment. Simply bend door latch in to
tighten door seal.
13. Excessive creosote The use of wet, frozen, or unseasoned wood. If you have to use wet wood, make
build-up. loads smaller and burn them hotter.
The use of soft wood, particularly those of high resin Avoid using if possible.
A reminder, whatever kind of content such as plywood or blandex with glue.
fuel you burn, there is some Poor natural draft or an obstruction in the stove Measure draft with gauge. Should
kind of residue build-up on pipe or chimney flue. have a minimum of .04-.06 water
the furnace and chimney. columns of draft.
Same with wood no matter Too long of burning times. Smaller and hotter fires.
how good the conditions. Inadequate amount of oxygen supplied to the Adjust draft for hotter fires or in
combustion chamber some homes, it has been deter-
mined there was not enough in the
basement due to such an air-tight
home. We recommend 4" round
hole to the outside with a screen
on to keep varmints out.
Low fire or flue gas temperatures. Smaller loads of wood and hotter
fire. Stack temps. should maintain
minimum 300° to 400°.
Uninsulated stovepipe or chimney flues, espe- Never use uninsulated pipe for
cially if construction is exterior to the house. chimneys installed on the outside
of the house, INSULATE!
Air leaks in the stove pipe or chimney. Check chimney from top to bot-
tom. NOTE: Creosote is a tarry liq-
uid or solid coming from distillation
of wood during the combustion
process. The heavier buildups, the
greater chance of a chimney fire.
NOTE: No matter how seasoned
the wood, no matter how good the
draft, you always will get a small
amount of soot buildup. Should be
cleaned before winter firing and
during mid-winter’s firing.

14
 INSTALLATION
GENERAL REQUIREMENTS

CAUTION:
EQUIPMENT MUST BE INSTALLED BY A QUALIFIED
HEATING PERSON.

CAUTION:
ONLY “CLASS A” ALL-FUEL OR SOLID FUEL CHIM-
NEYS INTENDED FOR USE WITH YOUR WOOD-
CHUCK SHOULD BE USED.

FIRST AND ABOVE ALL is safety for you and your

family.

MUST USE: Class A Masonry or ULC listed, manufac-

tured Class A All Fuels Chimney.
RECOMMENDED SIZE: Rectangular 8"x12" or Round
8".

DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE

SERVING ANOTHER APPLIANCE. The Woodchuck is
to be used in conjunction with a listed gas or oil fired
furnace or as a central furnace.

ELECTRICAL SUPPLY: 115 volts, 60HZ, 1 Phase,

less than 12 amps.

Install system with 0.2 static pressure.

Flue setting .06 W.C. Max to .04 W.C. Min.

Wood or coal related fires are caused almost exclu-

sively by installation, operation or maintenance errors;
but not by unsafe equipment.

IMPORTANT: Check with your local state and federal

codes on installation at your local fire department.

PLACEMENT AND MINIMUM CLEAR-

ANCES

CAUTION:
FURNACE MUST BE INSTALLED ON A NON-COM-
BUSTIBLE FLOOR OR 3/8" THICK FIREPROOF MILL-
BOARD OR EQUIVALENT.

Locating your unit is very important for proper draft and

most efficient heating possible. See figure 7.
FIGURE 7 LOCATING THE WOODCHUCK

15
THE CAP SHOULD BE SUCH THAT IT HELPS TO PREVENT
DOWNDRAFT WHILE PROVIDING ADEQUATE EXHAUST
DRAFT.

MIN. 3’ FROM TOP OF CHIMNEY TO POINT AT

WHICH IT PASSES THROUGH THE ROOF

TOP OF CHIMNEY MUST BE AT LEAST 2’ HIGHER THAN PEAK

OR HIGHEST PORTION OF ROOF WITHIN 10’ HORIZONTALLY.
ALSO SEE FIGURE 9.

A CHIMNEY WHICH RISES WITHIN HOUSE IS BETTER

INSULATED THAN A CHIMNEY WHICH IS LOCATED OUTSIDE
THE HOUSE AND IS EXPOSED TO WEATHER.

THE CHIMNEY FLUE MUST HAVE A CROSS SECTIONAL AREA

AT LEAST EQUAL TO OR LARGER THAN THAT OF THE
STOVES FLUE COLLAR; BUT NO MORE THAN TWICE THAT
AREA. RECOMMENDED MIN. HEIGHT
APPROX. 20’

THE CHIMNEY THIMBLE SHOULD BE CONSTRUCTED OF

FIRE CLAY AND SHOULD HAVE AN INSIDE DIAMETER WHICH
IS NOMINALLY EQUAL TO THE OUTSIDE DIAMETER OF THE
SMOKE PIPE TO ASSURE A REASONABLY AIR TIGHT FIT.
THE THIMBLE MUST NOT EXCEED BEYOND THE FLUE
LINING.
FLUE SHOULD BE OF CONSTANT CROSS
SECTIONAL AREA THROUGHOUT ITS LENGTH

CLEANOUT DOOR SHOULD BE PROVIDED AND IT MUST

HAVE AN AIRTIGHT FIT. IT SHOULD NOT BE LEFT OPEN
FOR ANY LENGTH OF TIME WHEN STOVE IS IN
OPERATION

FIGURE 8 TYPICAL CHIMNEY CHECKLIST

16
Your unit should be place on a non-combustible floor or which can ignite and cause severe damage to any
3/8" thick fireproof millboard or equivalent which ex- chimney. MAKE SURE YOUR WOODCHUCK IS IN-
tends at least 8" from the sides and rear and extends STALLED INTO A PROPER CHIMNEY.
24" from the front. Leave a minimum clearance of 36" in
front of your unit. This is for safe, easy loading and For maximum safety and efficiency never install the
cleaning of your unit. Woodchuck furnace into the same chimney serving an-
other appliance.
Also be sure to allow enough room at the rear of the
Woodchuck for installation of the circulating blower and A typical chimney checklist of requirements is depicted
filter box. on figure 8.

If using your unit as an add-on, 6" minimum clearance The Model 526 furnace is equipped with a 6" flue collar
is required from your present furnace. having 28 sq. in. of exhaust area. Models 2900 and 4000
have an 8" flue collar having 50 sq. in. of exhaust area.
One very important step in locating your wood/coal fur- When connecting the furnace to the chimney maintain a
nace is how much distance you will be from your new or chimney flue section giving these minimum areas or
existing chimney. The unit should be installed as close larger but not exceeding twice this area. Some common
to the chimney as possible with a minimum of elbows sizes that are acceptable are 8" round, 10" round, or
(no more than 2) and no more than 6 feet horizontally 8"x12" rectangular. All Woodchuck furnaces must be in-
with ½" rise per foot. stalled into a chimney developing a minimum of .04 W.C.
to a maximum of .06 W.C. inches of draft. To maintain
CHIMNEY INSTALLATION this range of draft, a barometric damper should be in-
stalled (see pgs. 18-20) on each unit when the draft from
It is extremely important that your Woodchuck furnace the chimney is capable of exceeding .06 W.C. inches of
be installed into a CLASS A CHIMNEY ONLY. These draft.
chimneys consist of a flue-lined masonry chimney or
an approved Class A All Fuel factory built metal type. Insufficient draft can contribute to smoke spillage when
Any other installation constitutes a fire hazard, as wood the loading door is opened and to rapid creosote accu-
and coal burning units have stack temperatures as mulation. Excessive draft can cause high flue gas tem-
much as 300° to 1000° and may also deposit creosote perature, loss of overall efficiency and effect the degree
of control the operator can exert on the unit.

10’ MIN.
3’ MIN. 2’ MIN.
2’ MIN.

APPROVED
CHIMNEY

APPROVED CHIMNEY
6" OR 7" PIPE FOR
STOVE PIPE
MODEL 526
8" PIPE FOR
MODELS
2900/4000
DAMPER

DAMPER

SIDE VIEW
FRONT VIEW

FIGURE 9 CHIMNEY/ROOF CLEARANCE

TYPICAL STOVE PIPE INSTALLATION

17
When using approved factory built metal chimneys, you INSTALLATION OF A BAROMETRIC DRAFT
must have at least 2" of clearance when going through
a wall or next to a wall. A typical factory chimney instal- Some codes and NFPA require draft regulators in the
lation is shown on figure 9. chimney connector of wood or coal furnaces and boil-
ers, and manufacturers recommend their use with some
INSTALLING YOUR WOODCHUCK stoves. There is some doubt among wood heat experts
as to whether use of barometric draft regulators is wise.
Most of the Woodchuck furnace is factory assembled.
The factory assembly should be located as detailed in Draft regulators limit the draft-the suction pulling air into
the PLACEMENT AND MINIMUM CLEARANCES sec- the appliance. A pivoted, counter-balanced flap is
tion and on figure 7. pulled open by the draft when the draft reaches a criti-
cal amount (figure 10). This permits air to enter the
Remaining assembly will consist of mounting the con- chimney, thus preventing the draft in the appliance from
trols, draft and circulating blowers, filter box if used, and rising any higher.
electrical connection. These details will be provided af-
ter stove pipe and air duct installation. Use of draft regulators with oil-fired equipment is com-
mon. One objective is to keep the oil flame from being
blown out by excessive draft. This is more an annoy-
STOVE PIPE INSTALLATION ance than a safety problem since most oil burners have
primary safety controls which stop the fuel flow into the
Install your Wood/Coal unit as close to the chimney as burner whenever the flame goes out, and modern
possible with a minimum of elbows. We recommend no flame-retention burner design makes draft regulation al-
more than two elbows. The maximum horizontal run most unnecessary for this objective.
should not exceed 6 feet with a ½" rise per foot. The
pipe should maintain a ½" rise per foot and NEVER be A second objective is to limit the amount of air passing
installed closer than 18" from combustibles. Exceeding through the system in order to maintain high heat trans-
these recommendations normally represents creosote fer efficiency. Another desirable consequence is a de-
build-up, a smoking furnace, or one with poor draft. crease in peak chimney temperatures due to the added
air entering through the regulator.
When connecting stove pipe, all joints should be se-
cured with at least three #10 sheet metal screws. High draft does not blow out the flames but fans them in
wood and coal burning equipment. An especially hot
NOTE: If it is absolutely necessary to make a run fire can result. Control of the fire may be difficult, partic-
greater than 6 feet (not recommended), use extra sup- ularly if the wood burner is not airtight. Energy efficien-
port brackets every 3 ft. cies may be adversely affected, and chimney fires may
be ignited. A barometric draft regulator can alleviate
The connection to the wood furnace’s collar must also these problems by limiting the flow of combustion air
be more than just a snug fit. Drill holes through the into the appliance and by adding cooling air to the hot
Woodchuck’s collar and secure with sheet metal flue gases.
screws. Mark each connection for cleaning. This will
prevent frustration when matching up your hole pattern However the cooling air may result in more creosote
again. accumulation, and if a chimney fire does start, it will be
more intense because of the draft regulator. Large
DAMPERS IN STOVE PIPES: flows of air into the regulator will fan the fire in the
chimney. Thus the net effect of barometric draft
A manual damper may be installed at a safe convenient regulators is unclear-they help in some aspects, and
place between the barometric damper and the chimney. hurt in others. Note, though, that if a chimney is clean
In the event of chimney fire, it can quickly be closed so that chimney fires are impossible, a draft regulator
reducing draft to the chimney. See figure 10. does no harm, and does help limit the intensity of the
fire in the appliance, and it helps prevent the flue gases
SUGGESTED TYPE in the chimney from getting too hot. Barometric draft
DAMPER
regulators are recommended by JFPA for hand fired
thermostatically controlled solid fuel furnaces.

AIR HOLES

18
 MANUAL DAMPER MAY BE
INSTALLED BETWEEN BAROMETRIC
DAMPER AND CHIMNEY

With no draft in chimney, regulator

is closed, no air gets in.

Moderate suction in chimney pulls regulator open

enough to maintain desired draft for appliance.

FIGURE 10 A BAROMETRIC DRAFT REGULA- Excessive suction in chimney pulls regulator further
open, allowing substantial air into chimney connector.
TOR AND ITS INTENDED EFFECT

AIR DUCT INSTALLATION of 600 ft/min to 1000 ft/min at the registers. NEVER
supply less than 150 sq. in. of heated air outlet area.
SPECIAL AIR FLOW CONSIDERATIONS FOR
WOOD/COAL FURNACES Cold air returns must be at least equal in size to the
heated air outlets and preferably 10% larger. Every
With Wood/Coal furnaces, a special concern is pre- Woodchuck furnace MUST be installed with a cold air re-
venting wood joists and flooring close to the hot air turn.
ducts and plenum from overheating. A fire hazard is
created by the hot air flow circulating through ducts not ADD-ON INSTALLATIONS
designed for such high temperatures. Most Wood/Coal
furnaces produce much hotter air than oil or gas fired Before installing your Woodchuck furnace, consult
units. So most clearances from the existing ducts and your furnace man and local state building codes to de-
plenum are usually inadequate with a supplemental termine if your furnace will accept an add-on applica-
Wood/Coal furnace installation. tion. Some small furnaces and especially counter-flow
furnaces may not be used in add-on installations.
When installing the air duct, follow recommended
clearances shown in figure 11. Once it has been determined that your existing fur-
nace will accept an add-on installation, we recommend
The plenum on the Woodchuck should be 20"x23" and a parallel installation, with direct (ducted) feed of re-
no less than 18" high while maintaining a minimum of turn air to the Wood/Coal furnace, see figure 12. The
18" clearance to the ceiling or other combustible mate- back flow prevent damper assures that when either
rial. In a power outage situation, excessive heat unit is operating by itself, the hot air will flow into the
buildup at the plenum top may be dangerous, so make home, and not flow back through the other furnace.
sure clearances are maintained. For the Model 4000
allow at least 4" from ceiling to plenum. Figure 13 shows a central installation.

The ducts, fittings, grilles and registers should be We do not recommend supplemental wood furnace
sized so that the total external static pressure does not installations with series connection. These types of
exceed .02 W.C. inches while developing air velocities installation are not advisable in spite of their simplicity,
see figure 14.

19
 FIGURE 11 HOT AIR DUCT CLEARANCE REQUIREMENTS

FIGURE 12 PARALLEL ADD-ON INSTALLATION FIGURE 13 CENTRAL ADD-ON INSTALLATION

WOODCHUCK FINAL ASSEMBLY

2. Assemble the left front bar (different from right front bar,
has shorter extension shaft at front) to a rear bar. Slide a
OPTIONAL SHAKER GRATE INSTALLATION gear onto the front shaft.
FOR MODEL 526
3. Set this assembly into the front frame first and then into
1. Remove standard grates from firebox. Assemble com- the rear frame.
plete shaker grate kit outside of unit. Figure 16.

20
 4. Assemble the right front bar to a rear bar. Slide a gear
onto the front shaft, aligning it to engage the gear on the
left bar. Place the front bar onto the front frame and then
setting the rear bar onto the rear frame.

5. Place rear retainer in place, then the center and the

front retainers. Place all four bolts through retainers and
frame. Secure with locknuts. To prevent binding, it is ad-
visable to snug the locknuts but do not over tighten.

6. Try moving the shaker grate bars with the handle.

NOTE: Both bars in normal position should be flat. If not,
one or the other gear is not aligned correctly.

7. To install the assembly into the unit, place the front

end of the assembled grate on the loading door lower
frame. The grate should be the upside down position.
Slide the grate (front end first) into the firebox allowing
the front end to lower into the hearth area. Once the
back end of the grate has cleared the door frame, “flip” it
over toward the rear of the unit. If necessary, reach into
the ash pit door and pull the front of the grate forward
until it lodges into place.

INSTALL SHAKER GRATE HANDLE,

MODEL 2900 ONLY

1. Open the door ash door. Slide the shaker grate handle
through the opening in the side of the door frame and
guide it through the actuator arm and into the receiving
boss on the opposite side of the frame.

2. Secure handle to actuator with 1/4x1-1/2 bolt and nut.

See figure 15.

SHAKER GRATE HANDLE

ACTUATOR ARM

RECEIVING BOSS

1/4x1-1/2 BOLT

ALIGN HOLES ASH DOOR FRAME

FIGURE 14 POOR INSTALLATIONS FIGURE 15 INSTALL SHAKER GRATE HANDLE

21
 RETAINER

CENTER
RETAINER
REAR BAR

RETAINER

LEFT FRONT BAR

RIGHT FRONT BAR

(NOTE LONG SHAFT ON
FRONT)

REAR FRAME HANDLE

LOCKNUTS GEARS
FRONT FRAME

FIGURE 16 INSTALL OPTIONAL SHAKER GRATE FOR MODEL 526

INSTALL FIREBRICK
BEVEL CUT BRICKS
RECTANGULAR FRONT & BACK
Place firebrick into unit as follows: BRICKS ON
SIDES
1. Place two longer bricks with bevel cuts against the
rear wall of the firebox. See figure 17.

2. Place remaining two bricks with bevel cuts against

the front wall of firebox.

3. Place rectangular brick along side walls of firebrick as MODELS 2900/4000

illustrated. If Rectangular bricks are two different widths,
then an equal number of each will go on both sides of
firebox.
BEVEL CUT BRICKS
FRONT & BACK
INSTALL OPTIONAL CATALYTIC RECTANGULAR
BRICKS ON SIDES
COMBUSTOR (MODEL 2900/4000)

NOTE: Optional catalyst not recommended with 6" flue

adapter. Smoke spillage may occur out of door when
refueling.

Greater efficiency can be obtained when burning wood

by use of a catalytic combustor. In addition, it will de- MODEL 526
crease the accumulation of creosote and diminish the
possibility of a chimney fire.

FIGURE 17 INSTALL FIREBRICK

22
The pyrolysis of wood produces certain substances
which will not burn unless the temperature in the firebox
reaches 1000°F or higher. Under normal conditions
these temperatures are not attained and these sub-
stances simply escape up the chimney as wasted energy 1/4 LOCKNUT
and can form deposits in the chimney. By forcing these
unburned substances to come into contact with a cata-
lyst, we can cause them to burn at much lower tempera-
tures that are easily attainable during normal operation. DO NOT REMOVE
KNOCKOUT
Installation and removal of the combustor is simple, the MANUAL DRAFT
element fits inside a retainer. The retainer fits inside the CONTROL
furnace exhaust pipe which extends down into the fire-
box. The assembled combustor slides up into the ex- 1/4x1-1/2 BOLT
haust pipe stub which protrudes down into the firebox.
There are three rods on the retainer which engage slots
in the pipe and then turn slightly to lock in place. These
rods are not symmetrical. Two rods are welded together
to form a 90° angle. This angle points toward the rear of
the firebox.
FIGURE 19 INSTALL MANUAL DRAFT-MODEL 526

INSTALL COMFORT CONTROL CENTER

SLOTS IN EXHAUST PIPE
AND FORCED DRAFT BLOWER

1. Install all knobs to control levers and door handles.

See figure 20.

2. The comfort control center is factory wired to the

CATALYTIC ELEMENT
fan/limit control and the forced draft blower. It has a
prewired flexible conduit for connection to the circulating
blower.
RODS ON RETAINER
3. If you have optional temperature gauge on your con-
trol, then strip ½" of insulation from the two leads of ther-
mocouple wire protruding through the rectangular
opening on the furnace side. Connect these leads to the
terminals on the temperature gauge of the control. IM-
PORTANT: Remove the wire ground clip from the termi-
FIGURE 18 INSTALL OPTIONAL CATALYTIC nals of the gauge and connect White wire to + terminal
COMBUSTOR (MODEL 2900/4000) and Red wire to - terminal. See figure 22.

4. Mount the control to the side of the furnace with four

#10 sheet metal screws.

5. Remove the knockout section of the draft channel on

ASSEMBLE MANUAL DRAFT
model 526 by striking sharply with a hammer. Be careful
MODEL 526 ONLY so you do not damage the mechanism inside the chan-
nel and directly behind the knock-out. DO NOT allow the
Using a 1/4x1-1/2 bolt and locknut, mount manual draft knock-out to fall inside the draft channel.
control onto the draft channel, figure 19. If you are going
to install optional forced draft, disregard. Do not tighten 6. Align the forced draft blower outlet flange over the
too tight to damper draft adjustment, but not too loose to knockout and secure with three #10 sheet metal screws.
let more air in than required. DO NOT remove knockout
on draft channel. Locknut can be held with wrench in- 7. Secure conduit to furnace side using conduit clamps
serted through air opening. and #10 sheet metal screws.

23
 THERMOCOUPLE WIRE
COMFORT CONTROL CENTER

FAN/LIMIT CONTROL

INSTALL ALL CONTROL

AND HANDLE KNOBS

KNOCKOUT IN DRAFT
CHANNEL REMOVED SECURE CONDUIT WITH
CONDUIT CLAMPS AND
#10 SHEET METAL SCREW

FORCED DRAFT
BLOWER

PRE-WIRED FLEXIBLE CONDUIT

TO CIRCULATING BLOWER

FIGURE 20 INSTALL COMFORT CONTROL

CENTER AND FORCED DRAFT BLOWER

INSTALL CIRCULATING BLOWER

3. With filter box set against back of furnace, bend
The flanges on the circulating blower simply slide be- down the tabs on the support angles so they lock be-
hind the angle mounts welded to the rear of the furnace. hind the flanges of the top and bottom panels of the
Slide in from the top side, figure 21. box.

INSTALL FILTER BOX 4. Install the access door. Install filter not supplied
and install a cold air return system to the filter box fil-
The filter box is standard on Model 526. Installation in- ter side opening.
structions are included with Model 526 filter box.
5. Route flexible conduit from comfort control through
1. The filter box can be installed with the filter on either hole in top panel and to box connector on blower
side. The access door will fit the opening either side and connection box. Connect wires to blower motor by
the handle should face forward. joining wires of the same color.

2. Find two factory shipped support angles. Force sup- FEED MOTOR
port angle sides without tabs into the groove of the White White/Purple
mounting strip on both rear sides of the furnace. Posi- Red Red
tion at correct height to accept filter box, figure 21. Blue Blue
Black Black

24
 SLIDE FLANGES OF
CIRCULATING BLOWER
BEHIND ANGLES ON BACK
OF FURNACE

ELECTRICAL GROOVE IN
CONNECTION BOX FURNACE
MOUNTING STRIP,
BOTH SIDES

FORCE FLANGE OF SUPPORT

ANGLE INTO GROOVE ON FURNACE
MOUNTING STRIP

HOLE FOR
CONDUIT

FILTER (NOT
SUPPLIED)

SUPPORT ANGLE

ACCESS DOOR

FILTER
ANGLES
BEND TABS ON SUPPORT ANGLE
OVER, BEHIND FLANGE ON FILTER
BOX, TOP & BOTTOM

FIGURE 21 INSTALL CIRCULATING BLOWER AND FILTER

ELECTRICAL HOOKUP (FIGURE 22) former in the comfort control. These connections have
been routed to a terminal strip on the outside of the
1. If you have an optional temperature gauge to monitor comfort control box for convenient connection.
heat exchanger temperature in your comfort control
center, then the thermocouple wires must be connected 4. The circulating blower limit control is factory wired to
to the gauge when installing the control. See figure 20. the comfort control center. Jumper removed, normal fan
IMPORTANT: Remove the wire ground clip from the ter- limit control settings are 160°F ON, and 110°F OFF.
minals of the gauge and connect White wire to + termi-
nal and Red wire to - terminal. See figure 22. 5. Route 110VAC power through conduit from your
power supply to the comfort control center box. Route
2. A prewired conduit is connected to the comfort con- through box connector provided and connect hot (L1) to
trol center for the circulating blower. The opposite end is BLACK, Neutral to WHITE and ground to GREEN as
to be connected in the junction box on the blower motor. shown on figure 22. You must provide a power discon-
Connect like colored wires. Secure conduit to junction nect in the power supply line to your furnace which is
box with box connector. within sight of the Woodchuck and not more than 30
feet away. Your circuit breaker at the power supply may
3. The comfort control is factory wired to the forced draft meet these requirements.
motor (optional on Model 526). If you have the forced
draft, locate a wall thermostat in the desired location of
you house and run #18 thermostat wire (not furnished)
from this thermostat to R and G terminals of the trans-

25
 WARNING:
ELECTRICITY CAN KILL, SHOCK, OR BURN. DISCONNECT AND LOCKOUT POWER SOURCE BEFORE
SERVICING OR INSTALLING ELECTRICAL COMPONENTS. FAILURE TO HEED MAY RESULT IN SERIOUS
PERSONAL INJURY OR DEATH.

CAUTION:
ALL WIRING MUST MEET LOCAL, STATE AND NATIONAL CODES AND BE INSTALLED BY A QUALIFIED
ELECTRICIAN.

W R

FIGURE 22 ELECTRICAL WIRING DIAGRAM

26
 REPAIR PARTS
BASIC UNIT FOR MODEL 526

KEY NO. PART NO. DESCRIPTION KEY NO. PART NO. DESCRIPTION
1 01-0526 Welded Assembly 15 06-0215 Spring
2 03-5262 Shroud - Right Side 16 814-2520-Z 1/4 Lock Nut
3 03-5263 Shroud - Left Side 17 05-0002 Small Grate
4 03-5261 Shroud - Top 18 05-0001 Large Grate
5 08-0005 Circulation Blower 19 07-5263 Front Brick Kit (2 pc.)
6 06-1001 Ash Pan 20 07-5262 Rear Brick Kit (2 pc.)
7 02-5261 Fuel Door 21 07-5261 Side Brick Kit (18 pc.)
8 02-5262 Ash Door 22 07-5260 Complete Brick Kit
9 06-1014 Door Knob 23 01-0526-19 Heat Exchanger Gate
10 06-5261 Fuel Door Gasket 24 03-5264 Z-Lock 25-1/2"
11 06-5262 Ash Door Gasket 25 06-5263 Heat Exchanger Rod
12 06-0200 1/4 Door Pin 26 05-0005 Manual Draft Butterfly
13 05-0004 Handle Access Cover 27 06-0221 Stainless Steel Cotter Pin
14 801-2520-1.5Z 1/4x1-1/2 Bolt

27
 BASIC UNIT FOR MODEL 2900

KEY NO. PART NO. DESCRIPTION KEY NO. PART NO. DESCRIPTION
1 01-2900 Welded Assembly 13 02-2901 Fuel Door
2 03-2901 Shroud - Top 14 06-2902 Fuel Door Gasket
3 03-2904 Shroud - Front 15 07-2901 Side Brick Kit (4 pc.)
4 03-2902 Shroud - Right Side 16 07-2902 Rear Brick Kit (2 pc.)
5 03-2903 Shroud - Left Side 17 07-2903 Front Brick Kit (2 pc.)
6 05-2908 Shaker Handle 18 07-2900 Complete Brick Kit
7 06-1001 Ash Pan 19 06-2907 Insulation - Front
8 06-1013 80/20 Selector Knob 20 06-2906 Insulation - Side
9 06-0200 1/4" Door Pin 21 08-0005 Circulation Blower
10 06-2903 Ash Door Gasket 22 03-2905 Z-Lock 28-1/2"
11 02-2902 Ash Door 23 03-2906 Z-Lock 44-3/4"
12 06-1014 Handle Knob (Large)

28
 BASIC UNIT FOR MODEL 4000

KEY NO. PART NO. DESCRIPTION KEY NO. PART NO. DESCRIPTION
1 01-4000 Welded Assembly 12 06-0200 Door Pin
2 03-4001 Shroud - Top 13 02-2901 Fuel Door
3 03-2904 Shroud - Front 14 06-2902 Fuel Door Gasket
4 03-4003 Shroud - Left Side 15 02-2902 Ash Door
5 03-4002 Shroud - Right Side 16 06-2903 Ash Door Gasket
6 06-4001 Insulation - Side 17 07-4003 Front Brick Kit (2 pc.)
7 06-2907 Insulation - Front 18 07-4002 Rear Brick Kit (2 pc.)
8 08-0005 Circulation Blower 19 07-4001 Side Brick Kit (4 pc.)
9 06-1014 Handle Knob (Large) 20 07-4000 Complete Brick Kit
10 06-1013 80/20 Selector Knob 21 03-4004 Z-Lock 34-1/4"
11 06-1001 Ash Pan 22 03-4005 Z-Lock 48"

29
 #05-5260-OPTIONAL SHAKER GRATE FOR MODEL 526
KEY NO. PART NO. DESCRIPTION
1 801-2520-1.25Z 1-1/2x1/4 Bolt
2 05-5265 End Retainer (S-5)
3 05-5266 Center Retainer (S-6)
4 05-5268 Rear Bar, Female (S-3)
5 05-5263 Front Bar, w/Extension (S-2-1)
6 05-5262 Front Bar, Male (S-2)
7 05-5264 Gears (S-4)
8 05-5267 Handle (S-7)
9 05-5261 Front Frame (S-1)
10 814-2520-Z 1/4 Lock Nut

#05-2900 SHAKER GRATE FOR

MODELS 2900/4000 KEY NO. PART NO. DESCRIPTION
1 05-2902 Side Rail (W-9)
2 05-2903 End Rail (W-10)
3 05-2904 Shaker Bar (CC-130)
4 05-2905 Shaker Rail (WC-2900)
05-4001 Shaker Rail (WC-4000)
5 05-2906 Sleeve (WC-2900)
05-4003 Sleeve (WC-4000)
6 05-2908 Handle (WC-2900) E423
05-2907 Handle (WC-4000)
7 06-1014 Knob
8 801-2520-1.5Z 1/4x1-1/2 Bolt
9 814-2520-Z 1/4 Lock Nut
10 05-2901 Linkage

FILTER BOX

KEY NO. PART NO. DESCRIPTION

526 2900/4000
1 04-2900-6 04-2900-6 Door
2 04-5260-7 04-2900-7 Cabinet Assy.
3 NA 04-2905 Mounting Cleat
4 04-5260 04-2900 Complete Filter
Box

30
CIRCULATING BLOWER

#08-0100 #08-0090 COMPLETE BLOWER ASSY.

COMFORT CONTROL
KEY NO. PART NO. DESCRIPTION
DRAFT BLOWER
1 08-0001 Motor
2 08-0002 Capacitor
9 3 08-0005 Blower Assembly (no motor)
Wiring Decal,
4 08-0048 Electrical Connection Box
See Next
2 COVER 5 08-0004 Capacitor Boot
Page.
(not shown) 6 08-0003 Capacitor Bracket
7 08-0049 Electrical Box Cover
8 08-0005-2 Large Motor Mount Bracket
9 08-0005-3 Short Motor Mount Bracket
10 08-0005-4 Motor Clamps

KEY NO. PART NO. DESCRIPTION

1 08-0100-1 Box Enclosure
2 08-0100-3 Cover
3 08-0029 Therm-O-Disc
4 08-0017 Fan Relay Center
5 08-0026 3 Speed Switch
6 08-0089 Switch Toggle
7 08-0106 Terminal Strip
8 08-0015 Fan Limit Control
9 462900-8 Wiring Decal
10 08-0006 60 CFM Draft Blower
11 08-0084 Flue Temperature Gauge

31
46-2900-8 Wiring Diagram

32
 PERSONAL DATA INFORMATION FOR FUTURE
REFERENCE
Model No. Of Unit Date Of Purchase

Serial No. Of Unit Date Of Installation

Dealer Name Name Of Installer

Address Address

Phone Phone

Equipment Options
q Filter Box
q Shaker Grate
q Domestic Coil

33
This Page Intentionally Blank

34
 LIMITED WARRANTY

Card must be completed and mailed within 10 days of the purchase of your This card is to be sent to your Home Owners Insurance company for their
What is covered:

Name____________________________________________________
Address__________________________________________________
City_____________________ State__________ Zip______________
Home Owners Policy No.____________________________________
Meyer Manufacturing Corporation warrants to the original owner only, all parts in
this model Woodchuck solid fuel appliance to be free from defects in material and
workmanship.
For how long:

MEYER MANUFACTURING CORPORATION

For a period of one (1) year (from date of purchase) of normal use.
Additional Coverage:

Manufacturers Of Woodcoal Furnaces

In addition, Meyer Manufacturing Corporation separately warrants the firebox for
an additional five (5) years on a prorated basis. Proration will begin with the 13th

Dorchester, Wisconsin 54425

month of ownership.
Exclusions:
The firebrick and grates which are expendable and replaceable parts as well as

P.O. Box 405

cosmetic changes due to normal operation are not covered.
What the Customer must do:
In the event a Woodchuck solid fuel appliance is defective in workmanship or ma-
terials, Meyer Manufacturing Corporation will repair or, at our option, replace the
defective part. To obtain a remedy the purchaser must ship the part(s), freight pre-
paid, to:
MEYER MANUFACTURING CORPORATION

records and your protection.

P.O. Box 405
Dorchester, Wisconsin 54425
All claims must be accompanied by a proof of purchase substantiating date of pur-
chase. In the event date of purchase cannot be obtained, Meyer Manufacturing
Corporation will assume it to be 90 days after date of production.
What We will do and will not do:
Meyer Manufacturing Corporation will ship the repaired or replacement part to the
Purchaser freight collect. The Purchaser is responsible for service, removal and
reinstallation labor cost.
Other Conditions:
The warranty applies only if the unit is installed and operated as recommended in
the owners manual and used with a class “A” all-fuel chimney. The draft from the
chimney must be .04 to .06 inches W.C. draft. The warranty will not apply if the
unit is used for commercial purposes, if damage is caused by abuse, accident, im-
Address__________________________________________________

Address__________________________________________________
Installer Name_____________________________________________
proper installation, overheating or negligence, or from an attempt to repair the unit
Name ___________________________________________________

Phone___________________________________________________
City_____________________ State_________ Zip______________
Date Purchased_______________ Date of Instation______________

City_____________________ State_________ Zip______________

Serial No.__________ Model No.___________ Price Paid_________
by any person not expressly authorized by Meyer Manufacturing Corporation to do
the repair.
Limit of Obligation:
No one is authorized to make any other warranties on behalf of Meyer Manufac-
turing Corporation. We will NOT be responsible for any promises NOT in our war-

>Yes > No Have you ever owned a wood heater before?

ranty. Any special, incidental or consequential damages are excluded to the
extent permitted by law. Any implied warranty, including merchantability or fitness
for a particular purpose shall NOT extend beyond the warranty stated above.
Woodchuck for your warranty to come into affect.

State Law Rights:

Some states do not allow limitations on how long an implied warranty lasts, so the
above limitations may not apply to you. This warranty gives you specific legal
rights and you may also have other rights which vary from state to state.

P.O. Box 405 — Dorchester Wisconsin 54425

 Manufactured By
MEYER MANUFACTURING CORPORATION
P.O. Box 405
Dorchester, Wisconsin 54425
MEYER MANUFACTURING CORPORATION
Dorchester, Wisconsin 54425
P.O. Box 405