HP DB-102 User Manual

ALL INSTALLATIONS MUST BE MADE IN ACCORDANCE

OF WARRANTY.

SCOTTY

WOOD FURNACE

Model DB-102

OWNER’S MANUAL

IMPORTANT

READ OWNER’S MANUAL THOROUGHLY BEFORE

INSTALLING FURNACE OR LIGHTING FIRE.

CONSULT LOCAL AUTHORITIES IF IN DOUBT

ABOUT YOUR LOCAL FIRE SAFETY REGULATIONS.

WITH LOCAL AND STATE OR PROVINCIAL CODES

WHICH MAY DIFFER FROM THIS MANUAL.

IMPROPER INSTALLATION WILL RESULT IN VOIDING

SCOTTY WOOD FURNACE – INSTRUCTION MANUAL

TABLE OF CONTENTS

Specifications 3

1.0 Operating Instructions 4

1.1 Introduction 4

1.2 Wood-Burning 4

1.3 Storage of Wood 5

1.4 Maximum Solid-Fuel Charge 6

1.5 Maintenance 6

1.5.1 Cleaning 6

1.5.2 Servicing 7

1.6 Safety 7

1.7 Controls 7

1.8 Electrical Power Failure 8

1.9 Homeowner Checklist 9

2.0 Installation Instructions 9

2.1 Introduction to Installers 9

2.2 Uncrating 10

2.3 Locating the Furnace 10

2.4.1 Combustion Air Supply 11

2.4.2 Flue Pipe & Chimney 11

2.5 Clearances 12

2.6 Duct Connection 13

2.7 Free Standing 14

2.8 Control System 14

2.9 Installers Checklist 15

DIAGRAMS

S102 – 1 Clearances S102 – 2 Combustible Floor Base S102 – 3 Control Placement Detail S102 – 4 Free Standing Wiring Diagram S102 – 5 Control Placement S102 – 6 Cleaning S102 – 7 Ductwork Configurations

Appendices

APPENDIX A – Warranty Rear Cover

Scotty

Oct-06

SCOTTY WOOD FURNACE – INSTRUCTION MANUAL

KERR SCOTTY Wood Furnace Model DB-102

Certified by the Canadian Standards Association

Manufactured by: Parrsboro Metal Fabricators Ltd.

P.O. Box 637, Crossroads 12118, Highway 209 Parrsboro, Nova Scotia, Canada B0M 1S0

SPECIFICATIONS

Length 46 1/2” Width 22 1/2” Height 43” Shipping Weight 344 lb Fire Box 1/8”plate Length 27 1/2” Diameter 18” Secondary Heat Exchanger 14 gauge steel Fire Box Door Cast Iron 12” x 12” Warm Air Plenum 29” x 20 3/4” Return Air Plenum 14 ½” x 20 3/4” Air Filter Size 16” x 20” x 1” Blower Size G9 – 10 Blower Motor 1/4 hp CFM 1000 (Required) Smoke Pipe 7” Inside Diameter Floor to smoke pipe center 36” Output (max) 70,000 Btu/h Fuel Wood 24” logs Electrical Rating Volts 120, Cycles 60, Amps 15

NOTE – Keep this manual in a safe place for future reference. Follow manual carefully for the correct way to install and operate this unit.

CAUTION – Do not fire this unit until operating instructions have been read and fully understood.

INSTALL WOOD FURNACE ONLY ON A FURNACE DUCT SYSTEM AND CHIMNEY

THAT ARE IN GOOD CONDITION AND APPROVED FOR USE.

SAVE THESE INSTRUCTIONS

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Oct-06

SCOTTY WOOD FURNACE – INSTRUCTION MANUAL

1.0 OPERATING INSTRUCTIONS

1.1 INTRODUCTION

Congratulations on your purchase of the KERR SCOTTY Wood Furnace. Developed in Atlantic Canada, this KERR Furnace has been designed to allow you to heat your home with wood, one of North America’s most abundant fuels. Designed with you in mind, the KERR SCOTTY Wood Furnace will provide you with many years of safe, efficient central heating.

To ensure you have a clear understanding of the operating procedures of this furnace, please take the time to read the remainder of this section on operating procedures. If you have any questions, your KERR DEALER will be happy to answer them for you.

1.2 WOOD-BURNING

The SCOTTY Wood Furnace will burn most wood fuels, however it is recommended that only dry, seasoned hardwood be used as much as possible since it affords cleaner, safer and more efficient operation. Burning seasoned hardwood will leave less ash, soot and creosote residue and will require fueling less often. Use smaller loads of wood on warmer days.

WARNING: DO NOT use chemicals or fluids to start the fire or during operation.

DO NOT burn driftwood or manufactured logs (compressed wood).

Before adding fuel to an existing fire turn up the thermostat for about five minutes or lift damper chain to hold damper fully open for about one minute before opening the loading door. This action will allow residual smoke to clear from the combustion chamber and reduce smoke entering the basement during refueling.

Twice daily refueling may be sufficient in modern well-insulated homes. However, KERR recommends that small fuel loads be added morning, noon and early evening and late evening, rather than large quantities infrequently. A small intense fire will burn more efficiently than a large smoldering fire in the SCOTTY Wood Furnace and will produce less creosote.

When refueling the SCOTTY, the remaining coals should be raked to the front of the combustion chamber before adding any new fuel. Place the fresh supply of wood to the rear of the combustion chamber. This gives more of an even cigar type fuel burn, rather than a large hot fire to a slow amber fire. This will help create a more even and efficient burn. The SCOTTY owner should attempt to gauge fuel quantities with outdoor temperatures; a little practice will provide greater satisfaction and efficiency.

WARNING: This furnace is not to be used with an automatic stoker. Keep firing door tightly

closed and maintain door seal in good condition.

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SCOTTY WOOD FURNACE – INSTRUCTION MANUAL

CREOSOTE

Wood combustion is never 100% complete. Wood smoke always contains some unburned gases and a mixture of unburned tar-like liquids. A percentage of these materials will condense out on any cool surface, leaving a dark brown or black substance with an unpleasant acrid odour. This substance is commonly called creosote.

These wood gases condense out on cool surfaces such as a cold chimney or a long smoke pipe; they retain large amounts of water and will be very fluid. At higher temperatures the condensed creosote will resemble tar (thick and tacky).

Creosote generation is highest during low heat outputs common with long smoldering burns. Creosote generation is lowest during high heat outputs common with intense fires. It is recommended that a small intense fire be used for best results against creosote build up even though the wood furnace will require refueling more often.

Creosote generation is also higher when burning green wood. The moisture in the green wood absorbs the heat from the fire, cooling the fire below the point at which the creosote can be consumed. The low temperature smoke is then further cooled in the upper furnace chambers’ smoke pipe and chimney allowing large amounts of creosote to form.

To reduce creosote build-up during periods of low heat requirements (i.e. Spring and Fall) it is recommended to fuel the wood furnace with smaller quantities of smaller diameter logs. Matching fuel loads and heat requirements will generally result in cleaner combustion and higher efficiency.

IN CASE A SERIOUS CREOSOTE FIRE BEGINS:

a) Close the damper door by disconnecting chain b) Close all draft regulators c) Throw 1/2 lb of coarse or table salt on the fire and close door immediately. d) Call the FIRE DEPARTMENT at once!

Have a firmly established Emergency Procedure in place for the handling of a flue fire.

1.3 STORAGE OF WOOD

Once cut, green wood dries (or seasons), quickly at first and then at a slower and slower rate. When the wood has been cut to the proper length and split, it should be piled outside during the summer months. Place two poles on the ground to serve as rails to keep the firewood off the moist ground. Stack the wood so that both ends of the logs are exposed to the air if space is available, since more drying occurs through the cut ends than through the sides. This is true even with wood that has been split. The woodpile should be under cover so that it will not absorb moisture from the rain and snow before it is used, but still open on the sides and ends to the drying effect of the wind and sun. Store wood in neat, well-supported piles.

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Oct-06

SCOTTY WOOD FURNACE – INSTRUCTION MANUAL

1.4 MAXIMUM SOLID-FUEL CHARGE

The maximum level for a solid-fuel charge is the middle of the loading door, or the level of the handle. DO NOT OVERFILL.

The KERR SCOTTY Wood Furnace will accept whole or split logs up to 27 in. (686 mm) long, but a 24 in (610 mm) log length is recommended for convenience and ease in handling.

Maximum damper gate opening is 11/16”. Do not tamper or adjust to greater opening in an attempt to increase fire or over-firing and hazard may result.

1.5 MAINTENANCE

Some regular maintenance is necessary on the KERR SCOTTY furnace. A good practice is to establish a routine for the storage of fuel, care of the appliance, and firing techniques.

1.5.1 CLEANING (Fig S102-6)

The KERR SCOTTY Wood Furnace must be cleaned regularly to maintain top efficiency. The furnace needs cleaning more often when burning green wood, or during long periods of low fire. When the KERR SCOTTY Wood Furnace is first installed the furnace heat exchanger should be checked visually from the firebox and smoke pipe hole every week to determine the rate at which creosote or ash is accumulating within the furnace. Cleaning should be done whenever there is more than 1/4 inch of build-up on the heat exchanger or 3 inches of ash in the base. If the wood furnace is to be left unused for an extended period of time (more than one month) then the appliance should be cleaned of all ash and residual left from the burning of wood. See fig. S102-6

CLEANING PROCEDURE:

1) Make sure fire is completely out and the furnace has cooled.

2) Remove the smoke pipe located on the rear of the furnace heat exchanger.

3) The heat exchanger is now accessible for cleaning.

4) Use the scraper provided to remove all soot and ash from the furnace heat exchanger and exposed surfaces.

5) Scrape all residues in the top heat exchanger towards the front of the furnace where it will fall into the firebox.

6) Always check flue pipe for creosote or ash build-up in the pipe and clean if necessary.

7) Reinstall smoke pipe making sure that all joints are secured with at least 3 sheet metal screws.

8) Check chimney cleanout for ash build-up and remove any accumulation.

9) Residue may be removed from the firebox or left to be burnt during the next fire. It is good practice to leave a layer of ash approximately one inch deep in the base of the firebox.

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SCOTTY WOOD FURNACE – INSTRUCTION MANUAL

DISPOSAL OF ASHES

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. If the ashes are disposed of by burial in soil or otherwise locally dispersed, they should be retained in the closed container until all cinders have thoroughly cooled.

WARNING – Ashes usually contain live dormant coals, which may burn for many hours after a recognizable flame has disappeared. Use extreme caution when handling and disposing ashes.

IMPORTANT – No other waste shall be placed in this container.

1.5.2 SERVICING

The furnace air filter must be checked monthly and replaced each year. Annually lubricate the blower motor, if it is not permanently lubricated, with 4-6 drops of SAE-30 oil in each bearing.

CAUTION: Failure to keep air filter clean will result in poor furnace performance and

possible damage to wood furnace heat exchanger.

1.6 SAFETY

If the furnace overheats due to improper operation the following precautions should be taken:

1) DO NOT shut off power. The blower must be kept running to disperse excessive heat.

2) Manually close the damper door by unhooking the chain.

3) Check controls for proper operation before starting a new fire.

WARNING – The maximum opening of the combustion air damper is preset at the factory. DO NOT adjust the stop or attempt to increase the combustion air by any means.

1.7 CONTROLS (Fig S102-3)

Thermostat

The primary control is the room thermostat located near the center of the house on the main floor or near an existing thermostat. The thermostat operates the damper motor to open and close the damper door thus allowing more or less air into the combustion area to control the fire.

Fan & Limit

The fan and limit control mounted in the plenum controls the operation of the circulating blower and prevents the furnace from over-heating. When the air temperature in the plenum reaches the “ON” set point of the fan switch (usually 140º F (60º C)) the blower starts and runs until the plenum cools to the “OFF” set point (usually 100º F (38º C)) when the blower is switched off. The limit function in this control is usually set at (250º F (121º C)) and will override the room thermostat to close the damper door if the furnace overheats, and will also prevent the oil furnace from starting.

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Oct-06

SCOTTY WOOD FURNACE – INSTRUCTION MANUAL

1.8 ELECTRICAL POWER FAILURE

If no one is home during a power failure, the damper will automatically close and some gravity heating will take place. Combustion air will continue to enter through the secondary air holes and a fire should be maintained.

IMPORTANT – This furnace is CSA certified for operation under Power Failure only if the following procedure is followed.

For optimum heating during a power failure follow the procedure listed below:

1) Manually open the blower compartment access door of the wood furnace to allow gravity flowing air to all areas. (Check with your installer)

2) Place a coin under the damper flap in such a way that it will fall clear when power is restored.

3) Maintain a careful watch on the furnace temperature. If it should exceed 200º F (95º C) close the damper door.

4) Do not leave the furnace unattended in this position.

5) Refuel frequently with small load to maintain a small fire at 1/2 normal maximum volume.

6) Do not expect to maintain maximum comfort under no power conditions.

7) Do not allow anyone who is unfamiliar with the operation of the furnace to attend it during a power failure.

Scotty

Oct-06

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