IP FD100 User manual

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LUMBER DRYER
FD100
OWNER’S MANUAL
www.eipl.co.uk

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INTRODUCTION
You have probably never seriously considered kiln drying your own lumber
before, believing it to be too expensive or too complicated to undertake on a
small scale.
Prior to the introduction of the Ebac Small Scale Lumber Dryers this was true.
Kiln drying was for the world of specialists: a confusing maze of kiln
schedules, sampling techniques, relative humidity’s and complex controls –
hardly inviting to the small woodworking business which merely wanted to be
sure of a regular supply of quality wood at a reliable and consistent moisture
content.
Ebac Small Scale Lumber Dryers have changed all that. Whether yours is a
one-man business or somewhat larger, whether you are in the woodworking
business or woodworking is just your hobby, you do not need any previous
experience with drying. As well as being simple to install and operate, Ebac
dryers are quiet and cause no pollution.
The Lumber Dryers themselves are installed in easily made chambers of the
appropriate size.
This manual has been designed to guide you through the problems of
choosing the correct size of wood dryer for your needs, constructing a suitable
chamber and operating the kiln to obtain maximum output of wood.
Use it carefully and thoroughly and you will quickly find out everything that you
need to know.
For further information and details of constructions and applications not
covered, we will be pleased to offer advice and assistance as required.
Please do not hesitate to contact us.

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SIMPLIFIED SCHEMATIC DIAGRAM OF LUMBER
COMPONENTS
Figure 2
Though the fastest drying is achieved at high temperature, the risks of
degrade in the wood, particularly hardwood, increases at high temperature.
The general rule is that the lower the temperature the better the quality.
Ebac dryers are designed to operate in the temperature range, which is the
best compromise between speed and quality – about 140°F (60°C) and lower.
Drying at these temperatures insures that the wood is of the highest quality,
and that the equipment is reliable.

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UNPACKING
Upon receipt of your FD100, carefully inspect the shipping container and its
contents for any damage. If damage is discovered, contact the Service
Department for instructions.
CONTENTS
Your FD100 shipment consists of the following items:
1. LD3000 Lumber Dryer with Power Cord
2. Discharge Hose
3. STC1 Controller
4. (2) Wall Mounting Brackets
5. (2) 16 – inch Circulation Fans

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DRYER CAPACITIES
Table 1 below shows average drying times for the FD100. Table 2 shows the
optimum load capacities for the FD100. If larger quantities than those shown
in Table 2 are dried, drying speed will be proportionately slower. If small
quantities are dried, the controls can be adjusted to allow for this.
Table 1 – Average Dying Times in Days*
MOISTURE CONTENT RANGE
FROM
–
TO
50%
-
8%
405
–
8%
30%
-
8%
20%
-
8%
Type Thickness Days Days Days Days
Hardwoods** 1” 50 37 25 13
2” 90 68 45 25
3” 158 119 81 43
Softwoods 1” 14 10 6 4
2” 32 25 15 8
3” 53 40 27 14
* Drying times may vary depending on species, starting moisture
content, thickness, and size of load.
** Drying of Claro Walnut is not recommended.
Table 2 – Optimum Lumber Capacities in Board Feet
Lumber Type Softwoods Hardwoods
Thickness
(Inches)
1” 2” 3” 1” 2” 3”
LD3000 1440 3210 5400 3000 5150 8875
(Some capacities can be smaller or larger – consult Ebac)
Example 1: You wish to dry 4/4 Oak from a starting moisture content 30% to
8%.
From Table 1, you see that it will take 25 days to dry 4/4 (1”) hardwood for
30% to 8%.
Then from Table 2, the optimum capacity for 1” hardwood fro the FD100 is
3000BF. Therefore, 3,000BF can be dried in about 25 days, and 42,000BF in
a year. (365/25 days = 14 loads per year x 3,000BF per load).

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KILN CHAMBER
LUMBER STACK SIZE
The first step in determining your kiln chamber size is to determine the most
suitable lumber stack size (or configuration) for your purposes. This will
depend primarily on the longest length board to be dried. Normally, the length
of the stacks will be equal to the length of the longest board. If you lumber is
in short lengths (i.e.: approximately 3 feet), then the stack length should be
multiples of these lengths.
The width and height of the stack can be adjusted to suit your conditions. The
“stack” may actually be made up of two or more smaller stacks, or packs.
In order to allow air-flow through the lumber stack, each “layer” must be
separated from the below by a spacer or “sticker” of ¾ to 1” thickness. The
air spaces thus created must be included in the overall stack height when
calculating volume.
Use this procedure to determine stack height and width: First select an
appropriate width and then calculate stack height including stickers. If this
calculated height would result in an awkward height to width, select a new
width. See example 2 which follows.
Example 2: Desired kiln capacity is 3,000BF of 1” hardwood, and the longest
board is 16 feet. Add 10% to the lumber quantity to allow for non-uniformity in
the stack. If that stack width is 6 feet, then each layer of lumber would
contain:
BF per layer = 16’ x 6’ x 1” thick = 96BF
Layers required = 3,000BF x 1.1 = 34.4 of 35 layers
96BF/layer
Each layer is 1” ¾” sticker = 1 ¾“ high
Stack height = 35 layers x 1 ¾” high = 61 ¼” high (rounded up to 5 ¼’)
Thus, the stack size is:
16’ long x 6’ wide and 5 ¼’ high

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CHAMBER INTERIOR DIMENSIONS
Having calculated the stack size, it is now possible to calculate the
appropriate internal dimensions of the chamber. This is done by adding the
required additional space around the stack for the dryer and the fans as well
as for good air circulation. Suggested additional space is:
Length: 1’
Width: 2 ½’
Height: 2’
Example 3: Using the information from Example 2, where the stack size is
16’ long and 6’ wide and 5 ¼’ high, we can find the required internal
dimensions.
Length: 16’ + 1’ = 17’
Width: 6’ + 2 ½’ = 8 ½’
Height: 5 ¼’ + 2’ = 7 ¼’

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CHOOSING PROPER INSULATION THICKNESS
The wall thickness (insulation) is very important and is related to the size
(surface area) of the chamber.
After adding the required internal clearances to the stack size, the internal
dimensions are known, and the approximate chamber surface area can be
calculated. Table 3 shows the recommended thickness of insulation (wall
thickness) in relation to the total surface area of the walls, ceiling and floor of
the chamber.
To determine wall (insulation) thickness we must calculate approximate
surface area of the chamber.
Example:
Kiln Dimensions: 8 ½’ x 8 ½’ x 18’ (H x W x L)
Ends: 8 ½’ x 8 ½’ x 2 pieces 145 sq.ft
Top and Bottom: 8 ½’ x 18’ x 2 pieces 306 sq.ft
Front and Back: 8 ½’ x 18’ x 2 pieces 306 sq.ft
_______
757 sq.ft surface area
Pick proper insulation thickness from Table 3.
Table 3 – Thickness of Insulation
Surface Area of
Camber in Sq.Ft
500 800 1100 1400 1800 2100
Optimum R-
Value
11 16 19 19 21 21
Fiberglass Insulation Blue Styrofoam
R-11 = 3 ½” R-19 – 6” R-7 = 1”
The thicknesses in the table are optimum for year round operation. If you
wish to increase efficiency during the winter in cold climates, increase
thickness by about 50% and remove extra insulation during the summer. This
extra insulation may cause the kiln to overheat in the summer.

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EXAMPLE KILN SIZES
If you would rather not design the dimensions of you kiln, simply choose the
best size for you operation from Table 4.
All of the kiln dimensions shown are exterior dimensions. The load sizes refer
to 1” hardwood with ¾” stickers, and all the wall thickness and air spaces
have been added in.
Table 4 – Example Kiln Sizes
(Height x Width x Length)
6’ Lumber
2 Stacks – See 12’ Lumber
8’ Lumber
2 Stacks – See 16’ Lumber
10’ Lumber
10 x 10 x 12 = 3000BF
10 x 9 ½ x 12 = 2700BF
9 ½ x 9 ½ x 12 = 2500BF
12’ Lumber
9 ½ x 9 ½ x 14 = 3000BF
9 ½ x 9 x 14 = 2700BF
9 x 9 x 14 = 2500BF
14’ Lumber
9 x 9 x 16 = 3000BF
9 x 8 ½ x 16 = 2700BF
8 ½ x 8 ½ x 16 = 2500BF
16’ Lumber
8 ½ x 8 ½ - 18 = 3000BF
8 ½ x 8 x 18 = 2700BF
8 x 8 x 18 = 2500BF

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CONSTRUCTION OF CHAMBER
Floor:
An insulated concrete floor is recommended.
•Start with a gravel base.
•Lay down 2” of rigid Styrofoam.
•Pour 4” of reinforced concrete.
•Seal concrete with any commercially prepared sealer
Notes: A slightly pitched floor leading to drain may be incorporated.
This will helpful if large amounts of softwood are to e dried.
Should an insulated concrete floor not be feasible, a well-built,
insulated wooden floor will work.
See Figure 3.
Wall/Ceiling Construction:
•Make a 2” x 4” studded frame.
•Cover exterior with ½” exterior grade plywood or waferboard.
•Insulate to proper R-Value.
•Staple or tack 4mm. Plastic over insulation prior to installing inside the
wall. This vapor barrier protects insulation from moisture.
•Spray paint over staples to prevent corrosion.
•Hand ¼” exterior grade plywood as inside wall.
•Coat the inside wall and ceilings with a vapor barrier grade sealer.
This protects the inside walls and ceiling from moisture and insures
long life for your kiln. (Aluminized mobile home roofing paint works
well).
•Use a silicone caulk to seal up all cracks and seams.
See Figures 4 and 5.

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Door Construction:
•The door section should be constructed the same as the walls and
ceiling.
•Exterior plywood should overlap the door frame by 3”. This will allow
space to attach a rubber gasket and enable the door to be bolted to the
kiln chamber. Anchor bolts are recommended for continued usage.
•For front loading kilns, hinged double doors are needed.
See Figures 6 and 7.
Fan Truss:
The FD100 kiln accomplishes air circulation with the aid of two (2)
supplemental overhead fans. The 110 Volt, 60 Hz fans are wired in separate
from the drying unit.
•The fan truss, which hangs from the ceiling, should run the length of
the kiln.
•The truss should be located 18” from the front of the drying unit.
•The truss should be framed with 2” x 42 studs.
•The circulation fans should be evenly positioned within the truss.
•Air flow should move away from the dryer.
•Plywood or waferboard is used to cover the open area of the fan truss.
•For all dry kiln, baffles or curtains should be used above and to the side
of the stack to force the air flow through the lumber stack, not around it.
Heavy plastic is the most common baffling.
See Figure 8.
Material List: (Numbers correspond with drawings)
1. ¼” or ½” CDX plywood or article board.
2. 4mil. Poly under CDX plywood or particle board.
3. Fiberglass or Blue Styrofoam insulation.
4. Fiberglass or Blue Styrofoam insulation.
5. 2” x 4” or 2” x 6” Construction.
6. Rubber Gasket (Garage door seal works well).

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FD100

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INSTALLATION AND TESTING
Installation
All wiring should be carried out by a competent electrical contractor in
accordance with local regulations.
The 16-inch circulation fans do not connect to the STC1 Controller. They
must be connected to separate switchgear.
Check the voltage at the power supply to insure correct voltage is 220 Volt +/-
10%, 1 Phase, 60 Hz.
The FD100 must be plugged into a suitable fused 220 Volt outlet.
Using the mounting brackets provided with the unit, mount the FD100 4” – 8”
from the ceiling, centered on the back wall.
Attach the discharge hose to the drainage nipple.
Locate and drill three (3) holes fro the following:
Discharge hose – ensure that the water discharge will gravity feed from
the kiln chamber. The hose should be ran to a permanent drain.
Power cord and Controller cord – Ensure that the power cord reaches
the 220 Volt, 1 Phase, 60 Hz outlet and that the controller cord reaches
the plug connection on the STC1 Controller.
Use silicone rubber caulking or a similar material to seal the holes after proper
installation of the discharge hose, power cord, and controller cord. This will
aid in preventing heat loss from the kiln.
Warning:
OSHA complying guards are strongly recommended
when fans are installed with 7’ of floor, working level,
or within reach of personnel. Review OSHA codes.

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TESTING FOR PROPER INSTALLATION
Remove lower front panel by removing four retaining screws.
Adjust the temperature control and the drying control on the STC1 Controller
to the minimum setting.
Attach the controller cord to the STC1 Controller and latch in place.
Plug the FD100 power cord into the 220 Volt, 1 Phase, 60 Hz receptacle.
(Insure that power to the receptacle has been achieved).
The fans in the FD100 will start to rotate immediately. Set the STC1 drying
control to C and the temperature control to 45ºC.
The above settings will result in the following:
1. The heating element will produce heat.
2. After a 6 minute delay, the compressor will start to run.
When the compressor has been running for 6 minutes, the bare copper coils
above the draintray should be covered with either frost or condensation. (The
last two or three turns on the rear coils may not have frost or condensation
because the refrigerant is picking up superheat for the return to the
compressor).
After insuring proper operation of the FD100, disconnect the power cord and
reinstall the lower front panel.
Warning:
Do not operate the FD100 for an extended period of time with
the covers removed. This will cause improper operation of
the machine and may cause damage to components.

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