Alternate Heating COAL GUN S130 Installation And Operator'S Manual Download | Manualshive

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Summary of Contents for COAL GUN S130

Page 1: ...ratures and flames in the ignition box area are capable of causing ignition or explosion of explosive or flammable products or explosion of the boiler itself if maximum safe water temperature is exceeded Maximum safe water temperature is 210 Fahrenheit Flammable or explosive products must never be stored in the same room or in the vicinity of a boiler and the boiler water temperature must never be...

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Page 3: ...y available with the ASME H stamp It is the customer s responsibility to determine whether the boiler must include the stamp to satisfy local code requirements Coal Gun boilers bearing the mark seen at right are thereby designated as compliant e Coal Gun has undergone thorough testing and is certi1ed to the Underwriter s Laboratories test standard 5253 2009 and Canadian Test Standard CSA B366 1 20...

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Page 5: ...c Systems 12 Piping the Boiler in Parallel with another Boiler 12 Checklist When the Boiler is Added to an Existing System 12 Pressure Relief Valve 13 Pressure Reducing Auto Fill 13 Expansion Tank 13 Low Water Cutoff 13 Boiler Conditioner Sealant 13 Boiler Piping and Controls for Steam Systems 14 Forced Hot Air Systems Water to air Coil in Duct 14 Domestic Hot Water Coil Piping 14 Illustrated Inst...

Page 6: ...x B Wiring Diagrams 31 Appendix C Exploded Parts Drawing 34 Parts Listing 35 Appendix D Maintenance 36 End of season cleaning 36 Cleaning Exhaust End of Swirl Tube 36 Cleaning Rear of Heat Exchanger 37 Cleaning coal pot feed tube and grate 38 Fan Assembly Removal Repair 39 Direct Drive Motor Bearing Replacement 41 Additional Information 43 Operation and Maintenance Schedule for Models S130 and S26...

Page 7: ...erienced personnel be consulted to ensure that the necessary safety controls are installed and properly wired Read the entire instruction manual carefully and understand it thoroughly before installing or operating this unit Save these instructions and review them periodically to refresh your memory regarding safe operating practices and routine maintenance required All Alternate Heating Systems B...

Page 8: ... the possibility of the accumulation of explosive vapors Must have adequate air supply which must be kept clear and unobstructed at all times Since the combustion process requires a continuous supply of air it is essential that provisions are made to supply adequate air to the boiler room is air supply is necessary to insure complete combustion and venting of any gases or smoke that would be emi e...

Page 9: ...This unit is not approved or recommended for use in mobile homes CLEARANCES REQUIRED FOR SAFETY AND OPERATION It is important to provide suIcient clearance around the boiler for convenient servicing and cleanout e required minimums for Coal Stoker boilers when measured from the exterior of the boiler are Rear 30 inches to the rear end of boiler with fan assembly Right Side 36 inches to the right s...

Page 10: ...e chimney must be leak free from the standpoint of air entering through cracks or other chimney defects or through loose stovepipe 1 ings 3 2 10 Rule for Chimneys If the chimney must go through a combustible wall be sure to use a metal thimble specially designed for this purpose e proper way to install a thimble is to cut an oversize hole in the sheetrock about 6 or 7 inches larger than the thimbl...

Page 11: ...can prevent this Barometric Damper e standard type M 1eld control with a T is recommended for satisfactory performance For proper operation and eIcient fuel consumption in oil gas and or coal 1red heating appliances draE must remain relatively constant and above 04 inches water column as measured with a manometer Proper draE will normally result in greater eIciency with less heat wasted by escapin...

Page 12: ... control the same size as the ue pipe that is a 6 control for a 6 round pipe a 12 control for a 12 pipe etc 2 For intermediate sizes of smoke pipe use the next larger size draE control to provide ample capacity It is a simple ma er to install a round control on a pipe an inch or so larger or smaller than the control 3 If the ue pipe or breaching is square use the round equivalent For example on a ...

Page 13: ... air into the home Stovepipe Use only 22 24 gauge single wall stove pipe in open areas that are no closer than 18 inches from walls or ceiling If the stovepipe must be closer than 18 inches from the nearest wall or ceiling or if it must go through walls closets or boxed in areas then UL listed insulated stovepipe must be used Stovepipe that runs along the outside walls of a building must also be U...

Page 14: ...m rise is a quarter inch per foot of horizontal run Ensure that there is at least 18 clearance between horizontal piping and combustible ceiling Ensure that the chimney connection pipe extends at least 2 into the chimney but does not extend so far into the chimney that it blocks air ow A T should always be used where the stovepipe changes directions rather than an elbow to allow for easy cleanout ...

Page 15: ...ney liner but not beyond the inner surface of the liner It must be cemented in place with refractory cement is method is illustrated For details on the other three options refer to the most recent edition of the NFPA 211 code U S Wall Pass Through Wall Pass Through Canada ree methods are approved by the Canadian Standards Association e diagram following this pararaph shows one method requiring an ...

Page 16: ... pipe Prefabricated Chimneys When venting your Coal Gun boiler using a prefabricated chimney be sure to contact local building code authorities and to follow the manufacturer s instructions exactly Use only the manufacturer s parts do not use makeshiE installation techniques All prefabricated chimneys must be tested to either the U S or Canadian high temperature standards UL 103 or ULC 629 Your ma...

Page 17: ...t the structure and make sure there is no latent damage or hazard 2 Shut the boiler down by turning the main power oD 3 If you have a chimney 1re use a chemical are type 1re extinguisher If you don t have an extinguisher go to step 4 4 Using a water hose wet down the area of the roof surrounding the chimney Do not wet the chimney itself or try to put water down the ue as it will very likely damage...

Page 18: ...ams provides detailed information on how each model should be connected e washout plugs in the bo om of the unit are a requirement of the ASME boiler code and must be closed before 1lling the unit with water A boiler drain should be inserted in the tapping on the opposite side of the boiler from the tapping used for the return Optionally a T and short nipple could be a ached to the return tapping ...

Page 19: ...on tank capacity based on the total volume of water in the system is is particularly true if the Coal Gun is added to an existing boiler Check the chart to determine the water capacity of the Coal Gun installed If you are adding a Coal Gun to your system most likely the expansion tank or air cushion tank installed originally is not adequate for the additional water volume added to the system with ...

Page 20: ...T AIR SYSTEMS WATER TO AIR COIL IN DUCT e Coal Gun boiler may be easily adapted to any forced hot air heating system by installing a heat exchange coil in the hot air supply duct e size and type of coil or heat exchanger required may be established aEer several factors are determined ese factors include the heat output required BTUH the capacity of the existing fan blower CFM and the size of the d...

Page 21: ...ot water heater It is also necessary to include a tempering valve or temperature controller on the supply side of the storage tank water heater to prevent super heated water from reaching the domestic hot water tank and ultimately the faucets Plumbing Coil with circulator ILLUSTRATED INSTRUCTIONS FOR INSTALLING COAL HOPPER ON S130 AND S260 Step 1 Disconnect all power to the boiler Step 2 Loosen ho...

Page 22: ...d Step 6 Connect reconnect power ELECTRICAL CONNECTIONS IN THE COAL GUNTM All hydronic Coal Guns are prewired to maintain boiler water temperature at approximately 180 F S130 S260 Power Requirements e S130 and S260 Coal Guns require a dedicated power circuit of 120 volts 15 ampere Power Connections Power connections are made inside the large enclosure for the controls A photo of the area where con...

Page 23: ...f 200 F Also refer to the dump zone wiring instructions for speci1c use applications See Appendix H for example dump zone wiring applications Mode Switch Ash Removal e Mode Switch oDers two modes for ash removal in addition to an OFF position In Mode 1 the controller may cycle the grates while the boiler fan operates or not In Mode 2 the controller will only operate when the draE fan is running is...

Page 24: ...er the 1re and more opportunity for coal to burn completely before dropping into the ash tub ere will also be less likelihood that you will experience coal gas building up and lighting oD suddenly in the boiler e main downside is greater likelihood that the 1re will go out during an extended period of low demand Deeper ash can also mean lower peak air ow and therefore typically lower peak output W...

Page 25: ...orrect timing Always allow 48 hours for the boiler to acclimate to the adjustment made previously before making another 30 second adjustment CAUTION if the timer is adjusted to keep the grate motor oD too long it will cause the 1re to travel towards the hopper triggering the heat sensor which will turn oD the boiler e same can happen if the grate switch is leE oD too long In circumstances that inc...

Page 26: ...ty of dump zone wiring examples If the dump zone is connected to provide heat to a domestic hot water tank or heat exchanger a mixing valve must be installed on the potable system supply to prevent an unsafe condition of overheating the domestic hot water e mixing valve outlet should be set no higher than 125º F for potable use for this type of dump zone see Appendix H Example 5 Non Powered Dump Z...

Page 27: ...Figure 9 Non Powered Dump Zone is arrangement will allow a gravity ow of heat release in the event of a power failure For other dump zone applications see Appendix H 21 ...

Page 28: ...al At this point when you look into the coal pot through the sight hole cover you will see coal lying close to the opening Insert several 1re starters such as Rutland Safe Lite Easy Light Charcoal or Match Light Charcoal so that they are nearly covered by the coal Turn on the Coal Gun boiler switch e induction fan will be running at this time Light the starters with a match wand type lighter or pr...

Page 29: ...ng a gap of 3 8 or more between it and cover seat is allows air to bypass the 1re bed preventing over heating of unit during the oD cycle e sight tube ap is located behind the sight tube cover To ensure safety it is imperative that the sight tube cover be in place during operation Sight Tube Cover in Place Sight Tube Cover Removed Except for boiler lighting maintenance or inspection the sight tube...

Page 30: ...al to the hopper Allow the remainder of the coal to burn out before turning oD the main switch Keep in mind the boiler draE motor will continue to run aEer the coal is used up until the main switch is turned oD AUTOMATIC FUEL DELIVERY SYSTEMS e Coal Gun has two methods of fuel delivery a hopper or an auger and hopper combination When the hopper alone is used the Coal Gun can run una ended for up t...

Page 31: ... reduces the need for post install adjustments Typically no adjustment other than the factory adjustment is necessary to have the boiler perform at peak output throughout the burn season Minor on site adjustments may be necessary when the boiler is 1rst installed to provide for a more complete burn less unburnt coal or to optimize position of the 1re See the section in the Installation portion of ...

Page 32: ...boiler tubes and plates and to provide for the precipitation of scale forming salts Below a Ph of 5 0 the water is acidic enough to dissolve the steel boiler plates Under these conditions the steel gradually becomes thinner and thinner until it is destroyed At a Ph between 5 and 9 4 pi ing of steel plates will occur at a rate dependent upon the amount of dissolved oxygen in the boiler Dissolved Ox...

Page 33: ...nable the complete reaction of the phosphates with the calcium hardness entering the boiler through the feed water Hardness e hardness of water is caused by calcium and magnesium ions Water hardness will vary greatly throughout the country depending on the source of the water In boilers hard water can cause the formation of scale and sludge or mud e hardness must be removed in the makeup water to ...

Page 34: ...Appendix A Boiler Specification Diagrams 28 ...

Page 35: ... 29 ...

Page 36: ...owing are given as examples of gallons per minute water ow required to deliver hot water in order to provide heating of a given number of degrees and at a certain BTU level 500K BTU s at 20 degrees temperature diDerential requires 50 gallons per minute 250K BTU s at 20 degrees temperature diDerential requires 25 gallons per minute 1M BTU s at 20 degrees temperature diDerential requires 100 gallons...

Page 37: ...Appendix B Wiring Diagrams 31 ...

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Page 40: ...Appendix C Exploded Parts Drawing 34 ...

Page 41: ... one on each side 7 Grate Assembly 8 ermocouple for ermo Controlled Grates 9 Grate Motor 10 Pitman Block 11 Domestic Water Coil 12 Pitman Connecting Pin 13 Fan Disk 14 Abrasion Shield 15 Ceramic Heat Shield 16 Fan Motor Mounting Plate Fan Cover 17 Fan Motor 18 LeE Insulation Cover 19 Top Insulation Cover Two Pieces 20 Flue Tube Assembly 21 Cyclone Funnel 35 ...

Page 42: ...ongevity To clean safely wait until the 1re has gone out and ash and water temperatures have cooled to ambient temperature If in the process of cleaning you encounter hot ash or evidence of a still burning 1re stop and wait as long as needed to be sure the 1re is extinguished and everything has cooled completely Cleaning Exhaust End of Swirl Tube e swirl tube heat exchanger vents into the ash remo...

Page 43: ...the mounting bolts as shown in the following photo Removing Fan Assembly Once the nuts are removed carefully pull the fan assembly back directly oD the mounting bolts and set the fan assembly oD to the side e wiring harness for the fan is too short to allow se ing the fan assembly directly on the oor so a 1ve gallon bucket or other temporary platform will be needed As an alternative you may discon...

Page 44: ...months caused by accumulated ash If your boiler is in a damp location use any means available to reduce moisture in the area and humidity in the air A heat source inside the 1re tube of the boiler will help dry moisture inside the 1re side and heat exchange surfaces A piano heater or 40 wa incandescent rough surface light bulb are good for this task Any free moisture will readily combine with resi...

Page 45: ...d retighten the pillow block bearing set screws To tighten the fan belt loosen the four bolts that hold the motor to the bracket Slide the motor down and re tighten being careful that the motor is properly aligned with the fan shaE Some models have a hinged motor mount with adjusting screws To check for proper alignment of the pulleys use a straight edge lying across both pulleys AEer rea aching t...

Page 46: ...kbench 4 Remove the two 20 square head set screws in the fan hub 5 read a hex nut size 1 14 NF to the hub of the fan 6 Using a manual jaw puller a ached to the 1 inch nut carefully pull the fan from the motor shaE 6 b Alternately you may use part number 01 10 80100 FAN PULLER as shown in following images to remove the fan 40 Note Mark connections before disconnecting wires ...

Page 47: ...eyed part of shaE Notes Fan hub should extend inch beyond the shaE 9 Apply anti seize to the two set screws and install both securing the fan to the shaE 10 A ach fan assembly to boiler and reconnect the wires DIRECT DRIVE MOTOR BEARING REPLACEMENT is guide may be used for replacement of direct drive induction fan motor bearings We recommend you contact your Alternate Heating Systems for this repa...

Page 48: ... motor with this cover already removed It is secured with 3 screws on the outside of the motor 7 From back of motor remove the four long screws holding motor and plates together 8 Set motor on back shaE end up on a workbench 9 Using a small hammer gently tap up on the end plate at shaE end 10 e plate along with the armature will come loose which should be gently liEed out 42 ...

Page 49: ... jaw puller remove bearing from shaE 14 Install new bearing Do not apply force on outer bearing race ADDITIONAL INFORMATION For additional information on using your boiler safely obtain a copy of the National Fire Prevention Association publication Using Coal and Wood Stoves Safely NFPA No HS 8 1974 e address of the NFPA is 470 Atlantic Avenue Boston Massachuse s 02210 You can also 1nd them online...

Page 50: ...Grease with high temperature grease Check and tighten set screws on the shaft and pulleys Every 6 months Abrasion shield Check for leakage around gasket Adjust or replace if necessary Every 6 months Flue pipe Check for leakage around seams and re seal if necessary End of season Cam bearing on grate Check to make sure bearings are free to rotate End of season Fire box Clean and inspect fire box End...

Page 51: ...Appendix E Troubleshooting Guide 45 ...

Page 52: ... a Check cyclone funnel and remove restriction b Reduce length of pipe run 7 Fly ash build up on swirl tube a Condensation causing fly ash to stick to heat exchange surfaces a Raise return water temperature check problem item 9 8 Excessive sulfur odor in boiler room a Coal quality low b Chimney draft problem c Down draft d Restriction in Chimney e Cyclone funnel on Coal Gun has deteriorated a Find...

Page 53: ...ory pulley arrangements Clinkers can be reduced or eliminated by changing the se ings of the ash controller on the boiler Clinkers that are approximately baseball size or smaller will be carried to the ash pan Larger sized clinkers could cause the 1re to go out if the boiler is unable to remove them To help remove large clinkers remove the draE ap cover and move draE ap to the side Be sure to wear...

Page 54: ...Appendix F Table of Figures 48 ...

Page 55: ...ote Your grate control comes preprogrammed from the factory If you merely wish to change the temperature set value SV at which the grate operates this is accomplished by going directly to step 5 on the next page Setting Grate Operation Control ...

Page 56: ...u see until the readout shows D Press twice 4 Setting Temperature offset for Grate Control Heating Hysteresis A Press or to set the bottom readout to a value of 1 twice 5 Set Grate Operation Temperature or whatever offset value is entered in step 4 below the set value the grate system will remove ash LOCKING CONTROL twice LOC will be displayed press UNLOCKING CONTROLS Press at the same time until ...

Page 57: ...Appendix H Dump Zone Wiring Applications 51 ...

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Page 63: ...Appendix I Boiler Piping Examples 57 ...

Page 64: ...ivate one or more zones System Circulator and Boiler Circulator 4 Do not bypass temperature supply control system on radiant heat system In radiant heat applications permit activation of a call for heat but allow system controls to regulate water temperature Not all system components valves and devices are shown in this drawing Actual conditions and application requirements will vary Please consul...

Page 65: ... must be determined by taking into account the distance involved and flow required The new circulator should be wired to the power for the Coal Gun When power to the Coal Gun is on the circulator should be running An alternate option is to attach a strap on aquastat on the Coal Gun supply line that closes on temperature rise This will automatically activate the pump at a given temperature The add ...

Page 66: ...te Heating Systems products if these are not fuels recommended by Alternate Heating Systems C WHAT THE CUSTOMER MUST DO 1 Contact the dealer who sold you the unit 2 If said dealer cannot be located contact any other Alternate Heating Systems dealers in your area 3 If you are unable to locate a dealer submit your warranty claim directly to Alternate Heating Systems at the address listed below 4 Whe...

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