woodmizer SolarKiln SD3000 User manual

Wood-Mizer®SolarKiln
Safety, Construction &
Operator’s Manual
Model SD3000 rev. C.00
Model SD3000-50 rev. A.00
Model KS50 rev. A.00
Model KS50-50 rev. D.00
Safety is our #1 concern! Read and understand
all safety information and instructions before oper-
ating, setting up or maintaining this machine.
April 2003
Form #462

Table of Contents Section-Page
ii SD3000doc010317 Table of Contents
SECTION 1 MATERIALS 1-1
SECTION 2 SD3000 CONSTRUCTION 2-1
2.1 Choosing A Location For The Kiln........................................................................... 2-1
2.2 Slab Construction ...................................................................................................... 2-1
2.3 Sill Plate Construction............................................................................................... 2-2
2.4 End Wall #1 Construction ......................................................................................... 2-2
2.5 End Wall #2 Construction ......................................................................................... 2-3
2.6 End Wall Installation................................................................................................. 2-3
2.7 Front Wall Construction............................................................................................ 2-4
2.8 Front Wall Installation............................................................................................... 2-4
2.9 Back Wall Construction ............................................................................................ 2-4
2.10 Back Wall Installation ............................................................................................... 2-5
2.11 Exterior Sheathing Installation .................................................................................. 2-5
2.12 Interior Sheathing/Insulation Installation .................................................................. 2-6
2.13 Support Wall Construction ........................................................................................ 2-6
2.14 Support Wall Installation........................................................................................... 2-6
2.15 Fan Shelf Construction .............................................................................................. 2-7
2.16 Fan Shelf Plywood Installation ................................................................................. 2-7
2.17 Loading Door Construction....................................................................................... 2-7
2.18 Lower Rafter Installation........................................................................................... 2-8
2.19 Upper Rafter Installation ........................................................................................... 2-8
2.20 Door Stop Installation................................................................................................ 2-8
2.21 Loading Door Installation.......................................................................................... 2-9
2.22 Service Door Installation........................................................................................... 2-9
2.23 Screen Installation ................................................................................................... 2-10
2.24 Fan Installation ........................................................................................................ 2-10
2.25 Electrical Installation............................................................................................... 2-11
2.26 Spacer/Furring Strips............................................................................................... 2-11
2.27 Inner Plastic Installation.......................................................................................... 2-12
2.28 Outer Plastic Installation ......................................................................................... 2-12
2.29 Intake/Exhaust Hardware Installation ..................................................................... 2-13
SECTION 3 OPERATION 3-1
3.1 Pre-Drying Procedures .............................................................................................. 3-1
3.2 Drying Procedures ..................................................................................................... 3-3
3.3 Solar Kiln Maintenance............................................................................................. 3-5

Materials
Materials SD3000doc081806 1-1
1
SECTION 1 MATERIALS
Congratulations on the purchase of a Wood-Mizer®SolarDry™ Kiln! Enclosed are com-
plete construction instructions for the kiln. This manual contains drawings and lists of
building materials required to construct the SolarDry SD3000 SolarKiln. Follow the
instructions carefully, strictly heeding all special WARNINGS and NOTES.
IMPORTANT! Before beginning construction, check your
local building code authority to see if a building permit is
required.
See Table 1-1. Open the box and identify all parts listed below:
SD3000/SD3000-50 Box Assembly
Qty. Part No. Description
13 002681 Strip, 3’-6" Aluminum/Rubber
6 002685 Cap, 4’ Aluminum Drip
2 002688 Bolt, 24" Chain Release Door
2 002690 Bolt, 12" Cane Bottom Steel
2 002693 Handle, 6" Galvonized Door Pull
1 002694 Knob Assy, 1 3/4" Door
2 002695 Panel, 12" x 12" Wall Grill
3 002680 Hinge, Door
4 002696 Hinge, 6" x 36" x 3/8" Pin Steel
2 002684 Bracket Assembly, Fan Mount
2 P02549 Blade, 24" Three Wing Fan
2 P02646 Motor, 1/4Hp Fan (SD3000)
P02646-1 Motor, 50Hz 1/4Hp Fan (SD3000-50)
8 F05010-41 Nut, #8-32 Self-Locking Fan Motor
1 A02583 Door, Aluminum Air Intake
2002697 1
1 Replaced UV Plastic 002706. 002706 becomes 002697 after re-
packaging into a box by shipping (8/06).
Plastic, 20’ x 24’ 6 mil UV
4 002699 Guard, Expanded Metal Fan
1 SD3000-462 Manual, SD3000 Const./Operation
TABLE 1-1

Materials
1
1-2 SD3000doc081806 Materials
See Table 1-2. Required materials to be supplied by the customer for the SD3000
SolarDry Kiln are listed below.
Material Total Qty
1” x 2” x 10’ Cedar 34 34
1" x 4" x 10’ 9 9
1” x 4” x 14’ 2 2
2" x 2" x 10’ 23 23
2" x 4" x 8’ 11 2 14 13 3 43
2" x 4" x 10’ 10 10 10 4 14 48
2" x 4" x 12’ 6 6
2" x 4" x 14’ 6 10 16
2" x 4" x 16’ 6 2 8
2” x 4” x 20’ 3 3
2" x 4" x 10’ Treated 2 2 4
2" x 4" x 16’ Treated 2 2
2” x 6” x 20’ 1 1 2
4’ x 8’ x 1/2" BCX Plywood 20 2 10 6 38
4’ x 8’ x 1/4" BCX Plywood 10 10
4" x 16" Kraft Fiberglass Insulation 550 Sq Ft.
Foam Sill Seal/Insulation 50 Ft.
2’-8” x 6’-8” x 1 3/4” Solid Core Door 1
16D Sinker Nails 1 box
7D Galvanized Nails 1 box
3” Drywall Screws 1 box
1/4" x 2" Hex Head Lag Screws 40 40
8” Concrete Anchors, Washers, & Nuts 22
Black Kiln Coat Paint 3 Gal.
Exterior Paint (Customer Choice) 2 Gal.
Concrete (Slab & Loading Apron) 7.5 yds.
22’ x 20’ x 4 mil Black Plastic 1
6” x 6” x 10 Gauge wire mesh (remesh) 304 Sq Ft.
20 Amp Disconnect Switch 1
10 Oz. Tube Black Acrylic Latex Caulk 4
Standard Screen Door Mesh 213 Sq Ft.
TABLE 1-2
End walls (2) Front Wall Back Wall Support Wall Rafters Fan Shelf & Loading Furring Strips Baffles Doors & Door Stops

Materials
Materials SD3000doc081806 1-3
1
See Table 1-3. A list of suppliers for some materials are listed below.
See Table 1-4. A list of recommended books concerning lumber drying is provided
below.
Product Name Supplier
Log End Coating Anchorseal U.C. Coatings, Corp.
P.O. Box 1066
Buffalo, N.Y. 14215
[phone]
Kiln Coating Black Jack 6383
(Distributed by
Grainger, Menards
& Target)
Gibson-Homans Co.
1755 Enterprise Parkway
Twinsburg, OH 44087
1 [phone]
Kiln Seal Texas Refinery Corp.
One Refinery Place
Fort Worth, TX 76106
[phone]
Moisture Meters Wagner L606 Wood-Mizer Products, Inc.
8180 West 10th Street
Indianapolis, IN 46214
1 [phone]
TABLE 1-3
Publication Supplier
Wood Handbook AH No. 72, USDA Forest Service, Forest Products
Lab, Madison, WI, 1955; [phone]
Dry Kiln Operator's Manual AH No. 188, E.F. Rasmussen, USDA Forest Ser-
vice, Forest Products Lab, Madison, WI 1988
(Stock No. 001-000-04576-8); [phone]
Understanding Wood, A Craftsman's
Guide to Wood Technology
R. Bruce Hoadley, available from Wood-Mizer
(Part No. P05877)
TABLE 1-4

SD3000 Construction
Choosing A Location For The Kiln
2
2-1 SD3000doc010317 SD3000 Construction
SECTION 2 SD3000 CONSTRUCTION
2.1 Choosing A Location For The Kiln
Some considerations should be made when choosing a location for your SolarDry Kiln:
Build the kiln so the collector faces within 5 degrees of due south if building in Northern
latitudes. If you are building in Southern latitudes face the kiln within 5 degrees of due
north. Use a compass to determine the best position for your kiln.
Build the kiln in an area to avoid nearby obstructions of the sun if possible. Allow enough
room around the kiln to maneuver a fork lift or other handling equipment used to move
lumber piles.
Consider future expansion. Additional kilns may be added so they may share end walls
with the first one constructed.
2.2 Slab Construction
Refer to Drawing #1.
The recommended slab has a 6" base which thickens to 18" around the edge. Place con-
crete wire mesh across the entire base and a 1/2" reinforcing rod around the perimeter.
This creates an extremely stable, sturdy base. Install a black 16’ x 20’ 4 mil. plastic vapor
barrier under the slab. Save the remaining 6’ x 20’ plastic to use as a baffle between the
fan shelf and top of the wood stack. See Section 3.2.
The slab should taper 1" front to back to allow any moisture in the kiln to drain out the
loading door side of the kiln.
IMPORTANT! The slab must be level, square and the exact
length shown. If the slab is not level and square, the cham-
ber will not line up properly and adjustments in constructing
the chamber will have to be made.
Install anchor bolts in the slab for mounting the sill plates at the locations shown. Leave
the anchor bolts exposed 2" above the slab to mount the sill plates.
A 10-foot loading apron on the back side of the kiln is recommended to facilitate loading
equipment. The apron should taper 1" from front to back. Leave a 1/4" to 1/2" expansion
joint between the apron and the slab.

SD3000 Construction
Sill Plate Construction
SD3000 Construction SD3000doc010317 2-2
2
After the concrete slab has had sufficient time to cure, you may begin construction of the
kiln chamber.
2.3 Sill Plate Construction
Refer to Drawing #2.
Chalk a line 4" from each edge of the slab. Check the marked lines for squareness.
NOTE: If the lines show the slab is not square, make adjustments at this time.
Cut the sill plates out of treated lumber to the dimensions shown. Use a 16-foot treated
2x4 for each end wall sill plate. Use two 10-foot treated 2x4s for the front and middle wall
sill plates.
Lay the sill plates in place on the slab. Mark and drill 3/4" diameter holes for the anchor
bolts.
Remove the sill plates and use them in wall construction as described later.
2.4 End Wall #1 Construction
NOTE: These plans assume you will install the service door in end wall #2 (right side as
you are facing the kiln). If you prefer the door to be on the left side, simply reverse the
position of the end walls on the slab. You will have to place the lead-in boards for the mid-
dle wall on the opposite side as shown in the drawings.
Refer to Drawing #3.
Refer to the material table and cut lumber as shown. Construct the end wall as shown. Be
sure to keep the sill plate oriented so the holes will line up with the slab anchor bolts.
Install the end studs to the sill plate using 16D nails.
Install the first 45° cap. If two boards are used, position the seam over the lead-in as
shown.
After squaring the wall, mark the stud locations on the sill and the cap. Install the vertical
studs, being sure to keep the wall square.

SD3000 Construction
End Wall #2 Construction
2
2-3 SD3000doc010317 SD3000 Construction
Install the three studs that make up the lead-in for the interior wall. Be sure the middle
lead-in board is aligned with the inside face of the wall.
Install nailers between the vertical studs for mounting plywood sheathing.
Box in the area near the short end of the wall as shown for the air intake hole.
Install the top 45° cap, being sure to offset the seam with the bottom cap seam.
2.5 End Wall #2 Construction
Refer to Drawing #4.
Refer to the material table and cut lumber as shown. Build the second end wall using the
same procedure used to build the first end wall.
The middle lead-in board should be on the inside of the wall. Frame an area for the ser-
vice door.
2.6 End Wall Installation
Refer to Drawing #5.
Install sill seal foam or silicon caulk on the bottom of the wall sill plates and place each
end wall in position on the slab. Be sure the inside of the wall sill plate lines up with the
chalk lines on the slab to maintain squareness.
Secure the end walls to the slab anchor bolts with washers and nuts. Brace the walls as
needed to keep them square.

SD3000 Construction
Front Wall Construction
SD3000 Construction SD3000doc010317 2-4
2
2.7 Front Wall Construction
Refer to Drawing #6.
Refer to the material table and cut lumber as shown.
Build the front wall as shown. Install the end studs using 16D nails.
Cut the top plate from 2x6 lumber and install. Square the frame and mark the stud loca-
tions on the sill plate and top plate.
Be sure to keep wall square while installing the vertical studs.
2.8 Front Wall Installation
Refer to Drawing #7.
Install sill seal foam or silicon caulk on the bottom of the wall sill plate and place the front
wall in position on the slab. Be sure the inside of the wall sill plate lines up with the chalk
lines on the slab to maintain squareness.
Secure the front wall to the slab anchor bolts with washers and nuts. Brace the wall as
needed to keep it square. Secure the front wall to the end walls using 3" drywall screws.
2.9 Back Wall Construction
Refer to Drawing #8.
Refer to the material table and cut lumber as shown. The outer end studs are turned hor-
izontally to match the end walls. Install the first top plate and door header and square the
frame.
Check that the wall is square and mark the vertical stud locations on the door header and
top plate.
Cut and install vertical studs. Cut and install angled trusses and frame an area as shown
for the air exhaust.
Install the top plate.

SD3000 Construction
Back Wall Installation
2
2-5 SD3000doc010317 SD3000 Construction
2.10 Back Wall Installation
Refer to Drawing #9.
Cut spacers from 1/2" plywood and secure to the end wall studs.
Install 6 pieces of drip edge to the back side of the door header. Position the drip edge so
it points out to the rear of the wall (See detail). Overlap the pieces a few inches and
secure with 7D nails.
While keeping the wall square, install the 1/2" plywood sheathing to the exterior side of
the wall using 7D nails. Apply caulk between all plywood joints. The plywood will over-
hang the ends of the wall by 1/2".
Place the back wall in position against the end walls. Brace the wall as necessary to keep
it square. Secure the back wall to the end walls using 3" drywall screws. All walls should
now be secured to the slab, level, and braced from the interior.
2.11 Exterior Sheathing Installation
Refer to Drawing #10.
Install drip edge above the service door opening.
Install 1/2" exterior sheathing to all the walls with 7D nails. Apply caulk between all ply-
wood joints. Cut the top of the front wall exterior plywood at 45° as shown.
Be sure to cut holes where required for the intake and exhaust openings.