G A S I F I CAT I O N B O I L E R S EBW AND EBWC SERIES HIGH EFFICIENCY WOOD FIRED BOILERS C US INS TAL L AT I O N A N D OPE R AT I N G M A N UAL
G A S I F I CAT I O N B O I L E R S Manufactured by: Alternative Fuel Boilers 795 Deer Street PO Box 281 Dunkirk, New York 14048 United States of America Website: www.alternativefuelboilers.com Email: sales@alternativefuelboilers.com © 2008 Alternative Fuel Boilers L.L.C. all rights reserved. Rev.
INTRODUCTION SPECIFICATIONS BOILER DIAGRAM TABLE OF CONTENTS 1 2 3 SECTION 1 - INSTALLATION INSTRUCTIONS INTRODUCTION TO INSTALLERS APPLICABLE STANDARDS UNCRATING LOCATING THE BOILER COMBUSTION AIR SUPPLY CONNECTING BOILER TO AN EXISTING SYSTEM FLUE PIPE INSTALLATION CLEARANCES PLUMBING CONNECTIONS PLUMBING CONNECTIONS DIAGRAM FREESTANDING INSTALLATION INSTALLER INSTRUCTIONS TO THE BOILER OWNER WIRING DIAGRAMS INSTALLERS FINAL CHECKLIST 4 4 4 4 5 7 9 10 10 11 12 12 13-16 17 SECTION 2 – OPERATING INSTR
G A S I F I CAT I O N B O I L E R S INTRODUCTION Congratulations on the purchase of your new ECONOBURN™ Wood-Fired Boiler. Developed in the northeastern United States, the ECONOBURN™ Boiler has been designed to allow you to heat, and supply hot water for your home or business, by burning wood, one of North America’s most plentiful and affordable fuels.
SPECIFICATIONS ECONOBURN™ Specifications (subject to change without notice) Boiler Model EBW-100 EBW-150 EBW-200 EBW-300 EBWC-500 EBWC-1000 Depth Width Height 42” 25” 60” 42” 25” 64” 42” 30’ 64” 45” 36” 70” 50” 40” 78“ 80” 42” 82“ Firebox Length Width Height 23” 15” 29” 23” 16” 29” 23” 21” 30” 26” 24” 34” 37” 29” 36” 50” 29” 39” 12” X 23.5” 13”X32” 13”X32” Fire Box Door (Dim.
BOILER DIAGRAM Rigging Hook Access Supply Control Panel Pressure Relief Valve Emergency Cooling Connection Turbulator Agitation Lever Firebox Door Flue Draft Handle Draft Fan Cover Return (Lower back panel) Gasification Chamber and Ash Pit Door 3
SECTION 1 - INSTALLATION INSTRUCTIONS INTRODUCTION TO INSTALLERS (Save these Instructions!) ATTENTION:THIS UNIT MUST BE INSTALLED BY A QUALIFIED PROFESSIONAL! Before installing this ECONOBURN™ Wood-Fired Boiler, please read the following instruction manual carefully. This unit is designed to be a freestanding central heating boiler, or as an add-on to operate in conjunction with an existing oil, gas, or electric unit, to provide a complete central heating solution.
With the location of the boiler selected the next step is to position the unit and proceed with assembly. If a noncombustible base is not required ECONOBURN™ recommends that the boiler be placed on masonry blocks (bricks or 8” concrete blocks) if space permits, to allow easier fueling and to keep the ECONOBURN™ boiler above any possible water in the basement. These blocks should extend approximately 1” on all sides of the boiler for support and stability. Continue as follows: 1.
OUTSIDE COMBUSTION AIR MAY BE NECESSARY IF: 1. Fans that are installed in the fuel storage area create negative pressures in the room where the solid fuel-burning appliance is located. 2. The solid-fuel-fired appliance does not draw steadily, smell, experiences smoke roll-out, burns poorly, or back-drafts whether or not there is combustion present. 3. Any of the above symptoms are alleviated by opening a window slightly on a calm day. 4.
BOILERS CONNECTED TO AN EXISTING SYSTEM i. Shall be installed without interfering with the normal delivery of heated water from the original boiler. ii. Shall be installed without affecting the operation of the electrical and mechanical safety controls of the original boiler. iii. Shall provide for a changeover from one fuel to the other without requiring manual adjustment of the controls or components either than the thermostats. iv.
OPERATE THE (GAS, OIL, ELECTRIC) BOILER PERIODICALLY TO ENSURE THAT IT WILL OPERATE SATISFACTORILY WHEN NEEDED. DO NOT RELOCATE OR BYPASS ANY OF THE SAFETY CONTROLS IN THE ORIGINAL (GAS, OIL, ELECTRIC) BOILER INSTALLATION. THE OPERATION OF THE GAS BOILER MUST BE VERIFIED FOR ACCEPTABLE OPERATION BEFORE AND AFTER INSTALLATION OF THE ADD-ON APPLIANCE BY A GAS FITTER WHO IS RECOGNIZED BY THE REGULATORY AUTHORITY. DO NOT CONNECT TO ANY CHIMNEY OR VENT SERVING A GAS APPLIANCE.
FLUE PIPE AND CHIMNEY The Boiler must be located as close as possible to the chimney. It should be ducted so that there is a minimum number of elbows used. The flue pipe must be installed with a gradual rise of 1/2” or more per foot from the Boiler to the flue. WARNING - NEVER ALLOW THE SMOKE PIPE TO RUN DOWNHILL TO THE FLUE. The smoke pipe and chimney must be at least 8 inches in diameter, on the smaller sizes and 12” on the two larger sizes.
CLEARANCES The ECONOBURN™ Wood-Fired Boiler is to be installed in accordance with the National Building Code or local regulations. Allowances front and rear must be made for cleaning and servicing. Minimum safety clearances to combustibles are: Front: 48” Right Side: 18” Left Side: 24” Rear: 24” Above Wood-Fired Boiler: 28” Flue Pipe to combustible, Boiler and electrical wiring: 18” Floor: Non-Combustible These clearances will also allow adequate combustion air to reach the boiler.
DURING A POWER FAILURE NEVER REFUEL THE BOILER. GRAVITY LOOP (NO POWER) A normally open powered zone valve must be installed to allow a free flow of water in a power off situation. The override loop for the safety shall have at least 30 ft. of radiation above the wood boiler for a gravity flow. THE SAFETY GRAVITY LOOP SHOULD NOT RUN THROUGH ANY PLASTIC PIPE.
FREE STANDING INSTALLATION In the freestanding, or stand-alone system, the ECONOBURN™ boiler is the sole source of central heating. In this system connect the piping as you would for any conventional hydronic heating system (using zone valves, circulator zoning, or single zone flow check system). The boiler must not be installed as a gravity system, as the controls are not designed for this type of operation.
BOILER WIRING DIAGRAM FOR EWB-100 EWB-500 EWB-1000 Figure 3 13
BOILER WIRING DIAGRAM FOR EWB-150 EWB-200 EWB-300 Figure 4 14
Figure 5 15
Figure 6 16
INSTALLERS FINAL CHECKLIST PIPING INSPECTION 1. Boiler plumbed properly? 2. Is a new expansion tank or equivalent installed? 3. Normally closed by-pass zone valve installed? 4. Does the normally open zone valve by-pass to the main living area loop? 5. Is the normally open zone valve on the most direct piping loop (fewest elbows)? BOILER INSPECTION 1. Are clearances maintained? 2. Is the system full of water and air eliminated? 3.
SECTION 2 – OPERATING INSTRUCTIONS INITIAL STARTUP To remove any remaining moisture in the refractory, a small to medium fire should be maintained for 10 to 12 hours. WOOD-BURNING The ECONOBURN™ Wood-Fired Boiler will burn most solid wood fuels, however it is recommended that hardwoods be used for their superior energy content. Burning dry seasoned wood is alright, although unnecessary, as a residual moisture content of 20% is required for optimal gasification combustion.
CREOSOTE AND CLEANING 1. Establish a routine for the storage of fuel, care of the appliance, and firing techniques. 2. Check daily for creosote build up until experience shows how often cleaning is necessary. 3. Be aware that the hotter the fire, the less creosote is deposited, and that weekly cleaning may be necessary in mild weather, even though monthly cleaning may be enough in the coldest months. A small intense fire is preferable to a large smoldering fire to reduce the amount of creosote deposition. 4.
FLUE DRAFT CONTROL OPERATION The purpose of the Flue Draft Control (Fig. 6) is to prevent flames from coming out of the fire door toward the operator. The draft control lever is designed in such a way so that the upper door may not be opened without opening the rear damper and allowing the draft to go up the chimney. WARNING - NEVER OPEN EITHER DOOR WHEN THE BOILER IS IN OPERATION WITHOUT OPENING THE FLUE DRAFT CONTROL.
DRAFT FAN CONTROL UNIT The Draft Fan Controller (Fig.10) is an Aquastat which is set at the temperature desired for the temperature of the water jacket of the boiler. A probe is clamped to the top of the boiler to monitor this temperature. This is normally set at 160 degrees Fahrenheit. When the temperature of the water is less then the Aquastat setting, the speed of the Draft Fan is raised to maximum RPM, forcing air into the combustion chamber.
The Thermo Overload switch protects the Control Panel from any electrical shorts or power surges in excess of 5 amps with any external electrical devices wired through the rear of the boiler. This could include the main or circulating pump, or an overheat valve if installed, and connected to the electrical box at the rear of the boiler. In the event of the breaker tripping, the switch will pop outwards. Simply press the switch back into place to reset the breaker.
BOILER OPERATING CHECKLIST a. Keep area around ECONOBURN™ boiler clean and clear of combustibles. b. Use only wood. DO NOT burn any other combustible material, or liquid. c. Remove ashes as directed. d. Watch for soot in flue pipe - clean regularly. e. Be aware of danger due to over firing unit. f. This unit is NOT suitable for automatic stoking. g. Load carefully. DRAFT CONTROL FAN MUST BE STOPPED, AND FLUE DAMPER FULLY OPENED FOR AT LEAST ONE MINUTE BEFORE OPENING THE LOADING DOOR TO REFUEL.
SECTION 3 - MAINTENANCE AND CLEANING The ECONOBURN™ Wood-Fired Boiler must be cleaned regularly to maintain top efficiency. A good practice is to establish a routine for the storage of fuel, care of the appliance, and firing techniques. BOILER MAINTENANCE 1) TURBULATOR ARMS AND SHAFT SHOULD BE CLEANED EVERY 3 DAYS OF BOILER USAGE WHEN THE UNIT IS HOT. 2) ASHES SHOULD BE REMOVED AS NEEDED. 3) CLEAN HEAT EXCHANGERS ANNUALLY WITH A 2 INCH BORE BRUSH OR SIMILAR DEVICE.
ASH DISPOSAL Before removing ashes, cease refueling and allow the fire to die down. Before opening the Ash Pit door, ensure the fire in the boiler is completely extinguished. 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.
CHIMNEY MAINTENANCE Inspect monthly during heating season. For extra safety, have your chimney inspected by an accredited professional yearly, prior to the heating season. TROUBLESHOOTING GUIDE PROBLEM Boiler doesn’t reach desired temperature. Smoke escaping while loading wood. Smoke escaping from closed boiler doors. CAUSE SUGGESTED REMEDY Wood too moist. Nozzle plugged. Use properly seasoned wood. Clean firebox. Chimney plugged. Clean chimney. Intense wind or down draft.
SECTION 4 - ECONOBURN™ BOILER WARRANTY WARRANTY PERIOD The warranty period for the main boiler is 5 years against defects in workmanship. Any purchased components will carry such warranty as covered by the particular vendor. CONDITIONS OF WARRANTY 1. Your ECONOBURN™ boiler must be installed by a qualified, and licensed Plumbing and Heating professional. Any other method of installation will void this warranty. 2.
