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INSTALLATION AND
OPERATOR'S MANUAL
IMPORTANT: IN ORDER TO ACHIEVE SAFE AND SATISFACTORY
RESULTS FROM YOUR ALTERNATE HEATING SYSTEMS, INC. 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.
WARNING: Your Alternate Heating Systems Boiler is capable of generating very hot temperatures.
Boiler temperatures and flames in the ignition box area are capable of causing ignition or explosion of
explosive or flammable products or explosion of the boiler itself if maximum safe water temperature is
exceeded. Maximum safe water temperature is 210
must never be stored in the same room or in the vicinity of a boiler, and the boiler water temperature
must never be allowed to exceed 210
ALTERNATE HEATING SYSTEMS, LLC.
5171 LINCOLN WAY WEST ST. THOMAS, PA 17252
TELEPHONE: 717-369-2102
WWW.ALTERNATEHEATINGSYSTEMS.COM
COAL GUN™ BOILER
Models: S130, S260, S500, S1000
0
FAX: 717-369-2732
0
Fahrenheit. Flammable or explosive products
Fahrenheit.
Record Model and Serial Number Below
Model:
Serial:
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Summary of Contents for Alternate Heating COAL GUN S130
- Page 1 ACCORDANCE WITH STATE AND LOCAL CODES. SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE. WARNING: Your Alternate Heating Systems Boiler is capable of generating very hot temperatures. Boiler temperatures and flames in the ignition box area are capable of causing ignition or explosion of explosive or flammable products or explosion of the boiler itself if maximum safe water temperature is exceeded.
- Page 3 Copyright 2000 – 2009 Alternate Heating Systems, LLC. No portion of this publication may be reproduced without the express written consent of Alternate Heating Systems, LLC. The Coal Gun™ is listed by Underwriter’s Laboratories, INC. Coal Gun boilers bearing the mark seen at right are thereby designated as listed boilers.
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Page 5: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ............................ 1 BOILER INSTALLATION ........................2 ............................ 2 BOILER LOCATION Boiler Room Requirements ......................... 2 ....................2 IGGING AND OSITIONING OF OILER ................3 LEARANCES EQUIRED FOR AFETY AND PERATION ....................... 3 ENERAL HIMNEY EQUIREMENTS Technical Aspects of Chimney Performance ..................4 ........................ - Page 6 ALKALINITY ..........................20 PHOSPHATES ..........................20 HARDNESS ..........................20 OILS ............................. 20 APPENDIX A: BOILER SPECIFICATION DIAGRAMS ............... 22 ........................ 26 DDITIONAL PECIFICATIONS Pressure Drop ........................... 26 Explanation of GPM Flow ........................ 26 APPENDIX B: WIRING DIAGRAMS ....................27 APPENDIX C: EXPLODED PARTS DRAWING ................32 APPENDIX D: MAINTENANCE ......................
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Page 9: Introduction
Alternate required. Heating Systems, LLC. dealer or by an All Alternate Heating Systems, LLC. boilers experienced boiler installation technician who can be supplied with the ASME “H” stamp and has a thorough knowledge of hydronic heating National Board number for an additional fee systems and boilers. -
Page 10: Boiler Installation
All combustion of the fuel as well as ventilation of Alternate Heating Systems boilers have at least any by-products of combustion. one lifting lug in the center of the top. On some... -
Page 11: Clearances Required For Safety And Operation
by means of a pallet jack. Use of a pallet jack The required minimums for Coal Stoker boilers when measured from the exterior of the boiler with the Coal Gun requires that the boiler be are 30 in to the rear (end of boiler with fan skidded or that the installer has made other assembly), 36 in to the right side (when facing provisions to insert a pallet jack under the boiler... -
Page 12: Technical Aspects Of Chimney Performance
is very large, than a chimney that is protected from outside temperature extremes. CAUTION: SUFFOCATION HAZARD The chimney must be sufficiently tall (at least 20 feet for masonry chimneys) and should The airflow through the extend at least three feet above the highest part system and out the chimney of the roof to prevent downdrafts. - Page 13 WARNING: CODE COMPLIANCE Use of aluminum Type B gas vent for solid fuels is unsafe and prohibited by the National Fire Protection Association Code. Use of aluminum Type B gas vent for solid fuels is unsafe and prohibited by the National Fire Protection Association Code.
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Page 14: Combustion Air Supply
NOTE: See diagram below which has been of sufficient diameter for the boiler to be used. modified for this manual. Contact Alternate Heating Systems if an outside air ducting kit is required. Static pressure of the cool air (1) exerts pressure... -
Page 15: Choosing The Right Size
Choosing The Right Size 8” (Sizing the Control) 9” Simple rules of thumb to guide size selections: 10” 1.Use a draft control the same size as the 12” flue pipe, that is, a 6" control for a 6" round pipe, a 12" control for a 12" pipe, etc. 14”... - Page 16 Diameter of If Chimney Use This Size If Chimney Use This Size If Chimney Use this size Flue or Height is Control Height is Control Height is Control Breeching 15’ or less 4” 16’ or more 5” 15’ or less 5”...
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Page 17: Boiler Piping For Hydronic Systems
taking into account the distance involved and flow required. BOILER PIPING FOR Pressure Relief Valve HYDRONIC SYSTEMS The pressure relief valve is factory installed. A Normal operating temperature for the Coal Gun length of copper pipe must be connected to the is 180°... -
Page 18: Boiler Conditioner / Sealant
an existing boiler. Check the chart to determine since it prevents the boiler from firing should the water capacity of the Coal Gun™ installed. the water level drop below the safe operating The expansion tank or air cushion tank installed level. -
Page 19: Domestic Hot Water Coil Piping
duct or plenum where the coil will be installed. water heater so that the conventional water Sizing of the air coil will be the responsibility of heater may be used when the Coal Gun™ is not customer and/or installer. being fired (for example in the summer). The diagram below indicates how this can be done. -
Page 20: Illustrated Instructions For Installing Coal Hopper On S130 And S260
The third method of plumbing the domestic coil uses a small pump to circulate water continuously between the coil and existing hot water heater. It is also necessary to include a tempering valve or temperature controller on the supply side of the storage tank/water heater to prevent super-heated water from reaching the domestic hot water tank and, ultimately, the faucets (see Figure 7). -
Page 21: Electrical Connections In The
S130/S260 The S130 and S260 Coal Guns require a dedicated power circuit of 120 volts, 15 ampere. On models equipped with a thermal ash control, power connections are in the large enclosure for that control. On models with a timer for ash removal, power connections are in the 4”... -
Page 22: Steam
WARNING: The operating limit is designed to maintain boiler temperature under normal operating Fuses must be replaced with the conditions. The normal setting range for this same amperage and fuse type as control is from 150° F to 180° F. The normal supplied with the unit! factory setting is 180°... - Page 23 If the dump zone is connected to provide heat to a domestic hot water tank or heat exchanger, a mixing valve must be installed on the potable system supply to prevent an unsafe condition of overheating the domestic hot water. The mixing valve outlet should be set no higher than 125°...
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Page 24: Operating Information
OPERATING INFORMATION Please read this manual before operating the combustion will shut down. Before starting the boiler. Important requirements and instructions fire, turn off the grate switch (grate switch is must be followed for safety and satisfactory sometimes located on opposite side of the operation of the boiler. -
Page 25: Shutting Down The Coal Gun
to by-pass the fire bed, preventing over heating photos, the shield has been removed so that the of unit during the off cycle. sight tube cover may be observed. SHUTTING DOWN THE COAL GUN When the heating season has ended, or in anticipation of a long period with no demand for heat, it will be desirable to allow the fire to go out in the Coal Gun. -
Page 26: Basic Auger Operation
WARNING: The hopper lid must be on at all times during operation of the unit. Failure to keep the hopper covered could result in uncontrolled air entering the fire bed and extreme overheating. If an auger is used to feed coal, the hopper and lid are still also used except the lid is designed with a hole to allow the coal to fall from the auger through the lid and into the hopper. -
Page 27: Thermo Ash-Monitoring Grate Control Operation
WARNING: have thoroughly cooled to prevent inadvertently starting a fire. If the hopper is empty while the unit is burning, add only small amounts of coal for the first half CONDITIONING OF BOILER WATER hour in order to prevent ignition of flammable gases in flue pipe Proper treatment of make up water and boiler area. -
Page 28: Dissolved Oxygen
DISSOLVED OXYGEN test is unsuitable for feed water with low incoming concentrations, and the concentrations Aeration of city water supply is frequently used in the feed water must be averaged over time for to remove other noxious gasses, however, accuracy. efficient aeration results in saturation of the water with oxygen. - Page 29 the boiler should immediately be taken out of service and thoroughly cleaned.
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Page 30: Appendix A: Boiler Specification Diagrams
APPENDIX A: BOILER SPECIFICATION DIAGRAMS... -
Page 34: Additional Specifications
ADDITIONAL SPECIFICATIONS Pressure Drop Pressure Drop (Line Loss) within the boiler is less than the pipe rating of the pipe within the boiler, so there is no appreciable pressure drop. Explanation of GPM Flow The following are given as examples of gallons per minute water flow required to deliver hot water in order to provide heating of a given number of degrees and at a certain BTU level:... -
Page 35: Appendix B: Wiring Diagrams
APPENDIX B: WIRING DIAGRAMS... -
Page 40: Appendix C: Exploded Parts Drawing
APPENDIX C: EXPLODED PARTS DRAWING... - Page 41 Parts Listing (As Shown in Exploded Parts Diagram) 1.Hopper Lid 2.Coal Hopper (size varies) 3.Draft Inlet Cover 4.Draft Inlet Flap 5.Right Insulation Cover 6.Grate Base Door 7.Grate Assembly 8.Thermocouple for Thermo-Controlled Grates 9.Grate Motor 10.Pitman assembly 11.Pillow Block Bearings 12.Pitman Connecting Pin 13.Small Grate Motor Sprocket 14.Large Grate Sprocket 15.Chain...
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Page 43: Appendix D: Maintenance
APPENDIX D: MAINTENANCE units, adjust tension and alignment as needed, The Alternate Heating Systems Coal Gun is replace if worn or damaged. designed to provide years of reliable service. Nevertheless, it is necessary to provide basic Reinstall fan assembly, cyclone tube, and smoke service in order to maintain optimum efficiency pipe. -
Page 44: Fan Assembly Removal/Repair
This procedure is required when servicing the fan assembly or heat exchanger area. We recommend you contact your Alternate Heating Systems dealer for this repair procedure. 5. Thread a hex nut, size 1-14 (NF), to the WARNING: hub of the fan. -
Page 45: Direct Drive Motor Bearing Replacement
DIRECT DRIVE MOTOR BEARING REPLACEMENT This guide may be used for replacement of direct drive induction fan motor bearings. We recommend you contact your Alternate Heating Systems dealer for this repair procedure. WARNING: Disconnect power to boiler before beginning this procedure. - Page 46 6. Remove back cover (fan cover) from 8. Set motor on back, shaft end up, on a motor. The illustration in step 2 shows workbench. the motor with this cover already 9. Using a small hammer, gently tap up on removed.
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Page 47: Additional Information
13. Using a manual jaw puller, remove bearing from shaft. 11. Check to be sure the belleville (cupped spring) washer stayed in the end cap remaining with the motor housing. 12. Remove the two screws holding the bearing to the front end cap and gently tap end cap off. -
Page 48: Operation And Maintenance Schedule For Models S130 And S260
OPERATION AND MAINTENANCE SCHEDULE FOR MODELS S130 AND S260 INTERVAL ITEM PROCEDURE As Needed Ash removal Remove ash and observe condition of ash. Adjust grate timer if necessary. Weekly Fire bed (when Check for clinkers and remove if necessary. burning poor Note: poor coal quality produces clinkers. -
Page 49: Appendix E: Troubleshooting Guide
APPENDIX E: TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE SOLUTION 1.Boiler overheating a) Sight hole cover flap not a) Check spring for proper tension releasing when fan stops b) Install barometric damper in b) Excessive chimney draft flue c) Aquastat set too high c) Reduce aquastat setting 2. - Page 50 9. Coal gas ignitions a) Poor draft a) Assure a .04” of water with a (evidenced by an audible manometer. Increase flue height if bang) during off cycle necessary, or use an auxiliary power vent 10. Coal gas ignitions during a) High volatile coal or a) Adjust secondary air port on on (active firing) cycle...
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Page 51: Appendix F: Table Of Figures
APPENDIX F: TABLE OF FIGURES Figure 1: Proper chimney connection ......................5 Figure 2: Stove pipe passing through wall....................5 Figure 3: Pressure regulating valve and backflow prevention valve configuration ........9 Figure 4: Plumbing – Coil in Series ......................11 Figure 5: Plumbing –... -
Page 52: Appendix G: Programming Grate Control
APPENDIX G: PROGRAMMING GRATE CONTROL Note: Your grate control comes preprogrammed from the factory. If you merely wish to change the temperature (set value, SV) at which the grate operates, this is accomplished by going directly to step 5 on the next page (Setting Grate Operation Control):... -
Page 53: Locking Control
Dwyer 16C-2 Programming INITIAL PROGRAMMING 1. Selecting Input Type A. Hold button for three seconds, until you see: B. Scroll with until you see input type: C. Press 2. Setting Temperature Unit A. Hold button for three seconds, until you see: B. -
Page 54: Appendix H: Dump Zone Wiring Applications
APPENDIX H: DUMP ZONE WIRING APPLICATIONS... -
Page 58: Appendix I: Boiler Piping Examples
APPENDIX I: BOILER PIPING EXAMPLES... - Page 59 Not all system components, valves and devices are shown in this drawing. Actual conditions and application requirements will vary. Please consult a heating expert or your Alternate Heating Systems dealer for additional information.
- Page 60 Note: The above illustrates one possible method of connecting the Coal Gun with an existing boiler. This connection is as follows: using a small circulator (and with the backup boiler piped into the return tapping) run another pipe from the supply tapping T, of the Coal Gun™ to the supply line, of the existing boiler on the lower side of the flow control valve.
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Page 61: Limited Warranty
Alternate Heating System’s printed literature. - Page 62 IMPORTANT: READ AND KEEP IN YOUR POSSESSION!
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Page 63: Index
INDEX Cyclone funnel ....40 Abrasion shield ....39 leaks air supply ......2 chimney ........4 disconnect Air Supply Line Loss ......26 electrical ......... 2 combustion ......6 draft low water control ....10 air temperature chimney ......3, 4 low water cut-off .... - Page 64 tempering valve ....12 thimble Sealant WARNING3, 5, 14, 15, 16, 18, 19 in chimney installation ... 4 Boiler ........10 Warranty ......52 Troubleshooting ....40 sight hole cover ....16 washout plugs ..... 9 starting a fire ....16 Water Conditioning ..
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