DS Stoves DS5000 Manuel utilisateur
Be ore you install or operate a DS Power
Boiler, you must:
- Read all instructions care ully
- Install smoke and carbon monoxide
detectors.
MADE IN USA
By
D.S. MACHINE SHOP
Do Not
Discard
This
Manual
DS Power Boilers
High E iciency Boilers
Models: #DS5000 #DS6000 #DS7000
OWNER’S MANUAL
Power Boiler Manual 2017.qxp_Layout 1 2/13/17 9:32 AM Page 1
ALL BOILERS MUST BE INSTALLED BY A NFI CERTIFIED SPECIALIST AND PLUMBED BY A
QUALIFIED LICENSED PLUMBER OR D.S. IS NOT RESPONSIBLE FOR WARRANTY
Safety Instructions
1. Read all instructions before installing or operating any DS boiler
2. Never fire boiler without water in the system. Doing so could ruin boiler.
3. You must install smoke and carbon monoxide detectors before you install or operate any furnace or
boiler. Check your local codes, this installation must meet their rulings.
4. Do not open bottom ash door to increase draft. t is designed only to empty ash pan.
5. Never leave boiler doors open when boiler is unattended.
6. nstall barometric or manual damper when burning coal.
7. Do not use a manual, barometric or automatic damper when burning wood.
8. Do not hook up a wood or coal boiler to an aluminum Type B gas vent. Use a code approved Class A
chimney. A minimum of 20’ high.
9. On all new installs connecting to an existing chimney, a level 2 chimney inspection must be done by a
certified chimney sweep.
10. Clean chimney before installing boiler. f there is creosote attached to the liner you could create a seri-
ous chimney fire.
11. Never leave children unsupervised when they are in same room as boiler. Provide a sturdy barrier to
keep children and pets a safe distance from the boiler, or they could get burned.
12. Keep boiler area clear from all combustible materials, gasoline, other flammable vapors and liquids.
13. Use the required floor protection as shown on page 6.
14. Check the clearance to combustible walls and floors on page 6.
15. Do not allow anyone who is unfamiliar with the boiler to operate it.
16. Spend some time with your boiler to become well acquainted with the different settings and how each
setting will affect its burning patterns. t is impossible to state how each setting will affect your boiler.
17. Be extremely careful when removing the boiler ash pan. t may be very hot!
18. Make sure your single wall chimney connectors have at least 3 screws per joint.
19. When starting a fire, circulating pump must be running continuously.
20. f circulating pump is installed you must install a high limit aquastat set at 190 degrees Fahrenheit.
21. Always install a mixing valve when installing a domestic coil.
Operati nal W rk Practice Standards
1. When burning wood, burn only seasoned, dry cord-wood that has been dried; then warmed before firing.
(Warming cord-wood means placing in a heated building for 1 day before burning)
2. Keep wood under cover: in a wood shed, or a tarp.
3. Right after delivery: stack cord-wood under cover
4. Split cord wood before drying.
5. Do not burn green wood, it needs to have no more than 20% moisture.
6. All firewood must be seasoned at least 1 year.
7. Check cord-wood with moisture meter. Check wood moisture at least once a week!
8. Keep a 2” to 3” ash layer on top of your grates when burning wood. Note: Do not cover louvers.
9. The boiler is designed to burn air dried wood and coal at a predetermined firing rate. Over firing occurs
when the ash door is left open during operation or a highly volatile fuel, i.e. large amounts of small kindling is
used. Do not exceed 200 degrees water temperature.
10. When tending the firebox always open load door slowly to minimize smoke out the fire door or a “flash
back”.
11. Check the fit on the load door. t must fit tightly. f it does not, check for deterioration or wear of the ce-
ramic rope seal. Replace defective seals.
12. nspect and clean your chimney and single wall chimney connectors regularly.
13. n the event of a chimney fire, shut off all draft controls and blowers. Call your fire department immedi-
ately. Alert everyone in the house. f flue is still burning vigorously, throw baking soda into firebox or discharge a
fire extinguisher into fire box. After the chimney fire is over, have a certified chimney sweep complete a level 2
inspection of your chimney.
14. Equip your building with fire extinguishers, carbon monoxide and smoke detectors.
2
Power Boiler Manual 2017.qxp_Layout 1 2/13/17 9:32 AM Page 2
15. Do not burn garage, gasoline or any other flammable liquids in this boiler.
16. This is a wood and anthracite coal burning boiler and should not be altered in any way.
17. Do not burn boiler over 200 degrees water temperature or warranty will be void!
18. When used in a large greenhouse and they are forecasting a cold night it is advisable to load and fire
your boiler at 3 to 4 o’clock in the afternoon so that you do not fall behind. f you wait till the sun sets to fire your
boiler you may be playing catch up all night. n the morning when it is cold with a sunny day in the forecast you
may want to consider shutting the boiler down at 5 o'clock in the morning so that when the sun comes out and
it warms up so that there's not to much heat in your green house till the boiler fire dies down.
Note: When burning coal, shake ashes every 12 hours if possible. You must keep your ashes cleaned out from
under grating. This may require emptying your ash pan daily. f there is no air space under the grates, the
grates will warp and become inoperable.
Starting A Coal Fire
Fully open Samson Draft Regulator. Place crumpled paper and kindling wood on grate and ignite with match or
lighter. Use a good amount of kindling to get the fire started. Add larger pieces of wood to get a hot fire. Once
you have a hot fire, add 2” of coal over the entire grate area. As the coal starts burning and glowing red add an-
other 2” layer of coal. Keep adding coal until you have an 8” body of fire, but don’t add too much at a time or
you could smolder the fire. You can now add up to 50 lbs. of coal at a time, adjust draft on Samson Draft Regu-
lator to meet your desired water temperature. NOTE: You can also use charcoal briquettes for a fire starter.
With new steel there is a small amount of oil or dirt on the metal. You may smell an odor. This is normal during
the first operation. You may want to assemble the boiler out of doors and build a small fire in it to “BURN OFF”
this dirt and oil before installing unit.
Starting A Wood Fire
Fully open Samson Draft Regulator. Place crumpled paper and kindling wood on grate and ignite with match or
lighter. Use a good amount of kindling to get the fire started. Add larger pieces of wood to get a hot fire. Once
you have a hot fire add wood as needed, adjust draft on Samson Draft Regulator to meet your desired water
temperature. Allow ash to build up on top of grates, this will not choke fire until it covers louvers. For most effi-
cient burning keep approximately 2” to 3” of ash on grates at all times.
With new steel there is a small amount of oil or dirt on the metal. You may smell an odor. This is normal during
the first operation. You may want to assemble the boiler out of doors and build a small fire in it to “BURN OFF”
this dirt and oil before installing unit.
Creosote – Formation and Need for emoval
When wood is burned slowly, it can produce tar or other organic vapors, which combined with expelled mois-
ture will form creosote. The creosote vapors condense in the relatively cool chimney flue of a slow burning fire.
As a result, creosote residue accumulates on the flue lining. When ignited, this creosote
makes an extremely hot fire. The chimney connector and chimney should be inspected at least twice monthly
during the heating season to determine if a creosote build-up has occurred. f creosote has accumulated, it
should be removed to reduce the risk of a chimney fire.
NOTE: Firewood must be seasoned for one year. That means cut, split and stacked under shelter with sides
open so the wind can dry it. Wood needs to have no more than 20% moisture. Stack indoors 1 day prior to
burning.
3
Power Boiler Manual 2017.qxp_Layout 1 2/13/17 9:32 AM Page 3
Boiler Installation
Automatic
Air Vent
Air Purger
Back
of
tove
4 or 5 gallon
per minute
coil optional
2” nlets
2” nlets
3/4” Boiler Drain
(under fire box)
Existing Gas or
Oil Boiler
Valve
Valve
Return
Line
Zone
3
Union
Union
Union
T60
Expansion
Tank
Air
Bleed
Valve
Circulator
Pump
#1
#2
#3
#4
#5
#6
4 or 5 gallon
per minute
coil optional
#6
#7
#7
Automatic Air Vent
Air Purger
Back
of
tove
Circulator
Pump
Circulator
Pumps (3)
3/4” Boiler Drain
(under fire box)
Existing Gas or
Oil Boiler
Valve
Check
Valve
HOT
Union
T60
Expansion
Tank
#1
#2
#3
#4
#5
#1 Samson Control
#2 Temperature - Pressure Gauge
#3 Damper
#4 30# Safety Valve
#5 3/4” Boiler Coil
#6 4 or 5 Gallon Coil
#7 Aquastat
• All D. . Boilers must be plumbed by a Qualified Licensed Plumber
or D. . is not responsible for warranty.
• Failure to follow installation and basic operation will void the warranty
• All Boilers are tested to 100psi.
• Recommended working pressure - 12psi.
• NOTE: This Boiler set-up is only a D.S. Machine Design.
Each set-up can be different. Your local plumber could have different
concepts that work also.
Zone
1
Zone
2
NOTE: Add Boiler eal to all
new boilers. On initial setup, fill
boiler with water to the point where
you can still add Boiler Seal mixed
with water and pour into top of
boiler. OR, follow instructions
on Boiler Seal.
4
Power Boiler Manual 2017.qxp_Layout 1 2/13/17 9:32 AM Page 4
D 4GPM-FC, D 5GPM-FC
Domestic Coil / Circulator Pump
• This Domestic Coil has a 1 year Limited Warranty
• All Domestic water coils must be set up by a Qualified Li-
censed Plumber or it could void warranty
• A mixing valve is required to
prevent scalding
• nstall filter system if there is
calcium in the water
Valve
Hot
Water
Aquapure
Filter System
Hot Water
Heater
40 Gal.
Hot Rock
Tank
70-145
Mixing Valve
Cold Water
Dip Tube
Water
Fire Door
Ash Door
6” High Ash Pan
Drain
Valve
W
A
T
E
R
W
A
T
E
R
W
A
T
E
R
W
A
T
E
R
Valve Hot
Water
Aquapure
Filter System
Mixing Valve
Cold Water
Dip Tube
Water
Fire Door
Ash Door
6” High Ash Pan Circulator
Pump
Drain
Safety
Valve
D 4GPM-FC, D 5GPM-FC
Domestic Coil / On-Demand
Boiler Installation
5
Power Boiler Manual 2017.qxp_Layout 1 2/13/17 9:32 AM Page 5
1 - The boiler must be placed on a solid none combustible
floor. f you have a combustible floor it is
required to use a code approved none combustible floor board
(Type 1 Board)
2 - t is recommended that the boiler be centrally located.
3 - The most important consideration in installing your boiler
is adequate clearance between the boiler and any combustible
surface. A boiler that is placed too close to a wall or to furniture
can cause a fire. See chart at right for clearances to
combustibles.
4 - The non-combustible base must extend at least 16” be-
yond the front and 8” of the back, and sides of fuel opening,
and must extend under and 2” beyond either side of the single
wall chimney connectors if it’s elbowed towards a wall.
5 - The boiler or furnace must have its own flue. Do not con-
nect this unit to a chimney flue serving other appliances.
6 - Connection of the boiler to the chimney should be made as
directly as possible (6 feet maximum horizontal) and not more
than two bends. No reduction in flue pipe below the exhaust di-
ameter should be used.
The pipe connecting the stove to the chimney should be at least
24 gauge. Thicker gauges are available and will resist corrosion
longer and need fewer replacements. Slope the flue pipe back
towards the heater, 1/4” per foot of horizontal run. That way if any condensation forms in the pipe it will be car-
ried back into the heater. The connector pipe should be installed so that the upper pipe section fits inside the
lower section. This way any condensation building up
inside the pipe will stay inside the pipe as it flows
down the inside surface. Horizontal pipe runs should
have the pipe seams turned up. Particular attention
should be paid to the point where the flue passes
through a wall or ceiling. This penetration should al-
ways be made with a thimble, insulated pipe, and
then proper accessories following manufacturers in-
structions. Chimney connectors must not pass
through the ceiling, concealed spaces, or enter the
chimney in the attic, unless proper clearance or
insulated pipe is used following manufacturers
instructions.
REMEMBER single wall chimney connector adapter.
Where the pipe connects to a masonry chimney. The
flu to the chimney should be larger than the single
wall chimney connector so you can insert the pipe out
to the inside edge of the chimney, but not past. Then
seal as tight as possible and cover with a single wall
chimney connector collar.
Locating Boiler
CAUTION:
Keep furnishings and other combustible
materials away from the boiler.
ALL BOILERS MUST BE INSTALLED BY A NFI CERTIFIED SPECIALIST AND PLUMBED BY A
QUALIFIED LICENSED PLUMBER OR D.S. IS NOT RESPONSIBLE FOR WARRANTY
Clearance to Combustibles
A - 30# Safety Valve
B - Domestic Coil
C - Exhaust
D - 2” Hot Water Out
E - Temp. Pressure Gauge
F - High Limit Aquastat
G - Samson egulator
H - 2” Water eturn on side
6
Power Boiler Manual 2017.qxp_Layout 1 2/13/17 9:32 AM Page 6
Chimney Requirements
The minimum height of a chimney system for the D.S. Boiler is 20 feet. The chimney must
exceed the roof of a building at a minimum of 3 feet at any point of exit. n a pitched roof
installation the chimney must be 2 feet higher than anything within a 10 foot radius of the
chimney. t is important to have a chimney draft of 0.06 water column. t is required to
abide by the manufacturer’s instructions on Class A chimneys as well as local building
codes. t is not recommended to build a chimney on an addition that is lower than the
main part of your building. Do Not extend the stovepipe past the inside of a masonry
chimney liner. Never connect this unit to a chimney serving another appliance. Should
you have a problem with inadequate draft you should see page 11.
10 feet
3 feet minimum
20 feet minimum
2 feet
7
Power Boiler Manual 2017.qxp_Layout 1 2/13/17 9:32 AM Page 7
8
1 Samson egulator
The Samson Reg. is designed to regulate the draft going into the draft intake.There is no electricity needed to
operate the Samson reg.
Set Up - thread Samson Reg. into 3/4” fitting at top left (see page 6) when installing chain from Samson Reg. to
draft intake. Turn knob clockwise and connect chain so lid is shut and chain is tight. Then turn knob counter-
clockwise to increase draft.
2 Temperature Pressure Gauge
The Temperature Pressure Gauge has two features:
A - Needle shows temperature of water
B - Needle shows water pressure
Note: Normal pressure for closed systems are 12-15 lbs.
Warning: Do not exceed 200 degree water temperature.
Thread temperature pressure gauge into 1/2 inch fitting at top right corner (see page 6)
3 30# Safety Valve
This is a pop-off valve. At 30 PS hot water will dump out of the 30# safety valve.
nstallation nstruction: You must run some sort of high temperature pipe down to the floor from the safety
valve. nstall a drain in the floor if possible.
Thread 30# safety valve into 3/4 fitting at top left back (see page 6)
4 Automatic Fill Valve / Pressure educung Valve
The Automatic Fill Valve needs to be hooked up to the water supply line connected to your system.
The Automatic Fill Valve will reduce pressure to 12 lbs. and keep water supplied.
A water line with an automatic fill valve can be hooked up anywhere in your system.
5 Expansion Tank
An Expansion Tank is designed to maintain the boiler pressure at 12-15 lbs.
Every degree the temperature rises the boiler will gain 1 lb. of pressure. The expansion tank will absorb the
pressure and keep it at 12-15 lbs. in normal temperature ranges. This normally gets hooked up to the hot water
horizontal line close to the boiler.
6 Circulator Pump
A Circulator Pump is designed to circulate water through your heating system. This normally runs off 110 volts,
12 volts, or air. The thermostat controls the circulator.
We recommend the circulator pump be set up in the return line close to the boiler, pushing water into the boiler.
7 Aquastat (High Limit)
The Aquastat is a safety feature. t will override the thermostat. f the thermostat is not calling for
heat the circulator will not run. f water is not circulating through your system the water temperature will rise
slowly. The Aquastat wires get hooked up to the thermostat wires. Set the High Limit Aquastat to 190 degrees.
f the water temperature rises to 190 degrees, the circulator will run.
8 Domestic Water Coil
The Domestic Water Coil will heat 4 gallons per minute when the water temperature is set at 160 - 180 de-
grees. The coil has a bolt on flange with a gasket that holds coil into the back of the boiler.
NOTE: Always hook up a mixing valve when using a domestic water coil, or someone could get burnt.
9 Air Purger
The Air Purger can also be called an Air Scoup. t is designed to do three things:
• Capture air pockets, which is then released by the air vent.
• Mounts the automatic airvent
• Mounts an expansion tank
Boiler Controls
Power Boiler Manual 2017.qxp_Layout 1 2/13/17 9:32 AM Page 8
F rced Draft Kit Setup
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• emove the
rear draft
intake plate
• eplace with
draft fan
• Use bolts to
cover holes
9
Power Boiler Manual 2017.qxp_Layout 1 2/13/17 9:32 AM Page 9
10
B iler Sheet Metal Installati n
Install in rder as numbered - 1,2,3,4
Boiler Models
D 5000, D 6000, D 7000
DS5000
20 - #14x3/4 screws
DS6000
22 - #14x3/4 screws
DS7000
24 - #14x3/4 screws
• Install side and back panels first.
• Back panel goes inside of side panels.
• Top panel goes outside of all panels.
Power Boiler Manual 2017.qxp_Layout 1 2/13/17 9:32 AM Page 10
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2
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