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U.S. ENVIRONMENTAL PROTECTION AGENCY
Certified to comply with 2020 particulate
emission standards using cord wood.
ALTERNATE HEATING SYSTEMS
2395 LITTLE EGYPT RD
HARRISONVILLE, PA 17228
717-987-0099
WWW.WOODGUN.COM
EMAIL:SERVICE@WOODGUN.COM
INSTALLATION AND
OPERATOR'S MANUAL
WOOD GUN™ WOOD GASIFICATION BOILER
IMPORTANT: IN ORDER TO ACHIEVE SAFE AND SATISFACTORY
RESULTS FROM YOUR ALTERNATE HEATING SYSTEMS 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.
Model: Super E210
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 200° Fahrenheit. Flammable or explosive
products 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 200° Fahrenheit.
Record Model and Serial Number Below:
Model: SUPER E210
Stainless Steel (Yes/No):
Serial Number:
Date of Purchase:____/___/_____
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Table of Contents
Troubleshooting
Related Manuals for Alternate Heating WOOD GUN Super E210
Summary of Contents for Alternate Heating WOOD GUN Super E210
- Page 1 ACCORDANCE WITH STATE AND LOCAL CODES. SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE. 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 – 2021 Alternate Heating Systems. No portion of this publication may be reproduced without the express written consent of Alternate Heating Systems. Revision: 11/08/21...
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Page 4: Table Of Contents
Table of Contents ⚠ CAUTIONS AND WARNINGS: RISK OF FIRE, INJURY OR DEATH ............1 Introduction.................................2 Explanation of Wood & Biomass Combustion....................2 Wood Moisture Content & Wood Gasification....................2 Mode of Operation............................3 Reduce or Prevent Condensation.......................5 Proper Pressurization of the Wood Gun.....................5 Boiler Installation..............................6 Boiler Location...............................6 Boiler Room Requirements........................6... - Page 5 Forced Hot Air Systems (Water to air Coil in Duct)..................21 Thermal Storage Basics..........................22 Thermal Storage Types..........................22 Sizing Your Thermal Storage........................22 Conditioning of Boiler Water........................23 pH................................23 Dissolved Oxygen..........................24 Solids (Primarily for Steam Boilers)....................24 Alkalinity............................24 Phosphates............................24 Hardness..............................24 Oils..............................24 Domestic Hot Water Coil Piping........................25 Oil Burner Assembly............................26 General Information..........................26 Oil/Gas Burner Combustion Chamber.....................26...
- Page 6 Direct Drive Fan bearing replacement procedure..................44 Refractory Replacement..........................47 Center Brick.............................47 Refractory Replacement.........................47 Additional Information..........................49 Efficiency..............................49 Appendix A: Boiler Specification Diagram......................50 Wood Gun Super E210 Specifications....................50 Appendix B: Wiring Diagrams..........................51 Appendix C: Exploded Parts Drawings......................52 Parts Listing..............................55 Appendix D: Troubleshooting Guide........................57 Appendix F: Boiler Piping and Ducting Examples...................60 APPENDIX G: Markings..........................64 Datalabel..............................65...
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Page 7: Cautions And Warnings: Risk Of Fire, Injury Or Death
⚠ CAUTIONS AND WARNINGS: RISK OF FIRE, INJURY OR DEATH INSTALLATION IS TO BE PERFORMED BY A CAUTION! HOT SURFACES – DO NOT TOUCH QUALIFIED INSTALLER AND WILL COMPLY WITH ALL DURING OPERATION! THE REQUIREMENTS OF THE AUTHORITY HAVING CAUTION! HOT SURFACES – MAXIMUM DRAFT JURISDICTION OVER THE INSTALLATION MARKED ON NAMEPLATE. -
Page 8: Introduction
Introduction The purpos of this manual is to assist you in th F to 1125º F. Theis h lps to xplain why maintaining a installation, op ration and maint nanc of your n w high combustion t mp ratur is so important in boil r in ord r to achi v th b st p rformanc achi ving “compl t ”... -
Page 9: Mode Of Operation
will b fac d with signifiecant and troubl som Most pyrolysis occurs b tw n 540º F (280º C) cond nsation. and about 900º F (500º C). The most abundant gas s produc d ar carbon monoxid , m than , m thanol, Wood with moisture content higher than 28% is formald hyd , and hydrog n as w ll as formic and more likely to produce condensation issues and... - Page 10 function, acting as a h at stor to initiat r -ignition th r fractory to nsur compl t combustion on afte r a p riod of no d mand. Wh n th air valv s start-up. Theis f atur will provid h at until th clos and th drafte inducing fan stops, th fier is tim r r ach s th nd of th programm d cycl , or...
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Page 11: Reduce Or Prevent Condensation
✔ Us wood that is 19-28% moistur . found in th cyclon and/or h at xchang r, attaack th issu as on r lat d to cond nsation. ✔ Cl an boil r, or tak oth r m asur s to improv air flaow Note: Condensation in the heat exchanger can be ✔... -
Page 12: Boiler Installation
Boiler Installation 2. A conv ni nt wat r supply should b BOILER LOCATION availabl for boil r flaushing and to cl an th Indoor wood burning boil rs ar d sign d to boil r room flaoor. radiat h at fr ly, but this h at can b dang rous if 3. -
Page 13: Rigging And Positioning Of Boiler
RIGGING AND POSITIONING OF BOILER Do not atta mpt to mov or off -load th boil r without th aid of a cran or dolly. Your Alt rnat H ating Syst ms boil r has a lifteing lug in th c nt r of th top. -
Page 14: Installation And Maintenance Of Electrical Controls And Gauges
Most municipaliti s r quir a sp cifie d cl aranc t mp ratur with a s cond th rmom t r or b tw n th flau pip and combustibl s (normally 18 t mp ratur gaug . in). The custom r/install r must follow all local and INSTALLATION OF SMOKE DETECTORS stat building cod s for cl aranc s. -
Page 15: Installation Of Bottom Insulation
v nting p rformanc will b b tta r with larg r stov 2. Push th m both toward th c nt r of th boil r. pip . You will nd up with a 2-3” gap in th c nt r of th boil r b tw n th two pi c s of insulation. -
Page 16: Draft
b caus atmosph ric pr ssur is naturally low r at th chimn y top than bottaom. Poor chimneys with cold walls can cause creosote buildup. Sharp bends and horizontal flues should also be avoided. The exhaust must be kept moving through the piping/flue to prevent creosote or fly ash buildup. -
Page 17: Masonry Chimneys
(A thimbl is a masonry pip which is ins rt d through th chimn y wall, and is fr qu ntly th pr f rr d m thod; a br ch pip is a pi c of st l pip us d th sam way.) In Canada, a br ch pip has ridg s or protrusions to lock it fiermly into th r fractory c m nt. - Page 18 r quir d cl aranc b tw n th chimn y pip passing through a flaammabl wall. The Chimn y Conn ctor (H) must b approv d singl wall, or a low cl aranc pip , install d with r quir d cl aranc s in plac .
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Page 19: Proper Chimney Connection
PROPER CHIMNEY CONNECTION The chimney selected must comply with the requirements for type HT chimneys with UL 103 or ULC S629 Use of aluminum Type B gas vent ratings. Do not use makeshift for solid fuels is unsafe and compromises during construction. prohibited by the National Fire Protection Association Code. -
Page 20: Stovepipe Specifics For Se210
Stovepipe Specifics for SE210 Wh n plumbing th stov pip from th boil r to th chimn y it installing an 18”-24” pi c of 6” straight pip dir ctly to th boil r b for any lbows/”T”s. Theis will allow mor ar a for ash to s ttal and incr as cl aning int rvals to v ry 3 Inspect stove pipe at least twice months v rsus every month if an lbow/”T”... -
Page 21: Wall Pass-Through: Canada
Stove pipe passing through wall Canadian Wall Pass-Through COMMON CHIMNEY PROBLEMS In ord r to hav a prop rly op rating h ating syst m, th chimn y n ds to b capabl of providing sufficci nt, but not xc ssiv drafte. The approach to improving drafte in an xisting chimn y may includ on or mor of th following: raising chimn y h ight, adding or changing th flau lin r, or s l cting... -
Page 22: In Case Of Chimney Fire
air curr nts to flaow downward ov r th p ak IN CASE OF CHIMNEY FIRE of th roof. Theis would l ad to a down drafte ff ct on th chimn y. Theis can also b caus d 1. -
Page 23: Make-Up Or Combustion Air
Do not op n th loading door v n in pow r MAKE-UP OR COMBUSTION AIR outag , until th pow r is r stor d and th gr n “Purg ” turns on! The airflow through the system and out the chimney means that oxygen is leaving the home and will create Do not open the loading door even in... -
Page 24: Boiler Piping For Hydronic Systems
Boiler Piping for Hydronic Systems Du to th d sign r quir m nts of th various Wood Gun™. For sampl illustrations of multipl Wood Gun™ mod ls, th fiettaings and burn r boil r confiegurations, s App ndix F. attaachm nts ar not always in th sam location on Pressure Relief Valve ach boil r mod l. -
Page 25: Expansion Tank Selection
wat r t mp ratur s. Theis would optimally includ a th rmom t r on th r turn lin nt ring th boil r for monitoring purpos s, and a mixing valv to maintain minimum r turn wat r t mp ratur s. R turn wat r t mp ratur n ar or b low 140º... -
Page 26: Additional Specifications
1. The orang #2 wir will b t rminat d with th ADDITIONAL SPECIFICATIONS black wir and on of th Y llow wir s. Pressure Drop 2. The orang 2 wir will t rminat with th Pr ssur Drop (Lin Loss) within th boil r is l ss r maining y llow wir . -
Page 27: Low Water Cutoff Maintenance
(B) Ch ck for prop r ground b tw n prob and Theis gaug is locat d in tapping FF on th r ar of th boil r sh ll. Exc ssiv us of T flaon tap or s aling boil r and a s ction of piping, which originat s from compound may insulat th prob from th boil r a tapping in th top of th boil r n ar th r ar. -
Page 28: Thermal Storage Basics
180º F and a d sirabl output air t mp ratur is 115° - pr ssur s. Tanks may b purchas d n w, or pr ssur - 125º F. rat d r cycl d tanks may b us d. Us d propan tanks ar som tim s r purpos d for us with th rmal Tip: To increase coil performance, increase boiler storag . -
Page 29: Conditioning Of Boiler Water
An individual burn cycl , using high quality fu l CONDITIONING OF BOILER WATER that is tightly pack d into th Wood Gun SE210 CS fier box, can produc as much as a million BTUs. As a Note: The guidelines in this section are to be used in conjunction with the advice of a water practical matta r, to accommodat a full load of wood, treatment specialist. -
Page 30: Dissolved Oxygen
B low a pH of 5.0 th wat r is acidic nough to conductanc of boil r wat r vari s proportionat ly dissolv th st l boil r plat s. Und r th s with th amount of various ioniz d solids pr s nt. conditions th st l gradually b com s thinn r and Anoth r way to d t rmin th dissolv d solids thinn r until it is d stroy d. -
Page 31: Domestic Hot Water Coil Piping
DOMESTIC HOT WATER COIL PIPING Plumbing – Coil in Series Figure: Domestic Coil Tempering Valve The Wood Gun™ may b fietta d with on dom stic hot wat r coils, which thr ad into 4 inch tapping in th boil r. The r ar thr m thods for plumbing th dom stic coil. -
Page 32: Oil Burner Assembly
Manual. Ensur that th corr ct siz nozzl is in plac on th burn r b for installing on th boil r. The corr ct nozzl siz for th Ri llo Oil Burn rs install d in th Sup r E210 is 0.65 gph, 45º, s mi- solid. -
Page 33: Oil Burner Electrical Connection
flaang of th oil burn r to pr v nt air l akag . The gas str am. In addition, products of incompl t wood burn r should b position d so that th nd of th air combustion, which r sult from initial start-up, r - tub is back approximat ly ¼... -
Page 34: Gas Burner Assembly
this incr as d air v locity, th Burn r Adjustm nt For larg r units consult th sp cial instructions Tabl s in th Ri llo manual ar a good starting point provid d in th suppl m nt to this manual. for initial fiering of th burn r;... -
Page 35: Operating Information
Operating Information Pl as r ad this ntir manual b for op rating EXPLANATION OF SWITCH AND BUTTONS th boil r. It contains important r quir m nts and The SE210 us s a simpl asy-to-us touchscr n instructions must b follow d for saf and int rfac which will b xplain d b low. - Page 36 OFF: Theis buttaon will turn off th wood or oil Wood Screen (second) burning functions. It is only visibl if th boil r is in wood or oil mod . Settings: Theis buttaon will tak you to th “S ttaings” scr n. Wood Screen (first) Explanation of buttaons: ON (und r Low T mp Shutdown): this buttaon...
- Page 37 Down Arrow: Theis buttaon allows you to d cr as Temperatures Screen th purg tim by 1 minut ach tim it is pr ss d with a min of 1 min. Safe To Open: this is not a buttaon, it simply t lls you wh n you may op n th loading door.
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Page 38: Sequence Of Operations
Advanced: Theis buttaon tak s you to th advanc d blow r motor will turn on. The unit will op rat on s ttaing that should only b acc ss d by qualifie d high (55Hz) until th wat r r ach s 167F at that point p rsonn l. -
Page 39: Manual/Automatic Switchover
Manual/Automatic Switchover to allow th us r to vi w r mot ly wh n th boil r n ds to b r start d. To us th Automatic Switchov r option, if quipp d, Go to th s cond “Wood” scr n and pr ss Resetting the Controls its on/off buttaon. -
Page 40: Wood Fuel Characteristics And Wood Storage
• Mat rials containing rubb r, including tir s found in a cord of wood. G n rally, wood should b stor d outdoors in a dry plac with only a limit d • Mat rials containing plastic supply k pt indoors. •... -
Page 41: Charging The Boiler With Wood
touchscr n will pow r up and will display th practic s includ k ping ash and charcoal build-up “Hom ” scr n. to a minimum. Wh n d mand is to low, mod rat simply load charg s of fu l that ar just ad quat for th l ngth of th anticipat d burn cycl . -
Page 42: Back-Puffing Prevention Checklist
Onc th c nt r slots hav b n cl ar d and th Back-Puffing Prevention Checklist coal b d l v l d you may load wood into th fier box. ✔ Us fu l with high r moistur cont nt, Plac th wood in th fier box l ngth-wis and ✔... -
Page 43: For Carbon Steel Boilers
On Wood Gun™ mod ls quipp d with oil or gas assur st ady load wh n fiering, and assist in k ping backup, th control s ttaings should b as follows: cond nsation und r control. K p in mind that b caus th Wood Gun swirl tub h at xchang r ✔... -
Page 44: Maintenance
Maintenance 9. Op n th air-valv cov r and insp ct th valv gask t disks for vid nc of air l akag . The disk should hav som wobbl , so it can mov and fiend its own s al. S “Air Valve Cleaning and Maintenance”... -
Page 45: Yearly Cleaning
and in tim produc a d posit that pr v nts th AIR VALVE MOTOR REPLACEMENT gask t from s aling tightly. Cl an off any d posit on Removing Old Damper Motor th gask t disc with a cloth soak d in warm wat r 1. -
Page 46: Door Adjustment
4.R stor pow r to th unit. 5. Ent r th “Cl aning Mod ”, mak sur th spring r turn will op rat in th corr ct dir ction. Install clamp so that th arrow is pointing at th 0º mark, and install th clip s curing th clamp. -
Page 47: Load Door Seal Replacement
LOAD DOOR SEAL REPLACEMENT 1. Allow door to compl t ly cool b for you touch or start installation, r mov door. 2. Cut flaat fieb rglass tap (whit tap ) into 4 qual strips. The tap shall stop 1” from ach corn r. 3. - Page 48 Marking to Trim Load Door with Fiberglass Braid Tape and More High Trimming Preformed Silicone Bead Temperature Silicone 6. Start th gask t in th middl of th hing sid . Squ z th gask t into plac on top of th b ad of silicon .
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Page 49: Front Inspection Door High Temperature Rope Installation
nds tog th r tuck all loos nds down insid th Reinforcing Corners with High Temperature Silicone chann l. The rop should protrud about 3/8” abov th door fram . 6. Look ov r th door to fiend any high spots or bumps in th s al. -
Page 50: Fan Assembly
FAN ASSEMBLY The fan-motor ass mbly may b r mov d by loos ning th nuts from th studs. Be sure to disconnect power to the Mark Assembly Orientation unit before servicing or removing the fan. Plac th fan ass mbly on your workb nch with th fan facing up. - Page 51 AHS Fan Puller Tool at the Ready One Inch Nut for Pulling Fan R mov th (4) 5/16” nuts and wash rs from th Using a jaw typ pull r, r mov th fan from th motor plat allowing you to r mov th abrasion motor shafte: shi ld and th h at shi ld from th motor plat .
- Page 52 To s parat th motor housing you must r mov th four bolts from th nd of th motor opposit of th shafte. The s bolts hav a 5/16 bolt h ad. Motor Frame Assembly Bolts Onc th s bolts ar r mov d, tap th mounting nd of th motor on th sid with a rubb r mall t, or us a r gular hamm r along with a block of wood.
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Page 53: Refractory Replacement
Center Brick The C nt r Brick contain th slots through which burning gas s ar drawn by th induction fan. The c nt r brick ar subj ct d to th most s v r flaam rosion and high st t mp ratur s and will most lik ly b th fierst r fractory compon nts to show signs of d t rioration. - Page 54 troubl r moving th old upp r bricks follow th s its front and back, this brick will go in th c nt r. The instructions. oth r two brick with larg r ind nt on on sid ar th front and r ar brick. Install th brick so that th 4.
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Page 55: Additional Information
d liv r d to th hom . Ofte n adv rtis m nts will list ADDITIONAL INFORMATION combustion rath r than ov rall fficci ncy sinc it is For additional information on using your boil r th high r of th two calculat d fficci nci s for any saf ly, obtain a copy of th National Fir Pr v ntion giv n d vic . -
Page 56: Appendix A: Boiler Specification Diagram
Appendix A: Boiler Specification Diagram Wood Gun Super E210 Specifications SE210 BTU/Hour Range 25,500—170,000 BTU 8 Hour Avg Output* 100,000 Water Capacity 80 gallons Fire Box Capacity 8.5 ft Fire Box Length 29'' Standard Door Opening 14'' x 14'' Height 72'' Width (without burner) 36''... -
Page 57: Appendix B: Wiring Diagrams
Appendix B: Wiring Diagrams - 51 -... -
Page 58: Appendix C: Exploded Parts Drawings
Appendix C: Exploded Parts Drawings - 52 -... - Page 59 - 53 -...
- Page 60 - 54 -...
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Page 61: Parts Listing
Parts Listing Item Description Item ID Quantity Unit REFRACTORY SET pieces OVAL CENTER BRICK-SE210 . 484-200 pieces TOP MIDDLE BRICK-SE210 B1 . 484-210 pieces TOP FRONT/REAR BRICK-SE210 B2 . 484-211 pieces BOTTOM TOP BRICK-SE210 B3 . 484-212 pieces BOTTOM TOP BRICK-SE210 REAR . - Page 62 HOOK LATCH HANDLE . . 412-141 pieces WOOD HANDLE pieces FHN 1/2-13 3-30-80501313 pieces HCS 3/8-16 X 2 . . 3-30-1371610012 pieces HLN 3/8-16 . . 3-30-8303716 pieces FW 3/8 USS . . 3-30-02003714 pieces UNTHREATHED SPACER . . 412-143 pieces 3/8ID LW 5/16 IN...
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Page 63: Appendix D: Troubleshooting Guide
Appendix D: Troubleshooting Guide Theis guid is int nd d to h lp you diagnos and r pair basic probl ms with you boil r. If you b li v your probl m is s rious or th probl m p rsists afte r following all th proc dur s sp cifie d in this guid , contact AHS for support. - Page 64 f) The boiler water temperature is too d) Burn smaller wood, split wood, and/ low or Water temperature difference or dryer wood. Build a hotter fire. between supply and return may be Remember that more wood does not more than 20ºF always equate to more heat.
- Page 65 Wood Gun Air Inlet Ducting Installations....61 Load Door with Fiberglass Braid Tape and More Wood Gun in Primary/Secondary System....62 High Temperature Silicone........42 Operating an Alternate Heating Systems Boiler in Adding Preformed Silicone Bead to Door....42 Tandem with Existing Boiler........63 - 59 -...
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Page 66: Appendix F: Boiler Piping And Ducting Examples
Appendix F: Boiler Piping and Ducting Examples - 60 -... - Page 67 Wood Gun Air Inlet Ducting Installations - 61 -...
- Page 68 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 for additional information.
- Page 69 Operating an Alternate Heating Systems Boiler in Tandem with Existing Boiler Note: The above illustrates one possible method of connecting the Wood 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 Wood Gun™...
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Page 70: Appendix G: Markings
APPENDIX G: Markings - 64 -... -
Page 71: Datalabel
Datalabel - 65 -... -
Page 72: Stainless Steel Limited Warranty
Dealer’s name Type of fuel burned 5) The OWNER and not Alternate Heating Systems or its dealers will be liable for the following costs involved in repair or replacement of the defective unit or component part All necessary costs in returning the defective unit or component part to the factory or other location designated by Alternate Heating Systems. -
Page 73: Carbon Steel Limited Warranty
Dealer’s name Type of fuel burned 5) The OWNER and not Alternate Heating Systems or its dealers will be liable for the following costs involved in repair or replacement of the defective unit or component part All necessary costs in returning the defective unit or component part to the factory or other location designated by Alternate Heating Systems.
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