ENERGY KING 385EK Installation, Operation & Maintenance Manual Download Page 3 | Manualshive

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ENERGY KING

®

Wood/Coal Furnaces

Installation and Operating Instructions

Model 385EK

Congratulations on your purchase of an ENERGY KING solid fuel heating appliance!

Your ENERGY KING Wood/Coal Furnace is designed for a lifetime of durable, reliable
performance and easy operation. This manual describes the installation, operation and
maintenance of your ENERGY KING Wood/Coal Furnace.

ENERGY KING Wood/Coal Furnace has been designed to use independently or as an
add-on to an existing central heating system. The installation of any furnace

is not a do-it-

yourself project

. To ensure the ENERGY KING Wood/Coal Furnace will operate safely

and efficiently, the

installation must be performed by a qualified installer 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. [MANUFACTURER NAME], the manufacturer of this product, reserves the right to alter its products,
their specifications and/or prices without notice.

[MANUFACTURER NAME]

[ADDRESS]

[CITY, STATE ZIP]

[TELEPHONE]

www.energyking.com

Email: [email protected]

ENERGY KING is a registered trademark of [MANUFACTURER NAME].

Save these instructions.

Before installing your ENERGY KING Wood/Coal Furnace,
please read and be sure you understand the entire o

wner’s

manual and safety instructions.

Refer to markings on the appliance for additional
instructions.

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Summary of Contents for 385EK

Page 1: ...ENERGY KING Wood Coal Furnaces Model 385EK Installation Operation Maintenance Manual MANUFACTURER NAME ADDRESS CITY STATE ZIP TELEPHONE www EnergyKing com ...

Page 2: ......

Page 3: ...qualified installer 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 MANUFACTURER NAME the manufacturer of t...

Page 4: ......

Page 5: ...ne 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 paper...

Page 6: ...ipally designated areas A working smoke detector must be installed in the same room as this product For additional safety MANUFACTURER NAME 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 available on...

Page 7: ...AL INSTRUCTIONS 22 FIRST FIRE 22 TYPICAL OPERATION CYCLE 23 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 31 TROUBLESHOOTING GUIDE 33 DETAILED TROUBLESHOOTING 34 APPENDIX A WIRIN...

Page 8: ...Rev 03 12 14 ENERGY KING 385EK Wood Coal Furnace Owner s Manual U S 2 ...

Page 9: ...14 with glass viewing port Cast Iron Ash Removal Door Size H x W 7 25 x 11 5 Removable Ash Pan Standard Flue Size Rear Vent 6 Flue Collar Height to top of flue 43 Leg Height 3 5 Plenum Outlet Size 18 x 18 Insulated Cabinet Standard Double Wall Back Standard Pre wired Electrical Components Standard Draft Controls Automatic standard or Forced optional Wall Thermostat Standard 3 Speed Blower Capacity...

Page 10: ...imney See Venting for further instructions 1 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 Plenum Opening Not...

Page 11: ...hen 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 Filter Box optional Not pictured Provides air filtration for your cold air return system A non combustible filter is required when using the optional filter box Combustion Fan Not pictured If you selected Forced Air Draft this fan will supply air for combus...

Page 12: ...her 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 5 Ca...

Page 13: ...creases 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 a...

Page 14: ...GY KING solid fuel heating appliance and its components If you choose to burn bituminous coal be sure to select 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...

Page 15: ...l Furnace 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 place...

Page 16: ...ce 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 between your exi...

Page 17: ...wall and Row 1 lower sidewall firebrick will have been installed in your ENERGY KING at the factory However if they have shifted during shipment you may need to make adjustments according to Appendix C The Cast Plate J which holds the back wall firebrick in place is pre installed at the factory The Angle G which secures Row 1 lower sidewall firebrick is also pre installed The remaining brick and t...

Page 18: ...ation 5 Control Box a Remove the control box cover See Figure 3 Control Box for Automatic Draft or Figure 4 Control Box for Forced Air 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 385EK Wood Coal Furnace Owner s Manual U S 13 Installation Figure 4 Control Box for Forced Air Draft ...

Page 20: ...ated next to the ash removal door on the front of the Furnace c For Forced Air Draft Remove the draft port cover plate located to the left of the ash removal door Mount the prewired forced air draft blower to the draft port located next to the ash removal door and secure using the bolts found on the draft opening Attach the draft port cover plate to the automatic draft port located on the left sid...

Page 21: ...tep 9 Otherwise attach the conduit to Control Box and connect wire ends as detailed in Appendix A Wiring Diagrams Do not connect power to your ENERGY KING Wood Coal Furnace until the installation is complete 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 ...

Page 22: ...or 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 house ...

Page 23: ...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 MANUFACTURER NAME recommends using insulated chimney rather than triple wall or air cooled chimney Important venting installation clearances and ...

Page 24: ...e 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 MANUFACTURER NAME recommends a chimney height of at least 12 feet ...

Page 25: ...ra 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 connecti...

Page 26: ...nce burn chamber A pivoted counterbalanced flap is pulled open by the draft when the draft reaches a critical amount This permits air to enter the chimney thus preventing the draft in the solid fuel heating appliance from rising any higher After installation of the ENERGY KING Wood Coal Furnace is complete and a fire has been built the chimney draft should be established and maintained from 04 to ...

Page 27: ...ls 385EK 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 air supply duct system must be constructed...

Page 28: ...r 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 MANUFACTURER NAME recommends installing a magnetic chimney thermometer to monitor chimney temperature First Fire Before lighting your first fire inspect your ENERGY KING Wood Coal Furnace...

Page 29: ...ted as it flows through the air passage and enters the burn chamber through an airwash system located above the fuel loading door frame Forced Draft When burning coal a forced draft system will provide optimal performance When the thermostat calls for more heat the combustion fan turns on forcing combustion air into your burn chamber The manually operated spin dial located on the ash removal door ...

Page 30: ...r 3 Open all heat registers 4 Do not load the Furnace more than 1 4 full 5 Keep sliding smoke baffle closed Use extreme caution when operating your ENERGY KING Wood Coal Furnace during a power failure Over firing can damage the furnace and its components will void your warranty and may result in property damage bodily injury or even death Always closely monitor the operation of the ENERGY KING Woo...

Page 31: ...nutes for the fire to establish itself Once you have some red hot burning embers add larger pieces of wood a Vary the position of the wood in the burn chamber to maximize 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 con...

Page 32: ...y 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 clinker...

Page 33: ... 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 Gently...

Page 34: ...sh 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 down in ...

Page 35: ... 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 to han...

Page 36: ...ay the new door gasket in the channel cutting off any excess gasket rope 6 Reattach the door If gasket cement was applied keep the door closed until the cement has fully dried To replace the Glass Gasket you will need self adhesive 3 4 inch wide by 1 8 inch thick flat gasket 1 Remove the fuel loading door and lay it face down on a clean soft surface such as a towel 2 Remove the glass retaining cli...

Page 37: ...should be emptied and cleaned regularly Ash content is a good indicator of fuel efficiency and quality High quality fuel will produce less ash than lower quality fuel Never allow ash to build up to the level of the grates Every 2 3 Days Weekly Once a pattern of cleaning requirement is established the following components should still be monitored on a regular basis Burn chamber Ash Removal Pan Flu...

Page 38: ...o not allow fuel or ash to sit in the ENERGY KING Wood Coal Furnace over the summer months Fuel and ash can accumulate moisture over the summer months having a corrosive effect on metal and cast iron parts and causing the fuel to mold Failure to clean and maintain this Furnace as indicated can result in poor performance and safety hazards Please use Appendix E Purchase Service Record to keep a rec...

Page 39: ...ng 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 Furnace s cl...

Page 40: ... the draft controls are operating correctly 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 contractor Check your chimney for downdraft caused by taller surrounding trees or b...

Page 41: ... recommend using a vacuum designed for ashes Be sure to check the exhaust system for leaks and repair as necessary 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 contractor P...

Page 42: ...Your furnace may have a faulty fan limit control or blower motor Please contact your ENERGY KING dealer for replacement parts The ENERGY KING heating appliance has power but is not responding Check the power supply for adequate voltage See the Installation section for power supply requirements Your ENERGY KING heating appliance may have been installed incorrectly Please contact your ENERGY KING de...

Page 43: ...Rev 03 12 14 ENERGY KING 385EK 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 385EK Wood Coal Furnace Owner s Manual U S 38 Appendix A Wiring Diagrams A 2 Forced Air Draft Wiring Diagram ...

Page 45: ... 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 46: ...Rev 03 12 14 ENERGY KING 385EK Wood Coal Furnace Owner s Manual U S 40 This page is intentionally left blank ...

Page 47: ...Rev 03 12 14 ENERGY KING 385EK Wood Coal Furnace Owner s Manual U S 41 Appendix C Firebrick Layout ...

Page 48: ...Rev 03 12 14 ENERGY KING 385EK Wood Coal Furnace Owner s Manual U S 42 This page is intentionally left blank ...

Page 49: ...DTUBEASSY Forced Draft Blower Tube Assembly 4 MOT 60CFMBLOWER 60CFM Forced Draft Blower 4 MOT 60CFMROTARY Rotary switch for 60CFM Forced Draft Blower 4 DRA FORCEDTUBE Forced 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 Circulati...

Page 50: ...T Cast Iron Stationary Wood Grate Set 360EK 365EK 385EK 4 CAS WDGR365 360EK 365EK Stationary Wood Grate 1 required 4 CAS WDGR480 480EK Stationary Wood Grate 1 required 4 DOR ASHDOORASSY Cast Iron Ash Removal Door Assembly 4 DOR ASHDOOR Cast Iron Ash Removal Door 4 CAS DRAFTDIAL Cast Iron Draft Spin Dial with Hardware 4 GAS DOOR 3 4 Rope Gasket 4 GAS GSKTGLUE2OZ Gasket Cement glue 2 oz Bottle optio...

Page 51: ...ally 2 Required 4 FIR 6 1 4x4x2DIA Firebrick 6 1 4 x 4 x 2 Cut Diagonally 2 Required 4 GAS DOOR 3 4 Rope Gasket for Fuel loading and Ash Removal Doors 4 GAS GLASS 385 385EK Door Glass Gasket Self adhesive 3 4 x 1 8 4 GAS GSKTGLUE2OZ Gasket Cement glue 2 oz Bottle optional not included 4 GLA DOOR 385 385EK Door Glass 4 HAN 1 2CHROME 1 2 Chrome Spring Handle for Ash Removal Door Sliding Smoke Baffle...

Page 52: ...Rev 03 12 14 ENERGY KING 385EK Wood Coal Furnace Owner s Manual U S 46 This page is intentionally left blank ...

Page 53: ...ower 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 TECHNICIAN D...

Page 54: ...nance 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 provi...

Page 55: ...DRESS 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 MANUFACTURER NAME reserves the right to refuse any warranty claim subject to the terms condition...

Page 56: ...Rev 03 12 14 ENERGY KING 385EK Wood Coal Furnace Owner s Manual U S 50 This page is intentionally left blank ...

Page 57: ...vers 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 altered tamp...

Page 58: ...service If warranty service is needed during the warranty period notify your authorized ENERGY KING dealer If there is no ENERGY KING dealer in your area contact MANUFACTURER NAME 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...

Page 59: ... 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 66: ...e Owner s Manual U S 60 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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