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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.
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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 2.1 Introduction 9 2.2 Uncrating 9 2.3 Locating t
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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” Shipp
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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-F
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL 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
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL 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 i
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL (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
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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 chec
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL 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 loadin
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL SECTION 2 INSTALLATION INSTRUCTIONS TW2000 9 10/6/05
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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 well- insulated homes. Before installing be sure unit is
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL 2.3 Locating the Boiler The location of the Boiler 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. To lighten the boiler for placement, all parts including firebrick and baffles can be removed. It is important to provide adequate combustion air to the Boiler. It may be necessary
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL 8. Adjust chain length by squeezing or expanding links with pliers. Adjust the chain so that the damper is open to the maximum of 11/16” without putting any extra strain on the damper motor. 9. Install the aquastats and complete the wiring, plumbing, smoke pipe and fire extinguishing tube installations as shown in the appropriate electrical and plumbing diagrams. 10. IMPORTANT: Always test all functions under actual firing conditions before l
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL 2.4.2 Flue Pipe and Chimney The Boiler must be located to meet a minimum venting distance needed between the Boiler and the flue. It should also be ducted so that there is a minimum number of elbows used. The flue pipe must be installed with a gradual rise of ½” or more per foot from the Boiler to the flue. NEVER ALLOW THE SMOKE PIPE TO RUN DOWNHILL TO THE FLUE! The smoke pipe and chimney must be at least 7 inches in diameter. The flu
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL The National Standard of Canada, Installation Code for Solid-Fuel-Burning Appliances and Equipment, CSA-B365-01 clause 5.2.9 states that: Two or more appliances shall not be connected to the same chimney flue unless: a. The appliances are located on the same story; b. A negative pressure is maintained at the flue collar of each appliance; c. Each appliance is provided with a means to control the rate of flow of air or flue gases through the
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL 2.5 Clearances The KERR TW2000 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” 1220 mm One Side 6” 152 mm Other Side (for rear access) 24” 610 mm Rear 24” 610 mm Above Wood-Fired Boiler 24” 610 mm Flue Pipe to combust
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL 2.6.1 Free Standing Free Standing installation requires additional components, which are not included in the TW2000 boiler kit. Check wiring diagrams TW – 5 and TW – 6 for additional required components. In the freestanding, or stand-alone system, the Kerr TW2000 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
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL 2.7 Control System The Kerr TW2000 boiler control system serves the following functions: 1. Maintaining the boiler water temperature by controlling the combustion air entering the boiler. A double pole, double throw aquastat and the air damper control this function. 2. Protects the Kerr TW2000 boiler from an overfire by overriding the home’s thermostat and by putting any excess heat into the living area. Opening the “normally open by-p
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL 2.9 DEALER INSTRUCTIONS TO THE HOMEOWNER 1. Keep area around unit clean. 2. Use DRY wood only. Hardwood is preferred. 3. Load carefully. 4. Load level no higher than center of door. 5. Remove ash regularly as directed. 6. Watch for soot build up in smoke pipe. 7. Realize the danger of extreme overheating due to overfiring. 8. Danger of flue fire if poor fuel or poor maintenance produces creosote buildup. 9. Operation of
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TW2000 WOOD-FIRED BOILER – INSTRUCTION MANUAL 2.10 Installers Final Checklist PIPING INSPECTION 1. Boiler plumbed properly? 2. Is a 12” x 36” expansion tank or equivalent installed? 3. Normally open 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. Are all firebricks in place in the boiler? 3
