Scotsman Ice DB-101 User Manual

SCOTSMAN

WOOD FURNACE

Model DB-101

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.

ALL INSTALLATIONS MUST BE MADE IN ACCORDANCE WITH LOCAL AND STATE OR PROVINCIAL CODES WHICH MAY DIFFER FROM THIS MANUAL.

IMPROPER INSTALLATION WILL RESULT IN

VOIDING OF WARRANTY.

			SCOTSMAN WOOD FURNACE – INSTRUCTION MANUAL
			TABLE OF CONTENTS
		Specifications		2
1.0	Operating Instructions			3
	1.1	Introduction		3
	1.2	Wood-Burning		3
	1.3	Storage of Wood		4
	1.4	Maximum Solid-Fuel Charge		5
	1.5	Maintenance		5
	1.5.1	Cleaning		5
	1.5.2	Servicing		6
	1.6	Safety		6
	1.7	Controls		6
	1.8	Electrical Power Failure		7
	1.9	Homeowner Checklist		8
2.0	Installation Instructions			8
	2.1	Introduction to Installers		8
	2.2	Uncrating		9
	2.3	Locating the Furnace		9
	2.4.1	Combustion Air Supply		10
	2.4.2	Flue Pipe & Chimney		10
	2.5	Clearances		12
	2.6.1	Free-Standing		13
	2.6.2	Add-On		13
	2.7	Duct Connection		15
	2.8	Control System		16
	2.9	Installers Checklist		17
			Appendices
APPENDIX A – Warranty
DIAGRAMS
	S101-1		Add-On to Oil – Clearances
	S101-2		Add-On to Oil – “S” type duct
	S101-3		Gravity Return Air Kit
	S101-4		Base for use on Combustible Floor
	S101-5		Controls Placement
	S101-6		Add-On to Oil – Electrical Schematic Belt Drive
	S101-7		Add-On to Oil – Electrical Schematic Direct Drive
	S101-8		Add-On to Oil – Electrical Schematic Direct Drive
	S101-9		Clearances Free Standing
	S101-10		Cleaning
	S101-11		Free Standing Wiring Diagram
	S101-12		Approved Furnace Ductwork Configurations
	S101-13		Prohibited Furnace Ductwork Configurations

Scotsman

1

Oct-06

	SCOTSMAN WOOD FURNACE – INSTRUCTION MANUAL
KERR SCOTSMAN Wood Furnace		Model DB-101-ADD
Tested and Listed by:	Energy Testing Laboratory of Maine
Certified by the Canadian Standards Association		(CSA) Sept. 1981
COSP No. WCP 001	– Free-Standing
COSP No. WCP 005	– Add-On

Manufactured by: Parrsboro Metal Fabricators Ltd. P.O. Box 637, Crossroads 12118 Highway 209

Parrsboro Nova Scotia, Canada B0M 1S0

SPECIFICATIONS

Length		39”
Width		29”
Height		44 1/2”
Shipping Weight		392 lb.
Fire Box 1/8”plate	Length	36”
	Diameter	23”
Secondary Heat Exchanger		14 gauge steel
Fire Box Door	Cast Iron	13” x 13”
Warm Air Plenum		32 1/4” x 25 1/2”
Return Air Plenum		N/A
Air Filter Size		20” x 20”
Blower Size		G9 – 10
Blower Motor		1/4 hp
C.F.M.		1000 (Required)
Smoke Pipe		7” Inside Diameter
Floor to smoke pipe center		38 3/4”
Output (max)		140,000 Btu/h
Fuel		Wood 30” 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.

SAVE THESE INSTRUCTIONS

Scotsman

2

Oct-06

SCOTSMAN WOOD FURNACE – INSTRUCTION MANUAL

1.0OPERATING INSTRUCTIONS

1.1INTRODUCTION

Congratulations on your purchase of the KERR SCOTSMAN 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 SCOTSMAN 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.

1.2WOOD-BURNING

The SCOTSMAN 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 SCOTSMAN Wood Furnace and will produce less creosote.

When refueling the SCOTSMAN, 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 SCOTSMAN 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.

Scotsman

3

Oct-06

SCOTSMAN 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 odor. This substance is commonly called creosote.

If 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 result in cleaner combustion and higher efficiency.

IN CASE A SERIOUS CREOSOTE FIRE BEGINS: o Close the damper door by disconnecting chain. o Close all draft regulators.

o Throw 1/2 lb. of coarse or table salt on the fire and close door immediately. o Call the FIRE DEPARTMENT at once!

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

1.3STORAGE 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.

Scotsman

4

Oct-06

SCOTSMAN WOOD FURNACE – INSTRUCTION MANUAL

1.4MAXIMUM 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 SCOTSMAN Wood Furnace will accept whole or split logs up to 34 in. (865 mm) long, but a 30 in. (765 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.

1.5MAINTENANCE

Some regular maintenance is necessary on the KERR SCOTSMAN 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 S101-10)

The KERR SCOTSMAN 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 SCOTSMAN 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.

CLEANING PROCEDURE

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

oRemove the cleanout cover, located on the rear of the furnace heat exchanger, the smoke pipe, and internal breech baffle.

o The heat exchanger is now accessible for cleaning.

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

oScrape all residues in the top heat exchanger towards the rear of the furnace where it will fall into the firebox.

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

oReinstall cleanout cover, internal breech baffle (See section 2.4.2) and smoke pipe making sure that all joints are secured with at least 3 sheet metal screws.

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

oResidue 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.

Scotsman

5

Oct-06

SCOTSMAN 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.

1.6SAFETY

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

DO NOT shut off power. The blower must be kept running to disperse excessive heat. Manually close the damper door by unhooking the chain. 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.

1.7CONTROLS

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 and 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 (280º F (138º 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.

Scotsman

6

Oct-06

SCOTSMAN WOOD FURNACE – INSTRUCTION MANUAL

1.8ELECTRICAL POWER FAILURE (Fig S101-3)

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 optional gravity air inlet kit is installed.

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

For Power Failure operation remove the power failure gravity air inlet cover before starting or refueling during power failure. The cover is an option available from your KERR dealer. The kit must be installed on the cabinet side directly opposite to the entry of the blower or oil furnace “S” connection ductwork.

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

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

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

Do not leave the furnace unattended in this position.

Refuel frequently with small loads to maintain a small fire at ½ normal maximum volume.

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

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

Scotsman

7

Oct-06

SCOTSMAN WOOD FURNACE – INSTRUCTION MANUAL

1.9HOMEOWNER CHECKLIST

o Keep area around unit clean and clear of combustibles.

o Use only dry wood. DO NOT burn garbage, gasoline or naphtha. o Load carefully.

o Remove ashes as directed.

o Watch for soot build up in smoke pipe – clean regularly. o Clean furnace heat exchanger regularly.

o Be aware of danger due to over firing unit.

oDo not load above maximum loading level (middle of loading door) or overheating may result.

o This unit is NOT suitable for automatic stoking.

oLoad carefully. Do not slam fuel against rear or sides of firebox. This may damage the firebox.

oAlways observe the following minimum clearances to combustible materials – Front 48” (1220 mm); one side 6” (152 mm); opposite side and rear 24” (610 mm); and flue pipe 18” (465 mm).

oDo not store solid fuel within the above clearances or within the space required for charging and ash removal.

o Establish a routine for storage of fuel, care of the appliance, and firing techniques.

2.0INSTALLATION INSTRUCTIONS

2.1INTRODUCTION TO INSTALLERS

Before installing this KERR SCOTSMAN Wood Furnace, please read the following instruction manual carefully. This unit is designed to be a freestanding or add-on central heating furnace to provide complete central heating in medium sized wellinsulated homes. Before installing be sure unit is properly sized for the intended application. Warranty does not cover misapplication of unit.

Applicable Standards

The KERR SCOTSMAN Wood Furnace must be installed in accordance with the requirements of the National Fire Protection Association codes, the Canadian Heating, Ventilation and Air Conditioning Code, The National Board of Fire Underwriters, and the CSA Standards for solid fuel burning equipment as outlined in B365-01. In all cases consult your local authorities and fire insurance company for specific regulations.

Scotsman

8

Oct-06

SCOTSMAN WOOD FURNACE – INSTRUCTION MANUAL

2.2UNCRATING

When you receive your KERR SCOTSMAN Wood Furnace, check it carefully to ensure that all components are present and in good condition. If there has been any damage or loss in transportation, please notify the carrier and retailer at once. Inspect for the following:

o Firebox/Heat exchanger o Poker/coals rake

o Marking template (return air and power failure bypass inlet) o Internal Breech Baffle (Scotsman only)

oFor free-standing model optional equipment required:

a)BC-9 Blower Kit (Scotsman only)

b)Control Kit “B” (Scotsman only)

CONTROL KIT A (Oil add-on), B (free-standing with BC–9 blower) or E (Electric addon) selected according to installation, which includes:

o L4064R Fan and Limit Control o Control Mounting Plate

o Damper Motor

o Thermostat (T822D or equivalent) o Wiring Harness and Parts

o Switching Relay R8405C (8A05A – 4) – Kit “A” & “E” only o Transformer – Kit “B” only

NOTE: Some parts may be packed inside furnace firebox. Check shipment carefully before assuming shortage.

2.3LOCATING THE FURNACE (Fig S101-1, Fig S101-4)

The location of the furnace must be as close as possible to the tile-lined brick chimney, or factory-built solid-fuel approved chimney (ULC S629). Keep in mind also the day-to- day operation, and place for ease of fueling and cleaning. KERR recommends installation if possible, in a central location in relation to the outlet registers and the use of large warm air ducts to improve heat distribution during a power failure.

It is important to provide adequate combustion air to the furnace. It may be necessary to add a ventilator to an exterior wall of a closed furnace room or an airtight basement.

The furnace must be installed so that the clearances as shown in Fig S101-1, or those of local authorities are met. If the furnace must be installed on a combustible floor, a non-combustible base must be built as shown in Fig S101-4. Two layers of hollow masonry block (4” thick) are placed at right angles to each other so that the ventilation holes of one layer are opposite to those of the other layer. Also there must be a minimum of one layer of fireproof board and one layer of 26 gauge galvanized metal beneath the masonry blocks. This base must extend beyond the furnace to a minimum distance of 18 in (457 mm) in front and 8 in. (204 mm) on all sides.

Scotsman

9

Oct-06

SCOTSMAN WOOD FURNACE – INSTRUCTION MANUAL

2.4.1 COMBUSTION AIR SUPPLY

Air inlets of at least 200 square inches free area (1.5 in2/1000Btu) must be provided to the room occupied by the wood fired or oil fired furnace. These fresh air inlets must provide or allow free access of fresh outside air to the furnace. At no time or under any circumstances can a wood or oil-burning appliance be starved of combustion air.

The appliance must at all times be able to maintain the approved stack draft. The barometric draft regulator must be installed on the furnace smoke pipe in the same room or at least in such a way that there is unrestricted free passage of air between the combustion air inlet to the furnace or burner and the barometric draft regulator.

It is important to provide adequate combustion air to the furnace. It may be necessary to add a ventilator to an exterior wall of a closed furnace room or an airtight basement.

Operating a wood or oil fired appliance with inadequate combustion air could be hazardous.

2.4.2 FLUE PIPE & CHIMNEY

The internal breech baffle should be inserted through the breech towards the front of the furnace until it hits the internal baffle stop. The open slot running the length of the baffle should be located on the top. This baffle is removed during the cleaning procedure. The purpose of the baffle is to prevent short-circuiting of the flue gases out through the rear breech. The flue gases are forced to fully heat the secondary heat exchanger, which will maintain higher furnace efficiency.

The furnace must be located to meet a minimum venting distance needed between the furnace and the flue. It should also be ducted so that there are 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 furnace to the flue.

NEVER ALLOW THE SMOKE PIPE TO RUN DOWNHILL TO THE FLUE!

The smoke pipe and chimney should be at least 7 inches in diameter. The flue pipe or a chimney may be of different cross-sectional area than that of the appliance smoke pipe, provided that sufficient draft is available at the appliance. Space must be provided around the smoke pipe and the back of the furnace to allow easy access for the purpose of cleaning. Smoke pipes must not be lighter than 24 gauge black steel. All pipes must be securely fastened with at least 3 sheet metal screws at every joint, and properly supported.

Always meet or exceed flue pipe clearance specifications - 18” clearance from flue pipe to combustibles in all directions.

Connect the furnace only to an approved chimney suitable for solid fuel appliances and capable of venting the products of combustion. The chimney must be installed with proper clearances above roof and from adjacent structures and trees. If a masonry chimney is used it must be in good condition and be equipped with a tile liner. Flue thimble or flue pipe must not extend into the chimney flue, as it will reduce the draft.

Scotsman

10

Oct-06