SCOTTY SS DB-202A User manual

SCOTTY SS
WOOD FURNACE
Model DB-202A
OWNER’S MANUAL
IMPORTANT
READ OWNER’S MANUAL THOROUGHLY BEFORE
INSTALLING FURNACE OR LIGHTING FIRE.
CONSULT LOCAL AUTHORITIES IF IN DOUBT
ABOUT YOU
R LOCAL FIRE SAFETY REGULATIONS.
ALL INSTALLATIONS MUST BE MADE IN
ACCORDANCE WITH LOCAL AND STATE OR
PROVINCIAL CODES WHICH MAY DIFFER FROM
THIS MANUAL.
IMPROPER INSTALLATION WILL RESULT IN
VOIDING OF WARRANTY.

SCOTTY SS
–
INSTRUCTION MANUAL
Scotty SS Oct-06
1
TABLE OF CONTENTS
Specifications 3
1.0 Operating instructions 4
1.1 Introduction 4
1.2 Wood-Burning 4
1.3 Storage of Wood 5
1.4 Maximum Solid-Fuel Charge 6
1.5 Maintenance 6
1.5.1 Cleaning 6
1.5.2 Servicing 7
1.6 Safety 7
1.7 Controls 7
1.8 Electrical Power Failure 8
1.9 Homeowner Checklist 9
2.0 Installation Instructions 9
2.1 Introduction to Installers 9
2.2 Uncrating 10
2.3 Locating the Furnace 10
2.4 Flue Pipe & Chimney 11
2.5 Clearances 12
2.6 ADD-ON to Another Furnace 13
2.7 Duct Connection 15
2.8 Control Systems 17
2.8.1 Static Pressure Drop Test 17
2.8.2 Temperature Rise Test 18
2.9 Additional Notes 19
2.10 Installers Checklist 19
3.0 Add-On to Oil Furnace 20
3.1 Combustion Air for Wood & Oil Furnaces 20
3.2 Duct Connections 21
3.2.1 S-Type Duct Connection 21
3.2.2 Divided Plenum 21
3.3 Control Systems 22
3.3.1 Add-On to Oil Control Kit “A” 22
4.0 Add On to Electric Furnace 23
4.1.1 Nortron 21 FRK 10H –25 Series 23
4.1.2 Other Approved Electric Furnaces 24
4.2 Duct Connection to an Electric Furnace 24
4.2.1 Duct Connection 25
4.2.2 Minimum Duct Sizes 25
4.2.3 L-Type Duct Connection & Frame 25
4.3 Installation Summary 25
4.4 Control System 25
4.5 Add-On to Electric Control Kit “E” 26

SCOTTY SS
–
INSTRUCTION MANUAL
Scotty SS Oct-06
2
DIAGRAMS
S202-1 Add-On to Oil –Clearances
S202-2Add-On to Oil –“S” type duct
S202-3A Gravity Return Air Kit
S202-3B Base for use on combustible floor
S202-4Add-On to Oil –Divided Plenum
S202-5A Add-On to Oil –Electrical Schematic Belt Drive
S202-5B Add-On to Oil –Electrical Schematic Direct Drive
S202-5C Add-On to Oil –Electrical Schematic Direct Drive
S202-6Add-On to Electric –Clearances
S202-7Add-On to Electric –Installation
S202-8Add-On to Electric –Nortron Wiring Schematic
S202-9Add-On to Electric –General Schematic
S202-10 Cleaning
S202-11 Approved Furnace Ductwork Configurations
S202-12 Prohibited Furnace Ductwork Configurations
Appendices
APPENDIX A –Warranty Rear Cover
Copyright 2004 Kerr Heating Products, 2004 Parrsboro Metal Fabricators Ltd.
KERR SCOTTY SS Wood Furnace Model DB-202A
Certified by the Canadian Standards Association (CSA) Sept. 1982 and Sept. 1988
Manufactured by: Parrsboro Metal Fabricators Ltd.
12118 Highway 209
P.O. Box 637, Crossroads
Parrsboro Nova Scotia, Canada
B0M 1S0

SCOTTY SS
–
INSTRUCTION MANUAL
Scotty SS Oct-06
3
SPECIFICATIONS
Length 34”
Width 22 1/2”
Height 43”
Shipping Weight 238 lb
Fire Box 1/8”plate Length 27 1/2”
Diameter 18”
Secondary Heat Exchanger 14 gauge steel
Fire Box Door Cast Iron 12” x 12”
Warm Air Plenum 21” x 30 1/2”
Return Air Plenum Not Applicable
Air Filter Size Not Applicable
Blower Size Not Applicable
Blower Motor Not Applicable
CFM 1000 (Required)
Smoke Pipe 7” Inside Diameter
Floor to smoke pipe center 36”
Output (max): 70,000 Btu/h
Fuel: Wood up to 24” logs
Electrical Rating: Volts 120, Cycles 60, Amps 15
NOTE –Keep this manual in a safe place for future reference. Follow manual carefully for the
correct way to install and operate this unit.
CAUTION –Do not fire this unit until operating instructions have been read and fully
understood.
INSTALL WOOD FURNACE ONLY ON A FURNACE DUCT SYSTEM AND CHIMNEY THAT
ARE IN GOOD CONDITION.
SAVE THESE INSTRUCTIONS

SCOTTY SS
–
INSTRUCTION MANUAL
Scotty SS Oct-06
4
1.0 OPERATING INSTRUCTIONS
1.1 INTRODUCTION
Congratulations on your purchase of the KERR SCOTTY SS Wood Furnace. Developed in
Atlantic Canada, this KERR Furnace has been designed to allow you to heat your home with
wood, one of North America’s most abundant fuels. Designed with you in mind, the KERR
SCOTTY SS Wood Furnace will provide you with many years of safe, efficient central heating.
To ensure you have a clear understanding of the operating procedures of this furnace, please
take the time to read the remainder of this section on operating procedures. If you have any
questions, your KERR dealer will be happy to answer them for you.
1.2 WOOD-BURNING
The SCOTTY SS Wood Furnace will burn most wood fuels, however it is recommended that
only dry, seasoned hardwood be used as much as possible since it affords cleaner, safer and
more efficient operation. Burning seasoned hardwood will leave less ash, soot and creosote
residue and will require fueling less often. Use smaller loads of wood on warmer days.
WARNING: DO NOT use chemicals or fluids to start the fire or during operation.
DO NOT burn driftwood or manufactured logs (compressed wood).
Before adding fuel to an existing fire turn up the thermostat for about five minutes or lift damper
chain to hold damper fully open for about one minute before opening the loading door. This
action will allow residual smoke to clear from the combustion chamber and reduce smoke
entering the basement during refueling.
Twice daily refueling may be sufficient in modern well-insulated homes. However, KERR
recommends that small fuel loads be added morning, noon and early evening and late
evening, rather than large quantities infrequently. A small intense fire will burn more efficiently
than a large smoldering fire in the SCOTTY SS Wood Furnace and will produce less creosote.
When refueling the SCOTTY SS, the remaining coals should be raked to the front of the
combustion chamber before adding any new fuel. Place the fresh supply of wood to the rear of
the combustion chamber. This gives more of an even cigar type fuel burn, rather than a large
hot fire to a slow amber fire. This will help create a more even and efficient burn. The
SCOTTY SS owner should attempt to gauge fuel quantities with outdoor temperatures; a little
practice will provide greater satisfaction and efficiency.
WARNING: This furnace is not to be used with an automatic stoker.
Keep firing door tightly closed and maintain door seal in good condition.

SCOTTY SS
–
INSTRUCTION MANUAL
Scotty SS Oct-06
5
CREOSOTE
Wood combustion is never 100% complete. Wood smoke always contains some unburned
gases and a mixture of unburned tar-like liquids. Apercentage of these materials will
condense out on any cool surface, leaving a dark brown or black substance with an unpleasant
acrid odor. This substance is commonly called creosote.
If these wood gases condense out on cool surfaces such as a cold chimney or a long smoke
pipe, they retain large amounts of water and will be very fluid. At higher temperatures the
condensed creosote will resemble tar (thick and tacky).
Creosote generation is highest during low heat outputs common with long smoldering burns.
Creosote generation is lowest during high heat outputs common with intense fires. It is
recommended that a small intense fire be used for best results against creosote build up even
though the wood furnace will require refueling more often.
Creosote generation is also higher when burning green wood. The moisture in the green wood
absorbs the heat from the fire, cooling the fire below the point at which the creosote can be
consumed. The low temperature smoke is then further cooled in the upper furnace chambers’
smoke pipe and chimney allowing large amounts of creosote to form.
To reduce creosote build-up during periods of low heat requirements (i.e. Spring and Fall) it is
recommended to fuel the wood furnace with smaller quantities of smaller diameter logs.
Matching fuel loads and heat requirements will result in cleaner combustion and higher
efficiency.
IN CASE A SERIOUS CREOSOTE FIRE BEGINS:
a) Close the damper door by disconnecting chain
b) Close all draft regulators
c) Throw 1/2 lb of coarse or table salt on the fire and close door immediately.
d) Call the FIRE DEPARTMENT at once!
Have a firmly established Emergency Procedure in place for the handling of a flue fire.
1.3 STORAGE OF WOOD
Once cut, green wood dries (or seasons), quickly at first and then at a slower and slower rate.
When the wood has been cut to the proper length and split, it should be piled outside during
the summer months. Place two poles on the ground to serve as rails to keep the firewood off
the moist ground. Stack the wood so that both ends of the logs are exposed to the air if space
is available, since more drying occurs through the cut ends than through the sides. This is true
even with wood that has been split. The woodpile should be under cover so that it will not
absorb moisture from the rain and snow before it is used, but still open on the sides and ends
to the drying effect of the wind and sun. Store wood in neat, well-supported piles.

SCOTTY SS
–
INSTRUCTION MANUAL
Scotty SS Oct-06
6
1.4 MAXIMUM SOLID-FUEL CHARGE
The maximum level for a solid-fuel charge is the middle of the loading door, or the level of the
handle. DO NOT OVERFILL. The KERR SCOTTY SS Wood Furnace will accept whole or
split logs up to 27 inch (686 mm) long, but a 24-inch (610 mm) log length is recommended for
convenience and ease in handling. Maximum damper gate opening is 9/16”. Do not tamper or
adjust to greater opening in an attempt to increase fire or over-firing and hazard may result.
1.5 MAINTENANCE
Some regular maintenance is necessary on the KERR SCOTTY SS furnace. A good practice
is to establish a routine for the storage of fuel, care of the appliance, and firing techniques.
1.5.1 CLEANING (Fig S202-10)
The KERR SCOTTY SS Wood Furnace must be cleaned regularly to maintain top efficiency.
The furnace needs cleaning more often when burning green wood, or during long periods of
low fire. When the KERR SCOTTY SS Wood Furnace is first installed the furnace heat
exchanger should be checked visually from the firebox and smoke pipe hole every week to
determine the rate at which creosote or ash is accumulating within the furnace. Cleaning
should be done whenever there is more than 1/4 inch of build-up on the heat exchanger or 3
inches of ash in the base. If the wood furnace is to be left unused for an extended period of
time (more than one month) then the appliance should be cleaned of all ash and residual left
from the burning of wood. See FIG. S202-10
CLEANING PROCEDURE:
1) Make sure fire is completely out and the furnace has cooled.
2) Remove the smoke pipe, located on the rear of the furnace heat exchanger.
3) The heat exchanger is now accessible for cleaning.
4) Use the scraper provided to remove all soot and ash from the furnace heat exchanger
and exposed surfaces.
5) Scrape all residue ash in the top heat exchanger towards the front of the furnace where it
will fall into the firebox.
6) Always check flue pipe for creosote or ash build-up in the pipe and clean if necessary.
7) Reinstall the smoke pipe making sure that all joints are secured with at least 3 sheet
metal screws.
8) Check chimney cleanout for ash build-up and remove any accumulation.
9) Residue may be removed from the firebox or left to be burnt during the next fire. It is
good practice to leave a layer of ash approximately one inch deep in the base of the
firebox.
DISPOSAL OF ASHES
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. IMPORTANT –No other waste shall be placed in this container.
WARNING –Ashes usually contain live dormant coals, which may burn for many hours after a
recognizable flame has disappeared. Use extreme caution when handling and disposing
ashes.

SCOTTY SS
–
INSTRUCTION MANUAL
Scotty SS Oct-06
7
1.5.2 SERVICING
The furnace air filter must be checked monthly and replaced when necessary. Annually
lubricate the blower motor, if it is not permanently lubricated, with 4-6 drops of SAE-30 oil in
each bearing.
CAUTION: Failure to keep air filter clean will result in poor furnace performance and
possible damage to wood furnace heat exchanger.
1.6 SAFETY
If the furnace overheats due to improper operation the following precautions should be taken:
1) DO NOT shut off power. Blower must be kept running to disperse excessive heat.
2) Manually close the damper door by unhooking the chain.
3) Check controls for proper operation before starting a new fire.
WARNING–The maximum opening of the combustion air damper is preset at the factory.
DO NOT adjust the stop or attempt to increase the combustion air by any means.
1.7 CONTROLS
Thermostat
The primary control is the room thermostat located near the center of the house on the main
floor or near an existing thermostat. The thermostat operates the damper motor to open and
close the damper door thus allowing more or less air into the combustion area to control the
fire.
Fan and Limit
The fan and limit controlmounted in the plenum controls the operation of the circulating blower
and prevents the furnace from over-heating. When the air temperature in the plenum reaches
the “ON” set point of the fan switch (usually 140º F (60º C)) the blower starts and runs until the
plenum cools to the “OFF” set point (usually 100º F (38º C)) when the blower is switched off.
The limit function in this control is usually set at (280º F (138º C)) and will override the room
thermostat to close the damper door if the furnace overheats, and will also prevent the oil
furnace from starting.
1.8 ELECTRICAL POWER FAILURE (Fig S202-3A)
If no one is home during a power failure, the damper will automatically close and some gravity
heating will take place. Combustion air will continue to enter through the secondary air holes
and a fire should be maintained.
IMPORTANT –This furnace is CSA certified for operation under Power Failure only if optional
gravity air inlet kit is installed.

SCOTTY SS
–
INSTRUCTION MANUAL
Scotty SS Oct-06
8
For optimum heating during a power failure follow the procedure listed below:
1) Remove the power failure gravity air inlet cover before starting or refueling during power
failure. The cover is an option available from your KERR dealer. The kit must be installed
on the cabinet side directly opposite to the entry of the blower or oil furnace “S”
connection ductwork. (See Fig. S202-3A).
2) Manually open the blower compartment access door of wood or connected oil furnace to
allow gravity flowing air to all areas. (Check with your installer)
3) Place a coin under the damper flap in such a way that it will fall clear when power is
restored.
4) Maintain a careful watch on the furnace temperature. If it should exceed 200º F (95º C)
close the damper door.
5) Do not leave the furnace unattended in this position.
6) Refuel frequently with small load to maintain a small fire at 1/2 normal maximum volume.
7) Do not expect to maintain maximum comfort under no power conditions.
8) Do not allow anyone who is unfamiliar with the operation of the furnace to attend it during
a power failure.
1.9 HOMEOWNER CHECKLIST
a) Keep area around unit clean and clear of combustibles.
b) Use only dry wood. DO NOT burn garbage, gasoline or naphtha.
c) Load carefully.
d) Remove ashes as directed.
e) Watch for soot build up in smoke pipe –clean regularly.
f) Clean furnace heat exchanger regularly.
g) Be aware of danger due to over firing of the unit.
h) Do not load above maximum loading level (middle of loading door) or overheating may
result.
i) This unit is NOT suitable for automatic stoking.
j) Load carefully. Do not slam fuel against rear or sides of firebox this may damage the
firebox.
k) Always observe the following minimum clearances to combustible materials –Front 48”
(1220 mm); one side 6” (152 mm); opposite side and rear 24” (610 mm); and flue pipe 18”
(465 mm).

SCOTTY SS
–
INSTRUCTION MANUAL
Scotty SS Oct-06
9
l) Do not store solid fuel within the above clearances or within the space required for
charging and ash removal.
m) Establish a routine for storage of fuel, care of the appliance, and firing techniques.
2.0 INSTALLATION INSTRUCTIONS
2.1 INTRODUCTION TO INSTALLERS
Before installing this KERR SCOTTY SS Wood Furnace, please read the following instruction
manual carefully. This unit is designed to be an add-on to a central heating furnace to provide
complete central heating in medium sized well-insulated homes. Before installing be sure unit
is properly sized for the intended application. Warranty does not cover misapplication of unit.
Applicable Standards
The KERR SCOTTY SS Wood Furnace must be installed in accordance with the requirements
of the National Fire Protection Association codes, the Canadian Heating, Ventilation and Air
Conditioning Code, The National Board of Fire Underwriters, and the CSA Standards for solid
fuel burning equipment as outlined in B365-01. In all cases consult your local authorities and
fire insurance company for specific regulations.
2.2 UNCRATING
When you receive your KERR SCOTTY SS Wood Furnace, check it carefully to ensure that all
components are present and in good condition. If there has been any damage or loss in
transportation, please notify the carrier and retailer at once. Inspect for the following:
1) Firebox/Heat exchanger
2) Poker/Coals rake
3) Marking template (return air and power failure bypass inlet)
CONTROL KIT A (Oil add-on), or E(Electric add-on) selected according to installation, which
includes:
1) L4064R Fan and Limit Control
2) Control Mounting Plate
3) Damper Motor
4) Thermostat (T822D or equivalent)
5) Wiring Harness and Parts
6) Switching Relay R8405C (8A05A –4) –Kit “A” & “E” only
NOTE: Some parts may be packed inside furnace firebox. Check shipment carefully before
assuming shortage.