Alternate Heating WOOD GUN Super E210 Installation And Operator'S Manual Download

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Wood Gun Air Inlet Ducting Installations

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Summary of Contents for WOOD GUN Super E210

Page 1: ...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 200 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 allowed to exceed 200 Fahrenheit ALTERNATE HEATING SYSTEMS...

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Page 4: ...n 9 Technical Aspects of Chimney Performance 9 Draft 10 Barometric Damper 10 Manometer 10 Masonry Chimneys 11 Prefabricated Chimneys 11 Proper Chimney Connection 13 Stovepipe 13 Stovepipe Specifics for SE210 14 Wall Pass Through United States 14 Wall Pass Through Canada 15 Common Chimney Problems 15 In case of chimney fire 16 In Case of Runaway Fire 16 In Case of Power Loss 16 Make up or Combustio...

Page 5: ... LTSD 32 Manual Automatic Switchover 33 Other Functions 33 Resetting the Controls 33 Fuel Type 33 The Wood Gun is designed to burn split or unsplit wood 33 Wood dimensions 33 Prohibited fuels 33 Wood Fuel Characteristics and Wood Storage 34 Starting a Fire Procedure 34 Charging the Boiler with Wood 35 Back Puffing Prevention Checklist 36 Removal and Disposal of Ashes 36 Recommended Boiler Control ...

Page 6: ... Appendix A Boiler Specification Diagram 50 Wood Guntm Super E210 Specifications 50 Appendix B Wiring Diagrams 51 Appendix C Exploded Parts Drawings 52 Parts Listing 55 Appendix D Troubleshooting Guide 57 Appendix F Boiler Piping and Ducting Examples 60 APPENDIX G Markings 64 Datalabel 65 Stainless Steel LIMITED WARRANTY 66 Carbon Steel LIMITED WARRANTY 67 ...

Page 7: ...NSTALLATION CLEARANCES WARNING RISK OF FIRE INSPECT AND CLEAN FLUES REGULARLY CAUTION HOT SURFACES KEEP CHILDREN AWAY CAUTION HOT SURFACES DO NOT TOUCH DURING OPERATION CAUTION HOT SURFACES MAXIMUM DRAFT MARKED ON NAMEPLATE DANGER TO AVOID INJURY FROM MOVING PARTS SHUT OFF THE BOILER BEFORE REMOVING OPENING SERVICE PANELS AND DRAFT INDUCING FAN FOR INDOOR INSTALLATION ONLY IN THE EVENT OF A RUN AW...

Page 8: ...d have ignition temperatures ranging from 540º F to 1125º F This helps to explain why maintaining a high combustion temperature is so important in achieving complete combustion in burning wood In a conventional wood stove a significant portion of the combustible gases released from the wood goes up the chimney unburned to become deposited on the chimney walls as creosote or escape as visible smoke...

Page 9: ...he fuel reaches 900º F 500º C pyrolysis is complete and the final solid product is charcoal which is almost pure carbon MODE OF OPERATION The Wood Gun operates on the well known principle of gasification which makes it possible to burn wood at high efficiency and free of creosote formation in the chimney The bottom of the fuel chamber is lined with pieces of dense refractory casting which contain ...

Page 10: ...aintain sufficient temperature in the refractory to ensure complete combustion on start up This feature will provide heat until the timer reaches the end of the programmed cycle or until the boiler temperature high limit is reached It is essential that all combustion air be prevented from entering the Wood GunTM at shutdown Where a strong chimney draft is present during the off cycle a unit with l...

Page 11: ...gth Use wood that is 19 28 moisture Clean boiler or take other measures to improve air flow If you are observing back puffing take care of this issue promptly as performance is compromised in a back puffing boiler possibly contributing to condensation Keep refractory relatively clear of charcoal and ash Watch loading technique and other firebox management aspects making sure that the fire burns pr...

Page 12: ... as ventilation of any by products of combustion Boiler Room Requirements 1 The room should be well lit and should have a source of emergency light 2 A convenient water supply should be available for boiler flushing and to clean the boiler room floor 3 Unobstructed floor drains 4 A boiler must not be installed where there is the possibility of the accumulation of explosive vapors 5 Must have adequ...

Page 13: ...th that building plumbing and electrical codes Alternate Heating Systems recommends that a qualified technician experienced in boiler installations perform the installation of the Wood GunTM Wiring on the boiler must be properly grounded The installation of this unit must comply with state and local requirements and must be inspected by the state or local building inspector where required Do not i...

Page 14: ... than the aqua stat should be replaced If there is a discrepancy in the temperatures be sure that the temperature gauge is accurate This can be done by testing the boiler water temperature with a second thermometer or temperature gauge INSTALLATION OF SMOKE DETECTORS AND CO MONITORS Any fuel burning appliance produces smoke whether or not it is enough to see or not is a different question The SE21...

Page 15: ...push it over and down toward the bottom center of the boiler One side will rest on the 1 board installed earlier and the other side will rest on the insulation board laying on the floor of the cabinet General Chimney Introduction One of the most important considerations in installing a boiler is the type of chimney that will be used The condition and construction of the chimney is important to pro...

Page 16: ...sote buildup Sharp bends and horizontal flues should also be avoided The exhaust must be kept moving through the piping flue to prevent creosote or fly ash buildup If a horizontal section must be used it must rise slightly to prevent dead air space Barometric Damper A barometric damper is a device that allows room air to enter the chimney bypassing the air intake on the heater A heater and chimney...

Page 17: ...and both must be firmly cemented in place with refractory cement A thimble is a masonry pipe which is inserted through the chimney wall and is frequently the preferred method a breech pipe is a piece of steel pipe used the same way In Canada a breech pipe has ridges or protrusions to lock it firmly into the refractory cement In either case the chimney connector vents to the chimney through the thi...

Page 18: ...uired to secure pipe at the joint An approved Chimney Pipe Adapter K is required A Ceiling Support L will provide structural support for the chimney and is typically part of a kit that includes items that maintain required clearances to flammables A Storm Collar M and Adjustable Flashing N prevent water from entering the home by running down the outside of the chimney Additional items or a kit O p...

Page 19: ...th UL 103 or ULC S629 ratings Do not use makeshift compromises during construction STOVEPIPE It is recommended that overall flue connecting pipe length be kept to a minimum Any horizontal runs must slope upward towards the chimney with a minimum rise of 1 4 inch per foot Use a minimum number of elbows preferably no more than two to make the chimney connection Particular attention should be paid to...

Page 20: ...ing the stovepipe from the boiler to the chimney it installing an 18 24 piece of 6 straight pipe directly to the boiler before any elbows T s This will allow more area for ash to settle and increase cleaning intervals to every 3 months versus every month if an elbow T is connected directly to the boiler with no straight piece before It is also recommended to use a T where any elbows would be used ...

Page 21: ...ey height adding or changing the flue liner or selecting a different style of cap to be placed on the top of the chimney Reasons for insufficient draft include but are not limited to the following 1 Leaking chimney Air leaking in around a loose fitting clean out door joints or seams in connector pipe are not secured properly cracks or other defects in masonry 2 Chimney needs to be cleaned 3 Improp...

Page 22: ...auses If draft is excessive review instructions on installing a barometric damper IN CASE OF CHIMNEY FIRE 1 Be sure everyone is out of the house 2 Call the fire department In the event the fire is out before they get there you will want them to inspect the structure and make sure there is no latent damage or hazard 3 Shut the boiler down by turning the main power off 4 If you have a chimney fire u...

Page 23: ...ough the system and out the chimney means that oxygen is leaving the home and will create an oxygen deficit if this air is not replaced Adequate combustion air is critical for the performance of your heater There is usually sufficient leakage in older homes to provide for this but in well insulated homes it may be necessary to provide additional outside air into the home A louvered vent can also b...

Page 24: ...that when the boiler switch is on the circulator will also run The power to the Wood gun should then be controlled by an aqua stat located in the supply piping This aqua stat should be set 10ºF above operating temperature of the existing boiler That will shut the Wood gun down if it runs out of fuel The aqua stat will need to have a bypass switch that will allow the wood boiler to have power and e...

Page 25: ...ntly builds too much pressure when hot you do not have adequate expansion capacity We recommend at minimum to install a 90 expansion tank 14 gallon capacity RETURN WATER TEMPERATURE As a rule water returning to the boiler should be not more than 20º F less than supply water temperature going to the system A re circulation loop is a requirement to maintain optimum return water temperatures This wou...

Page 26: ... one of the Yellow wires 2 The orange 2 wire will terminate with the remaining yellow wire 3 The White or neutral wire will terminate with the white wire in the LWCO If the conduit is not run from factory You will need a piece of conduit with 3 wires labeled as above Run the conduit from the high limit aquastat through the hole in the sheetmetal the insulation will need to be drilled out to the LW...

Page 27: ...uld the water level drop below the safe operating level A water level gauge glass is also provided to give a visual indicator of the level of water in the boiler This gauge is located in tapping FF on the rear of the boiler and a section of piping which originates from a tapping in the top of the boiler near the rear An automatic water feeder or combination water feeder low water control such as a...

Page 28: ...chased new or pressure rated recycled tanks may be used Used propane tanks are sometimes repurposed for use with thermal storage There are many types of open sometimes referred to as atmospheric tanks available for thermal storage as well These include insulated prefabricated tanks that are site assembled and made of fiberglass or metal concrete tanks recycled tanks of a wide variety and even used...

Page 29: ... treatments can lead to operation faults or total boiler failure Where a choice is available pre treatment external to the boiler is always preferred and more reliable than treatment within the boiler Instructions for feed water treatment as prepared by a competent feed water chemist should be followed Do not experiment with homemade treatment methods or compounds Representative samples of feed wa...

Page 30: ...uspended solids are those that can be removed by filtration while dissolved solids are in solution with the water The best way to determine the dissolved solid content of boiler water is a conductance test The conductance of boiler water varies proportionately with the amount of various ionized solids present Another way to determine the dissolved solids content is to measure the chlorides present...

Page 31: ...mestic coil is to connect the coil in parallel with an existing water heater so that the conventional water heater may be used when the Wood Gun is not being fired for example in the summer The diagram below indicates how this can be done Plumbing Coil in Parallel Figure Domestic Coil Tempering Valve Plumbing Coil with circulator In installations where the coil discharges directly into the hot wat...

Page 32: ...amber The Super E210 has an oil burner combustion chamber that is needed to use an oil burner which is exterior to the boiler and located on the right hand side of the boiler when viewed from the front To mount the combustion chamber apply the enclosed piece of 1 8 in x 1 2 in self stick silicone strip to the combustion chamber flange just inside of the bolt holes Attach the combustion chamber to ...

Page 33: ... prevent raw fuel from being discharged into the combustion chamber should ignition fail to occur a CAD cell is employed to proof the flame If the CAD cell does not see a flame within a preset time period usually 20 30 seconds a relay will shut down the burner and it cannot attempt to re fire until the reset button is pressed When contamination from the wood combustion process coats the CAD cell i...

Page 34: ...r or found in Appendix B Wiring Diagrams For larger units consult the special instructions provided in the supplement to this manual Before allowing gas that is under pressure into the piping all openings from which gas can escape should be closed Immediately after turning on the gas the system should be checked for leaks This can be done by watching the cubic foot test dial and allowing five minu...

Page 35: ...e bottom of the fuel chamber contains dense cast refractory blocks The refractory is baked in a kiln at the factory to dry out nearly all moisture before it is placed in the boiler but it does not reach maximum strength unless heated to operating temperature gradually cured EXPLANATION OF SWITCH AND BUTTONS The SE210 uses a simple easy to use touchscreen interface which will be explained below The...

Page 36: ...off Temperatures This button will take you to the Temperatures screen OFF This button will turn off the wood burning functions and takes you to the Home screen Back Arrow when pushed it will take you back to the Home screen Forward Arrow when pushed it will take you to the second Wood screen Wood Screen second Explanation of buttons ON under Low Temp Shutdown this button allows you to turn on or t...

Page 37: ...ill turn off the oil burning functions and takes you to the Home screen Back Arrow when pushed it will take you back to the Home screen Temperatures Screen Explanation of buttons Note Water and Exhaust temperatures are shown in Fahrenheit Safe To Open this is not a button it simply tells you when you may open the loading door Home this button takes you to the Home screen Back Arrow when pushed it ...

Page 38: ...67F at that point the fan will slow down The fan will modulate in attempt to keep the water temperature at 170F If the water drops below 150F the blower motor will switch into high The unit will continue to operate in this fashion until it overcomes demand and reaches 170F The water temperature will most likely continue to increase until it reaches 180F at which point the boiler will go into Off C...

Page 39: ...irculators Connect to the bottom terminal 8 on the back of the PLC Terminal 8 puts out 120v 2amp output It is recommended to use this to control a relay This output can be turned on and off and the temperature can be changed from the Operating Limits screen Terminal 9 gives a 120v 2amp output when the LTSD limit has been reached This output is intended to allow the user to view remotely when the b...

Page 40: ...ignificantly lowers the maximum heat output of the boiler It is advantageous to let the sun remove that extra 100 to 250 gallons of water found in a cord of wood Generally wood should be stored outdoors in a dry place with only a limited supply kept indoors Using wood that has a moisture content of greater than 30 can be detrimental to the operation of the boiler Results of using wood with too hig...

Page 41: ... management Best practices include keeping ash and charcoal build up to a minimum When demand is moderate to low simply load charges of fuel that are just adequate for the length of the anticipated burn cycle Do not overfill fuel storage area firebox Charging the Boiler with Wood When it is time to reload the Wood GunTM make certain the green PURGE light is on If the PURGE light is off push the PU...

Page 42: ...ention Checklist Use fuel with higher moisture content Load wetter fuel on the top of your fuel charge Use a good percentage of full rounds as large as 10 inches Stack wood tightly using a combination of full rounds and split pieces to form a more solid block of fuel inside the fuel chamber Utilize shorter burn cycles to prevent over drying of the fuel charge that occurs with long cycles Remember ...

Page 43: ...several causes but can always be attacked systematically and greatly reduced or eliminated Properly utilized thermal storage will assure steady load when firing and assist in keeping condensation under control Keep in mind that because the Wood Gun swirl tube heat exchanger extracts so much heat from the exhaust the gases leaving the system are often not far above temperatures that can lead to con...

Page 44: ...anifold using ash rake 11 Clean excessive ash out of fire box Air Valve Cleaning and Maintenance To Operate the Air Valve Manually for Cleaning and Service 1 Make sure the SE210 is not in Wood or Oil mode that the water temp is below 130F and that the exhaust temp is below 95F 2 Go to the Maintenance screen and press Cleaning Mode 3 Once in the Cleaning Mode you will see buttons for the 1st Air Va...

Page 45: ...nit 2 Disconnect wiring a Primary 1st air valve Use a 2 phillips screwdriver to remove the screw in the center bottom of the red cap With the screw out pull the cap off b Secondary 2nd air valve Use a 2 phillips screwdriver to remove the cover on the 2x4 junction box Disconnect wires leading to the 2nd air valve Remove conduit connector nut 3 Use a 10 mm wrench to loosen the mounting bolt 4 Remove...

Page 46: ...inst the air intake collar 7 It is very important that when placing the red end cap on the motor The pins must align properly If the pins do not align properly you will experience issues as such Air Valve Motor Clamp Alignment Air Valve Disk in Open Positioning DOOR ADJUSTMENT For proper operation of the Wood Gun it is important to have an effective seal of the loading door and clean out door All ...

Page 47: ... the door handle wear pad door hinges and door handle with the grease LOAD DOOR SEAL REPLACEMENT 1 Allow door to completely cool before you touch or start installation remove door 2 Cut flat fiberglass tape white tape into 4 equal strips The tape shall stop 1 from each corner 3 Insert silicone tube into a Caulking Gun Load Door with Old Seal Removed and High Temperature Silicone 4 Run a small bead...

Page 48: ... entire door to prevent any raised or uneven areas These appear as bumps in the contour of the silicone bead Adding Preformed Silicone Bead to Door 7 The gasket should meet evenly if it doesn t you may trim excess Place a small amount of silicone on one of the edges to create a seal Marking to Trim Trimming Preformed Silicone Bead Adding High Temperature Silicone to Butt Joint of Trimmed Bead 8 On...

Page 49: ...a clean cut rope end Place the rope end in the rope channel mid way up on the hinge side of the door Press the rope in by hand or with a flat headed screwdriver Stretch the rope as much as you can while pushing it in Go from corner to corner until reaching the end When putting the two ends together tuck all loose ends down inside the channel The rope should protrude about 3 8 above the door frame ...

Page 50: ...ts located along the outer edge of the motor mounting plate It is a good idea to mark orientation of components for reassembly Mark Assembly Orientation Place the fan assembly on your workbench with the fan facing up Remove the two set screws from the fan hub It might be a good idea to let a good penetrate soak down into the area between the hub and the shaft Letting it soak in for an hour or long...

Page 51: ...ou to remove the abrasion shield and the heat shield from the motor plate Be careful when removing the ceramic heat shield It is very fragile It is advisable to use a putty knife to separate the heat shield from the motor plate Separate Heat Shield from Motor Mount Plate To remove the motor from the motor mounting plate use an allen wrench to remove the four motor mounting bolts that are counter s...

Page 52: ...ted gently out of the motor frame Be sure that the beveled waster remains inside the motor housing Lifting the End Shield with Armature Removing the two screws located beside the shaft will allow you to separate the shaft with the still attached bearing from the end shield Loosening Screws Securing Bearing to End Shield Use a pulley puller or our custom bearing puller tool 01 100 80101 to remove t...

Page 53: ...d every 10 15 cords of wood and must be ordered from Alternate Heating Systems Center Brick are removed by simply lifting them out They are likely to have become snug as wood ash will settle into voids around them making them tight They are likely to require just a bit of effort to loosen them enough that they may be lifted upward Once the old Center Brick are removed clean ash out of their holder...

Page 54: ...ehind the target brick against the boiler wall 5 Place the 3 top upper bricks on top of the bottom upper bricks with the flat surface facing up There will be one brick with and smaller indent on its front and back this brick will go in the center The other two brick with larger indent on one side are the front and rear brick Install the brick so that the indents face each other creating a space fo...

Page 55: ...n combustion efficiency of the amount of heat that is delivered to the home Often advertisements will list combustion rather than overall efficiency since it is the higher of the two calculated efficiencies for any given device For example an advertisement on a website or brochure may say 85 efficient and although not specified it is the combustion efficiency The overall efficiency may be 10 to 20...

Page 56: ...Water Capacity 80 gallons Fire Box Capacity 8 5 ft3 Fire Box Length 29 Standard Door Opening 14 x 14 Height 72 Width without burner 36 Depth 54 Flue Size 6 Weight w o gas oil 2 450 lbs Typical Heating Capacity 4 000 ft2 Heating Efficiency high output 80 Based on loading firebox with seasoned firewood Subject to building design construction 50 ...

Page 57: ...Appendix B Wiring Diagrams 51 ...

Page 58: ...Appendix C Exploded Parts Drawings 52 ...

Page 59: ... 53 ...

Page 60: ... 54 ...

Page 61: ... 482 064 1 pieces 26 AIR VALVE GASKET DISC 5 3 4IN 413 040 1 pieces 27 OUTER DISC 5 3 4 IN DIA 412 131A 1 pieces 28 INNER DISC 4IN 412 132A 1 pieces 29 SILICONE DISC 5 3 4IN 412 145 1 pieces 30 HCS 1 4 20 X 1 1 4 SS 3 30 125200125SS 1 pieces 31 HLN 1 4 20 3 30 8302520 1 pieces 32 AIR VALVE GASKET DISC 3 3 8IN 482 066 1 pieces 33 OUTER DISC 3 3 8 IN DIA 482 067 1 pieces 34 INNER DISC 2IN 482 068 1 ...

Page 62: ...E 2A MIDGET FLM 250V 200 381 1 pieces 82 FUSE 1 1 2A MIDGET FLM 250V 200 382 1 pieces 83 LAMBDA SENSOR 200 505 1 pieces 84 SE210 LAMBDA SENSOR CONTROLLER 3 20 00964 1 pieces 85 CONTROL BOX COVER SE210 482 055 1 pieces 86 SE210 SM REAR ACCESS COVER 482 056 1 pieces 87 FLUE TUBE 4 6 STOVE TRANS 482 057 1 pieces 88 THERMOCOUPLE J TYPE 2 5IN WELL 210 472 1 pieces 89 THERMOCOUPLE J TYPE 2IN 210 473 1 p...

Page 63: ...instructions for building a fire b Seal refractory with Trowleze refractory cement c Replace damaged ceramic pad at center cleanout plug d Check doors for airtight seal e Repair replace air valve gasket disc f Clean ash from boiler See weekly maintenance routine 4 Fire goes out a Boiler not cycling frequently enough refractory cools to below kindling temperature b Wood bridging in fuel chamber a I...

Page 64: ...e air valve assembly has been moved of knocked out of position a Reposition and tighten the air valve and reseal the sleeve where enters the boiler Be careful not to knock the air valve out of position when loading fuel into the boiler 11 There is excessive creosote buildup on boiler vessel located behind the lower front inspection door area a The fire box is being filled too full for the heat dem...

Page 65: ... High Temperature Silicone 42 Adding Preformed Silicone Bead to Door 42 Marking to Trim 42 Trimming Preformed Silicone Bead 42 Adding High Temperature Silicone to Butt Joint of Trimmed Bead 42 Finished Joint 42 Reinforcing Corners with High Temperature Silicone 43 Finishing the Corners 43 Finished Level Bead 43 Front Inspection Door 43 Direct drive fan attached to boiler 44 Mark Assembly Orientati...

Page 66: ...Appendix F Boiler Piping and Ducting Examples 60 ...

Page 67: ...Wood Gun Air Inlet Ducting Installations 61 ...

Page 68: ...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 69: ...he lower side of the flow control valve A minimum of 1 in diameter pipe should be used for this connection on the model Super E210 The pipe size must be determined by taking into account the distance involved and flow required The new circulator should be wired to the power for the Wood Gun When power to the Wood Gun is on the circulator should be running An alternate option is to attach a strap o...

Page 70: ...APPENDIX G Markings 64 ...

Page 71: ...Datalabel 65 ...

Page 72: ...listed in Alternate Heating System s printed literature d the unit is fired with fuels other than those recommended by Alternate Heating Systems This includes fuels recommended by dealers and distributors selling Alternate 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 ...

Page 73: ...its rated output which is shown on the nameplate attached to the unit and listed in Alternate Heating System s printed literature d the unit is fired with fuels other than those recommended by Alternate Heating Systems This includes fuels recommended by dealers and distributors selling Alternate Heating Systems products if these are not fuels recommended by Alternate Heating Systems C WHAT THE CUS...

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