MODEL 521FB WOOD-BURNING FURNACE MANUAL Manufactured in the U.S.A. by DAKA CORPORATION 955 Industrial Street NE Pine City, Minnesota 55063 Phone: 320-629-6737 Fax: 320-629-3677 www.dakacorp.com DAKA 521FB Manual Page 1 of 32 January 2009 Rev.
I. LIMITED WARRANTY This furnace meets U.S. Test Standard: UL 391-2010 – MARCH 2010 AND SEPT. 2010 This model has been tested and listed in accordance with Underwriters Laboratories Standard UL 391-2010 – March 2010 and Sept. 2010 for Solid Fuel Central and Supplementary Furnace by Intertek Testing Services/Warnock Hersey Inc. International Conference of Building Officials (ICBO) Report No. TL116 Council of American Building Officials (CABO) Report No. NER QA219 Purchase Date: SAVE THESE INSTRUCTIONS.
II. TABLE OF CONTENTS DAKA 521FB WOOD-BURNING FURNACE MANUAL I. II. III. IV. V. VI. VII. VIII. IX. X. XI. XII. XIII. XIV. LIMITED WARRANTY .................................................................................................. 2 TABLE OF CONTENTS ............................................................................................... 3 FEATURES .................................................................................................................. 4 SPECIFICATIONS...........
III. FEATURES 2 Sides and Back Fire Brick Lining – Durable construction for long life and consistent heat. UL Tested by WHI – Tested to UL Standard 391-2010 – March 2010 and Sept. 2010. Ensures safety and efficiency. USE AS AN ADD-ON or CENTRAL FURNACE – Add-on utilizes existing central ductwork and distribution system – Central application has its own ductwork. Heavy Duty Cast Iron Grates – High heat resistance provides longer life. 2-8” Warm Air Outlets – for secure connection of 8” round duct pipe.
IV. SPECIFICATIONS DAKA MODEL 521FB WOOD-BURNING FURNACE SPECIFICATIONS Manufacturer: DAKA Corporation Model: 521FB U.L. Approval: Tested to U.L. Standard 391–March 2010 & Sept. 2010 by WHI Fuel Type: Wood / Coal Dimensions: 44” Height x 24” Width x 25-½” Depth BTU Output: 42,000 – 105,000 per hour Fuel Capacity: 22” Log Length / 90 lb. Air Outlet Size: 2 – 8” round Flue Outlet Size: 6” round Weight: 432 lbs. DAKA 521FB Manual Page 5 of 32 January 2009 Rev.
V. OPTIONAL FURNACE ACCESSORIES DAKA CORPORATION 955 Industrial St NE, Pine City MN 55063 Telephone: 320-629-6737 Fax: 320-629-3677 Email: sales@dakacorp.com Website: www.dakacorp.com Visit our website or call 1-800-884-3252 for pricing and shipping information. 273 - TWIN 550-CFM BLOWER KIT For installations requiring additional air pressure, such as for use as a central furnace. Kit includes one 550-cfm splitcapacitor blower, wiring and instructions.
VI. GENERAL WOOD-BURNING SAFETY STOP FOR SAFETY! Safe assembly, operating and maintenance practices should always be followed whenever using any equipment. READ THROUGH THE ENTIRE MANUAL BEFORE BEGINNING YOUR INSTALLATION OR OPERATING YOUR FURNACE. FOLLOW ALL STEPS EXACTLY! WARNING: Disconnect all power before making electrical connection. For power supply connections, use No. 14 AWG or larger wires acceptable for at least 105C. Check local codes for acceptable components.
VI. GENERAL WOOD-BURNING SAFETY Building Codes: Check local building and mechanical codes prior to installation to ensure conformance with all requirements. Home Insurance: Review home insurance policy for coverage. Paint Odor: During initial start-up, the unit may omit fumes as the paint outside shell cures. Please provide outside ventilation throughout the home to help clear the odor. Ash Disposal: Ashes should be placed in a metal container with a tight-fitting lid.
VII. CHECKING SHIPMENT UNPACKING DO NOT LIFT FULL CARTON THAT CONTAINS FIREBRICK AND BLOWER FROM INSIDE THE FIREBOX. FIG. 1 Open box and remove individual firebricks and blower first. Check piece count against parts list in back of manual. MISSING OR DAMAGED PARTS PLEASE DO NOT RETURN THE PRODUCT TO THE STORE WHERE PURCHASED. CALL DAKA CORPORATION DIRECTLY.
VIII. PLANNING YOUR INSTALLATION PLANNING YOUR INSTALLATION Read through the entire manual before beginning your installation. Follow all steps exactly. Your Model 521FB Furnace can be installed as a supplementary/Add-on Furnace or as a free-standing central furnace with its own plenum and ductwork. Review the location options below and determine how you are going to install your system. B. CLEARANCES 1) FLOOR PROTECTION 1.
VIII. PLANNING YOUR INSTALLATION B. CLEARANCES – continued 2) Wall Clearances to Combustibles See FIG. 4. C. CHIMNEY 1) General Chimney Requirements: 1) Minimum 6” inside diameter 2) “Type HT” (High Temperature)-listed appliance-type chimney or a code-complying tile-lined masonry chimney. 3) Chimney must extend 3’ above roofline and be at least 2’ higher than any point of roof within 10’. See FIG. 5.
VIII. PLANNING YOUR INSTALLATION C. CHIMNEY – continued FIG. 5 2) Chimney Options a) Masonry – Before using an existing masonry chimney, have the chimney inspected, cleaned and make all necessary repairs before attaching the furnace. The flue pipe and fittings you will need to connect your furnace directly to a masonry chimney are shown in FIG. 5. If the flue pipe must go through a combustible wall or ceiling before entering the masonry chimney, consult a qualified mason or chimney dealer.
VIII. PLANNING YOUR INSTALLATION GENERAL INFORMATION This furnace model is designed for a conventional up flow residential central force air heating system. It may be installed as a SUPPLEMENTARY/ADD-ON or CENTRAL FURNACE APPLICATION. It is designed to operate with a maximum warm air duct pressure of 0.2” water column and a maximum warm air duct temperature of 250° degrees F. The warm air supply duct system must be constructed of materials with a minimum temperature rating of 250° degrees F.
VIII. PLANNING YOUR INSTALLATION E. CENTRAL FURNACE APPLICATION When installed with its own plenum and ductwork, the furnace will operate as a freestanding Central furnace. See FIG. 8. The 550-cfm blower provided is often sufficient to provide air distribution for smaller homes with short duct runs. A second optional 550-cfm blower (DAKA #273), or a large side-mounted multi-speed blower & filter box (DAKA #218), may be required for larger homes with longer ductwork (available online at www.dakacorp.com).
IX. ASSEMBLY INSTRUCTIONS FIG. 9 INSTALL FIRE DOOR 1. Attach fire door hinge to front of furnace. See FIG. 9. Position hinge against furnace with hinge pinhole closest to door opening. When viewing hinge bracket from top, make sure that the notched corner is facing away from door opening. 2. Insert two ¼” hex bolts through hinge bracket and holes located just to the right of the door opening. Place washer and nut on bolt from INSIDE furnace.
IX. ASSEMBLY INSTRUCTIONS INSTALL FIRE BRICK With everything removed from inside firebox, install firebrick. 1. To install firebrick, hold firebrick in standing position and angle top of firebrick toward outside wall. Slip top edge of firebrick under retaining angle. Stand firebrick up so bottom of brick sits evenly on support rail. 2. Center rear firebrick (3) across back of firebox. Insert sidewall firebrick (5 ea) at front of furnace.
IX. ASSEMBLY INSTRUCTIONS INSTALL BLOWER FIG. 14 NOTE: For Add-On furnace installation, do NOT remove the back-draft damper plate. For Central Furnace installation, back-draft damper plate may be removed. (It is located inside the blower inlet on the right hand side of back of furnace. Break wire nut to remove). Blower Install 550-cfm blower over inlet on right hand side of back of furnace using four (4) No. 12 x ½” screws. See FIG. 14. CAUTION: Handle blower by the housing unit.
IX. ASSEMBLY INSTRUCTIONS MOUNT JUNCTION BOX, INSTALL FAN CONTROL, INSTALL CONDUIT WITH PRE-RUN WIRES, & WIRING INSTALL FAN CONTROL ASSEMBLY FIG. 16 Junction Box and Conduit (FIG. 16): 1. Remove cover plate from junction box. 2. Mount junction box using two (2) No. 12 x ½” screws onto left side of furnace in outer pre-punched holes. NOTE: Screws go in upper left and bottom right slotted corners. 3.
IX. ASSEMBLY INSTRUCTIONS WIRING INSTRUCTIONS FIG. 18 WARNING: Disconnect all power before making electrical connection. Power Supply Connections 1. Using an approved conduit and connector, bring a 3-wire 120V AC 15-amp minimum electrical service to the Junction Box. 2. Use minimum No. 14 AWG or larger wires, rated for at least 105C (not provided). NOTE: Power connections should be made by a qualified installer to comply with The National Fire Protection Association (NFPA) Standard No.
IX. ASSEMBLY INSTRUCTIONS COLD AIR RETURN FILTER BOX ASSEMBLY & INSTALLATION 1. Using the sheet metal screws provided (Key 6) first attach the bottom panel (Key 2) to side panel A (Key 3) 2. Next, attach side panel B (Key 4) and side panel C (Key 5) to bottom panel (Key 2). 3. With blower and wiring already installed on DAKA furnace, the next step is to loosen, but not remove, all four screws holding the fan hole cover plate. (See FIG. 2). 4.
X. INSTALLATION A.1. CONNECTING TO DUCTWORK (SUPPLEMENTARY/ADD-ON) IMPORTANT: Installation of a cold air return line to the DAKA furnace is mandatory. (EXAMPLE) FIG. 19 FIG. 20 (See other options on page 23) IMPORTANT: The plenums installed to the furnaces must be of metal construction. Verify beforehand that sufficient clearance is available above air conditioner coil, etc.
X. INSTALLATION IMPORTANT: In a Supplementary/Add-on installation, the blower on the DAKA furnace is not used as a circulation blower for heating the house, but as a lift blower to get the heat into the supply plenum. From there, the primary blower will turn on as heat is received from the DAKA furnace. A fan control will have to be installed, wiring it in parallel with the primary blower fan control at the heat exchanger level. See next page for necessary position of this fan control.
X. INSTALLATION A3. ALTERNATIVE CONNECTION OPTIONS DAKA 521FB Manual Page 23 of 32 January 2009 Rev.
X. INSTALLATION B. CONNECTING TO CHIMNEY Mount and secure 6” non-galvanized smoke pipe, 24-ga. or heavier, to rear smoke outlet collar on DAKA furnace. The collar is sized so that the crimped end of a standard 6” stove pipe will fit inside collar. Continue same gauge single-wall pipe to chimney connection. At chimney connection, use a double-crimped end stove pipe adapter to connect to chimney. Smoke pipe should normally be installed with crimped ends leading from chimney to furnace.
X. INSTALLATION B. CONNECTING TO CHIMNEY (cont’d) DAKA 521FB Manual Page 25 of 32 January 2009 Rev.
XI. OPERATING INSTRUCTIONS FUEL TYPES Burn wood only or burn coal only. Do not burn garbage, flammable fluids, drain oil, wood chips or any other non-approved items. Wood should be cut & split and seasoned for at least 6 months. FUELING PROCEDURE Start fires by first taking single sheets of newspaper and rolling them tight. Lay them on the grate. Place finely-split kindling on top of newspaper. much heat to keep the house warm.
XI. OPERATING INSTRUCTIONS OPERATING CONTROLS – continued Automatic Damper Control (ADC) The Automatic Damper Control (ADC) controls Fresh air to fire Heat output Burn time Amount of fuel burned Efficiency Stack temperature. By understanding how simple adjustments to the ADC will affect the output of the furnace you will be better able to obtain the results you are looking for.
XII. MAINTENANCE INSTRUCTIONS AUTO DAMPER CONTROL See FIG. 22 & FIG. 23. Also, refer to XIII. Troubleshooting Section for adjustment procedures. FIG. 22 Blower PREVENTING CREOSOTE FORMATION The amount of creosote that is produced when burning wood is directly related to the temperature at which the wood is being burned. Generally, higher temperature fires are more efficient and create less creosote. If an excessive amount of creosote is being produced, the burn temperature needs to be increased.
XIII. TROUBLESHOOTING PROBLEM Smoke puff back when loading, poor burning, insufficient heat CAUSE 1. Insufficient draft. 2. Insufficient make-up. Poor heat throughout house while burning wood 1. Poor quality wood. 2. Cold air return closed or blocked. 3. Duct joints leaking air. 4. Check flue gas temperature. 5. Fan control not adjusted properly. Auto Damper Control won’t hold setting 1. Auto damper control not in adjustment. Loose Knob on Auto Damper Control 1. Loosened through usage.
XIV. PARTS LIST & EXPLODED VIEW 3 2 4 13 15 13 17 19 12 1 14 10 9 17 6 7 16 5 No. 1.1 1.2 1.
THIS PAGE LEFT BLANK INTENTIONALLY. DAKA 521FB Manual Page 31 of 32 January 2009 Rev.
LEARN MORE ABOUT DAKA FURNACES BY VISITING WWW.DAKACORP.COM Order Optional Accessories Order Replacement Parts Watch Videos on Installation, Operation & Maintenance Download Manuals Contact Us with Questions or Comments DAKA 521FB Manual Page 32 of 32 January 2009 Rev.
