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INSTALLATION AND
OPERATOR'S MANUAL
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.
ALTERNATE HEATING SYSTEMS
2393 LITTLE EGYPT RD
HARRISONVILLE, PA 17228
717-987-0099
WWW.WOODGUN.COM
EMAIL:SERVICE@WOODGUN.COM
WOOD GUN™ WOOD GASIFICATION BOILER
Model: E155 SS
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:
Serial Number:
Date of Purchase:
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Summary of Contents for Alternate Heating WOOD GUN E155 SS
- 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 – 2015 Alternate Heating Systems. No portion of this publication may be reproduced without the express written consent of Alternate Heating Systems. Revision: 10/10/17...
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Page 4: Table Of Contents
Table of Contents Introduction.................................1 Explanation of Wood & Biomass Combustion....................1 Wood Moisture Content & Wood Gasification....................1 Mode of Operation............................2 Reduce or Prevent Condensation.......................4 Proper Pressurization of the Wood Gun.....................4 Boiler Installation..............................5 Boiler Location...............................5 Boiler Room Requirements........................5 Rigging and Positioning of Boiler........................6 Clearances to Combustibles Required for Safety and Operation..............6 Boiler Assembly.............................6 Cyclone Ash Collector..........................6... - Page 5 Charging the Boiler with Wood: Manual Feed..................23 Back-Puffing PreventionChecklist......................24 EPA Side Tunnel Refractory Plug......................24 Wood Fuel Characteristics and Wood Storage.....................25 Low Water temperature Option........................25 Cool Down Cycle............................26 Wood FUEL CHARACTERISTICS AND WOOD STORAGE..............26 Removal and Disposal of Ashes........................26 Conditioning of Boiler Water........................27 pH................................27 Dissolved Oxygen..........................27 Solids (Primarily for Steam Boilers)....................28...
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Page 6: Introduction
All Alternate Heating Systems boilers can be WOOD MOISTURE CONTENT & WOOD supplied with the ASME “H” stamp and National... -
Page 7: Mode Of Operation
30% is optimum for burning wood in the gasi cation Wood with moisture content higher than 30% is process. more likely to produce condensation issues and will produce markedly less BTU’s per pound of Because of the downdra9 design of the Wood fuel. - Page 8 Alternate Heating Systems cannot promise stack as water vapor. Water will likely be evident in that summer time use of a Wood Gun will be the ash pan and, in severe cases, may even collect in practical for you.
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Page 9: Reduce Or Prevent Condensation
water moisture in the wood, but is formed as a Increase run cycle length ✔ byproduct of combustion. Excellent combustion will Use drier fuel ✔ maximize the amount of the main byproducts of Clean boiler, or take other measures to ✔... -
Page 10: Boiler Installation
Boiler Installation 2. A convenient water supply should be BOILER LOCATION available for boiler Gushing and to clean the Wood & Coal Burning Boilers are designed to boiler room Goor. radiate heat freely, but this heat can be dangerous if 3. -
Page 11: Rigging And Positioning Of Boiler
Alternate Heating Systems recommends that a quali ed technician experienced in boiler BOILER ASSEMBLY installations perform the installation of the Wood . -
Page 12: Air Valve
the boiler and connected as documented in the wiring diagram for the model being installed. Wiring diagrams are found in Appendix B. Draft-Inducing Fan Assembly e dra9-inducing fan assembly may be shipped in a separate box. See Fan Assembly in the Maintenance section for assembly guidance. -
Page 13: General Chimney Requirements
an aqua stat. Turn the dial 20° past the boiler water temperature. Use an ohmmeter to test the terminals for continuity. If the contacts are closed before you turn the dial it should open a9erward. If it is opened before you turn the dial it should be closed a9erward. -
Page 14: Flue Pipe
is important to try to preserve exhaust heat. Always be necessary to provide additional outside air into check with your local building inspector and the home. It is possible to duct outside air directly to insurance agent to assure compliance. the boiler. -
Page 15: Proper Chimney Connection
Do not connect more than one heating appliance in into the chimney, but does not extend so far into to a single chimney. Be sure to check all local codes the chimney that it blocks airGow. and your insurance provider’s requirements for any In installations where the chimney dra9 is too additional restrictions and/or guidelines regarding strong, the problem may be eliminated by allowing... -
Page 16: Boiler Piping For Hydronic Systems
boiler near the front. Alternately, a “T” and short nipple could be a7ached to the return tapping for the location of the boiler drain. Piping the Boiler in Parallel with Another Boiler e Wood Gun™ may be connected to a heating system supplied by one or more boilers that are It is important to make provision for adequate already in place. -
Page 17: Pressure Reducing Fill Valve
Speci cations to determine the water capacity of the Wood Gun™ installed (do not use the BTU rating). e expansion tank or air cushion tank that was originally installed will not likely be adequate for the additional volume of water added to the system with the inclusion of a Wood Gun™. -
Page 18: Low Water Cutoff
creates the risk of severe condensation issues. Low Water Cutoff will o9en produce unpleasant odors and possible liquid runo: in the boiler room. More seriously, it will lead to creosote formation on heat exchange surfaces and inside the chimney, with accompanying risk of a chimney re. -
Page 19: Recommended Boiler Control Settings In Hydronic Systems
RECOMMENDED BOILER CONTROL BOILER CONDITIONER / SEALANT SETTINGS AHS provides two bo7les of Boiler IN HYDRONIC SYSTEMS Conditioner/Sealant with the purchase of your boiler. e following control se7ings are recommended When lling your boiler with water for the rst time, for parallel installations: mix the contents of each bo7le with 2 gallons of High limit 200°... -
Page 20: Forced Hot Air Systems (Water To Air Coil In Duct)
For steam systems other than gravity return DOMESTIC HOT WATER consult Alternate Heating Systems for proper COIL PIPING controls. Do not a7empt to connect two di:erent steam boilers in parallel since the water level in each boiler will not be the same. -
Page 21: Oil Burner Assembly
OIL BURNER ASSEMBLY General Information If an oil burner is supplied with the Wood Gun™, connection of fuel lines and the adjustment of the burner should be done by a quali ed oil burner In installations where the coil technician. e oil burner is normally shipped discharges directly into the hot water distribution system a... -
Page 22: Oil Burner Electrical Connection
washers. e metal jacket cover and insulation on the combustion chamber must be removed to gain Oil Burner Adjustment access to the holes in the Gange as shown below. For proper oil burner adjustment, refer to the burner installation manual. Note: If the oil tank has a two-pipe system, then it is necessary to insert the bypass plug into the burner pump as described in the manual for the... -
Page 23: Gas Burner Assembly
Gun™ and the mounting Gange of the gas burner. backup, Alternate Heating Systems strongly Connect the burner according to the wiring diagram recommends the unit be red on oil periodically to included with your boiler or found in Appendix B: assure that the oil burner will function when needed. -
Page 24: Gas Burner Adjustment
SMOKE FLAP e smoke Gap must be installed before operating the boiler. All gas piping must comply with local codes and ordinances or the National Fuel Gas Code ANSI Z 223.1-1980 and NFPA No. 54. Gas Burner Adjustment Please see the Riello Burner Installation Manual section entitled Se7ing up the Burner for information on gas burner adjustment. -
Page 25: Operating Information
Operating Information Please read this entire manual before operating indicator light does not come on when the purge the boiler. It contains important requirements and timer is activated, it means the oil/gas burner is instructions must be followed for safe and ring and the door must not be opened. -
Page 26: Starting A Fire: Switch Positions
FUEL TYPE The Wood Gun is designed to burn split or unsplit wood e Wood gun is designed to burn log wood. Wood gun is able to burn both hard wood and so9 Do not remove the smoke flap in the wood fuel. -
Page 27: Charging The Boiler With Wood: Manual Feed
charge in su<cient quantity to last for up to ten Charging the Boiler with Wood: Manual Feed hours. Longer cycles are possible, but you will want to plan for utilizing shorter burn cycles periodically to provide for good rebox management. Best practices include keeping ash and charcoal build-up to a minimum. -
Page 28: Back-Puffing Preventionchecklist
Load we7er fuel on the top of your fuel ✔ Note: Spent ash should not be allowed to build up charge on or in the refractory. Any ash buildup will insulate the fuel charge from the heat generated Use a good percentage of full rounds, as large ✔... -
Page 29: Wood Fuel Characteristics And Wood Storage
in a dry place with only a limited supply kept indoors. Using wood that has a moisture content of greater than 30% can be detrimental to the operation of the boiler. Results of using wood with too high of a moisture content are likely to include loss of BTU output, reduced e<ciency, and condensation issues. -
Page 30: Cool Down Cycle
When it is time to start the boiler, load the boiler heat output of the boiler. It is advantageous to let the as you would for a normal start. When it is time to sun remove that extra 100 to 250 gallons of water have the dra9 fan turn on, simply push the black found in a cord of wood. -
Page 31: Conditioning Of Boiler Water
the ground well away from all combustible materials, Note: For hydronic situations where the system is pending nal disposal. If the ashes are disposed of by not closed, the following water treatment burial in soil or otherwise locally dispersed, they guidelines still apply and become even more critical! should be retained in a closed container until all... -
Page 32: Solids (Primarily For Steam Boilers)
(basic) corrosion. A minimum value for alkalinity for Solids (Primarily for Steam Boilers) adequate protection is 200 ppm CaCO3. High boiler solids will lead to foaming, priming, High boiler alkalinity (in excess of 700 ppm surging, carry over or boiler sludge in steam boilers. CaCO3) should be avoided. -
Page 33: Maintenance
Maintenance On models with dual dra9, use a pu7y knife or scraper inside the rebox. 8. Open the dra9 valve cover and inspect the valve gasket disk for evidence of air leakage. e disk should have some wobble, so it can move and nd its own seal. -
Page 34: Yearly Cleaning
place. In the locked position, cleaning and or Remove the top connecting Gange from the ✔ replacement of the air valve disc can be performed. cyclone. Clean the inside of the main body and funnel ✔ 5. To release the actuator, use the hex key wrench of the cyclone with a wire brush. -
Page 35: Door Adjustment
3. Manually move the air valve disc to the open position, (see Figure 12) ensure that the jaws on the clamp align with the contour of the sha9 as shown in Figure 11. 4. Tighten 10 mm bolt. 5. Using the Allen wrench, release the lock. is is accomplished by rotating the wrench in the direction of the arrow one quarter turn and then let go. -
Page 36: Load Door Seal Replacement
LOAD DOOR SEAL REPLACEMENT 1. Allow door to completely cool before you touch or start installation, remove door. 2. Cut Gat berglass tape (white tape) into 4 equal strips. e tape shall stop 1” from each corner. 3. Insert silicone tube into a Caulking Gun. Door Hinge Plate Adjustment To adjust the latch side of the door, remove the two bolts that secure the latch keeper in place and... -
Page 37: Load Door With Fiberglass Braid Tape And More High Temperature Silicone
Marking to Trim Load Door with Fiberglass Braid Tape and More High Trimming Preformed Silicone Bead Temperature Silicone 6. Start the gasket in the middle of the hinge side. Squeeze the gasket into place on top of the bead of silicone. -
Page 38: Front And Rear Inspection Door High Temperature Rope Installation
e rope sent from the AHS factory will be too long and will need to trimmed to the proper length. is is important because you need to start and nish with a straight end. Use sharp scissors to cut the rope. 4. -
Page 39: Fan Assembly
If the fan assembly gasket is damaged, all of the old material must be removed and a new gasket inserted. Use only 5/8 in diameter high-density berglass rope. On units that have a sha9 drive fan, the motor bearing will need to be replaced approximately every two years. -
Page 40: Direct Drive Fan Bearing Replacement Procedure
penetrant soak down into the area between the hub DIRECT DRIVE FAN BEARING and the sha9. Le7ing it soak in for an hour or longer REPLACEMENT PROCEDURE is recommended. Make sure the power is turned o: and/or Fan Hub Set Screws disconnected. -
Page 41: Ahs Fan Puller Tool At The Ready
AHS Fan Puller Tool Closeup of Motor Mounting Bolts To separate the motor housing you must remove the four bolts from the end of the motor opposite of the sha9. ese bolts have a 5/16 bolt head. AHS Fan Puller Tool at the Ready Remove the (4) 5/16”... -
Page 42: Loosening Motor End Shield From Motor
Loosening Screws Securing Bearing to End Shield Use a pulley puller, or our custom bearing puller tool [01-100-80 101] to remove the bearing from the Loosening Motor End Shield from Motor sha9. You can use it on the motor bearing on either e end shield, along with the armature, can then end of the sha9. -
Page 43: Refractory Replacement
Center Brick refractory pieces should be changed every 10-15 cords of wood and must be ordered from Alternate Heating Systems. Center Brick are removed by simply li9ing them out. are likely to have become snug, as wood ash will se7le into voids around them, making them tight. -
Page 44: Side Brick Refractory Replacement
Please wear the proper safety equipment while SIDE BRICK REFRACTORY REPLACEMENT performing this task. Proper equipment includes, e large refractory (Side Bricks) are typically work gloves, safety glasses, and steel toe boots. replaced every 10-15 years in residential boilers. ey are usually held in place only by their own 1. -
Page 45: Fuel Diverter Blocks: Auto Feed Only
whether the # 4 bricks are installed on the right or on 4. Applying the Troweleze will be your last step. the le9. It ma7ers that all the numbers on the right e Troweleze will ll in the gap between the brick are the same, and all the numbers on the le9 are the and the vessel at the front and rear inspection door. -
Page 46: Appendix A: Boiler Specification Diagram
Appendix A: Boiler Specification Diagram - 41 -... - Page 47 - 42 -...
- Page 48 - 43 -...
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Page 49: Additional Specifications
order to provide heating of a given number of ADDITIONAL SPECIFICATIONS degrees and at a certain BTU level: Pressure Drop 500K BTU’s at 20 degrees temperature • di:erential requires 50 gallons per minute. Pressure Drop (Line Loss) within the boiler is less than the pipe rating of the pipe within the boiler, so 250K BTU’s at 20 degrees temperature •... -
Page 50: Appendix B: Wiring Diagrams
Appendix B: Wiring Diagrams - 45 -... - Page 51 - 46 -...
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Page 52: Appendix C: Exploded Parts Drawings
Appendix C: Exploded Parts Drawings - 47 -... -
Page 53: Parts Listing
Parts Listing KEY DESCRIPTION E100 SF E140 SF E180 SF E250 SF Domestic Hot Water Coil 100-002 100-002 100-002 100-002 Rear Insulation Jacket Rear Hinge Plate Mounting Bolt Rear Inspection Door Hinge Plate Rear Inspection door, complete 423-015 423-015 433-010 433-010 Rear Insp. - Page 54 - 49 -...
- Page 55 KEY DESCRIPTION E100 E140 E180 E250 61 Draft Box Lid Gasket 200-052-32 200-052-32 200-052-32 200-052-32 62 Right Side Insulation Jacket 63 Fiberglass Insulation 65 Exhaust Hood Attachment Bolts 66 Exhaust Hood Blower (wired) 67 Exhaust Hood Connecting Flange Assembly 68 Draft Motor 200-422B 200-422B 200-422B...
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Page 56: Appendix D: Troubleshooting Guide
Appendix D: Troubleshooting Guide is guide is intended to help you diagnose and repair basic problems with you boiler. If you believe your problem is serious or the problem persists a9er following all the procedures speci ed in this guide, contact AHS for support. - Page 57 f) The boiler water temperature is too d) Burn smaller wood, split wood, low or Water temperature difference and/or dryer wood. Build a hotter between supply and return may be fire. Remember that more wood more than 20ºF does not always equate to more heat.
- Page 58 Wood Gun Air Inlet Ducting Installations....64 Marking to Trim............34 Wood Gun in Primary/Secondary System....65 Trimming Preformed Silicone Bead......34 Operating an Alternate Heating Systems Boiler in Adding High Temperature Silicone to Butt Joint of Tandem with Existing Boiler........66 Trimmed Bead............34 - 53 -...
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Page 59: Appendix F: Boiler Piping And Ducting Examples
Appendix F: Boiler Piping and Ducting Examples - 54 -... -
Page 60: Wood Gun Air Inlet Ducting Installations
Wood Gun Air Inlet Ducting Installations - 55 -... -
Page 61: Wood Gun In Primary/Secondary System
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 62: Operating An Alternate Heating Systems Boiler In Tandem With Existing Boiler
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™... -
Page 63: 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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