Alternate Heating WOOD GUN E155 SS Setup guide
INSTALLATION AND
OPERATOR’S MANUAL
WOOD GUN™ WOOD GASIFICATION BOILER
Model: E155 SS
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 200° 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 200° Fahre heit.
ALTERNATE HEATING SYSTEMS
2393 LITTLE EGYPT RD
HARRISONVILLE, PA 17228
717-987-0099
WWW.WOODGUN.COM
EMAIL:SERVICE@WOODGUN.COM
Record Model and Serial Number Belo :
Model:
Serial Number:
Date of Purchase:
Copyrig t 2000 – 2015 Alternate Heating Systems.
No portion of t is publication may be reproduced wit out t e
express written consent of Alternate Heating Systems.
Revision: 10/10/17
Table of Contents
Introduction.........................................................................................................................................................1
Explanation of Wood & Biomass Combustion...............................................................................................1
Wood Moisture Content & Wood Gasification..............................................................................................1
Mode of Operation.........................................................................................................................................2
Reduce or revent Condensation...............................................................................................................4
roper ressurization of the Wood Gun.....................................................................................................4
Boiler Installation................................................................................................................................................5
Boiler Location...............................................................................................................................................5
Boiler Room Requirements.......................................................................................................................5
Rigging and ositioning of Boiler..................................................................................................................6
Clearances to Combustibles Required for Safety and Operation...................................................................6
Boiler Assembly.............................................................................................................................................6
Cyclone Ash Collector...............................................................................................................................6
Air Valve....................................................................................................................................................7
Draft-Inducing Fan Assembly....................................................................................................................7
Installation and maintenance of Electrical Controls and Gauges...................................................................7
General Chimney Requirements.....................................................................................................................8
Specific Chimney Requirements for the Wood Gun™..............................................................................8
Flue pipe.........................................................................................................................................................9
roper Chimney Connection..........................................................................................................................9
Boiler iping for Hydronic Systems.............................................................................................................10
iping the Boiler in arallel with Another Boiler....................................................................................11
ressure Relief Valve...............................................................................................................................11
ressure Reducing Fill Valve...................................................................................................................11
Expansion Tank Selection........................................................................................................................11
Return Water Temperature.......................................................................................................................12
Return water temperature.............................................................................................................................12
Low Water Cutoff....................................................................................................................................13
Recommended Boiler Control Settings in Hydronic Systems.....................................................................13
Boiler Conditioner / Sealant.........................................................................................................................14
Boiler iping and Controls for Low ressure Steam Systems.....................................................................14
Forced Hot Air Systems (Water to air Coil in Duct)....................................................................................14
Domestic Hot Water Coil iping..................................................................................................................15
Oil Burner Assembly....................................................................................................................................16
General Information.................................................................................................................................16
Oil/Gas Burner Combustion Chamber: Models E155.............................................................................16
Oil Burner Electrical Connection............................................................................................................16
Oil Burner Fuel Line Connection............................................................................................................16
Oil Burner Adjustment.............................................................................................................................17
Gas Burner Assembly...................................................................................................................................17
Gas Burner Adjustment............................................................................................................................18
Oil Automatic Switchover and Lockout Control..........................................................................................18
Smoke flap....................................................................................................................................................18
Operating Information.......................................................................................................................................21
Starting a Fire: Switch ositions..................................................................................................................22
Switch ositions: Cold Boiler Start-up....................................................................................................22
Fuel Type......................................................................................................................................................22
The Wood Gun is designed to burn split or unsplit wood........................................................................22
Starting a Fire: rocedure.............................................................................................................................22
Charging the Boiler with Wood: Manual Feed........................................................................................23
Back- uffing reventionChecklist..........................................................................................................24
E A Side Tunnel Refractory lug............................................................................................................24
Wood Fuel Characteristics and Wood Storage.............................................................................................25
Low Water temperature Option....................................................................................................................25
Cool Down Cycle.........................................................................................................................................26
Wood FUEL CHARACTERISTICS AND WOOD STORAGE..................................................................26
Removal and Disposal of Ashes...................................................................................................................26
Conditioning of Boiler Water.......................................................................................................................27
pH........................................................................................................................................................27
Dissolved Oxygen...............................................................................................................................27
Solids ( rimarily for Steam Boilers)...................................................................................................28
Alkalinity............................................................................................................................................28
hosphates...........................................................................................................................................28
Hardness..............................................................................................................................................28
Oils......................................................................................................................................................28
Maintenance......................................................................................................................................................29
Weekly Cleaning rocedure.........................................................................................................................29
Air Valve Cleaning and Maintenance......................................................................................................29
Yearly Cleaning............................................................................................................................................30
Air Valve Motor Replacement......................................................................................................................30
Removing Old Damper Motor.................................................................................................................30
Installing the New Damper Motor...........................................................................................................30
Door Adjustment..........................................................................................................................................31
Load Door Seal Replacement.......................................................................................................................32
Front and Rear Inspection Door High Temperature Rope Installation.........................................................34
Fan Assembly...............................................................................................................................................35
Direct Drive Fan bearing replacement procedure........................................................................................36
Refractory Replacement...............................................................................................................................39
Center Brick..................................................................................................................................................39
Side brick Refractory Replacement.............................................................................................................40
Fuel Diverter Blocks: auto Feed Only..........................................................................................................41
additional Information..................................................................................................................................41
Appendix A: Boiler Specification Diagram......................................................................................................42
Additional Specifications.............................................................................................................................45
ressure Drop...........................................................................................................................................45
Explanation of G M Flow.......................................................................................................................45
Wood Gun E Series Specifications..........................................................................................................45
Appendix B: Wiring Diagrams..........................................................................................................................46
...........................................................................................................................................................................47
Appendix C: Exploded arts Drawings............................................................................................................48
arts Listing......................................................................................................................................................49
Appendix D: Troubleshooting Guide................................................................................................................52
Appendix F: Boiler iping and Ducting Examples...........................................................................................55
LIMITED WARRANTY...................................................................................................................................59
Introduction
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EXPLANATION OF WOOD & BIOMASS
COMBUSTION
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WOOD MOISTURE CONTENT & WOOD
GASIFICATION
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MODE OF OPERATION
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- 2 -
Wood ith moisture content higher than 30% is
more likely to produce condensation issues and
ill produce markedly less BTU’s per pound of
fuel.
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- 3 -
Note: Some of the byproducts produced by
incomplete combustion of ood are
formaldehyde, formic acid and acetic acid, hich
are mildly corrosive. A Wood Gun™ operating
under light demand may never generate
refractory temperatures sufficient to reduce these
organic compounds to ater and carbon dioxide.
Any air leak around the inspection doors or air
valve may contribute to the formation of
corrosive products. Therefore it is important to
inspect your Wood Gun™ regularly to ensure that
it is being operated in a manner that does not
contribute to excessive corrosion of the steel. We
recommend that boilers operating ith lo er duty
cycles be manufactured ith the stainless steel
option. It does not override the high limit.
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Reduce or Prevent Condensation
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Proper Pressurization of the Wood Gun
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This unit is not certified nor
designed for use ith any type of
automatic underfed stoker device
- 4 -
Note: Condensation in the heat exchanger can be
caused by ood that is too et for the application
and/or by lo return ater temperatures.
Recommended return ater temperature is
operating temperature minus 20º F
Boiler Installation
BOILER LOCATION
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Boiler Room Requirements
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- 5 -
A fire could be started if the boiler
is installed too close to alls,
carpet or draperies.
RIGGING AND POSITIONING OF BOILER
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CLEARANCES TO COMBUSTIBLES
REQUIRED FOR SAFETY AND OPERATION
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Front 48 Inches
Rear 36 Inches
Left 12 Inches
Right 18 Inches
Top 24 Inches
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BOILER ASSEMBLY
Cyclone Ash Collector
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- 6 -
The installation of this unit must
comply ith state and local
requirements and must be
inspected by the state or local
building inspector here required.
Cyclone Attachment
Air Valve
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Draft-Inducing Fan Assembly
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INSTALLATION AND MAINTENANCE OF
ELECTRICAL CONTROLS AND GAUGES
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IMPORTANT: Do not tighten the 5/16 nuts
excessively as this may damage the gasket or the
ceramic board heat shield.
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INSTALLATION OF SMOKE HOOD OPTION
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Smoke Hood Installed
9
GENERAL CHIMNEY REQUIREMENTS
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Specific Chimney Requirements for the
Wood Gun™
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- 8 -
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Never decrease the cross-sectional
area of the stovepipe/chimney
because the velocity of the exhaust
ill increase thus increasing the
likelihood of particle discharge in
the exhaust
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Never use a prefabricated chimney
connected directly to the ash
recovery cyclone and leading to the
outside ithout any elbo s or
cleanout T-joints.
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FLUE PIPE
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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.
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PROPER CHIMNEY CONNECTION
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Proper chimney connection
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Stove pipe passing through all
- 10 -
Use of aluminum Type B gas vent
for solid fuels is unsafe and
prohibited by the National Fire
Protection Association Code.
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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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Pressure Relief Valve
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- 11 -
Note: Be sure to close all fittings in the unit
before filling the unit ith ater.
Pressure Relief Valve
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Pressure Reducing Fill Valve
456
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Pressure regulating valve and backflo prevention
valve configuration
Expansion Tank Selection
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Return Water Temperature
RETURN WATER TEMPERATURE
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- 12 -
Note: A length of copper pipe must be connected
to the pressure relief valve continuing to a point 6
in from the floor as sho n in Figure 3 above.
It is very important to provide
adequate expansion tank capacity
based on the total volume of ater
in the system, particularly hen the
Wood Gun™ is added to an existing
boiler.
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Three Mixing Valve: Return Water Protection
Lo Water Cutoff
Photo: Lo Water Cutoff Installation
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RECOMMENDED BOILER CONTROL
SETTINGS
IN HYDRONIC SYSTEMS
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BOILER CONDITIONER / SEALANT
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BOILER PIPING AND CONTROLS
FOR LOW PRESSURE STEAM SYSTEMS
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- 14 -
It is very important that a steam
boiler be properly leveled so that
the ater feeder and lo ater
cutoff controls function properly.
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FORCED HOT AIR SYSTEMS
(WATER TO AIR COIL IN DUCT)
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DOMESTIC HOT WATER
COIL PIPING
Plumbing – Coil in Series
567
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Plumbing – Coil in Parallel
- 15 -
Tip: To increase coil performance, increase boiler
ater temperature.
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