Alternate Heating COAL GUN S130 Setup guide

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 2100Fahrenheit. 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 2100Fahrenheit.
ALTERNATE HEATING SYSTEMS, LLC.
5171 LINCOLN WAY WEST ST. THOMAS, PA 17252
TELEPHONE: [phone] FAX: [phone]
WWW.ALTERNATEHEATINGSYSTEMS.COM

Copyright 2000 – 2009 Alternate Heating Systems, LLC.
No portion of this publication 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

TABLE OF CONTENTS
INTRODUCTION....................................................................................................................................1
BOILER INSTALLATION.....................................................................................................................2
BOILER LOCATION....................................................................................................................................2
Boiler Room Requirements.................................................................................................................2
RIGGING AND POSITIONING OF BOILER ...................................................................................................2
CLEARANCES REQUIRED FOR SAFETY AND OPERATION..........................................................................3
GENERAL CHIMNEY REQUIREMENTS .......................................................................................................3
Technical Aspects of Chimney Performance......................................................................................4
COMBUSTION AIR SUPPLY.......................................................................................................................6
DRAFT CONTROLS ...................................................................................................................................6
How Draft Controls Work ..................................................................................................................6
Choosing The Right Size................................................................................................................7
BOILER PIPING FOR HYDRONIC SYSTEMS ................................................................................................9
Piping the Boiler in Parallel with Another Boiler..............................................................................9
BOILER CONDITIONER /SEALANT..........................................................................................................10
BOILER PIPING AND CONTROLS 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.....................................................................................................16
SHUTTING DOWN THE COAL GUN..........................................................................................................17
AUTOMATIC FUEL DELIVERY SYSTEMS.................................................................................................17
Basic Auger Operation .................................................................................................................18
AUGER ASSEMBLY.................................................................................................................................18
GRATE TIMER OPERATION.....................................................................................................................18
THERMO ASH-MONITORING GRATE CONTROL OPERATION...................................................................19
REMOVAL AND DISPOSAL OF ASHES......................................................................................................19
CONDITIONING OF BOILER WATER ........................................................................................................19
Ph..................................................................................................................................................19
DISSOLVED OXYGEN..............................................................................................................20
SULFITES....................................................................................................................................20
SOLIDS........................................................................................................................................20

ALKALINITY..............................................................................................................................20
PHOSPHATES.............................................................................................................................20
HARDNESS.................................................................................................................................20
OILS .............................................................................................................................................20
APPENDIX A: BOILER SPECIFICATION DIAGRAMS ...............................................................22
ADDITIONAL SPECIFICATIONS................................................................................................................26
Pressure Drop...................................................................................................................................26
Explanation of GPM Flow................................................................................................................26
APPENDIX B: WIRING DIAGRAMS................................................................................................27
APPENDIX C: EXPLODED PARTS DRAWING.............................................................................32
APPENDIX D: MAINTENANCE........................................................................................................35
CLEANING HEAT 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 APPLICATIONS...............................................................46
APPENDIX I: BOILER PIPING EXAMPLES...................................................................................50
LIMITED WARRANTY..........................................................................................................53
INDEX .....................................................................................................................................................55

1
INTRODUCTION
The purpose of this manual is to assist you in
the installation, operation and maintenance of
your new boiler in order to achieve the best
performance possible. We recommend that the
unit be installed by an authorized Alternate
Heating Systems, LLC. dealer or by an
experienced boiler installation technician who
has a thorough knowledge of hydronic heating
systems and boilers. Should your installation
require a steam boiler, it is even more
important that 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 Systems, LLC. boilers
can be supplied with the ASME “H” stamp and
National Board number for an additional fee
when requested prior to purchase. Alternate
Heating Systems boilers are built to rigid
quality control standards. You can be assured
of receiving a high quality product.

2
BOILER INSTALLATION
BOILER LOCATION
Wood & Coal Burning Boilers are designed to
radiate as much heat as possible, but this heat
can be dangerous if the boiler is improperly
installed.
CAUTION:
A building fire could be
started if the boiler is
installed too close to walls,
furniture, carpet or draperies.
The boiler must stand on a noncombustible
material such as brick, stone tile or concrete.
NEVER place a boiler directly on a wood floor.
The noncombustible material upon which the
boiler stands should extend at least 12 inches
beyond the base of the boiler in the rear and on
the sides and at least 36 inches in front. The
boiler must be installed in an area dedicated to
the boiler and its related equipment. This area
must be partitioned or separated from any living
area of a residence. The room must have a
constant fresh air supply to assure proper
combustion of the fuel as well as ventilation of
any by-products of combustion.
Boiler Room Requirements
1. The room should be well lighted 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 adequate air supply, which
must be kept clear at all times. 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 create negative
pressure, as this would adversely affect
boiler operation. This applies at the room
location of the intake end of the auger as
well
6. Electrical disconnect at point of entrance to
boiler room.
7. Walls and ceiling must be of fire-rated
construction. Consult local or state codes for
requirements.
RIGGING AND POSITIONING
OF BOILER
Do not attempt to move or off-load the boiler
without the aid of a crane or dolly. All
Alternate Heating Systems boilers have at least
one lifting lug in the center of the top. On some
units lifting lugs in the front and rear are
provided. Use caution whenever moving a
boiler. When choosing the equipment to move
and/or position the boiler, always be sure of the
load rating on the equipment prior to use.
A ratchet puller (come along) device may be
needed to move a boiler where the ground level
changes in elevation. AHS suggests that
professional movers should be used in any
unpredictable situation. This is to prevent
damage to the product, facility and to eliminate
the potential for bodily injury.
Once on the floor level where it will be installed
the unit may be rolled on pipe or may be moved

3
by means of a pallet jack. Use of a pallet jack
with the Coal Gunrequires that the boiler be
skidded or that the installer has made other
provisions to insert a pallet jack under the boiler
base without causing damage. The boiler must
be placed on a concrete slab or other rigid pad
of non-combustible material with sufficient
strength to adequately support the boiler,
including its contents of water. The boiler
should be positioned as closely as possible to
the chimney. The smoke pipe must pitch
continually upward toward the chimney and be
as straight as possible. Level the boiler after it
has been positioned.
Before proceeding with installation, inquire with
local building officials to ensure that the
installation is in compliance with all building,
plumbing and electrical codes.
A qualified technician experienced in boiler
installations is recommended for the installation
of this unit. Wiring on the boiler must be
properly grounded.
WARNING:
BUILDING CODE COMPLIANCE
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.
NOTE: This unit is not approved nor is it
recommended for use in mobile homes.
CLEARANCES REQUIRED FOR
SAFETY AND OPERATION
It is important to provide sufficient clearance
around the boiler for convenient servicing and
cleanout.
The required minimums for Coal Stoker boilers
when measured from the exterior of the boiler
are 30 in to the 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
local code or insurance company requirements.
Refer to Appendix A: Boiler Specification
Diagrams for exterior dimensions of the various
models.
GENERAL CHIMNEY
REQUIREMENTS
One of the most important considerations in
installing a wood or coal burning boiler is the
type of chimney that will be used. The
condition and construction of the chimney is
important to provide sufficient draft. The Coal
Gun produces its own draft during the on cycle,
but the chimney produces the draft during the
off cycle. It is necessary to have continual draft,
even during the off cycle, in order to move
Carbon Monoxide, sulfur, and other gases out of
the boiler.
NOTE: For insurance and building code
compliance check with your local building
inspector and insurance agent.
Natural drafts in a chimney result from two
factors. First, draft is created by the aspirating
effects of air currents blowing across the top of
the chimney. Second, drafts are also produced
when the temperature of the flue gases is higher
than the atmosphere around the chimney. For
this reason a chimney must be kept warm (about
250oF) for proper draft to occur. Please see
Draft Control section in this manual for more
information.
It is more difficult to maintain sufficient
temperature in an exposed chimney, or one that

4
is very large, than a chimney that is protected
from outside temperature extremes.
The chimney must be sufficiently tall (at least
20 feet for masonry chimneys) and should
extend at least three feet above the highest part
of the roof to prevent downdrafts. The chimney
must be leak-free from the standpoint of air
entering through cracks or other chimney
defects or through loose stovepipe fittings.
If the chimney must go through a combustible
wall, be sure to use a metal thimble specially
designed for this purpose. The proper way to
install a thimble is to cut an oversize hole in the
sheetrock about 6 or 7 inches larger than the
thimble (refer to Figure 2). However, be sure to
follow the manufacturer’s directions that come
with the thimble. A metal ring shield is used to
cover the hole. This way air can circulate and
cool the area around the passageway.
Never decrease the cross-sectional area of the
stovepipe/chimney because the velocity of the
exhaust will increase thus increasing the
likelihood of particle discharge in the exhaust.
Technical Aspects
of Chimney Performance
A device called a manometer is used in
describing the technical performance of a
chimney. A manometer is an instrument used
for measuring the pressure of liquids and gases.
An analog manometer consists of a glass tube
filled with a liquid and mounted in front of a
measuring scale against which the liquid level
can be measured. If a manometer were
connected to a leak-free chimney with a leak-
free connection, then the draft in the chimney
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 HAZARD
The airflow through 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.
The airflow through 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. There is usually sufficient leakage in
older homes, but in well-insulated homes it may
be necessary to provide additional outside air
into the home.
STOVEPIPE
Use only 22-24 gauge single wall stove pipe in
open areas 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 U.L. listed insulated stovepipe must
be used. Stovepipe that runs along the outside
walls of a building must also be U.L. listed
insulated pipe, even if it runs along a non-
combustible outside wall. This requirement is
in place in order to prevent cooling of the
stovepipe, which in turn cools the rising smoke
and causes creosote to form quickly (however,
this provision does not apply to the Coal Gun
because there is not sufficient gas generated in
the exhaust to cause creosote).
PROPER CHIMNEY CONNECTION
The boiler must be connected to a class ”A”
chimney (22 gauge preferred, stainless steel is
recommended).

5
WARNING:
CODE COMPLIANCE
Use of aluminum Type B gas
vent for solid fuels is unsafe and
prohibited by the National Fire
Protection Association Code.
Use of aluminum Type B gas vent for solid fuels
is unsafe and prohibited by the National Fire
Protection Association Code. The
recommended method for connecting the boiler
to the chimney is to place a T-joint at the top of
the vertical section leading from the breach
(exhaust) flange. The rear opening must be
covered with a cap, which can be removed for
cleaning and inspection. A horizontal run must
be included, with provision for pipe
disassembly, for pipe inspection and removal of
any fly ash that accumulates. If the horizontal
run to the chimney is inclined, it will encourage
any fly ash, which drops in the pipe to fall back
into the ash separator.
If a second change of direction is required
before 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 ¼” for each
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 airflow. A “T” must
always be used where the stovepipe changes
directions (rather than elbow) to allow for
cleanout.
Figure 1: Proper chimney connection
Particular attention should be paid to the point
where a flue passes through a wall or ceiling.
The pass-thru should always be made with
insulated pipe and the proper accessories or use
of a thimble that provides a diameter of not less
than three times the diameter of the stovepipe.
(see Figure 2)
Figure 2: Stove pipe passing through wall

6
COMBUSTION AIR SUPPLY
It is important to make provision for adequate
supply of combustion air, either via natural
infiltration through a door or window or by
ducting outside. If combustion air is ducted
from the outside, then install a metal vent pipe
of sufficient diameter for the boiler to be used.
Contact Alternate Heating Systems if an outside
air ducting kit is required.
When the intake is ducted outside, inspect the
opening regularly to be sure that it does not
become obstructed by debris.
DRAFT CONTROLS
Where excessive natural draft exists, a
barometric damper is required to prevent the
boiler from overheating. The likelihood of this
condition increases with increased chimney
height. It is a good idea to include a barometric
damper when chimneys are taller than 20 feet.
The standard type “M” field control with a “T”
is recommended for satisfactory performance.
Excessive draft through the boiler will allow an
excessive amount of heat from the boiler to
escape up the chimney. A draft control will
help reduce this loss.
NOTE: The information in the rest of this
section is provided by Field Controls, LLC,
Kinston, North Carolina, 252.522.3031. This
information is used with their permission.
Some information may not apply to coal
burning systems. The information 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,
combustion is more complete, fuels are utilized
efficiently and money is saved.
Field Draft Controls maintain consistent draft by
counteracting the negative forces caused by
changes in temperature and barometric pressure,
and the effects of wind.
How Draft Controls Work
NOTE: See diagram below which has been
modified for this manual.
Static pressure of the cool air (1) exerts pressure
on the outside of the furnace or boiler, the
breaching, and stack.
The pressure difference between the room air
and heated gas (air) causes products of
combustion (2) to flow (draft) through the unit
and rise through the breaching and chimney.
Room temperature air (3) enters through the
barometric draft control (4) in the precise
amount needed to overcome the excess drafts
caused by temperature variations, wind
fluctuations and barometric pressure changes.
Combustion of fuel is completed and the process
is stabilized. The velocity of combustion gases
through the heat exchanger is slowed so more
heat is extracted. The unit operates more
efficiently, reliably and requires less
maintenance.

7
Choosing The Right Size
(Sizing the Control)
Simple rules of thumb to guide size selections:
1.Use a draft control the same size as the
flue 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 draft control to provide
ample capacity. It is a simple matter to
install a round control on a pipe an inch or
so larger or smaller than the control.
3.If the flue pipe or breaching is square, use
the round equivalent. For example - on a 14"
x 14" breaching use a 14" control. Little
flow occurs in the corners of a square pipe
so that its capacity is approximately the
same 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
required, use more than one regulator with
combined cross-sectional areas equal to or
greater than that of the breaching. When
chimneys are of an unusual height or if the
draft to be maintained is either very high or
very low, it is advisable to deviate from the
rules of thumb outlined here. Refer to the
larger table.
Control Size
Nominal Cross-Sectional
Area (Sq. In.)
6”
28
7”
38
8”
50
9”
63
10”
78
12”
113
14”
154
16”
201
18”
255
20”
314
24”
452
28”
616
32”
804

8
Diameter of
Flue or
Breeching
If Chimney
Height is Use This Size
Control If Chimney
Height is Use This Size
Control If Chimney
Height is Use this size
Control
4
15’ or less
4”
16’ or more
5”
N/A
N/A
5
15’ or less
5”
16’ or more
6”
N/A
N/A
6
15’ or less
6”
16’ or more
7”
N/A
N/A
7
15’ or less
7”
16’ or more
8”
N/A
N/A
8
15’ or less
8”
16’ or more
9”
N/A
N/A
9
15’ or less
9”
16’ – 30’
10”
31’ or more
12”
10
20’ or less
10”
21’ – 40’
12”
41’ or more
14”
11
20’ or less
12”
21’ – 40’
12”
41’ or more
14”
12
20’ or less
12”
21’ – 40’
14”
41’ or more
16”
13
22’ or less
14”
23’ – 45’
16”
46’ or more
18”
14
22’ or less
14”
23’ – 45’
16”
46’ or more
18”
15
22’ or less
16”
23’ – 45’
16”
46’ or more
18”
16
30’ 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
40’ or less
28”
41’ – 70’
28”
71’ or more
28”
27
40’ or less
28”
41’ – 70’
28”
71’ – 100’
28”
28
50’ or less
28”
51’ – 100’
32”
100’ or more
32”
29
50’ or less
28”
51’ – 100’
32”
100’ or more
32”
30
50’ or less
32”
51’ – 100’
32”
100’ or more
32”
31
50’ or less
32”
51’ – 100’
32”
100’ or more
Two 24”
32 50’ or less 32” 51’ – 100’ 32” 100’ or more
One 24”
One 28”
33 50’ or less 32” 51’ – 100’
One 32”
One 20” 100’ or more
One 32”
One 24”
34 50’ or less 32” 51’ – 100’
One 32”
One 24” 100’ or more
One 32”
One 24”

9
BOILER PIPING FOR
HYDRONIC SYSTEMS
Normal operating temperature for the Coal Gun
is 180°F. This allows for optimum operation
and less fly ash accumulation on heat exchange
surfaces. Water returning to the boiler from
zones should be about 160°F, and at no time
(after initial startup) should be lower than 150°
F.
Note: Hydronic and steam distribution and
system design are ultimately the
responsibility of the customer or installer.
Due to the design requirements of the various
Coal Gun™ models, the tappings are not always
in the same location on each boiler model.
Appendix A: Boiler Specification Diagrams
provides detailed information on how each
model should be connected. The washout plugs
in the bottom of the unit are a requirement of the
ASME boiler code and must be closed before
filling the unit with water.
Note: Be sure to close all ports in the unit
before filling 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 attached to the return
tapping for the location of the boiler drain.
Piping the Boiler in Parallel with Another
Boiler
The Coal Gun™ may be connected to a heating
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 account the distance involved and
flow required.
Pressure Relief Valve
The pressure relief valve is factory installed. A
length of copper pipe must be connected to the
pressure relief valve continuing to a point 6”
from the floor. Extending the pipe to the floor is
a requirement of building codes. It reduces the
likelihood that a release of boiler pressure would
scald anyone standing near the boiler.
If the Coal Gun™ is installed as the primary
boiler it is necessary to provide for water supply
using a pressure regulating valve and backflow
prevention valve in the feed water line.
Figure 3: Pressure regulating valve and
backflow prevention valve configuration
CAUTION
It is very important to provide
adequate expansion tank
capacity based on the total
volume of water in the system,
particularly when the Coal
Gun™ is added to an existing
boiler.
It is very important to provide adequate
expansion tank capacity based on the total
volume of water in the system. This is
particularly true if the Coal Gun™ is added to

10
an existing boiler. Check the chart to determine
the water capacity of the Coal Gun™ installed.
The expansion tank or air cushion tank installed
originally may not be adequate for the additional
volume of the Coal Gun™.
IMPORTANT
Some states require that all
hydronic heating systems have
a low-water cut-off control.
Some states require that all hydronic heating
systems have a low-water cut-off control. In
cases where this control is required it should be
located in a “T” placed in the supply riser just
above the tapping in the boiler. The S500 and
larger Wood units are supplied with a low water
cut-off from the factory since the ASME code
requires that any heating boiler with a calculated
heat transfer capacity of 400,000 BTUH or
greater must be so equipped. On the S500 and
S1000 the low water control should be located
in tapping “FF” which is to the side of the 4”
domestic coil tapping.
BOILER CONDITIONER / SEALANT
AHS provides two bottles of Boiler
Conditioner/Sealant with the purchase of your
boiler. When filling your boiler with water for
the first time, mix content of each bottle with 2
gallons of warm water. Pour into boiler
opening. Replace plug. An MSDS is available
upon request.
BOILER PIPING AND CONTROLS
FOR STEAM SYSTEMS
All Coal Gun™ models are available with steam
tappings and controls upon special order. When
installing a steam boiler, be sure that the
installation conforms to all state and local codes.
All steam boilers will be supplied with a low
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 combination water
feeder/low water control such as a McDonnell-
Miller model 47-2 is required to ensure that the
proper water level is maintained. Some states or
cities require two low-water control devices in
series. The two controls described above will
meet this requirement.
CAUTION
It is very important that a steam
boiler be properly leveled so that
the water feeder and low water
cutoff controls function properly.
Connecting multiple steam
boilers requires further special
attention and must be performed
by a trained professional.
It is critical in steam applications to take into
account the BTU rating of the radiators in the
system. If the boiler cannot meet this capacity,
there will be areas that do not receive heat.
Steam boilers also have a different wiring
sequence, so the proper wiring diagram must be
consulted (see Appendix A: Boiler
Specification Diagrams).
FORCED HOT AIR SYSTEMS
(WATER TO AIR COIL IN DUCT)
The Coal Gun™ boiler may be easily adapted to
any forced hot air heating system by installing a
heat exchange coil in the supply duct. The size
and type of coil or heat exchanger required may
be established after several factors are
determined. These factors include: the heat
output required (BTUH), the capacity of the
existing fan blower (CFM) and the size of the

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duct or plenum where the coil will be installed.
Sizing of the air coil will be the responsibility of
customer and/or installer.
The coil creates increased resistance to air flow,
so this factor must be considered when
determining the final airflow. Design water
temperature is usually 180°F, and a desirable
output air temperature is 115°- 125°F. The
coil is connected in the same manner as in other
types of radiation heating equipment. The
thermostat should be wired to both the fan
blower and the circulator pump.
If a hole was cut in existing ducting to install the
coil, the opening should be closed tightly with a
metal cover and sealed with duct tape.
DOMESTIC HOT WATER
COIL PIPING
The Coal Gun™ may be fitted with a domestic
hot water 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 method of plumbing the domestic coil
is to connect the coil in parallel with an existing
water heater so that the conventional water
heater may be used when the Coal Gun™ is not
being fired (for example in the summer). The
diagram below indicates how this can be done.
Figure 5: Plumbing – Coil in Parallel
CAUTION: BURN DANGER!
In installations where the coil
discharges directly into the hot
water distribution system a
tempering valve must be
included to limit the temperature
of the water at the faucet to a
safe level.
Figure 6: Tempering valve

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The third method of plumbing the domestic coil
uses a small pump to circulate water
continuously between the coil and existing hot
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 (see Figure 7).
Figure 7: 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 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: Insert wires from hopper into the empty
conduit coupler on the side of the aquastat box.
Feed conduit through coupler and tighten until
conduit is snugly attached. Locate the blue and
yellow wires already inside the aquastat box.
Connect color to color to the hopper wires.