Alternate Heating COAL GUN S1000 Installation And Operator'S Manual Download | Manualshive

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Record Model and Serial Number Below

Model:

Serial:

INSTALLATION AND

OPERATOR’S MANUAL

COAL GUN™ BOILER

Models: S130, S260, S500, S1000

IMPORTANT:

IN ORDER TO ACHIEVE SAFE AND SATISFACTORY

RESULTS FROM YOUR ALTERNATE HEATING SYSTEMS, INC. BOILER,
READ SAFETY RULES AND INSTRUCTIONS CAREFULLY BEFORE
INSTALLING AND OPERATING. ALL INSTALLATIONS MUST BE IN
ACCORDANCE WITH STATE AND LOCAL CODES. SAVE THESE
INSTRUCTIONS FOR FUTURE REFERENCE.

WARNING:

Your Alternate Heating Systems Boiler is capable of generating very hot temperatures.

Boiler temperatures 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

0

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 210

0

Fahrenheit.

ALTERNATE HEATING SYSTEMS, LLC.

5171 LINCOLN WAY WEST ST. THOMAS, PA 17252

TELEPHONE: 717-369-2102 FAX: 717-369-2732

WWW.ALTERNATEHEATINGSYSTEMS.COM

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Summary of Contents for COAL GUN S1000

Page 1: ...g Systems Boiler is capable of generating very hot temperatures Boiler temperatures 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 0 Fahrenheit Flammable or explosive products must never be stored in the same room...

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Page 3: ...ation may be reproduced without the express written consent of Alternate Heating Systems LLC The Coal Gun is listed by Underwriter s Laboratories INC Coal Gun boilers bearing the mark seen at right are thereby designated as listed boilers UL File Number MH46626 Revision 091209 ...

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Page 5: ...FOR STEAM SYSTEMS 10 FORCED HOT AIR SYSTEMS WATER TO AIR COIL IN DUCT 10 Domestic Hot Water Coil Piping 11 ILLUSTRATED INSTRUCTIONS FOR INSTALLING COAL HOPPER ON S130 AND S260 12 ELECTRICAL CONNECTIONS IN THE COAL GUN 13 S130 S260 13 S500 S100 13 CONTROLS 13 Control Settings 13 Steam 14 Boiler Dump Zone Applications 14 OPERATING INFORMATION 16 LIGHTING THE COAL GUM 16 Operation of Sight Hole Cover...

Page 6: ...T EXCHANGER AND VENTING SYSTEM 35 CLEANING COAL POT FEED TUBE AND GRATE 35 FAN ASSEMBLY REMOVAL REPAIR 36 DIRECT DRIVE MOTOR BEARING REPLACEMENT 37 ADDITIONAL INFORMATION 39 OPERATION AND MAINTENANCE SCHEDULE FOR MODELS S130 AND S260 40 APPENDIX E TROUBLESHOOTING GUIDE 41 APPENDIX F TABLE OF FIGURES 43 APPENDIX G PROGRAMMING GRATE CONTROL 44 LOCKING CONTROL 45 APPENDIX H DUMP ZONE WIRING APPLICATI...

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Page 9: ...t experienced 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 Syst...

Page 10: ...es Since the combustion process requires a supply of air at all times it is essential that provisions are made to supply adequate air to the boiler room This air supply is necessary to insure complete combustion and venting of any gases or smoke that would be emitted from this solid fuel burning boiler in case boiler malfunctions Note Ventilation fans in the boiler and fuel storage rooms must not ...

Page 11: ...e rear end of boiler with fan assembly 36 in to the right side when facing the front of the boiler 16 in on the left 18 in from the hopper top and 24 in to the front end of boiler with sight tube For commercial and residential installations many boiler codes require a minimum of 3 feet of clearance on all sides It is the customer s responsibility to determine whether the installation complies with...

Page 12: ...should exert enough pressure or pull against the water in the manometer to cause it to move at least 0 04 inches in the tube A barometric damper or draft regulator must be installed in the smoke pipe or flue connector when installing the coal boiler Manually operated dampers must not be used The draft regulator should be adjusted to maintain a draft of 04 to 06 during operation CAUTION SUFFOCATION...

Page 13: ...fore entering the chimney a cleanout T should be placed at this point also as indicated in Figure 1 Each joint should be secured with three sheet metal screws and sealed with high temperature sealant capable of withstanding 650 F Any horizontal pipe should be pitched upward toward the chimney at least for each foot of horizontal run Ensure that there is at least 18 clearance between horizontal pip...

Page 14: ...nformation is taken from Field Controls LLC website at www fieldcontrols com draftcontrol php See the Field Controls website for specific models of draft controls or to place an order For proper operation and efficient fuel consumption in oil gas and or coal fired heating appliances draft must remain relatively constant and above 04 inches water column as measured with a manometer When it is combu...

Page 15: ...e as a round pipe of the same diameter 4 If the breaching is rectangular or oval compute its cross sectional area and select a draft control having the same or a greater nominal cross sectional area A breaching 14 high x 10 wide would have a cross sectional area of 140 square inches From the table select a 14 control with a cross sectional area of 154 sq inches 5 Where a control larger than 32 is ...

Page 16: ...0 or less 16 31 50 18 51 or more 20 17 30 or less 18 31 50 20 51 or more 20 18 30 or less 18 31 50 20 51 or more 20 19 30 or less 20 31 50 20 51 or more 24 20 30 or less 20 31 50 20 51 or more 24 21 30 or less 20 31 50 24 51 or more 24 22 30 or less 24 31 50 24 51 or more 24 23 35 or less 24 36 60 24 61 or more 28 24 35 or less 24 36 60 24 61 or more 28 25 35 or less 28 36 60 28 61 or more 28 26 4...

Page 17: ...ting system supplied by one or more boilers that are already in place There are many possible configurations that allow for an existing boiler to function as a backup to the Coal Gun For sample illustrations of multiple boiler configurations see Appendix I A minimum of 1 diameter pipe should be used for this connection on model S130 In any event the pipe size must be determined by taking into acco...

Page 18: ...water cut off which fits into a special tapping on the rear of a Coal Gun steam boiler This control must never be hot wired or disconnected since it prevents the boiler from firing should 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 An automatic water feeder mechanical type or combinati...

Page 19: ...ter coil which threads into a 4 tapping in the boiler Multiple coils can be installed into larger boilers the total number dependent on the size of the boiler and the number of fittings made available at time of manufacture There are three methods for plumbing the domestic coil One way is to connect the coil in series with an existing hot water heater Figure 4 Plumbing Coil in Series A second meth...

Page 20: ...OAL HOPPER ON S130 AND S260 Step 1 Disconnect all power to the boiler Step 2 Loosen hopper collar snug screws until they are flush with the hopper collar as shown below Step 3 Remove cover of high limit aquastat box on top of boiler Step 4 Insert hopper tube into the hopper collar and tighten screws until snug You may wish to make sure that the hopper is level or adjust to your preference Step 5 I...

Page 21: ...terminals in the main control enclosure CONTROLS Coal Guns for hydronic heating have no provision for control wiring connections to building thermostats As stated previously the boilers are designed and wired to maintain water temperature The control scheme for Coal Gun boilers requires that building thermostats control distribution of the hot water usually by circulator pumps zone valves or both ...

Page 22: ...e on operating until ash temperature climbs to the SV value The power switches are located on the front of the control panel The Main switch will shut off all power to the unit The Grate switch will shut down the grate motor function WARNING Fuses must be replaced with the same amperage and fuse type as supplied with the unit The S130 and S260 have two external fuses on the control panel The 15A f...

Page 23: ...H Example 5 WARNING DO NOT OPEN THE DOORS OR OPERATE THIS UNIT DURING A POWER FAILURE Non Powered Dump Zone Some states or municipalities require a way to dump boiler heat in the event that power loss occurs Figure 9 shows an application example of how this is accomplished Pipe to a dump zone must be a minimum of in Larger diameters may be needed as boiler size increases Figure 9 Non Powered Dump ...

Page 24: ...tch is sometimes located on opposite side of the boiler per customer request and fill the hopper full of pea or buckwheat coal 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 fire starters such as Rutland Safe Lite so that they are nearly covered by the coal Light the starters When they are burning and unlikely ...

Page 25: ...o allow the fire to go out in the Coal Gun Unlike non solid fuel boilers the fire in the Coal Gun will not go out instantly it will necessarily have to coast to a stop The procedure for shutdown is to turn off the boiler Main switch and to simply wait until the fire goes out It will be important during this time to maintain the sight tube cover in the open position as seen in Figure 10 Without pow...

Page 26: ... auger will be controlled by the hopper level sensor and will maintain the level of coal in the hopper The level sensor responds to the proximity of coal As the hopper empties coal will fall away from the sensor After a programmed delay normally one minute the sensor will turn on the auger The sensor will turn off the auger once a sufficient amount of coal makes contact with it Figure 12 Proper Au...

Page 27: ...l in soil or otherwise locally dispersed they should be retained in a closed container until all cinders have thoroughly cooled to prevent inadvertently starting a fire CONDITIONING OF BOILER WATER Proper treatment of make up water and boiler water are necessary to prevent scale or other deposits and corrosion within the boiler The absence of adequate external and internal treatments can lead to o...

Page 28: ...loride present in the boiler water The ratio of chlorides in the boiler water to that of the feed water can be used as a means to determine the amount of blow down required The chloride test is unsuitable for feed water with low incoming concentrations and the concentrations in the feed water must be averaged over time for accuracy High boiler solids will lead to foaming priming surging and carry ...

Page 29: ...21 the boiler should immediately be taken out of service and thoroughly cleaned ...

Page 30: ...22 APPENDIX A BOILER SPECIFICATION DIAGRAMS ...

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Page 34: ...lowing are given as examples of gallons per minute water flow 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 differential requires 50 gallons per minute 250K BTU s at 20 degrees temperature differential requires 25 gallons per minute 1M BTU s at 20 degrees temperature differential requires 100 g...

Page 35: ...27 APPENDIX B WIRING DIAGRAMS ...

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Page 40: ...32 APPENDIX C EXPLODED PARTS DRAWING ...

Page 41: ...mo Controlled Grates 9 Grate Motor 10 Pitman assembly 11 Pillow Block Bearings 12 Pitman Connecting Pin 13 Small Grate Motor Sprocket 14 Large Grate Sprocket 15 Chain 16 Chain Guard 17 Domestic Water Coil 18 Fan Disk 19 Abrasion Shield 20 Ceramic Heat Shield 21 Fan Motor Mounting Plate 22 Fan Motor 23 Left Insulation Cover 24 Top Insulation Cover may be two separate pieces 25 Flue Tube Assembly 26...

Page 42: ...34 ...

Page 43: ...at exchanger tube Inspect and replace any damaged gaskets a fiberglass rope gasket is used for the fan assembly and check the ceramic heat shield replacing as necessary Check the fan assembly belt on belt driven units adjust tension and alignment as needed replace if worn or damaged Reinstall fan assembly cyclone tube and smoke pipe Tighten the fan assembly bolts opposite from each other using eve...

Page 44: ...ystems dealer for this repair procedure WARNING Disconnect power to boiler before beginning this procedure 1 Remove electric wires and conduit at fan motor or junction box Note Mark connections before disconnecting wires 2 Remove the four nuts which hold the fan assembly to the boiler These are the outer circle of nuts on the fan plate 3 Remove the fan assembly from the boiler and place on workben...

Page 45: ... Alternate Heating Systems dealer for this repair procedure WARNING Disconnect power to boiler before beginning this procedure 1 Follow steps 1 6 of Fan Assembly Removal Repair procedure These will guide the removal of the fan assembly 2 On bottom of fan assembly mark all components to assure it can be reassembled in the same orientation 3 After fan is removed remove abrasion shield by removing th...

Page 46: ...red 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 shaft end up on a workbench 9 Using a small hammer gently tap up on the end plate at shaft end 10 The plate along with the armature will come loose which should be gently lifted out ...

Page 47: ...end cap off 13 Using a manual jaw puller remove bearing from shaft 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 The address of the NFPA is 470 Atlantic Boston Massachusetts 02210 ...

Page 48: ... brass bushings with a few drops of oil Every 3 months Fan shaft bearings belt drive models only Grease with high temperature grease 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 sea...

Page 49: ...coal pot a Check for problem in grate motor circuit or mechanical linkage b Remove clinkers fused coal ash 5 Fire goes out a Insufficient demand to maintain fire a Increase heat load 6 Excessive fly ash in chimney a Cyclone funnel plugged b Flue pipe between boiler and chimney too long a Check cyclone funnel and remove restriction b Reduce length of pipe run 7 Excessive sulfur odor in boiler room ...

Page 50: ...ary air a Adjust secondary air port on sight tube cover 11 Coal gas ignition at very end of firing cycle a Excess chimney draft resulting in delayed release of sight tube cover a Install barometric damper or adjust existing barometric damper to 04 water column 12 Coal gas ignition at beginning of firing cycle a Too much coal added to emptied hopper b Too small a fire relative to coal volume above ...

Page 51: ... Figure 2 Stove pipe passing through wall 5 Figure 3 Pressure regulating valve and backflow prevention valve configuration 9 Figure 4 Plumbing Coil in Series 11 Figure 5 Plumbing Coil in Parallel 11 Figure 6 Tempering valve 11 Figure 7 Plumbing Coil with circulator 12 ...

Page 52: ...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 53: ... top LED readout will display B Use the or to set the bottom readout to a value of 10 C Press twice 5 Set Grate Operation Temperature Use and to select temperature When the desired temperature setting is shown in the bottom readout press The grate operating temperature is set at the factory to 140 F When the ash temperature drops to 10 or whatever offset value is entered in step 4 below the set va...

Page 54: ...46 APPENDIX H DUMP ZONE WIRING APPLICATIONS ...

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Page 58: ...50 APPENDIX I BOILER PIPING EXAMPLES ...

Page 59: ...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 60: ...lower side of the flow control valve A minimum of 1 diameter pipe should be used for this connection on the model S130 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 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 o...

Page 61: ...tem 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 cannot be located contact any o...

Page 62: ...54 IMPORTANT READ AND KEEP IN YOUR POSSESSION ...

Page 63: ...zing 8 Drive belt 39 Drive belts 34 E expansion tank 9 EXPLOSION HAZARD3 18 19 F Fire bed 39 Fire box 39 floor installation area 2 floor drains 2 Flue pipe 39 forced hot air systems 10 G GPM Flow 26 grate switch 16 grate timer 18 H heat exchange coil 10 hot water domestic 11 hot water heater 11 I Installation 1 2 L leaks chimney 4 Line Loss 26 low water control 10 low water cut off 10 low water cu...

Page 64: ...2 temperature differential 26 tempering valve 12 thimble in chimney installation 4 Troubleshooting 40 U unloading the boiler 2 V valve backflow prevention 9 pressure regulating 9 W WARNING3 5 14 15 16 18 19 Warranty 52 washout plugs 9 Water Conditioning 19 water feeder automatic 10 water level gauge 10 water temperature coming from boiler 11 ...

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