ENERGY KING 385EK Installation, Operation & Maintenance Manual
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ENERGY KING 385EK Installation, Operation & Maintenance Manual

Wood/coal furnaces
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ENERGY KING
Wood/Coal Furnaces
Model 385EK
Installation, Operation & Maintenance Manual
[MANUFACTURER NAME]
[ADDRESS]
[CITY, STATE ZIP]
[TELEPHONE]
www.EnergyKing.com

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  • Page 1 ® ENERGY KING Wood/Coal Furnaces Model 385EK Installation, Operation & Maintenance Manual [MANUFACTURER NAME] [ADDRESS] [CITY, STATE ZIP] [TELEPHONE] www.EnergyKing.com...

  • Page 3: 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.

  • Page 5: Safety Instructions

    Opening fuel loading door rapidly heating appliance to cool before servicing. can cause smoke or flame to flash out the door. See Operation for further instructions. Rev 05/05/11 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...
  • Page 6 The National Fire Protection Association has information available on the safe use of solid-fuel heating appliances. You can contact the NFPA at: National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02169-7471 or www.nfpa.org. Rev 05/05/11 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 7: Table Of Contents

    S U P PL E ME N T A : 2 4 - V W A L L T HE R M O S T AT ....................... 53 S U P PL E ME N T B : FA N/ LI M I T C O NT R O L ....................... 60 Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...
  • Page 8 Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 9: Specifications

    1 Phase, 15 Amps Circuit Cast Iron Stationary (Wood) Grates Standard Cast Iron Shaker Grates Optional Cast Iron Hearth Plates (Front & Rear) Standard Complies with Standards UL391 Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 10: Component Description

    Plenum Opening. (Not pictured) Allows you to connect the Furnace into your home’s warm-air supply duct. The ENERGY KING 385EK Wood/Coal Furnace has a plenum opening of 18 inches by 18 inches. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...
  • Page 11 Furnace. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 12: Preinstallation Considerations

    Furnace cannot be placed where you want? Finally, do you have a reliable, consistent source of fuel for your Furnace? Please see Fuel Requirements for further information on fuel supply. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 13: Fuel Requirements

    It is important to use fuel that is clean, dry and consistent. Solid-fuel Furnaces, such as your ENERGY KING Wood/Coal Furnace, naturally produce ash as a byproduct of the burning process. Even with ENERGY KING Furnace’s highly efficient design, your Furnace will still produce some amount of ash which will need to be cleaned periodically.

  • Page 14: Coal

     Coal Size: Your ENERGY KING required for refueling, ash removal and Wood/Coal Furnace is designed to use coal other routine maintenance operations. that is Nut size or larger. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 15: Installation

    For additional safety, [MANUFACTURER NAME]. recommends installing working smoke detectors and a listed carbon monoxide warning device in the living areas of the home. The ENERGY KING Wood/Coal Furnace is designed to be used in conjunction with a listed gas- or oil-fired furnace, or as a central Furnace.

  • Page 16: As Add-On Furnace

     Additionally, when using your ENERGY KING wood/coal Furnace as an add-on, a 6-inch minimum clearance is required between the ENERGY KING and your existing furnace. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 17: Assembling Your Energy King Wood/Coal Furnace

    Your new ENERGY KING Wood/Coal Furnace will have been shipped on a pallet with several boxed components that will need to be assembled prior to installation. Please see Components for a list of everything that was shipped along with your ENERGY KING Wood/Coal Furnace.
  • Page 18 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 Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...
  • Page 19 Installation Figure 4: Control Box for Forced Air Draft Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...
  • Page 20 Furnace; when using forced air draft, the draft port cover plate must be attached to the automatic draft port. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...
  • Page 21 Recommended “Fan Off” setting is 90 º F. Risk of electric shock. Recommended “Fan On” setting is 145º F. Disconnect power at the service panel or breaker box before servicing ENERGY KING Wood/Coal Furnace. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 22: Combustion Air Requirements

    The ENERGY KING Furnace must have a minimum supply of 70 cubic feet of air per minute. All fuel-burning appliances must have air (oxygen) for proper combustion. The incomplete combustion that takes place when a solid-fuel appliance is “air-starved”...

  • Page 23: Venting System

     Do not connect the ENERGY KING heating appliance to any chimney flue servicing any other appliance.  Risk of Fire: Inspect and clean flues and chimney regularly.
  • Page 24 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. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 25: Masonry Chimney

    An unlined chimney could remain cold and cause a downward pressure which creates the environment for poor burning, incomplete combustion, or backdraft. Chimney Connector The connection from the ENERGY KING Wood/Coal Furnace to the chimney must be made using 6″ black steel material with a minimum 24 gauge. Do not use galvanized steel.

  • Page 26: Barometric Draft Control

    Figure 11: Barometric Draft Control Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 27: Air Duct Installation

    They must be properly designed and installed to be efficient, maintain uniform temperatures throughout the house, and not adversely affect comfort or indoor air quality. Important duct system installation details for safe and efficient operation of your ENERGY KING Wood/Coal Furnace: ...

  • Page 28: Operation

    CAUTION – Hot Surfaces: Keep children away! Do not touch Furnace during operation. Please read this manual in its entirety prior to the first firing of your ENERGY KING Wood/Coal Furnace. It is very important that you follow these suggestions and limitations in order to maintain your warranty and to guarantee the long life of your ENERGY KING Wood/Coal Furnace.

  • Page 29: Typical Operation Cycle

    Your ENERGY KING Wood/Coal Furnace can run efficiently over extended periods of time and at different heat output levels as long as the fuel supply is uninterrupted and cleaning and maintenance are performed routinely.

  • Page 30: Power Failure Instructions

    Always closely monitor the operation of the ENERGY KING Wood/Coal Furnace during a power failure. To operate your ENERGY KING Wood/Coal Furnace in the event of a power failure: 1. Close draft dial on ash door. 2. Remove air filter.

  • Page 31: Burning Wood

    ENERGY KING Wood/Coal Furnace. Your ENERGY KING Wood/Coal Furnace is capable of holding very large logs. Do not try to add a log that is larger than what you can easily place in the ENERGY KING Wood/Coal Furnace. You will get the best efficiency when you add only the amount of wood needed for a 6 to 8 hour burn.

  • Page 32: Burning Coal

    All coal contains small amounts of dangerous elements. Therefore it is essential that your coal ash be disposed of in municipally designated areas. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 33: Starting A Coal Fire

    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. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...
  • Page 34 Never overload your burn chamber. Do not load coal above the top of the firebrick. 6. Close the fuel loading door and sliding smoke baffle. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 35: Maintenance

    Maintenance Periodic maintenance is required to continue the performance of your ENERGY KING Wood/Coal Furnace. As with any solid-fuel heating appliance, the need for and frequency of cleaning depends on the amount and quality of fuel burned, the quality of the fire, and the length of time since the last cleaning.

  • Page 36: Gasket Replacement

    Maintenance Gasket Replacement The cast iron fuel loading and ash removal doors of your ENERGY KING Wood/Coal Furnace are equipped with gaskets to ensure safe operation and an airtight seal. When these gaskets become worn or damaged, you will need to replace them.

  • Page 37: Routine 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.
  • Page 38 It is important to give the entire ENERGY KING Wood/Coal Furnace a thorough cleaning:  Your venting system should be inspected  Scoop out any unburned fuel from the burn and cleaned annually.

  • Page 39: Troubleshooting Guide

    ENERGY KING Wood/Coal Furnace. Many problems in the ENERGY KING Wood/Coal Furnace can be traced to a few commonplace causes and are easily fixed. Before making any repairs or replacing any components, be sure to...

  • Page 40: Detailed Troubleshooting

    Once you have exhausted the above common problems, if you are still experiencing trouble with your ENERGY KING Wood/Coal Furnace, you may wish to consult the following list of problems, or consult with your ENERGY KING dealer for further assistance.
  • Page 41 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.  More air for proper combustion may be needed. Verify that your...
  • Page 42  Your ENERGY KING heating appliance may have been installed incorrectly. Please contact your ENERGY KING dealer or heating contractor.  Your ENERGY KING heating appliance may not have been The user is shocked when properly grounded or may have loose wires or wiring components.

  • Page 43: Appendix A: Wiring Diagrams

    Appendix A: Wiring Diagrams A-1: Automatic Draft Wiring Diagram Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 44: A-2: Forced Air Draft Wiring Diagram

    Appendix A: Wiring Diagrams A-2: Forced Air Draft Wiring Diagram Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 45: Appendix B: Filter Box Assembly Schematic

    REASON INCLUDING POWER FAILURE HIS WILL PREVENT OVERHEATING OF THE MOTOR HE AIR FILTER MUST BE COMBUSTIBLE Non-combustible air filters are available from your ENERGY KING dealer. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...
  • Page 46 This page is intentionally left blank. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 47: Appendix C: Firebrick Layout

    Appendix C: Firebrick Layout Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...
  • Page 48 This page is intentionally left blank. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 49: Appendix D: Parts List

    Forced Draft Parts Box  4-DRA-FDTUBEASSY Forced Draft Blower / Tube Assembly  4-ELE-CTRLBX-FD-F Control Box Assembly (Forced Draft)  4-ELE-24VTHERMOST 24 Volt Wall Thermostat  4-ELE-FAN/LIMIT Fan/limit Control Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...
  • Page 50 Shaker Grate Handle for Optional Shaker Grates  4-HAN-1/2CHROME 1/2″ Chrome Spring Handle with Hardware 4-CAS-WDGR365SET 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)
  • Page 51 Filter Box Kit, 20″ H x 26″ W x 22″ D 2-1-FILTER-385  Non-Combustible Filter 20″ x 20″ x 1″ Non-Combustible Filter (not included), available from your ENERGY KING dealer or Grainger Supply (Part No. 2TE96 “Aluminum mesh air filter”) 4-CAB-CAB-385-COMP 385EK Cabinet (Shroud) Assembly ...
  • Page 52 This page is intentionally left blank. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 53: Appendix E: Purchase & Service Record

    Service & Maintenance Record ECHNICIAN ESCRIPTION OF Have you completed & returned your warranty card? Date Mailed: Has Dealer / Installer gone over the operation and maintenance of appliance? Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 54: Appendix F: Warranty Claim Procedures

    We will replace or repair the part, as outlined in the applicable warranty, as soon as possible to keep your ENERGY KING heating appliance functioning safely and efficiently as intended.
  • Page 55 ENERGY KING Solid-Fuel Heating Appliances Warranty Claim Form For all ENERGY KING warranty claims, please complete this form IN FULL and return it to [MANUFACTURER NAME], via fax at [FAX] or via postal mail at: [MANUFACTURER NAME], [ADDRESS, CITY, STATE ZIP]...
  • Page 56 This page is intentionally left blank. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 57: Limited Warranty

    ARRANTY Who is covered? You are covered under this warranty if you are the original purchaser of a new ENERGY KING solid-fuel heating appliance and your purchase was made through an authorized distributor/dealer of the ENERGY KING solid-fuel heating appliance.
  • Page 58 What will we do to correct problems? We will repair, or at our option, replace any ENERGY KING solid-fuel heating appliance or appliance part, which upon inspection shows a defect in materials or workmanship. How can you get 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].

  • Page 59: 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. Rev 03/12/14 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

  • Page 66: 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. Rev 05/05/11 ENERGY KING 385EK Wood/Coal Furnace Owner’s Manual  U. S. ®...

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