White Rodgers TW2000 User Manual

TW2000

WOOD-FIRED BOILER

OWNER’S MANUAL

IMPORTANT

READ OWNER’S MANUAL THOROUGHLY BEFORE

INSTALLING BOILER 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.

TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL

CONTENTS

SECTION 1 – OPERATING INSTRUCTIONS Pg.

Specifications 2

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

1.6 Safety 6

1.7 Electrical Power Failure 6

1.8 Homeowner Checklist 7

SECTION 2 INSTALLATION

2.2 Uncrating 9

2.3 Locating the Boiler 10

2.4.1 Combustion Air Supply 11

2.5 Clearances 13

2.6 Plumbing Connection 13

2.7 Control System 14

DIAGRAMS
TW – 1 Parallel Piping Diagram

TW – 1EH Parallel Piping Electric Boiler

TW – 2 Parallel Wiring Diagram

TW – 4 Free Standing Piping Diagram
TW – 5 Free Standing Wiring Diagram
TW – 6 Alternate Free Standing Wiring Diagram
TW – 7 Heat Exchanger

2.1 Introduction 9

2.4.2 Flue Pipe and Chimney 11

2.6.1 Free Standing 13

2.6.2 Parallel Piping System 14

2.8 Wiring 15

2.9 Dealer Instructions to Homeowner 15

2.10 Installers Checklist 15
Parts List
TW-2000 Parallel Plumbing Wiring Explanation

TW – 3 Alternate Parallel Wiring Diagram
TW – 3EH Wiring Diagram Electric Boiler

TW – 8 Non-Combustible Floor Base
TW – 9 Accessory Layouts
TW – 10 Damper Motor Installation
TW – 11 USA Models – Fusible Plug

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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL

SECTION 1 – OPERATING INSTRUCTIONS

KERR TW2000 Wood-Fired Boiler

Tested by: Warnock Hersey Professional Services Ltd. to CSA standard B366.1
Certified by the Canadian Standards Association (CSA) May 1984

COSP. WWP-009

Manufactured by: Parrsboro Metal Fabricators Ltd.

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

Specifications

Cabinet Length 36”

Width 22”

Height 36”
Shipping Weight 600 lb.
Fire Box Length 36”
Width 16”
Height 26”
Water Volume US Gallons 26.10
IMP. Gallons 21.73
Liters 98.80
Heat Exchanger 3/16” & 12-gauge steel
Fire Box Door Cast Iron 13” x 13”
Supply 1 ¼”
Return 1 ¼”
Smoke Pipe 7” Inside Diameter
Smoke pipe exit Top
Output (max): 70,000 Btu/h
Fuel: Wood 30” logs maximum
Boiler Water Volume 26.0 U.S. gal.
Domestic Hot Water Coil Optional
Electrical Rating: Volts 120, 15Amps

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-FIRED BOILER ONLY ON A FLUE SYSTEM AND CHIMNEY

THAT ARE IN GOOD CONDITION.

SAVE THESE INSTRUCTIONS

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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL

SECTION 1 – OPERATING INSTRUCTIONS

1.1 Introduction

Congratulations on your purchase of the KERR TW2000 Wood-Fired Boiler.
Developed in Atlantic Canada, this KERR Boiler has been designed to allow you
to heat your home with wood, one of North America’s most abundant fuels. The
heat exchanger materials meet ASME (American Society of Mechanical
Engineers) requirements for domestic boilers. Designed with you in mind, the
KERR TW2000 Wood-Fired Boiler will provide you with many years of safe,
efficient central heating.

To ensure you have a clear understanding of the operating procedures of this
boiler, 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 TW2000 Wood-Fired Boiler 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 TW2000
Wood-Fired Boiler and will produce less creosote.

When refueling the TW2000, the remaining coals should be raked to the front of
the combustion chamber before adding any new fuel. New fuel shall be placed
on and behind the hot coals. This will help create a more even and efficient burn.
The TW2000 owner should attempt to gauge fuel quantities with outdoor
temperatures; a little practice will provide greater satisfaction and efficiency.

WARNING: This Boiler 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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IN CASE A SERIOUS CREOSOTE FIRE BEGINS:

a) Close the damper door by disconnecting chain
b) Close all draft regulators
c) Throw ½ lb, of coarse or table salt on the fire and reclose door immediately.
d) Call the FIRE DEPARTMENT at once!

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

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.

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-Fired Boiler 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 boiler chamber; 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-Fired Boiler with smaller quantities
of smaller diameter logs. Matching fuel loads and heat requirements will result in
cleaner combustion and higher efficiency.

1.3 Storage of Wood

Once cut, green wood dries (or seasons), quickly at first and then at a 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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DO NOT store wood within installation clearances or within the space required

for charging or ash removal.

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 or extreme over-heating may result,
causing warpage or damage to the boiler.

The KERR TW2000 Wood-Fired Boiler will accept whole or split logs up to 34 in.
(864 mm) long, but a 30 in. (762 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 TW2000 boiler. A good
practice is to establish a routine for the storage of fuel, care of the appliance, and
firing techniques.

1.5.1 Cleaning

The KERR TW2000 Wood-Fired Boiler must be cleaned regularly to maintain top
efficiency. The boiler needs cleaning more often when burning green wood, or
during long periods of low fire. When the KERR TW2000 Wood-Fired Boiler is
first installed the boiler 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 Boiler. Cleaning should be done whenever
there is more than ¼ inch of build-up on the heat exchanger or 3 inches of ash in
the base.

CLEANING PROCEDURE:

(1) Make sure fire is completely out and the Boiler has cooled.
(2) Remove the smoke pipe located on the top of the Boiler.
(3) Remove the overhead baffle in the combustion chamber if necessary.
(4) The heat exchanger is now accessible for cleaning.
(5) Use the scraper provided to remove all soot and ash from the boiler heat

exchanger and exposed surfaces.

(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. Also reinstall the overhead baffle.

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

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(9) Residue may be removed from the firebox or left to be burned during the

next fire. It is good practice to leave a layer of ash approximately one inch
deep in the base of the firebox.

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.

1.6 Safety

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

(1) DO NOT shut off power. The circulation pump must be kept running to

disperse excessive heat.
(2) Manually close the damper door by unhooking the chain.
(3) Increase all thermostats in the house to maximum to help disperse

excessive heat.
(4) Excessive heat caused by extreme over-firing or a control malfunction

may cause the relief valve to blow off water/steam into the firebox. Do not

be alarmed. The relief valve will reseat when the excessive pressure has

been released.
(5) Do not add more fuel until you are certain that all controls are functioning

properly and no damage has been done to the boiler.

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.

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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL

1.7 Electrical Power Failure

If no one is home during a power failure, the safety bypass zone valve will
automatically open and some gravity heating will take place. The damper door
will automatically close, but combustion air will continue to enter through the
secondary air holes and a fire should be maintained. For optimum heating during
a power failure follow the procedure listed below:

(1) Manually open all zone valves and flow check valves to allow

gravity flow 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 and the damper motor operates.

(3) Maintain a careful watch on the boiler water temperature. If it

should exceed 200º F (95º C) close the damper door.

(4) Do not leave the boiler unattended in this position.

(5) Refuel frequently with a small load to maintain a small fire at ½

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

Boiler to attend it during a power failure.

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1.8 HOMEOWNER CHECKLIST

(a) Keep area around TW2000 boiler clean and clear of combustibles.

(b) Use only dry wood. DO NOT burn garbage, gasoline, naphtha

engine oil or any other combustible liquid.

(c) Remove ashes as directed.

(d) Watch for soot in smoke pipe – clean regularly.

(e) Clean Boiler heat exchanger regularly.

(f) Be aware of danger due to overfiring unit.

(g) Do not load above maximum loading level (middle of loading door)

or overheating may result.

(h) This unit is NOT suitable for automatic stoking.

(i) Load carefully. Do not slam fuel against rear or sides of firebox.

This may damage the brick lining. See fig. TW-7 to order and install
replacement firebrick.

(j) Always 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) and the
floor must be non-combustible.

(k) Do not store solid fuel within the above clearances or within the

space required for charging and ash removal.

(l) Keep firing door closed and maintain seals in good condition.

(m) Establish a routine for storage of fuel, care of the appliance, and

firing techniques.

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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL

SECTION 2

INSTALLATION INSTRUCTIONS

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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL

SECTION 2 – INSTALLATION INSTRUCTIONS

2.1 Introduction to Installers

Before installing this KERR TW2000 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 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 TW2000 Wood-Fired Boiler 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 C.S.A. 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.

2.2 Uncrating

When you receive your TW2000 Wood-Fired Boiler, 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.
NOTE: Some parts may be packed inside boiler firebox.
Inspect for the following:

1. Firebox/Heat exchanger

2. Poker/Coals rake

3. Cabinet

4. Barometric damper

5. Firebrick (Factory installed in base) See fig. TW-7 for detail.

6. Front insert

7. Overhead baffle

8. Cast door handle assembly

9. Controls package

10. Optional domestic hot water coil

Control Package includes:

1. Dual aquastat, ½” well

2. Single aqustat wt well ½”

3. Damper Motor

4. N/O Zone valve, and fittings

5. Pressure relief valve

6. Tridicator

7. Transformer 120/24V

8. Wiring Harness and Parts

9. Black iron and copper fittings

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