Zanussi Oven ZOD35561 Woodburning Install
User Manual: Zanussi Oven ZOD35561
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Ouzledale Foundry Co. Limited, Long Ing, Barnoldswick, Lancashire BB18 6BN
Tel: 01282 813235 Fax: 01282 816876 Email: esse@ouzledale.co.uk Website: http://www.esse.com
Model:
Serial Number:
INFORMATION FOR USE WHEN ORDERING SPARES: 01/06
GUARANTEE
CONDITIONS OF GUARANTEE
Your esse cooker is guaranteed against defects arising from faulty manufacture for two years, subject to the
following express conditions:
1. A suitably qualified person must install the cooker, and upon installation the details must be recorded on the
warranty card and registered with esse by returning the correctly completed card. The guarantee period
commences upon delivery of the cooker.
2. The cooker has been used for normal domestic purposes only, and in accordance with the manufacturer’s
instructions.
3. The cooker has not been serviced, maintained, repaired, taken apart, or tampered with by any person not
authorised by us.
4. An approved dealer or representative must undertake all service work under this guarantee.
5. Any cooker or defective part replaced shall become the Company’s property.
EXCLUSIONS
This guarantee does not cover:
• Damage or calls resulting from transportation, improper use or neglect.
• Parts deemed to be replaceable in the normal usage of the cooker. These parts are listed herewith: firebox linings,
loading door glass, door seals.
This guarantee is personal to the original purchaser and is non-transferable.
CUSTOMER CARE
In the event you should require spare parts, please order through your esse dealer.
Should you have cause for dissatisfaction with your cooker, you should contact your esse dealer who will, in most
instances, be able to offer you immediate assistance. You will be required to give the following details:
• Your name, address and postcode.
• Your telephone/contact details.
• Clear and concise details of the fault.
• Model and serial number of the cooker (found on the data plate behind lower right door).
• Purchase date (please note that a valid purchase receipt or guarantee documentation is required for in-guarantee
service calls).
We will then check that we have an accurately completed warranty card, if not then any work carried out may be charged.
The nature of the complaint will be assessed and either replacement parts for your dealer to fit, an engineer to
inspect & report, or an engineer to remedy will be arranged. For any home visits that may be required, an
appointment will be made for either morning or afternoon, Monday to Friday.
If the fault is not actually due to faulty workmanship but some other cause such as misuse or failure to install correctly,
a charge will be made to cover the cost of the visit and any new parts required, even during the warranty period.
the ironheart
ESSE Cooking Stove
OPERATING & INSTALLATION INSTRUCTIONS
MODEL: EW/EWB
Figure 1 shows the cooking stove and its controls.
The large glass door on the left is the loading door
through which the fire is lighted and refuelled. The
small door at the bottom on the left is the ash door.
The large door to the right of the cooking stove is
the oven and the small door at the bottom right is
the oven flue access door.
Included inside your cooking stove is a multi
purpose-operating tool – for lifting the ash pan,
adjusting the primary and secondary air supply and
opening the doors.
The cooking stove is suitable for burning wood and
smokeless solid fuels.
A flue restrictor (fig.1) is fitted in the bottom of the
fluebox and is in the open position when lever is
pointing to rear of cooker. This is used on initial
light up and also gives a cooler oven temperature
when open. It can also help to control excessive
flue draught. This is done by pointing the lever to
the front of the cooker.
Note: Ordinary bituminous house coal is
not recommended and must not be burned
in smoke control areas. Burning bituminous
house coal will result in a sooty cooking stove
and chimney, and the cooking stove glass will
require regular cleaning. Pure Petcoke should
also be avoided as the high temperatures this
fuel can produce may damage the cooking stove.
INTRODUCTION
CONTENTS
We are pleased that you have chosen an ESSE
cooking stove. We would ask you to read the
following instructions very carefully. Correctly
installed and operated, your ESSE cooking stove will
give satisfactory service for many years. We feel
certain that you will enjoy the warmth and comfort
of your ESSE cooking stove and, perhaps more
importantly, you will more than enjoy the superb
quality of the cooking.
YOUR COOKING STOVE
The cooking stove - Fig.1
Oven door
900mm
Loading door
Flue access doorAsh door
Hob lids
Hob
Secondary
air control
(left to open)
Damper control
(pull out to open)
Primary
air control
(left to open)
600mm (Top casting)
85mm
Flue centre
90mm
430mm
460mm
900mm
Flue
restrictor
271mm
(feet)
OPERATING
Safety Notes Page 2
Your Cooking Stove Page 3
Door Hinge Adjustments Page 4
Lighting and Controlling the Fire Page 4
Correct Running Temperatures Page 6
Extended Burning Page 6
Types of Fuel Page 6
Operating the Oven and Hob Page 7
Cleaning the cooking stove Page 7
Hot Water System Page 8
INSTALLATION
Chimney and Flue Information Page 9
Flue Draught Reading Page 10
Installing the cooking stove, Positioning
and Flue Connection Page 11
Use this to remove
the ash pan
Use this to open
the doors
Use this to adjust
the damper control
and air controls
Operating tool - Fig.2
●Properly installed, operated and maintained, this
appliance will not emit fumes into the dwelling.
However occasional fumes from de-ashing and
re-fuelling may occur. Persistent fume emission is
potentially dangerous and must not be tolerated.
If fume emission does persist, open doors and
windows to ventilate the room. Let the fire burn
out or eject and safely dispose of fuel from the
appliance. Once the fire is cold, check the flue
and chimney for blockages and clean if required.
Do not attempt to relight the fire until the cause
of the fume emission has been identified and
corrected. Seek expert advice if necessary.
●Do not fit an extractor fan in the same room as
the appliance.
●An adequate air supply for combustion and
ventilation is essential. Air openings provided for
this purpose must not be restricted.
●It is important that flue ways are cleaned
frequently and the chimney swept regularly. Also
the cooking stove must be maintained in good
mechanical order. Regular sweeping means at
least once per year for smokeless fuel and a
minimum of twice per year for other fuels.
●If the chimney was previously used for an open
fire, it is possible that the higher flue gas
temperatures generated by the cooking stove
may loosen deposits that were firmly adhered to
the inner surface of the chimney and cause
blockage of the fluepipe. We recommend that in
such a situation a second sweeping of the chimney
should be carried out within one month of
regular use of the cooking stove after installation.
●Should it be likely that children, aged or infirm
people approach the fire, then a fireguard should
be used.
●Avoid the use of aerosol sprays in the vicinity of
the cooking stove when it is in operation.
Warning! The front of the cooking stove
becomes very hot when in use. Do not place towels
on the handrail when the cooking stove is alight
and keep pets and kids away.
OPERATING INSTRUCTIONSS
SAFETY NOTES
2 3
Back bricks
Steel Baffle
Side bricks
Grates
Ashpan
Firebox parts - Fig.3
LIGHTING AND CONTROLLING THE FIRE
DOOR HINGE ADJUSTMENTS Before lighting ensure that all the internal
components are in the correct position. (See Figure
3 above).
Open the ash door on the bottom left of the
cooking stove by inserting the operating tool (See
Figure 2 on page 3) into the handle slot and turning
it in an anti-clockwise direction.
Figure 1 on page 3 shows the primary air control
lever on the left. Push the lever left to open and
right to close. To light the cooking stove the
primary air control should be fully open.
Open the loading door by lifting the handle either
manually or using the operating tool.
Figure 1 shows the secondary air control to the left
and the damper control to the right. As with the
primary air control, the secondary air control lever
should be pushed left to open and right to close.
The damper control is open when the knob is
pulled out and closed when it is pushed in.
To light the cooking stove the secondary air control
should be fully open and the damper control pulled
out. The flue restrictor should be opened by
pointing the lever to the rear of the cooker (fig.1).
This will allow fumes to escape directly up the flue
whilst the cooking stove warms up.
Place some tightly rolled paper on top of some
crumpled paper on the base towards the back of
the cooking stove. On top of this, place some small
pieces of wood. Light the crumpled paper and
close the door.
Warning! When the cooking stove is running
the handle will become hot and the operating
tool alone should then be used.
WOOD
Once the fire becomes established add some
larger pieces of wood. As the cooking stove comes
up to temperature close the primary air control.
The burning rate of the cooking stove can now be
regulated by the rate at which fuel is added and by
adjusting the secondary air control.
SOLID FUEL
Once the fire becomes established add some solid
fuel. The rate at which solid fuel burns can be
controlled by using the primary air control and by
the amount of fuel added. The secondary air
control will affect the burning rate to a lesser
degree than the primary, but it should be left open
where possible in order to keep deposits away from
the glass window.
Whichever fuel is used, the damper control may be
closed once the fire is established depending on
oven requirements (See Operating the Oven and
Hob on page 6).
Fuel placed
at the rear
of the firebox
Alternative flue bar positions - Fig.4
Fuelbar fits into any of
the grate slots
4 5
1) Remove upper & lower locking grub screws
from hinges using the 3/16” allan key provided.
2) Using the same allan key, adjust either or both
eccentric pins in each door hinge to level the door.
3) Once the door is level, lock the eccentric pins in
place using the locking grub screws.
Eccentric
pin Locking
grub screw
Door Hinge
Door
3/16” Allan Key
NOTES ON WOODBURNING
Wood burns most efficiently when the air for
combustion is supplied from above the fire bed
rather than below. The air supplied above the fire
bed provides the oxygen necessary for the volatile
gases (smoke), given off by the wood as it heats, to
combust. This ensures that the gases are burnt and
used to heat the appliance instead of being wasted
up the chimney or condensing and forming tarry
deposits inside the cooking stove, in the flue or on
the loading door glass.
Running the cooking stove with the primary air
control open and the secondary air control closed
will provide oxygen for the wood to burn on the
fire bed but will not provide air for the volatile
gases above the fire bed to combust resulting in a
smoky inefficient fire.
With the above in mind the cooking stove should
ideally be run with the primary air inlet closed and
the secondary air control open whenever possible.
Another advantage of running the cooking stove
with the air wash open is that the air being drawn
into the cooking stove travels across the glass,
forming an air barrier between the glass and the
fire bed, helping to prevent smoke particles
sticking to the glass.
If the fire dies down too low, opening the primary
air control for a short period will revive it.
The temperature of the hob is graduated from left
to right. The left side is hotter and so is used for
boiling and the right side for simmering. The oven
door and the fire door are opened by lifting the
handle either manually or using the operating tool.
Both handles will become hot during operation
when a cloth or the operating tool provided is
recommended.
The oven and hob are heated directly by the fire. In
order to heat up the oven and hob the fire should
be lit as described above. Once the fire is
established the flue damper should be pushed in.
This will allow the hot fumes from the fire to circulate
around the inner cavity between the cooking stove
and the oven thus heating up both the hob and the
oven.
The hob lids can be left down when the hob is not
being used in order to keep the hotplates warm. In the
up position they will allow more heat into the room.
To reduce the heat going to the oven when the
cooking stove is up and running, the flue damper
knob can be pulled out. This will allow the hot
fumes to escape directly up the chimney via the
boiling side of the hotplate, thus reducing the heat
to the oven but maintaining a hot hotplate.
To maintain a good cooking temperature in the
oven requires only a small amount of fuel. To
reduce the effective size of the firebox, the fuel bar
can be moved towards the back and thus used to
hold a smaller amount of fuel at the rear of the
firebox, see Figure 4 on page 4. This also has the
advantage of reducing the heat radiated through
the window, making life easier for the cook.
The temperature gauge on the oven door provides
an indication of the oven temperature. It should be
noted however that since the gauge is attached to
the door it will drop if the door is left open for any
prolonged period, in which case, the oven may be
hotter than is indicated on the dial. Once the door
is closed again the gauge will come back to
temperature.
For best results use well seasoned hardwood such
as Oak, Ash, or Beech. Allow wood to dry out
under cover in well-ventilated conditions for at
least twelve months. Wood is ready for burning
when radial cracks appear in the end of the logs.
Burning wood that is not seasoned will result in tar
being deposited in the cooking stove, on the glass
and in the flueways.
This build up of tar is a hazard and if it ignites may
cause a chimney fire. Resinous softwood burns well
and gives a high output for short periods but is not
as efficient and does not last as long as hardwood.
PEAT
Peat is a fuel conveniently available in some areas
and should be burned in the same manner as wood.
ASH REMOVAL
Wood burns best on its own ash and a manageable
layer of ash on the grate is of benefit to the efficient
running of your cooking stove. To empty the ashes
from the ashpan below the grate, open the door on
the bottom left of the cooking stove using the
operating tool by inserting the tool into the slot
and turning anti-clockwise. Insert the tool into the
slot on the ash pan and pull forwards to remove.
Care should be taken when disposing of ashes that
are still warm. They should not be put into a plastic
receptacle or anything that might melt in contact
with heat.
TYPES OF WOOD FOR FUEL
OPERATING THE OVEN AND HOB
Loading a large amount of wood into the cooking
stove all at once will reduce the temperature inside.
If the temperature is too low, the gases given off
from the wood will be too low to combust,
resulting in a lot of smoke which will cover the
inside of the cooking stove, including the glass,
with soot. To combat this problem it is a good idea
to increase the temperature of the cooking stove
before loading by further opening the air inlets.
Load the wood and leave the air controls open
until the moisture is driven out of the wood and
the cooking stove is back up to an efficient
operating temperature. The air inlets can then be
reduced to hold the temperature of the cooking
stove. If excessive flue updraught is experienced,
pull the flue restrictor lever to the front of the
cooker to reduce the flue draught (fig.1). Loading
the cooker stove little and often will help keep the
cooking stove temperature steady.
Note: The above text should be used as a guide
only. The ideal operation of your cooking stove
depends on a number of factors, which vary with
each installation, and so gaining experience
operating your cooking stove is the only way to
learn its best operation.
EXTENDED WOOD BURNING
67
The cooking stove should only be cleaned when it
is cold. The exterior can be dusted with a firm brush.
Do not use a cloth to clean, as this will drag on the
paint finish leaving lint on the surface.
As the cooking stove top is used for cooking,
normal wear and tear will occur. Spills should be
mopped up immediately with a damp cloth, but
oven cleaners should not be used on the hob
surface.
The exterior of the cooking stove is painted with
high temperature cooking stove paint and from
time to time it may become necessary to renovate
the exterior by repainting. The surface must be
prepared by rubbing down with a wire brush. The
cooking stove paint will not key to the surface if
there are fat deposits or food particles on the area
to be resprayed. High temperature cooking stove
paints are available in aerosol form from your
cooking stove dealer. Do not use this paint until the
cooking stove is completely cold and always follow
the instructions on the container before starting to
paint. The usual precautions should be taken, such
as covering adjoining surfaces and protecting the
hob lids.
The hob lids are made from stainless steel. These
have been treated with oil at the factory to prevent
fingerprints and marks forming. The lids can be
wiped clean with a damp cloth and proprietary
stainless steel cleaners may be used. It is
recommended that after such cleaning, the lids be
again treated with oil by wiping over with a lint
free cloth. This will prevent fingerprints and
smears. Baby oil or similar is recommended for this
purpose.
The loading door glass should stay relatively clean
if the correct type of fuel is used as described
above, but from time to time this can be cleaned
when cold with a proprietary glass cleaner and a
dry cloth, or depending on soot build up, a nylon
pan scourer. Vinegar and newspaper may also
successfully be used.
CLEANING THE COOKING STOVE
CORRECT RUNNING TEMPERATURES FOR WOOD BURNING
To get the best results from your cooking stove it is
recommended that a wood stove thermometer
(available from your cooking stove dealer) be fitted
to the flue pipe above the cooking stove, at eye
level if possible. The figures below show the
recommended temperature of the flue gases:
115 °C - 245°C (240°F – 475°F)
The flue gases should be in this temperature band
for the safest, most efficient and most economical
operation of your cooking stove.
Below 115°C (240°F)
This is below the condensation point of wood gases
and may cause the build up of tar in the chimney,
dirty the cooking stove glass and result in the
inefficient burning of fuel.
Above 245 °C (475°F)
Too hot. Heat will be wasted up the chimney.
Excess heat may damage the cooking stove or
ignite an existing accumulation of tar resulting in a
chimney fire.
The installer has a responsibility under the Health
and Safety at Work Act 1974 to provide for the
safety of persons carrying out the installation.
Attention is drawn to the fact that fire cement is
caustic and hands must be washed thoroughly after
use. The appliance is heavy and care must be taken
during handling. Although the appliance does not
contain asbestos products, it is possible that
asbestos may be disturbed in existing installations
and every precaution must be taken.
These instructions give a guide for the installation
of the appliance but in no way absolves the installer
from responsibilities to conform to British
Standards, in particular BS8303 and BS6461,
relating to the installation of solid fuel appliances.
The installation should also comply with local
Building Regulations and Local Authority Bye-
Laws.
Any adjacent combustible material should be far
enough away from the cooking stove so as not to
rise 60°C above the room temperature when the
cooking stove is in operation. If necessary, any
adjoining walls should be protected from the
effects of heat.
8 9
INSTALLATION INSTRUCTIONSS
200mm
416mm
min. clearance
for hob lid
Clearances - Fig.5
Clearance to the back wall can
be zero if non-combustible.
For a wall containing any
combustible material the
clearance should be 400mm.
200mm
200mm200mm
HOT WATER SYSTEM
A) There are two connections, both 1” BSP Male –
on the left hand side one connection for hot
water. The storage cylinder should be 30
gallon nominal capacity insulated to prevent
Heat loss and as close to the cooker as possible.
Follow general notes below item (C) (6), (7) & (8).
B) The EWB or DE-LUXE boiler is plain
mild steel and capable of running a radiator in
addition to domestic hot water.
Follow all general notes.
C) General Notes on Water System: -
1) The cooker will produce hot water at
differing rates depending on how it is
operated. Heating control is manual, no
thermostat is fitted.
2) The system must be designed to cope with
loads between the maximum and minimum
output. When the central heating load is
turned off there must be sufficient gravity load
to absorb 15,000 Btu/h for periods when the
oven is being used for cooking, e.g. Domestic
hot water plus gravity operated radiator.
3) An indirect storage cylinder is essential for
domestic hot water supply, irrespective of
whether the water supply is hard or soft.
Minimum capacity 30 gallons.
Cylinder should be as close to cooker as possible.
4) The central heating circuit may be gravity
circulation, but a pumped system is preferred.
To allow heat from the boiler to be absorbed
should there be a pump stopage on an
accelerated circuit, the primary domestic
supply must be gravity operated.
5) Installation as a central heating system alone,
i.e. without a domestic supply, is not
recommended as the boiler will produce heat
when the cooker is in use, irrespective of
central heating demand, and primary absorption
must be provided.
6) Whichever system is chosen the layout must
follow established heating engineering practice.
To avoid trapping air in the boiler a 1” BSP
connection must be used on the flow trapping,
and any reduction in pipe size thereafter being
made on a vertical rising pipe. The cooker must
be level when fitted and the flow pipe must rise
from the boiler. A drain cock must be fitted on
the lowest point of the return pipe and a vent to
atmosphere at the highest point of each circuit.
7) The cylinder and pipe work should be lagged to
avoid heat loss.
8) The static head must not exceed 60 feet of water.
CHIMNEY AND FLUE
The successful operation of the cooking stove relies
on the adequate performance of the chimney to
which it is connected. The chimney must:
●Have an internal cross section of no less than 320
cm.sq (200mm dia.). (If a flue liner is used it
should be 6” diameter and suitable for solid fuel).
●Be a minimum 4.6m high from hearth level to pot.
●Be terminated at least 1m above roof level so
that the chimney does not terminate in a
pressure zone. See Figure 6 on page 10.
●Be free from cracks, severe bends, voids, and
obstructions.
●Be connected to this one appliance only.
●New chimneys must be built in accordance with
local building regulations.
High flue draught symptoms: fire difficult to control, fuel will not last, cooking stove too hot, cooking stove damage, chimney fire
Cause
External wind conditions combined with chimney terminal
Remedy
Fit stabilizer cowl. Fit flue draught stabilizer.
Low flue draught symptoms: difficult to light and smoke coming into the room.
Cause
Cold chimney
Chimney too short
Down draught
Chimney diameter too large
Chimney obstruction
Restricted air supply
Remedy
Line the chimney
Extend the chimney
Relocate/extend chimney terminal. Fit an anti down
draught cowl
Line the chimney
Clear/sweep the chimney
Check for competing draughts (other chimneys,
extractor hoods/fans). Fit an air vent if the room is
sealed.
FLUE DRAUGHT
The chimney can be checked, before the cooking
stove is installed, with a smoke match. If the
chimney doesn’t pull the smoke it may suggest the
chimney needs attention (see the Flue Diagnosis
Table on page 11).
Note: This test is only a guide as an apparently
poor flue may improve once the cooking stove is
installed, lit and the flue is warmed. If, once the
cooking stove is installed, there is any doubt that
the chimney is providing an adequate draught, a
flue draught reading should be taken.
FLUE DRAUGHT READING
Two flue draught readings should be taken, one
with the cooking stove at minimum firing rate and
one at maximum firing rate. The flue draught test
hole must be drilled in the flue pipe as close to the
cooking stove as possible and before any flue
draught stabiliser.
MINIMUM
The cooking stove should be lit and allowed to
warm the flue thoroughly. The air controls can
then be set so that the cooking stove burns on a low
setting. Allow the burning rate to become steady.
The flue draught reading should now be taken with
the primary air intake closed and the secondary air
control fully open.
MAXIMUM
The primary air intake can now be opened to allow
the cooking stove to burn at maximum rate. Give
the cooking stove some time for the burning rate to
become steady and then close the primary air
intake. Make sure the secondary air control is fully
open and take a flue draught reading immediately.
Ideally, the flue draught readings should range
between 1 mm wg (0.04 in wg) and 2.5 mm wg
(0.1 in wg).
Any readings significantly outside this range may
indicate the need for remedial action.
10 11
FLUE STABILIZER
A flue stabilizer can be fitted to reduce the draught
through the cooking stove if the flue draught is too
high. The flue stabilizer should be fitted in the
same room as the cooking stove, be the same size
as the flue pipe and be fitted no closer than 700mm
to the flue outlet of the appliance.
Chimney and Flue - Fig.6
INSTALLING THE COOKING STOVE
POSITIONING
The overall dimensions of the cooking stove are
shown in Figure 1 on page 3. Figure 4 on page 4
shows recommended distances between the
cooking stove and surrounding flammable
materials. As a rule, any surrounding flammable
material should not exceed 60°C above ambient
room temperature.
FLUE CONNECTION
The flue pipe used to connect the cooking stove to
the chimney is 6” (150mm) in diameter.
The flue connection is on the top of the cooking
stove, in the center at the back.
IMPORTANT INSTALLATION NOTES:
1. The installation must allow for adequate
chimney sweeping.
2. Avoid using bends greater than 45°to the
vertical. All flue pipe sections should be as close
to vertical as possible.
3. All joints in the flue system must be effectively
sealed.
4. All flue sockets must face upwards. On
completing the installation, check that all the
internal components of the cooking stove are
positioned correctly. Check: Grate, baffle, ash
pan, insulation bricks, fuel bar. See Figure 3 on
page 4.
●If the cooking stove is installed as a freestanding
appliance, it should not support any part of the
chimney.
●Voids in the chimney should be avoided as these
will prevent a steady flue draught. The cooking
stove flue pipe should pass beyond the
narrowing of the chimney.
●A flue/chimney access point may also be
required so that the state of the chimney can be
checked and any fallen soot removed.
●External flues must be insulated to prevent heat loss.
1 Upper Door Handles
2 Lower Door Handles
3 Fire Guard
4 Cast Fire Door
5 Ash Door
6 Magnet Catch
7 Temperature Clock
8 Ceramic Glass Window
9 Flue Access Door
10 Oven Door Liner
11 Fuel Guard
12 Stainless Baffle
13 Flue Access Plate
14 Ashpan
15 Grate
16 Oven Tray
17 Lower Slider
18 Cast Shelf Supports
19 Door Hinge Assembly
20 Wire Shelf
21 Steel Baffle
22 Upper Slider
23 Flue Heat Shield
24 Hand Rail
25 Flue Restrictor Guide
26 Side Panel
27 Hand Rail Bracket
28 Hotplate
29 Cast Top
30 Flue Restrictor
31 Stove Body
32 Bottom Heat Shield
33 Legs
34 Rear Heat Shield
35 Side Panel
36 Cast Flue Box and Door
37 5” to 6” Adaptor
38 Bolster Lid Assembly
39 Fire Bricks
40 Cast Iron Door
41 Charcoal Spray Can
SPARE PARTS
12 13
Engineers Name Date
Address
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COMMISSIONING RECORD
SERVICE RECORD
14 15
