Table of Contents
Troubleshooting
Related Manuals for ENERGY KING 35EKB
Summary of Contents for ENERGY KING 35EKB
- Page 1 ENERGY KING Wood/Coal Boilers Models 35EKB/45EKB & ASME-Certified Model A40EKB 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: Installation And Operating Instructions
ENERGY KING Wood/Coal Boilers have been designed to use independently or as an add- on to an existing hydronic heating system. The installation of any furnace or boiler is not a do-it-yourself project. -
Page 5: Safety Instructions
Proper installation of this heating seals must be maintained in good appliance is crucial for safe and efficient condition. operation. Save these instructions for later The ENERGY KING Wood/Coal Boiler is ▲ use. designed to burn air-dried wood, or anthracite or bituminous coal only. - 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 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
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Page 7: Table Of Contents
S U P P LE M E N T A : A QU A S T A T -IM M E R S I ON C ON T R O L ..................51 SUPPLEMENT B: 24-V WA LL THE RM OST AT .......................64 Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. - Page 8 This page is intentionally left blank. Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
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Page 9: Specifications
The actual BTU output depends on the type of fuel being burned and its condition, the thermostat setting, the draft adjustments and the chimney into which the unit is installed. Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. -
Page 10: Component Description
See Venting for the maximum amount of heat from the fire. further instructions. Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. - Page 11 14. Legs. Raise the ENERGY KING heating Grates is located at the front of the appliance off the floor to prevent the ENERGY KING, on the left side of the ash accumulation of moisture between the removal door. floor and the bottom of the appliance.
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Page 12: What Is Asme-Certification
SA516-70 steel plate and is welded by experienced, ASME-certified welders, to ensure safety and durability. For additional safety, a 30 PSI pressure relief valve is included with every Energy King boiler. You can rest easy knowing that ENERGY KING A40EKB boilers conform to an internationally recognized standard for safety and quality. -
Page 13: Preinstallation Considerations
Preinstallation Considerations The ENERGY KING Wood/Coal Boiler is intended for use in residential buildings. Do not install this heating appliance in a mobile or manufactured home—this can be dangerous and will void your warranty. This heating appliance has not been tested to meet the strict requirements necessary for installation into a mobile or manufactured home. -
Page 14: Fuel Requirements
KING Wood/Coal Boiler, naturally produce ash as a byproduct of the burning process. Even with the ENERGY KING heating appliance’s highly efficient design, your heating appliance will still produce some amount of ash which will need to be cleaned periodically. The type and quality of fuel you burn affects the amount of ash produced and the performance of your heating appliance. -
Page 15: Coal
One of the world’s most widely-used fuel sources, coal can provide the energy independence and low fuel prices sought by owners of solid-fuel heating appliances. • The ENERGY KING Wood/Coal Boiler has • DO NOT BURN: Treated wood, colored paper, garbage, cardboard, solvents, or been tested for operation with anthracite (hard) or bituminous (soft) coal. -
Page 16: Installation
For additional safety, RJM Manufacturing, Inc. recommends installing working smoke detectors and a listed carbon monoxide warning device in the living areas of the home. The ENERGY KING Wood/Coal Boiler is designed to be used in conjunction with a listed gas- or oil-fired boiler, or as a central boiler. -
Page 17: As Primary Boiler
Figure 2: Clearances to Combustibles • Sides: The ENERGY KING Wood/Coal Boiler must have clearances of 18 inches from the sidewall of the ENERGY KING Wood/Coal Boiler to combustibles. • Front: Leave a minimum clearance of 48 inches in front of your ENERGY KING heating appliance. -
Page 18: Assembling Your Energy King Wood/Coal Boiler
Your new ENERGY KING Wood/Coal Boiler 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 Boiler. - Page 19 The Pressure Relief Valve must be plumbed with a discharge tube that empties into a floor drain. See Plumbing for further instructions. Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
- Page 20 Unscrew & remove the 4″ plug located at Black the upper left on the back of the ENERGY KING Wood/Coal Boiler model 35EKB or 45EKB. b. Apply pipe joint compound (not included) to the threads of the 4″ domestic hot water coil.
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Page 21: Combustion Air Requirements
The ENERGY KING Wood/Coal Boiler 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 22: Venting System
• Do not connect the ENERGY KING heating appliance to any chimney flue serving any other appliance. • Risk of Fire: Inspect and clean flues and chimney regularly. - Page 23 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. Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
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Page 24: 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 Boiler to the chimney must be made using 8″ black steel material with a minimum 24 gauge. Do not use galvanized steel. -
Page 25: Barometric Draft Control
.06″ (14.95 Pa) water column. Proper draft must be provided for your Barometric draft controllers limit the draft (the ENERGY KING Wood/Coal Boiler. Draft is the suction pulling air into the solid-fuel heating force that moves air from the boiler up through appliance burn chamber). -
Page 26: Plumbing
Boiler is in use, Valves #1 and #2 are open drain. and Valve #3 is closed. o To isolate your ENERGY KING Wood/Coal Once installation is complete and you’ve filled Boiler from the heating system when not in the boiler with water, verify the Pressure Relief use, close Valves #1 and #2 and open Valve’s proper functioning by manually opening... - Page 27 In it is delivered to your in-floor heating system. this way it will prevent your ENERGY KING Wood/Coal Boiler from overheating. However, as a safety feature, if your Boiler should...
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Page 28: Operation
Do not touch Boiler during operation. Please read this manual in its entirety prior to the first firing of your ENERGY KING Wood/Coal Boiler. 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 Boiler. -
Page 29: First Fire
Your ENERGY KING Wood/Coal Boiler 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: Overfire
KING Wood/Coal Boiler during a power failure - this can be dangerous and will void your warranty. After power is restored, verify that there is power to the ENERGY KING Wood/Coal Boiler, and restart using the procedures described in Starting a Fire. -
Page 31: Burning Wood
ENERGY KING Wood/Coal Boiler. Your ENERGY KING Wood/Coal Boiler 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 Boiler. 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 home chimneys and hookups are different. After a few fires, you will find the best way to start a fire in your ENERGY KING Wood/Coal Boiler. You will get the best efficiency when you add only the amount of coal needed for a 6 to 8 hour burn. -
Page 33: Starting A Coal Fire
6. The burn time is controlled by the 24-V Wall Thermostat and the forced air draft controls 6. Close the fuel loading door and sliding on the Boiler. Allow your ENERGY KING smoke baffle. Wood/Coal Boiler to operate with draft controls fully open for approximately 15 minutes or until the fresh coal ignites. - Page 34 Be careful not to smother your existing coals. 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 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
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Page 35: Maintenance
Maintenance Periodic maintenance is required to continue the performance of your ENERGY KING Wood/Coal Boiler. 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 Boiler 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 It is important to give the entire ENERGY KING Wood/Coal Boiler a thorough cleaning: • Your venting system should be inspected • Scoop out any unburned fuel from the burn and cleaned annually.
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Page 38: Troubleshooting Guide
ENERGY KING Wood/Coal Boiler. Many problems in the ENERGY KING Wood/Coal Boiler can be traced to a few commonplace causes and are easily fixed. Before making any repairs or replacing any components, be sure to... -
Page 39: Troubleshooting Guide
Once you have exhausted the above common problems, if you are still experiencing trouble with your ENERGY KING Wood/Coal Boiler, you may wish to consult the following list of problems, or consult with your ENERGY KING dealer for further assistance. - Page 40 • Your venting may be improperly installed. If the ENERGY KING heating appliance is smoking from vents or from the draft controls, immediately shut down the ENERGY KING heating appliance, ventilate the area, and contact your ENERGY KING dealer or heating contractor.
- Page 41 15 PSI, as this could trigger the Pressure Relief Valve when the water temperature rises. • Check for leaks in your ENERGY KING Wood/Coal Boiler and in your plumbing system. • Your Pressure Relief Valve may be installed incorrectly, or may...
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Page 43: Appendix A: Wiring Diagram
Appendix A: Wiring Diagram Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. - Page 44 This page is intentionally left blank. Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
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Page 45: Appendix B: Example Plumbing Diagram
ENERGY KING Wood/Coal Boiler for an extended period (one or more weeks). When the ENERGY KING Wood/Coal Boiler is in use, Valves #1 and #2 are open and Valve #3 is closed. To isolate your ENERGY KING Wood/Coal Boiler from... - Page 46 This page is intentionally left blank. Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
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Page 47: Appendix C: Parts List
Heat-Conductive Grease (tube) 4-ELE-PRESSRELIEF Pressure Relief Valve 4-ELE-PRESSTEMPGA Pressure Temperature Gauge 4-HOT-COIL 4” Hot Water Coil, Copper (optional)(models 35EKB/45EKB only) • 4-CAS-PLUG-COIL 4″ Square-Head Plug for Domestic Hot Water Coil receptacle (models 35EKB/45EKB only) Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual... - Page 48 • 4-CAS-SHGRHNDL Shaker Grate Handle for Optional Shaker Grates • 4-HAN-1/2CHROME 1/2″ Chrome Spring Handle with Hardware 4-CAS-WDGR35 Cast Iron Stationary (Wood) Grate for 35EKB & A40EKB, 2 Required 4-CAS-WDGR45 Cast Iron Stationary (Wood) Grate for 45EKB, 2 Required 4-CAS-WDSPACERGR45...
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Page 49: Boiler Components
• 4-CAB-A40-TOP A40EKB Cabinet Panel (Shroud), Top Side 4-FIR-9X4-1/2-1-/4 Firebrick, 9″ x 4-1/2″ x 1-1/4″ • 35EKB requires 12 (6 per side) • 45EKB requires 14 (7 per side) • A40EKB requires 12 (6 per side) 4-GAS-DOOR 3/4″ Rope Gasket (for Fuel Loading and Ash Removal Doors) 4-GAS-GSKTGLUE2OZ Gasket Cement (glue) for 3/4″... - Page 50 This page is intentionally left blank. Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
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Page 51: Appendix D: Purchase & Service Record
*Model and serial number are located on the label on the left side of the unit. 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 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. -
Page 52: Appendix E: Warranty Claim Procedures
RJM Manufacturing, Inc. reserves the right to refuse any warranty claim, subject to the terms, conditions and restrictions of the warranty agreement found in the corresponding ENERGY KING™ or Bio-King™ installation & operation manual. Rev 07/13/09 ENERGY KING™... - Page 53 ENERGY KING™ Warranty Claim Form For all ENERGY KING heating appliance warranty claims, please complete this form IN FULL and return it to RJM Manufacturing, Inc., via fax at (715) 720-1797 or via postal mail at: RJM Manufacturing, Inc., 1875 Olson Drive, Chippewa Falls, WI 54729...
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Page 55: 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 56 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 RJM Manufacturing, Inc.
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Page 57: Supplement A: Aquastat-Immersion Control
Supplement A: Aquastat-Immersion Control The following document was prepared and published by Honeywell International for distribution with their models “L4081A,B and L6081A,C Multiple Aquastat Controllers.” It is reproduced here for reference purposes ONLY. Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. -
Page 70: Supplement B: 24-V Wall Thermostat
Supplement B: 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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