Alternate Heating COAL GUN S130 Setup guide
INSTALLATION AND
OPERATOR’S MANUAL
COAL GUN™ BOILER
Models: S130 • S260
IMPORTANT: IN ORDER TO ACHIEVE SAFE AND SATISFACTORY
RESULTS FROM YOUR ALTERNATE HEATING SYSTEMS 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.
Your Alter ate Heati g Systems Boiler is capable of ge erati g
very hot temperatures. Boiler temperatures a d flames i the
ig itio box area are capable of causi g ig itio or explosio of
explosive or flammable products or explosio of the boiler itself if
maximum safe water temperature is exceeded. Maximum safe
water temperature is 210° Fahre heit. Flammable or explosive
products must ever be stored i the same room or i the vici ity
of a boiler, a d the boiler water temperature must ever be
allowed to exceed 210° Fahre heit.
ALTERNATE HEATING SYSTEMS
2393 LITTLE EGYPT RD
HARRISONVILLE, PA 17228
717-987-0099
WWW.ALTERNATEHEATINGSYSTEMS.COM
EMAIL: SERVICE@WOODGUN.COM
Record Model and Serial Number Belo :
Model:
Serial Number:
Date of Purchase:
REV 170126
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Table of Contents
Introduction..............................................................................................................................................................1
Boiler Installation.....................................................................................................................................................2
boiler location......................................................................................................................................................2
Boiler Room Requirements............................................................................................................................2
Rigging and Positioning of Boiler.......................................................................................................................2
Clearances Required for afety and Operation...................................................................................................3
General Chimney Introduction............................................................................................................................3
Draft................................................................................................................................................................4
Technical Aspects of Chimney Performance..................................................................................................4
Barometric Damper - Draft Controls..................................................................................................................5
How Draft Controls Work..............................................................................................................................6
Choosing the Right ize Draft Control..........................................................................................................6
tovepipe........................................................................................................................................................7
Proper Chimney Connection..........................................................................................................................7
Wall Pass-Through: United tates..................................................................................................................9
Wall Pass-Through: Canada...........................................................................................................................9
Chimney Requirements.......................................................................................................................................9
Masonry Chimneys.......................................................................................................................................10
Prefabricated Chimneys................................................................................................................................10
In case of chimney fire......................................................................................................................................11
In case of runaway fire......................................................................................................................................11
Combustion Air upply.....................................................................................................................................11
Boiler Piping for Hydronic ystems.................................................................................................................12
Piping the Boiler in Parallel with another Boiler.........................................................................................12
Checklist: When the Boiler is Added to an Existing ystem.......................................................................12
Pressure Relief Valve....................................................................................................................................13
Pressure Reducing Auto Fill.........................................................................................................................13
Expansion Tank............................................................................................................................................13
Low Water Cutoff.........................................................................................................................................13
Boiler Conditioner / ealant..............................................................................................................................13
Boiler Piping and Controls for team ystems.................................................................................................14
Forced Hot Air ystems (Water to air Coil in Duct).........................................................................................14
Domestic Hot Water Coil Piping.......................................................................................................................14
Illustrated Instructions for Installing Coal Hopper on 130 and 260.............................................................15
Electrical Connections in the Coal Gun
TM
.........................................................................................................16
130/ 260 Power Requirements..................................................................................................................16
Power Connections.......................................................................................................................................16
Controls.............................................................................................................................................................17
Aquastat Controls.........................................................................................................................................17
Mode witch & Ash Removal......................................................................................................................17
Thermal Ash Monitor ettings.....................................................................................................................17
Grate Timers and ettings............................................................................................................................18
Thermostat Connection................................................................................................................................20
team.................................................................................................................................................................20
Boiler Dump Zone Applications.......................................................................................................................20
Non Powered Dump Zone............................................................................................................................20
Operating Information...........................................................................................................................................22
Lighting the Coal Gun
TM
...................................................................................................................................22
Warning- Risk of fire:...................................................................................................................................22
Caution.........................................................................................................................................................23
Operation of ight Hole Flap............................................................................................................................23
hutting Down the Coal Gun............................................................................................................................24
Automatic Fuel Delivery ystems....................................................................................................................24
Basic Auger Operation.................................................................................................................................24
Auger assembly............................................................................................................................................25
Thermo Ash-Monitoring Grate Control Operation...........................................................................................25
Fuel storage / Removal and Disposal of Ashes.................................................................................................25
treatment of Boiler Water..................................................................................................................................26
Ph..................................................................................................................................................................26
Dissolved Oxygen........................................................................................................................................26
ulfites..........................................................................................................................................................26
olids............................................................................................................................................................26
Alkalinity......................................................................................................................................................27
Phosphates....................................................................................................................................................27
Hardness.......................................................................................................................................................27
Oils...............................................................................................................................................................27
Antifreeze.....................................................................................................................................................27
Appendix A: Boiler pecification Diagrams.........................................................................................................28
Additional pecifications..................................................................................................................................30
Pressure Drop...............................................................................................................................................30
Explanation of GPM Flow............................................................................................................................30
Appendix 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 wirl 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 chedule for Models 130 and 260........................................................................44
Appendix E: Troubleshooting Guide.....................................................................................................................45
Checking/Removing Clinkers...........................................................................................................................47
Appendix F: Table of Figures................................................................................................................................48
Appendix G: Programming Grate Control.............................................................................................................49
Dwyer 16C-2 Programming..............................................................................................................................50
Initial Programming......................................................................................................................................50
LOCKING CONTROL................................................................................................................................50
Appendix H: Dump Zone Wiring Applications.....................................................................................................51
Appendix I: Boiler Piping Examples.....................................................................................................................57
LIMITED WARRANTY.......................................................................................................................................60
Introduction
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Boiler Installation
BOILER LOCATION
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A building fire could be started if the
boiler is installed too close to alls,
furniture, carpet or draperies.
Boiler Room Requirements
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Ventilation Fans in the boiler room
must not create negaive pressure.
Doing so ill create an unsafe
condition and negatively impact
boiler performance.
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RIGGING AND POSITIONING
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NOTE: This unit is not approved or recommended
for use in mobile homes.
CLEARANCES REQUIRED FOR SAFETY AND
OPERATION
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GENERAL CHIMNEY INTRODUCTION
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Use of aluminum Type B gas vent
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Draft
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Technical Aspects
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NOTE: For insurance and building code
compliance check ith your local building
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D yer Manometer
BAROMETRIC DAMPER - DRAFT CONTROLS
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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
ith their permission. Some information may not
apply to coal burning systems. The information is
taken from Field Controls, LLC ebsite at:
.fieldcontrols.com/draftcontrol.php. See the
Field Controls ebsite for specific models of draft
controls or to place an order.
Note: Do NOT use a barometric damper unless
excessive draft (in excess of -.08 inches of
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Ho Draft Controls Work
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Draft Control
Choosing the Right Size Draft Control
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NOTE: See diagram belo hich has been
modified for this manual.
If the draft regulator is set too high
it can cause the coal fire to burn out
of control.
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The airflo through the system and
out the chimney means that oxygen
is leaving the home and ill create
an oxygen deficit if this air is not
replaced.
Note: Manually operated dampers must not be
used ith the Coal Gun
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Use of aluminum Type B gas vent
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Stove pipe passing through all
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CHIMNEY REQUIREMENTS
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BOILER PIPING FOR
HYDRONIC SYSTEMS
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Piping the Boiler in Parallel ith another
Boiler
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Note: Be sure to close all ports in the unit before
filling the unit ith ater.
Note: Hydronic and steam distribution and
system design are ultimately the responsibility of
the customer or installer.
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Pressure regulating valve and backflo prevention
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Expansion Tank
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Lo Water Cutoff
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hydronic heating systems have a
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It is very important to provide
adequate expansion tank capacity
based on the total volume of ater
in the system, particularly hen the
Coal Gun™ is added to an existing
boiler.
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BOILER PIPING AND CONTROLS
FOR STEAM SYSTEMS
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FORCED HOT AIR SYSTEMS
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It is very important that a steam
boiler be properly leveled so that
the ater feeder and lo ater
cutoff controls function properly.
Connecting multiple steam boilers
requires further special attention
and must be performed by a trained
professional.
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