Alternate Heating WOOD GUN Super E210 Setup guide

INSTALLATION AND
OPERATOR’S MANUAL
WOOD GUN™ WOOD GASIFICATION BOILER
Model: Super E210
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
2395 LITTLE EGYPT RD
HARRISONVILLE, PA 17228
717-987-0099
WWW.WOODGUN.COM
EMAIL:[email protected]
Record Model and Serial Number Belo :
Model: SUPER E210
Stainless Steel (Yes/No):
Serial Number:
Date of Purchase:____/___/_____
U.S. ENVIRONMENTAL PROTECTION AGENCY
Certified to comply ith 2020 particulate
emission standards using cord ood.

Copyr ght 2000 – 2021 Alternate Heat ng Systems.
No port on of th s publ cat on may be reproduced w thout the
express wr tten consent of Alternate Heat ng Systems.
Rev s on: 11/08/21

Table of Contents
CAUTIONS AND WARNINGS: RISK OF FIRE, INJURY OR DEATH⚠......................................................1
Introduction.........................................................................................................................................................
Explanation of Wood & Biomass Combustion...............................................................................................
Wood Moisture Content & Wood Gasification..............................................................................................
Mode of Operation.........................................................................................................................................3
Reduce or Prevent Condensation...............................................................................................................5
Proper Pressurization of the Wood Gun.....................................................................................................5
Boiler Installation................................................................................................................................................6
Boiler Location...............................................................................................................................................6
Boiler Room Requirements.......................................................................................................................6
Rigging and Positioning of Boiler..................................................................................................................7
Clearances to Combustibles Required for Safety and Operation...................................................................7
Installation and maintenance of Electrical Controls and Gauges..................................................................8
Installation of Smoke Detectors and CO Monitors........................................................................................8
Installation of Smoke Hood Option................................................................................................................8
Installation of Bottom Insulation....................................................................................................................9
General Chimney Introduction............................................................................................................................9
Specific Chimney Requirements for the Wood Gun™..............................................................................9
Technical Aspects of Chimney Performance.............................................................................................9
Draft.........................................................................................................................................................10
Barometric Damper.................................................................................................................................10
Manometer...............................................................................................................................................10
Masonry Chimneys..................................................................................................................................11
Prefabricated Chimneys...........................................................................................................................11
Proper Chimney Connection........................................................................................................................13
Stovepipe......................................................................................................................................................13
Stovepipe Specifics for SE 10................................................................................................................14
Wall Pass-Through: United States...........................................................................................................14
Wall Pass-Through: Canada.....................................................................................................................15
Common Chimney Problems.......................................................................................................................15
In case of chimney fire.................................................................................................................................16
In Case of Runaway Fire..............................................................................................................................16
In Case of Power Loss..................................................................................................................................16
Make-up or Combustion Air.........................................................................................................................17
Boiler Piping for Hydronic Systems.................................................................................................................18
Piping the Boiler in Parallel with Another Boiler....................................................................................18
Pressure Relief Valve...............................................................................................................................18
Pressure Reducing Fill Valve...................................................................................................................18
Expansion Tank Selection........................................................................................................................19
Return water temperature.............................................................................................................................19
Additional Specifications............................................................................................................................. 0
Pressure Drop........................................................................................................................................... 0
Explanation of GPM Flow....................................................................................................................... 0
Low Water Cutoff......................................................................................................................................... 0
Low Water Cutoff Testing........................................................................................................................ 0
Low Water Cutoff Troubleshooting......................................................................................................... 0
Low Water Cutoff Maintenance............................................................................................................... 1
Boiler Conditioner / Sealant......................................................................................................................... 1
Boiler Piping and Controls for Low Pressure Steam Systems..................................................................... 1

Forced Hot Air Systems (Water to air Coil in Duct).................................................................................... 1
Thermal Storage Basics................................................................................................................................
Thermal Storage Types............................................................................................................................
Sizing Your Thermal Storage...................................................................................................................
Conditioning of Boiler Water....................................................................................................................... 3
pH........................................................................................................................................................ 3
Dissolved Oxygen............................................................................................................................... 4
Solids (Primarily for Steam Boilers)................................................................................................... 4
Alkalinity............................................................................................................................................ 4
Phosphates........................................................................................................................................... 4
Hardness.............................................................................................................................................. 4
Oils...................................................................................................................................................... 4
Domestic Hot Water Coil Piping.................................................................................................................. 5
Oil Burner Assembly.................................................................................................................................... 6
General Information................................................................................................................................. 6
Oil/Gas Burner Combustion Chamber..................................................................................................... 6
Oil Burner Electrical Connection............................................................................................................ 7
Oil Burner Fuel Line Connection............................................................................................................ 7
Oil Burner Adjustment............................................................................................................................. 7
Gas Burner Assembly................................................................................................................................... 8
Gas Burner Adjustment............................................................................................................................ 8
Operating Information....................................................................................................................................... 9
Explanation of Switch and Buttons.............................................................................................................. 9
SEQUENCE OF OPERATIONS.................................................................................................................3
Low Temperature Shutdown (LTSD)......................................................................................................3
Manual/Automatic Switchover................................................................................................................33
Other Functions.......................................................................................................................................33
Resetting the Controls..............................................................................................................................33
Fuel Type......................................................................................................................................................33
The Wood Gun is designed to burn split or unsplit wood........................................................................33
Wood dimensions.....................................................................................................................................33
Prohibited fuels........................................................................................................................................33
Wood Fuel Characteristics and Wood Storage.........................................................................................34
Starting a Fire: Procedure.............................................................................................................................34
Charging the Boiler with Wood..............................................................................................................35
Back-Puffing Prevention Checklist.........................................................................................................36
Removal and Disposal of Ashes...................................................................................................................36
Recommended Boiler Control Settings in Hydronic Systems.....................................................................36
*For Carbon Steel Boilers............................................................................................................................37
Condensation – Causes and Prevention...................................................................................................37
Reduce or Prevent Condensation.............................................................................................................37
Maintenance......................................................................................................................................................38
Weekly Cleaning Procedure.........................................................................................................................38
Air Valve Cleaning and Maintenance......................................................................................................38
Yearly Cleaning............................................................................................................................................39
Air Valve Motor Replacement......................................................................................................................39
Removing Old Damper Motor.................................................................................................................39
Installing the New Damper Motor...........................................................................................................39
Door Adjustment..........................................................................................................................................40
Load Door Seal Replacement.......................................................................................................................41
Front Inspection Door High Temperature Rope Installation........................................................................43
Fan Assembly...............................................................................................................................................44

Direct Drive Fan bearing replacement procedure........................................................................................44
Refractory Replacement...............................................................................................................................47
Center Brick.............................................................................................................................................47
Refractory Replacement.........................................................................................................................47
Additional Information.................................................................................................................................49
Efficiency.....................................................................................................................................................49
Appendix A: Boiler Specification Diagram......................................................................................................50
Wood Guntm Super E 10 Specifications..................................................................................................50
Appendix B: Wiring Diagrams..........................................................................................................................51
Appendix C: Exploded Parts Drawings............................................................................................................5
Parts Listing......................................................................................................................................................55
Appendix D: Troubleshooting Guide................................................................................................................57
Appendix F: Boiler Piping and Ducting Examples...........................................................................................60
APPENDIX G: Markings..................................................................................................................................64
Datalabel..................................................................................................................................................65
Stainless Steel LIMITED WARRANTY...........................................................................................................66
Carbon Steel LIMITED WARRANTY.............................................................................................................67

CAUTIONS AND WARNINGS: RISK OF FIRE, INJURY OR DEATH⚠
INSTALLATION IS TO BE PERFORMED BY A
QUALIFIED INSTALLER AND WILL COMPLY WITH ALL
THE REQUIREMENTS OF THE AUTHORITY HAVING
JURISDICTION OVER THE INSTALLATION
ALL COVER PLATES, ENCLOSURES, AND GUARDS
MUST BE MAINTAINED IN PLACE AT ALL TIMES,
EXCEPT DURING MAINTENANCE AND SERVICING.
USE ONLY WITH SEASONED LOG WOOD WITH A
MOISTURE CONTENT OF 19%- 5%.
THE UNIT IS NOT TO BE CONNECTED TO A CHIMNEY
FLUE SERVING ANOTHER APPLIANCE!
USE COPPER CONDUCTORS ONLY FOR FIELD WIRING
DANGER! RISK OF FIRE OR EXPLOSION – DO NOT
BURN GARBAGE, GASOLINE, DRAIN OIL OR OTHER
FLAMMABLE LIQUIDS!
WARNING! RISK OF FIRE – DO NOT OPERATE WITH
FLUE DRAFT EXCEEDING -0.08IN WATER COLUMN!
WARNING! RISK OF FIRE – DO NOT USE CHEMICALS
TO START UNIT FIRING!
WARNING! RISK OF FIRE – DO NOT BURN GARBAGE,
GASOLINE, FUEL OILS OR OTHER FLAMMABLE
LIQUIDS OR MATERIALS!
WARNING! RISK OF FIRE – DO NOT OPERATE WITH
FUEL LOADING OR ASH REMOVAL DOORS OPEN!
WARNING! RISK OF FIRE – DO NOT STORE FUEL OR
OTHER COMBUSTIBLE MATERIAL WITHIN MARKED
INSTALLATION CLEARANCES!
WARNING! RISK OF FIRE – INSPECT AND CLEAN
FLUES REGULARLY!
CAUTION! HOT SURFACES – KEEP CHILDREN AWAY!
CAUTION! HOT SURFACES – DO NOT TOUCH
DURING OPERATION!
CAUTION! HOT SURFACES – MAXIMUM DRAFT
MARKED ON NAMEPLATE.
DANGER – TO AVOID INJURY FROM MOVING PARTS,
SHUT OFF THE BOILER BEFORE
REMOVING/OPENING SERVICE PANELS AND DRAFT
INDUCING FAN.
FOR INDOOR INSTALLATION ONLY!
IN THE EVENT OF A RUN-AWAY FIRE… CUT POWER
TO UNIT, CLOSE LOADING AND ASH REMOVAL
DOORS. IF POSSIBLE TURN ON CIRCULATION
PUMPS/ZONE VALVES TO “DUMP” EXCESS HEAT.
USE COPPER CONDUCTORS ONLY
THIS WOOD HEATER NEEDS PERIODIC INSPECTION
AND REPAIR FOR PROPER OPERATION. IT IS
AGAINST FEDERAL REGULATIONS TO OPERATE THIS
WOOD HEATER IN A MANNER INCONSISTENT WITH
OPERATING INSTRUCTION IN THIS MANUAL
DO NOT TAMPER WITH OR REMOVE ANY
COMPONENTS AND FOLLOW ALL INSTALLATION
PROCEDURES IN THIS MANUAL.
THIS WOOD HEATER HAS A MANUFACTURER-SET
MINIMUM LOW BURN RATE THAT MUST NOT BE
ALTERED. IT IS AGAINST FEDERAL REGULATIONS TO
ALTER THIS SETTING OR OTHERWISE OPERATE THIS
WOOD HEATER IN A MANNER INCONSISTENT WITH
OPERATING INSTRUCTIONS IN THIS MANUAL
WARNING: DO NOT OVER-FIRE! OVER-FIRING WILL
CAUSE DAMAGE TO REFRACTORY AND GREATLY
SHORTEN THE LIFE OF THE BOILER.
- 1 -

Introduction






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EXPLANATION OF WOOD & BIOMASS
COMBUSTION

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$%
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,.84.
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WOOD MOISTURE CONTENT & WOOD
GASIFICATION
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
-K8,K<


-K8
,:<

*E
"CD


'4=.AB?,:.A6@
K..AB?4..A6@
>

>!


>
>*
K..AB?4..A6@


MODE OF OPERATION
"C

/
D

L
L
?@


M
>-:..AB?-...A6@#


!



E8

M

"9'
M/


8>


- 3 -
Wood ith moisture content higher than 28% is
more likely to produce condensation issues and
ill produce markedly less BTU’s per pound of
fuel.
You may not burn Unseasoned Wood!

8
E
E
>>
8
E8




*
>/


>
>
N3?@
E
!

N3?@



M



CAUTION! Positive pressure exists in the flue so it is
very important to seal every joint of the stove pipe
ith silicone. Do not use barometric damper!
"C

*

!# 
"

0
E
-454

/

8


0
"9'
EF


8

B


>0

>>
M

8
/


>

(>
>L
>'

 


- 4 -
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.

&>D

Reduce or Prevent Condensation
6
D
(
O
"
>>>
E

!


*


✔0?>
@
✔6
!G
✔0&

✔0
F

✔2-K8,:<
✔6
M
✔08/

8/

✔O

✔>


Proper Pressurization of the Wood Gun
"CL
*
9
-,8-4
!L>
>
L
>
O
L
*
>

- 5 -
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
0

"C



"C
M
2
F
M
"9'
6


)(G(
M

>7

,=





8
Boiler Room Requirements
- 8

, !
M
M
5 2M
= !

>
4 '

 




D
8
0




7 ;

P 
6

: 0

J



- 6 -
A fire could be started if the boiler
is installed too close to alls,
carpet or draperies.

RIGGING AND POSITIONING OF BOILER
JDF8
+!
# E

NM
2
*
/



8/




?,
@3E

*
/

!# 
>

"9'

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.
Do not install in a sleeping room!
Install a CO monitor in the room
here the heater is located, at about
table height.
CLEARANCES TO COMBUSTIBLES
REQUIRED FOR SAFETY AND OPERATION

1
66
Front 24 Inches
Rear 6 Inches
Left 6 Inches
Right 6 Inches
Top 6 Inches
Stovepipe 18 Inches
66B1?
8>@
8>
-78:8
0
LM
>,8

- 7 -
A fire could be started if the boiler is
installed too close to alls,
furniture, carpet or draperies.

'
M?-:
@&

(>

&
!>!>

0

(>


INSTALLATION AND MAINTENANCE OF
ELECTRICAL CONTROLS AND GAUGES
0&
8E
!>!
L
8


B
!>*1
J36N

0
BF9
9,.Q
2
0
E0

E0
R&84Q

0F
R&84Q
0




INSTALLATION OF SMOKE DETECTORS
AND CO MONITORS
!

F (,-.
?
@6N--,,&
6ND
D
B
N0
6N?>@
6N
D
>+
6ND
*
6N

JS
06N

0 

0



INSTALLATION OF SMOKE HOOD OPTION
!#  #?>@
 #

0
0

247
M
F27

- 8 -

D



 
E
> 

>
INSTALLATION OF BOTTOM INSULATION

"9
-4%-%N
T
--%
E
,;
+,85%

5 -4%E
-%O

=

E
25&:%
8
4 -4%
E
7N
D
N-%

M
General Chimney Introduction
N


/E0
&M

CAUTION: DO NOT TO CONNECT THIS
UNIT TO A CHIMNEY/FLUE SERVING
ANOTHER APPLIANCE.
Specific Chimney Requirements for the
Wood Gun™
"CEH
/
(>
>
N

#

*/
"
>!


L1
✔(,-.U70)
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
Technical Aspects of Chimney Performance
- 9 -

3-2-10 Rule for Chimneys
>
E
B
O58,8-.
8


D
Draft
JEF
D6


FE!
EDB
E0
//
>!


>!
?,4.AB@E!
V>F
M
E

D
Poor chimneys ith cold alls can
cause creosote buildup. Sharp
bends and horizontal flues should
also be avoided. The exhaust must
be kept moving through the
piping/flue to prevent creosote or fly
ash buildup. If a horizontal section
must be used, it must rise slightly to
prevent dead air space.
Barometric Damper
!

!
EE
(>E
>0
/
!
>E8.:
#
"E
>E
Manometer
!
!

!


0
88
E
>?@
8.=
B
>E8.:
- 10 -

D yer Manometer
'E
"


9EM
,4.BJ
DEB
E?@


E8.:
0
EW..=6
 66
;6
E
Masonry Chimneys
0>

!





8

B




?!

H
@06

0

 8

Prefabricated Chimneys


X
>2X
HE
!
2 6823
-.523687,K
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.
+

0!
?!@
!6!
?*@ (,-.*?6@
X
!X 
O?J@
 
!*D6?(
@
!B6?B@
!?"@
- 11 -


M6
6?#@

!*?0@
>
X
'
$%Y*?Y@
!
6;!?O@!
6 ?3@


M! 6?'@!
B?)@

!?N@


Note: Do not decrease the diameter of chimney
pipe to less than that of the flue collar! Chimney
connector and flue must be 6 inches in diameter
or greater
- 1 -

PROPER CHIMNEY CONNECTION
6!
29*
)B
;!6
6!1
-'
08

,0$6!%
?23-.5
2367,K@
598$6!%
?23-.5
2367,K@
0

?@
0


2V
V
JE
!"

The chimney selected must comply
ith the requirements for type HT
chimneys ith UL 103 or ULC S629
ratings. Do not use makeshift
compromises during construction.
STOVEPIPE
0M
!L

-&=2


;D
M
8


0


L
 7P
#
X
!


(>
2L
XM

- 13 -
Use of aluminum Type B gas vent
for solid fuels is unsafe and
prohibited by the National Fire
Protection Association Code.

Inspect stove pipe at least t ice
monthly for creosote buildup.
Creosote creates a risk of chimney
fire, and can obstruct stove pipe. An
obstructed stove pipe can result in
CO buildup in your boiler room.
B
9




0

Manual Dampers must not be
installed in the flue pipe. Improper
operation could result in death.

0

2,=
-:
0-:

>23
;

23
8



7
Stovepipe Specifics for SE210

-:%8,=%7%

&%9%
D5
every month&%9%


0$9%


$9%F
L?@
"E


;
-..<

Wall Pass-Through: United States
02 )B;!,--


)B;!?)B;
!@
!

-,Z?5..@

54Z?K.@!8
5&:Z?K@
?
@0

B
)B;!
,--
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