Econoburn EBW SERIES User manual

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G A S I F I C A T I O N B O I L E R S
EBW SERIES
HIGH-EFFICIENCY
WOOD-FIRED BOILERS
OPERATOR’S
MANUAL
C US

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G A S I FI C AT I O N B O I L ER S
Manufactured by:
ECONOBURN LLC
A Division of Abasco Inc.
2 Central Avenue
Post Office Box 689
Brocton, New York 14716
Telephone: [phone]
Toll Free: 1-866-818-5162
Facsimile: 716-792-2098
For technical assistance call: 716-792-2095
Website: www.econoburn.com
Email: [e-mail]
Email: [e-mail]
© 2008 EconoburnLLC
All Rights Reserved
Revised 9/12

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INTRODUCTION 5
BOILER DIAGRAM 7
CONTROLLER PROGRAMMING 8/9
OPERATING INSTRUCTIONS 10
WOOD-BURNING 10
STORAGE OF WOOD 11
INSPECTION & CLEANING 11
THE FLUE DRAFT CONTROL SYSTEM 11
FUEL LOADING 13
BOILER CONTROL 14
FIRING YOUR BOILER 15
COMBUSTION AIR & NEGATIVE PRESSURE 16
CLEANING CREOSOTE BUILD UP 16
GENERAL SAFETY TIPS FOR BOILER OPERATION 17
TIPS FOR MAXIMIZING BOILER EFFICIENCY 17
BOILER OPERATING CHECKLIST 18
MAINTENANCE AND CLEANING 20
BOILER MAINTENANCE 20
CLEANING THE HEAT EXCHANGER 20
ASH DISPOSAL 21
HEAT EXCHANGER MAINTENANCE 21
MAINTENANCE TIPS 22
TABLE OF CONTENTS

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CHIMNEY MAINTENANCE 22
TROUBLESHOOTING GUIDE 23
SPECIFICATIONS 24/25
ECONOBURNTM BOILER WARRANTY 26

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G A S I F I C A T I O N B O I L E R S
Congratulations on the purchase of your new ECONOBURNTM Wood-Fired Boiler. Developed in
the northeastern United States, the ECONOBURNTM Wood-Fired Boiler has been designed to allow
you to heat and supply hot water for your home or business, by burning wood, one of North
America’s most plentiful, affordable and environmentally friendly fuels.
Your ECONOBURNTM Wood-Fired Boiler has been engineered and manufactured to our highest
standards for dependability, ease of operation, and operator safety. When properly maintained and
cared-for, the ECONOBURNTM Wood-Fired Boiler will give you years of energy-efficient, rugged
and trouble-free performance.
The ECONOBURNTM Wood-Fired Boiler utilizes gasification burning technology to get an
astonishing eighty-seven percent (87%) energy efficiency out of traditional wood fuel sources, and
will provide you with many, many years of safe and cost effective space and water heating.
To ensure that you have a clear understanding of the operating procedures of your
ECONOBURNTM Wood-Fired Boiler, please take the time to read this manual carefully and
completely, and follow all instructions. If you have any questions regarding the operation of your
Boiler, please contact us by email, through the ECONOBURNTM website at www.econoburn.com or
call our technical support team at 1-716-792-2095. We will be happy to assist you.
IMPORTANT: The ECONOBURNTM Wood-Fired Boiler must be installed by a certified and
properly trained and qualified Heating, Ventilation and Air Conditioning (HVAC) professional. Do
not attempt to install this unit yourself unless you are a certified and properly qualified HVAC
professional. Improper installation could result in fire, personal injury and/or property damage.
KEEP THIS MANUAL IN A SAFE PLACE FOR FUTURE REFERENCE
INTRODUCTION

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WARNING
THIS UNIT MUST BE INSTALLED BY A
CERTIFIED AND PROPERLY QUALIFIED
HEATING, VENTILATION AND AIR
CONDITIONING (HVAC) PROFESSIONAL.
DO NOT ATTEMPT TO INSTALL THIS
UNIT YOURSELF UNLESS YOU ARE A
CERTIFIED AND PROPERLY QUALIFIED
HVAC PROFESSIONAL.
IMPROPER INSTALLATION COULD
RESULT IN FIRE, PERSONAL INJURY
AND/OR PROPERTY DAMAGE.

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BOILER DIAGRAM

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DFD CONTROL PANEL OPERATION
Ts
0%
Ts-5
Water Temperature (deg F)
40%
100%
Fan
Speed
Ts -10
Normal operating Mode:
To Enter Program mode:
Press Up and Enter together, Actual will flash Pro.
Press Down and Enter together, Actual will change to solid Pro.
Press Up and Down together and Programming mode is entered.
Any incorrect sequence, or no keys for few seconds, will return the display back to water temperature actual and setting for
fan speed.
Menu {hysteresis} (Description)
Notes
Top display
Bottom display/default value (Range, in F)
First Menu (setting Deg F or Deg C)
Sets display between °F and °C
[F]
P-°
F (F or C)
Second Menu {5} (Setting Pump set point)
Above sets: Primary pump is on and Circulator pump is off

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P-P
150 (50 –200)
Third Menu {20} (Setting Alarm set point)
Above sets: Alarm is on, Buzzer is on, display flashes, Fan is off (no pulse), and Primary is on
P-A
200 (50 –230)
Fourth Menu {10 + TBD delay} (Setting Stack off point)
Below sets: All outputs are off, On leaves system running.
P-S
100 (On, 50 –220)
Fifth Menu {N/A} (Setting Delay time)
Delay between high speed fan pulses when water at or above set point in minutes
P-d
15 (1 –30)
Sixth Menu {N/A} (Setting Pulse time)
On time of high speed fan pulses when water at or above set point in seconds
P-o
15 (1 –60)
In program mode up and down arrows will adjust the Setting value within the range given in 5 deg steps (except for delay
and pulse menus). Enter proceeds to the next menu. To exit the user enters through all six menus. The program is saved
after the last menu is exited. This allows the user to abort programming by cycling power before program completion.
However programming must be completed to save the program. No key presses for several seconds during programming
will abort the program and the controller will revert to the normal Fan setting mode and use the previously saved
parameters and ignore any new settings.

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WOOD-BURNING
The ECONOBURNTM Wood-Fired Boiler will burn most solid wood fuels; however, it is recommended
that hardwoods be used for their superior energy content. Burning dry, seasoned wood is also
recommended because a residual moisture content of between 15 and 25% is required for optimal
gasification combustion. The use of dry, seasoned wood will also significantly reduce the
accumulation of creosote in the combustion chamber and heat exchanger.
Use firewood that is that is the appropriate length for your firebox, as referenced in the technical data
sheet. Longer firewood will cause “bridging” which will prevent the wood from falling to the bottom of
the burn chamber and could cause gasification to cease. Do not use excessive amounts of wood that
is cut into tiny pieces. This can generate an intense coal bed that could overheat your Boiler. If you
have small scraps to bum, mix them with regular chunk wood. Do not burn driftwood, wood chips,
manufactured logs, sawdust or pellets.
Do not use chemicals or fluids to start the fire or during operation.
The ECONOBURNTM Wood-Fired Boiler is designed to burn wood, as detailed herein. Do not burn
garbage, gasoline, naphtha, engine oil, plastic or any item with glue or chemicals.
DO NOT BURN DRIFTWOOD, WOOD CHIPS, MANUFACTURED LOGS, SAWDUST OR PELLETS.
DO NOT BURN GARBAGE, GASOLINE, NAPHTHA OR ENGINE OIL.
If you are having problems with heat outputs, check the moisture content of your wood. Firewood
moisture meters are available on the Internet for minimal cost (typically less than $30) and can save
you a lot of time and energy spent trouble-shooting an easy-to-remedy problem. We cannot overstate
the effect that wood moisture content has on the overall performance of your Boiler.
For maximum efficiency when operating without thermal storage, keep an adequate coal bed
established in the upper chamber while adding only a few pieces of wood at a time to maintain the
desired Boiler temperature. This works well when you're at home and can reduce the overall amount
of wood that is used.
If you wait until the fire has burned to coals before refilling the upper firebox, you will have less chance
of smoke rollback into the Boiler room than if a partial load of wood is still burning inside.
Keep the firebox door tightly closed and check the door seal condition regularly. The 10.3-ounce tube
of high-temperature silicone provided with the Boiler should be used to maintain the integrity the seals
of the pressurized chambers. When applying silicon, use a caulking gun. Squeeze the silicone into the
track (i.e., the indentation on the door seal). A 3/16-inch diameter bead will work best, or approximately
half the diameter of a pencil.
OPERATING INSTRUCTIONS

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STORAGE OF WOOD
Do not store wood within installation clearances or within the space required for charging or ash
removal.
INSPECTION & CLEANING
During daily wood fuel loading, stoking of the wood in the upper chamber (also referred to as the
“firebox chamber”) should cause most ash to fall through the nozzle to the bottom chamber (also
referred to as the “lower combustion chamber”). Any dead ash that has not fallen through the nozzle
should be removed from the upper chamber. Ash acts as an insulator and will retard performance.
Check the bottom chamber weekly for ash buildup until experience shows how often cleaning is
necessary. Be aware that hotter fires yield greater boiler performance, higher efficiency, and
reduced maintenance. It is recommended that horizontal flue runs be inspected mid-season for
any accumulated ash that may have been entrained in the combustion stream and settled-out in
the flue runs.
THE FLUE DRAFT CONTROL SYSTEM
The ECONOBURNTM Wood-Fired Boiler has been designed so that the firebox door latch remains
locked, preventing the firebox door from opening unless the flue draft handle (see Figure 1) is first
pushed inward as far as it will go toward the rear of the unit. This opens the bypass damper. Opening
this bypass damper depressurizes the upper burn chamber and forces the smoke and flue gasses
directly up the chimney, thereby preventing a surge of smoke and/or flames toward the operator when
the firebox door is opened.
The forced draft fan must be stopped (via the toggle switch on the blower box; see Figure 10) and the
rear damper fully opened for at least one minute before opening the firebox door to refuel.
DO NOT RUN THE BOILER WITH THE FLUE DAMPER IN THE OPEN POSITION.
Running with the damper in the open position will damage the water jacket.
WARNING
NEVER OPEN EITHER DOOR ON THE UNIT (EITHER THE UPPER FIREBOX DOOR OR THE
LOWER COMBUSTION CHAMBER DOOR) WHEN THE BOILER IS IN OPERATION WITHOUT (1)
OPENING THE REAR DAMPER BY PUSHING THE FLUE DRAFT HANDLE ALL THE WAY
TOWARD THE BACK OF THE UNIT, (2) TURNING THE FORCED DRAFT FAN OFF, AND (3)
WAITING A MINIMUM OF ONE MINUTE.

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Figure A
FUEL LOADING
To load your ECONOBURNTM Wood-Fired Boiler with fuel (wood), ALWAYS use the following
procedure:
WARNING
THE FORCED DRAFT FAN MUST BE STOPPED AND THE FLUE BYPASS DAMPER FULLY
OPENED FOR AT LEAST ONE MINUTE BEFORE OPENING THE FIREBOX DOOR TO REFUEL.
THIS IS NECESSARY TO ENSURE THAT SMOKE AND FLAMES FROM THE FIRE WILL NOT EXIT
THE FIREBOX DOOR AND HARM THE OPERATOR.
NEVER OPEN EITHER DOOR ON THE UNIT (THE UPPER FIREBOX DOOR OR THE LOWER
COMBUSTION CHAMBER DOOR) WHEN THE BOILER IS IN OPERATION WITHOUT FIRST
OPENING THE FLUE DAMPER HANDLE AND WAITING A MINIMUM OF ONE MINUTE.
1. Open the Boiler’s bypass damper by pushing the flue
draft handle as far to the rear of the unit as it will go.
(See Figure A.)
2. Turn off the forced draft fan at the blower cover.
(Toggle switch.)
3. Wait a minimum of one minute.
4. SLOWLY open the firebox door. (See Figure B)
5. Load fuel into the firebox. Although your
ECONOBURNTM Wood-Fired Boiler is very ruggedly
built, do not throw wood into the firebox haphazardly
as you may chip the gasification nozzle.
6. Close the firebox door.
7. Close the bypass damper by pulling the flue draft
handle all the way forward. This will engage the
mechanical safety lock. (See Figure C.)
8. Turn the forced draft fan on once again at the blower
cover. (Toggle switch.)
Figure B
Figure C

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BOILER CONTROL
The Control Panel (see Figure10 below) includes an LED display which is set at the temperature
desired for the temperature of the water of the Boiler. An immersed temperature sensor is installed
at the top of the Boiler to monitor the water temperature. The factory default temperature is set at
160 degrees Fahrenheit.
When the temperature of the water is less than the desired set point, the forced draft fan is raised to
maximum RPM, forcing air into the upper combustion chamber and nozzle. This creates the highly
efficient gasification process. The fan remains on as long as the water temperature is below the
desired water temperature.
Packed with the ECONOBURNTM Wood-Fired Boiler is a pump which would be used in the near
boiler circulating loop. (See Diagram C - Plumbing Connections - Page 25) This pump circulates the
water (from a cold-start) in a short loop around and within the Boiler to rapidly heat the water in the
Boiler and more rapidly raise the temperature of the refractory to ensure optimum performance, and
prevent thermal shock. This pump is activated when the Boiler is turned on and shuts off at 150°F, at
which point another pump may send heated water to the distribution system.
FIGURE 10 –CONTROL PANEL

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The Controller display is made up of two temperature indicators.
The top numerical indicator is the actual temperature of the water in the Boiler.
The lower numerical indicator displays the desired Boiler water temperature setting. This is controlled
by the increment-decrement buttons on the right side of the display; it will change in 5 degree
increments.
The overheat audible alarm will sound and the control panel display will flash when the unit exceeds
200 degrees Fahrenheit. At the same time a relay will energize for the over temp zone.
The thermo overload/7 amp circuit breaker protects the Control Panel from any electrical shorts or
power surges in excess of 7 amps with any external electrical devices wired through the rear of the
Boiler. This could include the primary or circulating pump, or an overheat valve/pump if installed, and
connected to the electrical box at the rear of the boiler.
In the event of the breaker tripping, the switch will pop outwards. Simply press the switch back into
place to reset the breaker.
WARNING
DO NOT ADD MORE FUEL UNTIL YOU ARE CERTAIN THAT ALL CONTROLS ARE FUNCTIONING
PROPERLY AND NO DAMAGE HAS BEEN DONE TO THE BOILER.
FIRING YOUR BOILER
When first firing the Boiler, use dry kindling and leave the bypass damper open for approximately 15 to
20 minutes. This will allow time to establish the coal bed above the refractory nozzle, which will in turn
yield the most efficient gasification. You will likely find your own routine for firing your Boiler, but this
method works well.
We do not recommend leaving the Boiler off and the bottom door open to get your fire going faster. In
the event that you leave the Boiler and forget to close the door, the fire will grow to the point that the
Boiler overheats and produces steam.
As a starting point, set the temperature controller approximately 10 to 15 degrees below the
temperature you would like your system to operate. Unlike gas or oil fired boilers, when the
ECONOBURNTM Wood-Fired Boiler goes into stand-by mode, its temperature will continue to rise until
the lack of combustion air slows the fire enough to stabilize the water temperature. This setting will
vary from system to system and will be dependent upon the size of your Boiler, the amount of water in
the system, the time of year, and the heat load on the Boiler.
COMBUSTION AIR SUPPLY & NEGATIVE AIR PRESSURE
An adequate flow of air to the Boiler must exist at the location where the Boiler is to be installed in
order to ensure proper combustion and to maintain safe ambient room temperatures. For Boilers
located in a confined space, or in an unconfined space in a building or structure of unusually airtight
construction, outdoor air must be provided.

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Prior to installation of your Boiler, the installer MUST test for negative air pressure at the location
where the ECONOBURNTM Wood-Fired Boiler is to be installed. If needed, outdoor air may be
provided by the creation of two (2) permanent openings which communicate directly or by duct with the
outdoors. Any air openings, if needed, must be constructed at the time of installation by the installation
professional.
WARNING: If the ECONOBURNTM Wood-Fired Boiler does not draw air steadily, the Boiler may
experience smoke roll-out, burn poorly, or back-drafts might occur, whether or not there is combustion
occurring.
NOTE: Outside combustion air supply may be necessary if fans are installed in the same room where
the Boiler is to be installed, or if the house is equipped with a well-sealed vapor barrier and tight-fitting
windows, and/or has any powered devices that exhaust house air. Excessive condensation on
windows in the winter is also an indication that negative air pressure may exist in the structure.
Negative air pressure is also likely to exist where a ventilation system has been installed in the
structure.
CLEANING CREOSOTE BUILD-UP
Creosote is a flammable and corrosive substance that can build up on the walls of your fireplace and
chimney. Creosote is formed when unburned wood particles, fly ash and other volatile gases combine
as they exit the chimney. If there’s a poor draft, these unburned particles and gases can condense
and build up on the walls of your chimney. Over time, these creosote or soot buildups can become a
danger as they can potentially result in a chimney fire.
The failure to clean and remove any existing creosote build-up could result in chimney fire, property
damage and/or personal injury. Your installation contractor should inspect the chimney for creosote
build-up before beginning installation of your Boiler. If creosote exists in the chimney, it MUST be
cleaned by a professional (e.g., chimney sweep) prior to installation of the ECONOBURNTM Wood-
Fired Boiler.
WARNING
THE CHIMNEY MUST BE CLEANED AND FREE OF ALL CREOSOTE PRIOR TO INSTALLATION
AND OPERATION OF THE ECONOBURNTM WOOF-FIRED BOILER. THE FAILURE TO CLEAN
AND REMOVE ANY EXISTING CREOSOTE BUILD-UP COULD RESULT IN CHIMNEY FIRE,
PROPERTY DAMAGE AND/OR PERSONAL INJURY.

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BUILDING A NONCOMBUSTIBLE BASE AND/OR AN ELEVATED BASE
If the Boiler installation site has a combustible floor, a noncombustible floor MUST be constructed by a
professional contractor, as described in detail in the Installation Manual enclosed herewith.
For basement installation, if the existing floor is not level or if water might accumulate on the floor
around the Boiler, an elevated noncombustible base (such as a concrete pad) must be constructed for
your Boiler.
GENERAL SAFETY TIPS FOR BOILER OPERATION
Never refuel the boiler during a power failure. If a prolonged power failure occurs do not fire the unit
until the power supply resumes and stabilizes.
Never attempt to operate the boiler with natural draft by opening the flue gate.
During a power failure, do not refuel the Boiler, if refueled during a power failure it is possible for the
boiler to overheat causing damage to piping, and to the Boiler. Do not open the doors or damper. This
will stop the amount of oxygen to enter the burn chambers. It is recommended to let the gravity loop
handle the excess Btu’s or install a battery back-up to allow the pumps to circulate and dissipate the
excess heat.
TIPS FOR MAXIMIZING BOILER EFFICIENCY
Proper sizing and installation of your boiler by a qualified heating professional.
Burn clean hardwoods with a moisture content in the 15-25% range.
Ashes should be removed twice per week from the upper and lower chambers.
Add the proper amount of wood for the heat output required from the boiler. Short, hot, burns
yield the highest efficiency.
The integration of thermal storage will yield the highest efficiency and gain the most energy
from the wood.
It is advisable to install an auxiliary power supply to power the boiler during a power failure.
A gravity flow piping circuit should be installed.
BOILER OPERATING CHECKLIST
Keep area around your ECONOBURNTM Wood-Fired Boiler clean and clear of combustibles.
Use only wood. DO NOT burn any other combustible material, or liquid.

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Remove ashes as directed.
Watch for soot in flue pipe - clean regularly.
Be aware of danger due to over firing unit.
This unit is NOT suitable for automatic stoking.
Load the firebox chamber carefully.
Always observe the following minimum clearances to combustible materials:
Front 48”
Right side 18”
Left side and rear 24”
Flue pipe 18”
Floor must be non-combustible.
Maintain seals on firing door in good condition.
Establish a routine for storage of fuel, care of the appliance, and firing techniques.
DO NOT OPERATE WITH FUEL LOADING OR ASH REMOVAL DOORS OPEN. DO NOT STORE
FUEL OR OTHER COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES.
INSPECT AND CLEAN FLUES AND CHIMNEYS REGULARLY.
CAUTION - HOT SURFACES - KEEP CHILDREN AWAY! DO NOT TOUCH DURING OPERATION!
KEEP THE DOORS CLOSED AND MAINTAIN SEALS IN GOOD CONDITION.
OFF-SEASON MAINTENANCE BY A QUALIFIED PROFESIONAL..
CLEANING OF THE HEAT EXCHANGER, FLUE PIPE, CHIMNEY AND DRAFT INDUCER, IF
USED, IS ESPECIALLY IMPORTANT AT THE END OF THE HEATING SEASON TO MINIMIZE
CORROSION DURING THE SUMMER MONTHS CAUSED BY ACCUMULATED ASH.
INSTALLER INSTRUCTIONS TO THE BOILER OWNER
1. Keep area around unit clean.
2. Use SOLID wood only. Hardwood is preferred.

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3. Load carefully. Plan wood load based on BTU requirement. Maintain intense burns for
maximum efficiency.
4. Remove ash regularly as directed.
5. Watch for soot build up in Flue pipe, and Heat Exchanger.
6. Realize the danger of extreme overheating due to over firing.
7. Danger of flue fire if poor maintenance produces creosote buildup.
8. Operation of unit during power failure, (i.e. manual operation of zone valves and flow check
valves).
9. When shutting down for extended periods, clean unit thoroughly.
10. BEFORE RELOADING THE BOILER WITH WOOD, DRAFT CONTROL FAN MUST BE
STOPPED, AND FLUE DAMPER FULLY OPENED FOR AT LEAST ONE MINUTE BEFORE
OPENING THE LOADING DOOR TO REFUEL.
This is necessary to ensure that smoke and flames from the fire will not exit the loading door and harm
the operator.

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Figure 11
Figure 12
The ECONOBURNTM Wood-Fired Boiler must be cleaned regularly to maintain top efficiency. A good
practice is to establish a routine for the storage of fuel, care of the appliance, and firing techniques.
BOILER MAINTENANCE
Turbulator assembly should be exercised every day of boiler usage when the unit is hot.
Ashes should be removed as needed. Recommend weekly.
Clean heat exchangers annually with a 2 inch bore brush or similar device.
Inspect refractory and nozzles every month to check condition.
Grease door hinges annually.
CLEANING THE HEAT EXCHANGER
Every day of boiler use, the turbulator assembly should be exercised. To perform this
maintenance, grasp the turbulator agitation lever on the upper left side of the Boiler (see Figures
11 & 12) and firmly raise and lower it several times. The turbulator arm will only move a short
distance (from the 6 o’clock to the 3 o’clock position) back and forth, and should be left as shown
in Figure 12, below.
When the turbulator agitation lever is moved back and forth, it clears the heat exchanger tubes of
any buildup of soot and ash that might have collected from the normal functioning of the Boiler
combustion.
MAINTENANCE AND CLEANING

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ALWAYS FOLLOW THIS PROCEDURE TO CLEAN THE
HEAT EXCHANGER.
1. Remove back and top jacket panels of the Boiler.
2. Cut insulation to expose top clean out.
3. Remove 1/4” steel top cover plate and rear flue plate.
4. Disconnect the turbulator rod by removing the nut and
bolt which affixes it to the turbulator shaft.
5. Remove the turbulator arms by grasping the turbulator
connecting rod and lifting them out of the heat exchanger.
6. Using a steel brush, remove any soot and ash buildup from
the heat exchanger tubes and vacuum any ash
accumulated on the top of the heat exchanger.
7. Remove ash from the lower combustion chamber.
8. Replace 1/4” steel top cover plate and rear flue plate
making sure all connections are tight, sealed with a high
temperature silicone.
ASH DISPOSAL
Before removing ashes, cease refueling and allow the fire to die down. Before opening the lower
combustion chamber door, ensure the fire in the boiler is completely extinguished.
Ashes should be placed in a metal container with a tight fitting lid. The closed container of ashes
should be placed on a non-combustible floor or on the ground, well away from all combustible
materials, pending final disposal. If the ashes are disposed of by burial in soil or otherwise locally
dispersed, they should be retained in the closed container until all cinders have thoroughly cooled.
WARNING
ASHES USUALLY CONTAIN LIVE DORMANT COALS, WHICH MAY BURN FOR MANY HOURS
AFTER A RECOGNIZABLE FLAME HAS DISAP¬PEARED. USE EXTREME CAUTION WHEN
HANDLING AND DISPOSING ASHES.
HEAT EXCHANGER MAINTENANCE
The boiler Heat Exchanger must be thoroughly cleaned at least once a year. This consists of clean-
ing the Heat Exchanger tubes of accumulated soot and ash with a wire brush (Figs. 13 & 14)
MAINTENANCE TIPS
Figure 13
Figure 14