ENERGY KING 360EK Installation, Operation & Maintenance Manual Download Page 62 | Manualshive

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Summary of Contents for 360EK

Page 1: ... KING Wood Coal Furnaces Models 360EK 365EK and 480EK Installation Operation Maintenance Manual RJM Manufacturing Inc 1875 Olson Drive Chippewa Falls WI 54729 715 720 1794 Fax 715 720 1797 www EnergyKing com ...

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Page 3: ...ler with specific knowledge of central heating systems With proper installation and maintenance your ENERGY KING Wood Coal Furnace will give you years of trouble free service Thank you for choosing the ENERGY KING Wood Coal Furnace We are constantly improving and updating our products in order to provide the highest quality and value possible RJM Manufacturing Inc the manufacturer of this product ...

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Page 5: ... routine maintenance and service Allow the heating appliance to cool before servicing The fuel loading and ash removal doors must be closed tightly during operation All seals must be maintained in good condition This Furnace is designed to burn air dried wood or anthracite or bituminous coal only Burning of any other type of fuel will void your ENERGY KING warranty Do not burn Treated wood colored...

Page 6: ...unicipally designated areas A working smoke detector must be installed in the same room as this product For additional safety RJM Manufacturing Inc also recommends installing working smoke detectors and a listed carbon monoxide warning device in the living areas of the home Always keep a working fire extinguisher on hand in case of fire The National Fire Protection Association has information avai...

Page 7: ...ENERAL INSTRUCTIONS 23 FIRST FIRE 23 TYPICAL OPERATION CYCLE 24 POWER FAILURE INSTRUCTIONS 24 BURNING WOOD 25 Starting a Wood Fire 25 Refueling 25 BURNING COAL 26 Starting a Coal Fire 27 Refueling Recharging 27 MAINTENANCE 29 CREOSOTE FORMATION AND NEED FOR REMOVAL 29 DISPOSAL OF ASHES 29 GASKET REPLACEMENT 30 ROUTINE MAINTENANCE 30 TROUBLESHOOTING GUIDE 32 DETAILED TROUBLESHOOTING 33 APPENDIX A W...

Page 8: ...Rev 03 12 14 ENERGY KING 360EK 365EK 480EK Wood Coal Furnace Owner s Manual U S 2 ...

Page 9: ...prox 1 500 sq ft 2 000 sq ft Burn chamber Volume 6 3 cu ft 9 cu ft Flue Size Rear Vent 6 6 Flue Collar Height to top of flue 45 48 25 Log Length 21 26 Cast Iron Fuel Loading Door Size H x W 15 5 x 13 5 15 5 x 13 5 Cast Iron Ash Removal Door Size H x W 7 25 x 11 5 7 25 x 11 5 Sliding Smoke Baffle Standard Standard Insulated Cabinet Standard Standard Wall Thermostat Standard Standard Draft Controls ...

Page 10: ...her instructions 2 Sliding Smoke Baffle When open the sliding smoke baffle allows smoke and flue gases to flow into the chimney connector without restriction When closed smoke and flue gases are diverted around the sliding smoke baffle creating a longer path for the heated air and allowing your furnace to extract the maximum amount of heat from the fire 3 Plenum Opening Allows you to connect the F...

Page 11: ...ecomes damaged or worn 8 Circulation Blower The three speed circulation blower operated by the fan limit control forces air on all sides of the burn chamber then into the home s duct system The blower can be manually adjusted to run faster or slower to correspond to the amount of heat being produced 9 Filter Box optional Provides air filtration for your cold air return system A non combustible fil...

Page 12: ...ny other appliance b Has your chimney been inspected For your safety it is important your chimney be clean and free from defect or damage prior to installing your Furnace 3 This Furnace may require an outside air source for combustion air Will this be easily accessed in your desired location 4 Are there any local state or national codes or regulations governing the use and placement of the Furnace...

Page 13: ...s the risk of dangerous creosote build up in your appliance and chimney Softwoods such as pine and fir are easily ignited and burn rapidly with hot flames With softwoods you will spend more time reloading your Furnace and will have much more difficulty achieving an overnight burn For a longer lasting fire it is best to use more dense hardwoods Ideally you should burn a mixture of hardwoods and sof...

Page 14: ...cted lifespan your ENERGY KING solid fuel heating appliance and its components Only burn high grade bituminous coal Coal Size Your ENERGY KING Wood Coal Furnace is designed to use coal that is Nut size or larger DO NOT BURN Treated wood colored paper garbage cardboard solvents or trash burning these may result in toxic fumes or produce soot and large flakes of char or fly ash Burning treated wood ...

Page 15: ...urnace is designed to be used in conjunction with a listed gas or oil fired furnace or as a central Furnace Placement Floor Protection Floor protection must be provided because of possible spillage of ashes and burning fuel The ENERGY KING Wood Coal Furnace must be installed on a non combustible floor or 3 8 inch thick fireproof millboard or equivalent The non combustible material must be placed u...

Page 16: ...od Coal Furnace Install two backflow dampers to ensure that when either furnace is operating independently hot air will not flow back through the other furnace When using your ENERGY KING Wood Coal Furnace as an add on locate the ENERGY KING as close to the new or existing chimney as possible and as close to your existing furnace as practical However a minimum clearance of 6 inches is required bet...

Page 17: ...ype of fuel wood or coal will determine how to position the hearth plates The words Wood and Coal are cast into the end plate on opposite sides The purpose of proper location is to introduce the precise amount of combustion air into the burn chamber to promote the most efficient combustion for either fuel a If you are going to burn wood position the hearth plates with the word Wood facing out not ...

Page 18: ...ol Box a Remove the control box cover See Figure 3 Control Box for Automatic Draft Figure 4 Control Box for Forced Air Draft or Figure 5 Control Box for Manual Draft b Mount the pre wired control box on the lower left side of the Furnace using the screws provided Figure 3 Control Box for Automatic Draft ...

Page 19: ...Rev 03 12 14 ENERGY KING 360EK 365EK 480EK Wood Coal Furnace Owner s Manual U S 13 Installation Figure 4 Control Box for Forced Air Draft ...

Page 20: ...Rev 03 12 14 ENERGY KING 360EK 365EK 480EK Wood Coal Furnace Owner s Manual U S 14 Installation Figure 5 Control Box for Manual Draft ...

Page 21: ...ft opening located next to the ash removal door on the lower left front of the Furnace and secure using the bolts found on the draft opening d For Manual Draft Mount the manual draft tube with attached spin dial to the draft opening located next to the ash removal door on the lower left front of the Furnace and secure using the bolts found on the draft opening 7 Fan Limit Control a Remove the cove...

Page 22: ...lete 9 Cold Air Return Optional Filter Box a Determine whether your cold air return will enter on the left or right side of the furnace b Assemble the optional filter box per Appendix B Filter Box Assembly Schematic c Feed the conduit from your circulation blower through the hole located on the top of the filter box Attach the conduit to Control box and connect wire ends as detailed in Appendix A ...

Page 23: ...nded for all installations it may be necessary if The Furnace does not draw steadily smells experiences smoke roll out burns poorly or back drafts whether or not there is combustion present Any of the above symptoms are alleviated by opening a window slightly on a calm day The house is equipped with a well sealed vapor barrier and tight fitting windows and or has any powered devices which exhaust ...

Page 24: ...m defect or damage All connections must comply with NFPA Standard 211 and all applicable building codes and regulations When installing a factory built chimney follow all installation instructions provided by the chimney manufacturer For best performance RJM Manufacturing Inc recommends using insulated chimney rather than triple wall or air cooled chimney Important venting installation clearances ...

Page 25: ...ts The Chimney must be at least 3 feet higher than the highest point where it passes through the roof and at least 2 feet higher than the highest part of the roof or structure that is within 10 feet of the chimney measured horizontally For best performance RJM Manufacturing Inc recommends a chimney height of at least 12 feet ...

Page 26: ...se extra support hangers or brackets every three feet if it is absolutely necessary to have a run of more than six feet which is not recommended Chimney connector sections must be attached to the heating appliance and to each other with the crimped end toward the heating appliance Secure all chimney connector pipe joints with at least three sheet metal screws Avoid using more than two elbows in co...

Page 27: ... the draft in the solid fuel heating appliance from rising any higher Install the barometric draft control as close to the Furnace as possible On extremely tall chimneys or chimneys larger than 6 it may be necessary to install a second barometric draft control or reduce the outlet opening of the chimney to approximately 28 square inches or both to maintain the chimney draft to 04 to 06 water colum...

Page 28: ...65EK o 20 inches by 20 inches for the model 480EK The plenum must be no closer than 2 inches from the ceiling or any combustible material This clearance is critical during a power outage since excessive heat buildup in the plenum top may be dangerous When connecting the plenum to your warm air supply duct system never supply less than 150 square inches of constant heated air outlet area The warm a...

Page 29: ...her than the air supply Shorter hotter fires will allow your ENERGY KING heating appliance to operate at maximum efficiency and with minimum emissions For best combustion efficiency chimney temperature should be 350 degrees F to 450 degrees F RJM Manufacturing Inc recommends installing a magnetic chimney thermometer to monitor chimney temperature First Fire Before lighting your first fire inspect ...

Page 30: ...d low to achieve the desired burn rate for your home The 3 speed circulation blower is activated when the temperature sensor of the fan limit control indicates that air has been heated to the fan limit control ON temperature setting The circulation blower pushes air around the burn chamber through the heat exchanger area and into the plenum When the thermostat is satisfied it will deactivate your ...

Page 31: ...ximize the exposed surface area of each piece of wood b Only use wood properly sized for your unit s burn chamber 4 Push in the sliding smoke baffle after loading your ENERGY KING and the fire has been established 5 The burn time is controlled totally by the automatic or forced air draft controls on the furnace Manual Draft If you selected Manual draft you control the burn rate of your ENERGY KING...

Page 32: ...closely to the grates Removal of the coal ash will allow for passage of primary air to the coal bed and prevent damage or warpage to the grates 4 A coal fire should not be poked or broken up as this tends to bring ash to the surface of the coal bed where it may fuse If the ash fuses clinkers will form It may be necessary to remove all unburned material and ash from the burn chamber to remove the c...

Page 33: ...Furnace to operate with draft controls fully open for approximately 15 minutes or until the fresh coal ignites When the coal is properly ignited adjust the thermostat accordingly Check the fire periodically to make sure it is spreading throughout the coal bed Refueling Recharging To refuel recharge the anthracite coal fire in your ENERGY KING Wood Coal Furnace 1 Pull the sliding smoke baffle out 2...

Page 34: ...on fresh coal on the grate in front of the banked coal Be careful not to smother your existing coals 6 Close the fuel loading door and sliding smoke baffle Banking Banking allows you to recharge your coal fire in such a manner as to retain a hot coal bed throughout the night Approximately one hour before retiring for the night push the coals to the rear of the burn chamber with the coal tapered do...

Page 35: ... least twice monthly during the heating season to determine if a creosote buildup has occurred If creosote has accumulated it should be removed to reduce the risk of a chimney fire Be aware that the hotter the fire the less creosote is deposited and that weekly cleaning may be necessary in mild weather even though monthly cleaning may be enough in the coldest months Have a clearly understood plan ...

Page 36: ...utine Maintenance Please use the following timeline as a guide for determining how much maintenance your ENERGY KING Wood Coal Furnace requires to operate at peak performance Failure to clean and maintain this Furnace as indicated can result in poor performance and safety hazards Please use Appendix D Purchase Service Record to keep a record of your maintenance and service practices In the event o...

Page 37: ...rough cleaning Your venting system should be inspected and cleaned annually Clean and remove fly ash from chimney connector flue pipes and chimney Soot buildup should be removed to prevent the risk of a chimney fire and to minimize corrosion during the summer months Scoop out any unburned fuel from the burn chamber and empty and clean the burn chamber and ash removal pan Do not allow fuel or ash t...

Page 38: ...ll using only high quality clean dry fuel as outlined in Fuel Requirements Improper Draft Too little or too much draft Insufficient combustion air Solution Adjust the draft controls and observe until you determine which settings are most appropriate for your usage See Operation for further information Ash buildup in the ash removal pan Solution Be sure to maintain your ENERGY KING Wood Coal Furnac...

Page 39: ...y or dirty or startup is slow or smoky Your fire may need more combustion air Increase the amount of combustion air by adjusting your draft controls Your exhaust or combustion air systems may be blocked Verify all vents and pipes are free from obstruction and the draft controls are operating correctly Your home may have a negative pressure If your home is too airtight the ENERGY KING heating appli...

Page 40: ...Fuel Requirements Your fire may need more combustion air Increase the amount of combustion air by adjusting your draft controls Your home may have a negative pressure If your home is too airtight the ENERGY KING heating appliance cannot get enough combustion air to burn properly You may need to bring outside air to the ENERGY KING heating appliance Please contact your ENERGY KING dealer or heating...

Page 41: ...nd draft control systems are clean and free from obstruction Verify that all heat delivery systems are operating correctly The circulation blower runs continuously cycles on and off too much or won t run at all Make sure the Fan limit Control is set on Auto and is not on Manual The fan limit control ON OFF temperature settings may need to be adjusted ON OFF temperatures may be set too close togeth...

Page 42: ...Rev 03 12 14 ENERGY KING 360EK 365EK 480EK Wood Coal Furnace Owner s Manual U S 36 This page is intentionally left blank ...

Page 43: ...Rev 03 12 14 ENERGY KING 360EK 365EK 480EK Wood Coal Furnace Owner s Manual U S 37 Appendix A Wiring Diagrams A 1 Automatic Draft Wiring Diagram ...

Page 44: ...Rev 03 12 14 ENERGY KING 360EK 365EK 480EK Wood Coal Furnace Owner s Manual U S 38 Appendix A Wiring Diagrams A 2 Forced Air Draft Wiring Diagram ...

Page 45: ...Rev 03 12 14 ENERGY KING 360EK 365EK 480EK Wood Coal Furnace Owner s Manual U S 39 Appendix A Wiring Diagrams A 3 Manual Draft Wiring Diagram ...

Page 46: ...Rev 03 12 14 ENERGY KING 360EK 365EK 480EK Wood Coal Furnace Owner s Manual U S 40 This page is intentionally left blank ...

Page 47: ...ndix B Filter Box Assembly Schematic CAUTION THE FILTER MUST BE REMOVED IF THE FAN IS INOPERABLE FOR ANY REASON INCLUDING POWER FAILURE THIS WILL PREVENT OVERHEATING OF THE MOTOR THE AIR FILTER MUST BE NON COMBUSTIBLE Non combustible air filters are available from your ENERGY KING dealer ...

Page 48: ...Rev 03 12 14 ENERGY KING 360EK 365EK 480EK Wood Coal Furnace Owner s Manual U S 42 This page is intentionally left blank ...

Page 49: ...E Forced Draft Mounting Tube 4 DRA MDTUBEASSY Manual Draft Tube Assembly 4 CAS DRAFTDIAL Cast Iron Manual Draft Spin Dial 4 DRA MANUALTUBE Manual Draft Mounting Tube 4 MOT FURNBLWRASSY 1800CFM 3 Speed Circulation Blower Assembly 4 MOT FURNBLWRBRK Circulation Blower Mounting Brackets 4 MOT FURNBLWRHSG Circulation Blower Housing 4 MOT FURNBLWRMTR 1800CFM 3 Speed Circulation Blower Motor Draft System...

Page 50: ...0 Shaker Grate Frame for 480EK 2 required 4 CAS SHGRHNDL Shaker Grate Handle for Optional Shaker Grates 4 HAN 1 2CHROME 1 2 Chrome Spring Handle with Hardware 4 CAS WDGR365SET 360EK 365EK Cast Iron Stationary Wood Grate Set 4 CAS WDGR365 360EK 365EK Stationary Wood Grate 1 required 4 CAS WDGR480 480EK Stationary Wood Grate 1 required 4 CAS WDGR480 480EK Cast Iron Stationary Wood Grate Set 4 CAS WD...

Page 51: ... GAS DOOR 3 4 Rope Gasket for Fuel loading and Ash Removal Doors 4 GAS GSKTGLUE2OZ Gasket Cement glue 2 oz Bottle optional not included 4 HAN 1 2CHROME 1 2 Chrome Spring Handle for Ash Removal Door Sliding Smoke Baffle and Optional Shaker Grates Handles 4 HAN 5 8CHROME 5 8 Chrome Spring Handle for Fuel Loading Door Handle 4 HAR DOORPIN Door Pins 4 Required 2 per door 4 HAR HANDLE F B Door Handle H...

Page 52: ...Rev 03 12 14 ENERGY KING 360EK 365EK 480EK Wood Coal Furnace Owner s Manual U S 46 This page is intentionally left blank ...

Page 53: ... the lower left front of the unit Have you completed returned your warranty card Date Mailed Has Dealer Installer gone over the operation and maintenance of appliance Purchase Installation Record MODEL SERIAL NUMBER PURCHASE DATE INSTALLATION DATE DEALER INSTALLER ADDRESS ADDRESS CITY STATE ZIP CITY STATE ZIP CONTACT CONTACT PHONE NUMBER PHONE NUMBER COMMENTS Service Maintenance Record DATE TECHNI...

Page 54: ...tenance Log located in the Appendix of your Owner s Manual Without this information we will not be able to complete your requested warranty claim Once we receive your completed Warranty Claim Form and Warranty Registration Card we will ship a replacement for the faulty part s All transportation charges are to be paid for by the purchaser However if a faulty part is to be returned to us we will pro...

Page 55: ...TTENTION ATTENTION ADDRESS 1 ADDRESS 1 ADDRESS 2 ADDRESS 2 CITY ST ZIP CITY ST ZIP TELEPHONE TELEPHONE FAX EMAIL Model Serial No Date of Purchase Date of Failure Date of Repair Description of Failure Repairs Made please be specific Signature Date Copies of invoices receipts are required for all credits claimed on this form RJM Manufacturing Inc reserves the right to refuse any warranty claim subje...

Page 56: ...Rev 03 12 14 ENERGY KING 360EK 365EK 480EK Wood Coal Furnace Owner s Manual U S 50 This page is intentionally left blank ...

Page 57: ...nty covers any defects in materials or workmanship in your new ENERGY KING solid fuel heating appliance What is not covered by this warranty This limited warranty does not apply If your appliance has not been installed operated and maintained in strict accordance with instructions provided in the Installation Operation and Maintenance Manual If any part has been damaged in shipment modified altere...

Page 58: ...s needed during the warranty period notify your authorized ENERGY KING dealer If there is no ENERGY KING dealer in your area contact RJM Manufacturing Inc directly Provide your name address phone number serial number and model number of the furnace date of purchase name and address of installer and a description of the problem Disclaimer of Implied Warranties Consequential Damages Our obligation u...

Page 59: ...urnace Owner s Manual U S 53 Supplement A 24 V Wall Thermostat The following document was prepared and published by Honeywell International for distribution with their models T822K L T827K wall thermostats It is reproduced here for reference purposes ONLY ...

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Page 65: ...Furnace Owner s Manual U S 59 Supplement B Fan Limit Control The following document was prepared and published by Honeywell International for distribution with their models L4064B2640 B fan limit controls It is reproduced here for reference purposes ONLY ...

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