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OWNER'S
MANUAL
ASSEMBLY
INSTALLATION
OPERATION
REPAIR PARTS
MODEL NUMBERS
BJ90 AND SJ125
CANADIAN MODELS
BJ90-C AND SJ125-C
Read Rules and Instructions
Carefully for Safe Operation
IMPORTANT:
Installation must be made in
accordance with State and
Local Ordinances which may
differ from this Installation
Manual.
ALPHA AMERICAN CO., 10 INDUSTRIAL BLVD., PALISADE, MN 56469
SUPER JACK & BIG JACK
CAUTION:
SUPPLEMENTARY FURNACES
www.yukon-eagle.com
BIG JACK
MODEL BJ90
WOOD and COAL FIRED
WARM AIR CENTRAL
All furnaces in this owner's manual
are UL Listed under UL FILE #11473
SUPER JACK
MODEL SJ125
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Related Manuals for Jack SUPER JACK SJ125
Summary of Contents for Jack SUPER JACK SJ125
- Page 1 ASSEMBLY MODEL BJ90 INSTALLATION OPERATION REPAIR PARTS MODEL NUMBERS BJ90 AND SJ125 CANADIAN MODELS SUPER JACK & BIG JACK BJ90-C AND SJ125-C WOOD and COAL FIRED CAUTION: WARM AIR CENTRAL Read Rules and Instructions SUPPLEMENTARY FURNACES Carefully for Safe Operation...
- Page 2 FOR YOUR SAFETY: FOR YOUR SAFETY: If you smell gas: 1. Open windows Do not store or use gasoline or 2. Do not touch electrical switches other flammable vapors and 3. Extinguish any open flame liquids in the vicinity of this or 4.
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Page 3: Table Of Contents
Ash Removal .........................41 Maintain Gasket Material ..……………................…42 Cleaning Chimney, Smoke Pipe and Heat Exchanger ............43 Faulty Chimney and Draft Problems ................…44-45 EXPLODED VIEWS AND PARTS LISTS Super Jack (SJ125) ......................…46-47 Big Jack (BJ90) ......................…48-49 SERVICE HINTS & TROUBLESHOOTING..........….…...…50-51 YOUR NOTES ........................…52-55... -
Page 4: Safety Statements
Safety Statements Safety Statements SAVE THESE INSTRUCTIONS STOP FOR SAFETY! Safe assembly, operating and maintenance practices should always be followed whenever using any equipment. Wherever you see the caution sign, extra safety precautions should be taken. You must stop, read, and carefully follow the safety instructions before proceeding. READ THROUGH THE ENTIRE MANUAL It is recommended to read through the entire manual before beginning your installation and/or operating your furnace. -
Page 5: Safety Statements 2
ADD-ON to GAS FURNACE INSTALLATIONS When adding on to a gas furnace, the operation of the gas furnace must be verified for acceptable operation before and after installation of the Jack add-on furnace by a gas fitter who is recognized by the regulatory authority. -
Page 6: Epa Regulations
EPA Compliance Requirements This manual describes the installation and operation of the Models SJ125 Super Jack and BJ90 Big Jack wood or coal burning furnaces. These furnace models meet the 2015 U.S. Environmental Protection Agency’s (EPA) requirements for central forced air furnaces sold after May 15, 2015. - Page 7 EPA Compliance Requirements This furnace is designed to burn natural wood and coal only. Higher efficiencies and lower emissions generally result when burning air dried seasoned hardwoods, as compared to softwoods or to green or freshly cut hard- woods. DO NOT BURN: (1) Garbage;...
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Page 8: Safety Statement/Installation
85 degrees F (29° C). Shut off the primary furnace and build a fire in the Jack unit. When the fire is established, fill the fire box to the top of the firebrick (maximum level). Open the combustion blower air damper. -
Page 9: Unpack And Check Your Cartons
Unpack and Check your Cartons INSPECT SHIPMENT Note any damage to the shipping cartons. Remove all items from your shipping cartons. Check all items against the packing list below. Note any items lost or damaged in shipment. Refer to the exploded view and parts list in the back of the manual for the part names and numbers of missing or damaged items. -
Page 10: Features And Benefits Sj125
The surrounds the wood/coal fire. The 22 gauge painted side panels are de- Super Jack features 90 pounds of fire- signed to slide onto the flanged steel brick. This firebrick not only protects for easy installation. - Page 11 Furnace Features - SJ125...
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Page 12: Features And Benefits Bj90
10 gauge steel and painted surrounds the wood/coal fire. The with high temperature black paint. The Big Jack features 90 pounds of fire- 22 gauge painted side panels are brick. This firebrick not only protects designed to slide onto the flanged the steel from the extreme combustion steel for easy installation. - Page 13 Furnace Features - BJ90...
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Page 14: Sj125 Specifications
Specifications SUPER JACK 125 MODEL SJ125 BTU Capacity......................125,000 Wood Capacity......................5.25 Cu. Ft. Heat Exchanger (Total Area)...................24.5 Sq. Ft. Maximum Wood Length.......................24” Fire Box Dimensions..............16” wide x 24” long x 23” high Smoke Collar.........................7” Weight...........................645 lbs Height..........................47” Width..........................26.25” Depth..........................34.5” Warm Air Plenum Opening...................22” x 20”... -
Page 15: Bj90 Specifications
Specifications BIG JACK 90 MODEL BJ90 BTU Capacity......................90,000 Wood Capacity....................5.25 Cu. Ft Heat Exchanger (Total Area)................19 Sq. Ft Maximum Wood Length....................24” Fire Box Dimensions..........…………….16” wide x 24” long x 23” high Smoke Collar............….……………........6” Weight........................595 lbs Height..........................39.5” Width......................…..24.25” Depth.......................…....34.5”... -
Page 16: Plan Your Installation
Plan Your Installation PLAN YOUR INSTALLATION It is recommended to read through the entire manual before beginning your installation. Follow all steps exactly. Reading this manual will also help you get all the benefits from your furnace. CAUTION: Read these rules and the instructions carefully. -
Page 17: Locating The Furnace
Plan Your Installation LOCATING THE FURNACE Locate the furnace as close to the chimney or flue as possible. The furnace should be located no more than 10 feet away from the chimney. You will need 1” rise per linear foot of pipe as a minimum. -
Page 18: Typical Installations
Plan Your Installation • ‚ TYPICAL INSTALLATIONS • SERIES ADD-ON ‚ PARALLEL ADD-ON ƒ INDEPENDENT INSTALLATION IMPORTANT DUCTS AND PLENUMS SHALL BE CONSTRUCTED ENTIRELY OF SHEET METAL. ƒ... -
Page 19: Proper Chimneys
Plan Your Installation PROPER CHIMNEYS The National Fire Protection Association (NFPA) requires that all factory built chimneys be Listed and installed in accordance with conditions of the Listing in the manufacturers instructions. NFPA also requires that your chimney extend at least three (3) feet above the highest point when it passes through the roof and at least two (2) feet higher than any portion of the building within ten (10) feet of the chimney. -
Page 20: Furnace Located In Confined Space
Plan Your Installation FURNACE LOCATED IN CONFINED SPACE When the furnace is in utility room, install two open grilles. Place them in a wall or door opening to the rest of the house. One grille will supply combustion air. Locate it near the floor. The other grille is for ventilation. Locate it close to the ceiling. -
Page 21: Combustion Air (Make Up Air)
Plan Your Installation COMBUSTION AIR Make-up outside air must be provided to furnace for proper fuel combustion. This is provided by openings to outside of building. These openings shall have unobstructed areas not less than the areas of the flue pipe. -
Page 22: Installation
See Fig. 1 Place top panel over the front edge of the furnace and set down over the side panels. See Fig. 2 FIG. 1 Big Jack Model Shown FIG. 2... - Page 23 Installation CANADIAN FURNACES ONLY Super Jack (SJ125-C) All Jack furnaces that are shipped to Canada will Front panel installation: include an insulated front panel casing and an With firing door open, pull damper rod all the way insulated back panel casing.
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Page 24: Draft Inducer Motor
See Fig. 3 4x4 Junction Box Big Jack Attach the junction box with the transformer/relay to the mount provided at the top right hand side of the front of the furnace. See Fig. 4... -
Page 25: Fan And Limit Control
Installation INSTALLING THE HONEYWELL FAN AND LIMIT CONTROL Included in the accessory carton is a white sheet metal bracket that is 8-1/4 inches high and 3-1/4 inches wide. It has a 7/8” hole in it 6 inches from the bottom. Right below the 7/8”... -
Page 26: Mounting Thermostat
Installation MOUNTING THE THERMOSTAT The thermostat must be mounted on an interior centrally located wall. Place it away from direct sunlight, drafts, and approximately 5 feet above the floor. It is not required that they be level. Place them right next to each other. See Fig. -
Page 27: Electrical Wiring
All furnaces covered by this manual and installed in the United States of America operate on 115 Volts, 60 Cycle, 1-Phase Alternating Current with a 20 amp circuit protector device. Big Jack WARNING: Turn off electric power at Wiring Harness circuit protector device before making any line voltage connections. -
Page 28: Wiring Diagram
Wiring Diagram EXISTING FURNACE DRAFT INDUCER COMBUSTION BLOWER BLOWER HONEYWELL DIGITAL ADD-ON FURNACE THERMOSTAT BLOWER (Jack Furnace) FAN AND LIMIT CONTROL Rc R Y C W G INTERLOCK EXISTING EXISTING FURNACE FURNACE BLOWER BLOWER JUMPER TRANSFORMER TRANSFORMER RELAY BACK VIEW... -
Page 29: Wiring Diagram
Wiring Diagram Wiring for 4-SPEED - 1/4 HP MOTOR (OPTIONAL) BROWN/WHITE CAPACITOR BROWN WHITE COMMON BLACK (HIGH) YELLOW (MED HIGH) ORANGE (MED LOW) INSULATE UNUSED SPEED TAP LEADS SEPARATELY RED (LOW) GREEN GROUND ROTATION-SHAFT END BLACK WHITE WHITE BLACK BLACK BLACK WHITE WHITE... -
Page 30: Connecting Smoke Pipe
Installation CAUTION: Do not use any smoke pipes less than 24 gauge between furnace and chimney. CONNECTING SMOKE PIPE Set the smoke pipe end of the furnace as close to the chimney as possible. The rise of the smoke pipe toward the chimney must be at least one inch per linear foot of pipe. -
Page 31: Barometric Draft Regulator
Installation INSTRUCTIONS FOR INSTALLING FIELD CONTROLS TYPE R-C BAROMETRIC DRAFT REGULATOR DO NOT ATTACH DRAFT REGULATOR TO TOP OR BOTTOM OF THE FLUE PIPE, NOR IN A ROOM SEPARATED FROM THE FURNACE. BEST LOCATION IS AS CLOSE TO FURNACE AS POSSIBLE. - Page 32 Installation BAROMETRIC DRAFT REGULATOR Insert the draft regulator in the open end of the stub. Revolve it so it is right-side-up and imprinting on regulator reads normally. See Fig. 9 To function properly, the draft regulator must be mounted level and plumb in the tee joint stub. Using a carpenter’s spirit level placed vertically across the ring, position the draft regulator so it is plumb and does not lean forward or backward.
- Page 33 Installation SETTING THE BAROMETRIC DRAFT REGULATOR AND SOME INFORMATION ON CREOSOTE TO FUNCTION PROPERLY AND SAFELY, it is impera- CREOSOTE BUILD UP - Creosote, in a vaporized state, tive that the draft regulator when installed in the Tee is present in the gases emitted by burning wood and is stub, is pointing away from surrounding walls or obstruc- highly combustible in its solid and semi-liquid states.
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Page 34: Importance Of Draft
Installation IMPORTANCE OF DRAFT Draft is the force which moves air from the appliance up through the chimney. The amount of draft in in your chimney depends on the length of the chimney, local geography, nearby obstructions and other factors. Too much draft may cause excessive temperatures in the appliance and damage the steel of the furnace. -
Page 35: Best Wood To Burn
BTU’s Equivalent Pound per Cord Value #2 Our Jack furnaces are designed to wring the most Species Weight Air Dried Fuel Oil energy possible from each log. Your furnace is Per Cord... -
Page 36: Helpful Hints
Open the disc on the side of the Draft Inducer Motor (sup- plied with your Jack furnace) to allow air into the furnace for combustion. (For Coal) While lighting the coal fire, open disc all the way. -
Page 37: Best Burn Practices
Operating Instructions BEST BURN PRACTICES A properly installed, correctly used wood-burning appli- ance should be smoke free. If you see or smell smoke that means you may have a problem. Practice the fol- lowing guidelines to Burn Wise in your appliance and reduce smoke inside and outside your home. -
Page 38: Wood Firing The Furnace
Do not attempt to open door immediately after igniting (SUPER JACK ONLY) the fire. There could be a flame flash out. Super Jack models only: Pull out pull handle before light- ing fire. This opens the secondary heat exchanger damper. 3. Turn thermostat above room temperature. Draft inducer motor will start. -
Page 39: Burning Coal
Operating Instructions OPERATING INSTRUCTIONS FOR BURNING COAL ON 1/2-INCH OPENING GRATES (Optional) The following instructions are for burning various types of coal, storage of coal, and the cleaning of the furnace. Some coal is oil-treated at the mine. Some users have indicated that it tends to make the coal difficult to start. -
Page 40: Burning Coal
Operating Instructions WHAT SIZE COAL SHOULD I BURN? The air space between the furnace grates is 1/2 inch. Therefore, coal smaller than 1/2 inch can fall through the grates into the ash pan. • Pea size coal ranges from 9/16 to 11/16 inch. •... -
Page 41: Maintenance
Maintenance ASH REMOVAL When burning wood, every morning when there is just a bed of hot embers, run your poker over top of grates making sure grate slots are clear of burnt fuel. Once every week or two, depending on how much fuel you burn, ashes should be removed. -
Page 42: Maintain Gasket Material
Maintenance MAINTAIN GASKET MATERIAL As part of the annual maintenance of your furnace it is important to inspect the gasket material (1” rope gasket) around the inside of the firing door and ash pan door to ensure proper sealing of the firebox. The gasket material keeps added air from getting into the firebox, which could lead to over-firing of the furnace and causing excessive draft. -
Page 43: Cleaning Chimney, Smoke Pipe And Heat Exchanger
Maintenance 1. At the start of the heating season... Ÿ It is advisable to have your local furnace profes- sional inspect and service your furnace for the coming heating season. Ÿ The furnace, smoke pipe and chimney should be cleaned and checked for repairs. 2. -
Page 44: Faulty Chimney And Draft Problems
Maintenance FAULTY CHIMNEY AND/OR DRAFT PROBLEMS - CAUSES AND CURES A sound chimney system is imperative, especially when burning wood. Indoor chimney, either masonry or type “HT” metal chimneys are the best. Because warm air rises, a warm chimney allows the smoke and other by-products of combustion a natural exit up and out the chimney. - Page 45 Maintenance TOP OF CHIMNEY LOWER THAN SURROUNDING OBJECTS REMEDY: EXTEND CHIMNEY ABOVE ALL OBJECTS WITHIN 30 FEET CHIMNEY CAP PUSHED OVER FLUE OR FLUE OBSTRUCTED BY A VENTILATOR REMEDY: REMOVE OBSTRUCTION ACCUMULATION OF SOOT OR DEBRIS IN OFFSET REMEDY: REMOVE AIR LEAKS THROUGH CRACKS IN FLUE AND CHIMNEY DISCLOSED BY SMOKE TEST...
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Page 46: Exploded Views And Parts Lists
Exploded Views & Parts Lists SUPER JACK - SJ125... -
Page 47: Super Jack (Sj125)
Exploded Views & Parts Lists SUPER JACK - SJ125 Key No. Part No. Description Jacket (Top) Damper Plate w/Rod Damper Control Rod Jacket Side (Right) Clean Out Plate Gasket Clean Out Plate 10090332 Fire Door Assembly Screws (4) - Ash Door Screws (2) -... -
Page 48: Big Jack (Bj90)
Exploded Views & Parts Lists BIG JACK - BJ90... - Page 49 Exploded Views & Parts Lists BIG JACK - BJ90 Key No. Part No. Description Jacket (Top) Jacket Side (Right) Firebrick (9 x 4-½ x 1-¼) 19-1/2 Smoke Flap Assembly Grate Fillers Heavy Duty Cast Iron Grate Draft Inducer Gasket Draft Inducer Fire Door Gasket Fire Door &...
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Page 50: Service Hints & Troubleshooting
SERVICE HINTS & TROUBLESHOOTING Main blower vibrating when in use... POSSIBLE CAUSE SOLUTION Loose allen screw on squirrel cage Tighten the allen screw, be sure squirrel cage did not move to one side or the other. Defective motor or blower bearings Return motor or blower for a replacement. - Page 51 Chimney cap too close to top of chimney Remove and discard chimney cap. Too long of run of smoke pipe from Jack to chimney Relocate Jack closer to chimney. Negative pressure in home Install outside combustion air to furnace room.
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Page 52: Your Notes
Notes Model Number: __________________________________ Serial Number:__________ Installation Date:_______________________Contractor_________________________ Service Calls:__________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ Notes: _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _____________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ ______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________... - Page 53 Notes...
- Page 54 Notes Notes...
- Page 55 Notes...
- Page 56 MODEL BJ90-C SUPER JACK & BIG JACK WOOD BURNING FURNACES HOW TO ORDER REPAIR PARTS WHEN ORDERING REPAIR PARTS, OWNER’S ALWAYS GIVE THE FOLLOWING INFORMATION: Ÿ MODEL NUMBER MANUAL Ÿ PART NUMBER Ÿ PART DESCRIPTION Ÿ NAME OF ITEM ASSEMBLY INSTALLATION Our service technicians will help you...
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