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Summary of Contents for ENERGY KING 35EK-D
- Page 1 ENERGY KING Wood/Coal Boilers Models 35EK-D/45EK-D & ASME-Certified Model A40EK-D 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
Thank you for choosing the ENERGY KING Wood/Coal Boiler. 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, reserves the right to alter its products, their specifications and/or prices without notice. -
Page 5: Safety Instructions
Safety Instructions Failure to follow these safety instructions may result in property damage, bodily injury or even death. Read this entire manual before installing, The fuel loading and ash removal doors ▲ ▲ operating or maintaining this product. must be closed tightly during operation. All Proper installation of this heating seals must be maintained in good appliance is crucial for safe and efficient... - Page 6 The closed container of appliance. For additional safety, RJM ashes should be placed on a Manufacturing, Inc. also recommends noncombustible floor or on the ground,...
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Page 7: Table Of Contents
Table of Contents SAFETY IN ST RUCTI ON S ..............................i T A BLE OF CONT ENT S ..............................1 SP ECI FICA TI ON S ................................3 C OM P ONENT DE SC RI PTI ON ............................4 W HAT I S A SME -CE RTIF IC ATI ON? ..........................6 P R EIN STA LL AT I ON C ON SI DE RA TION S ........................ - Page 8 This page is intentionally left blank. Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
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Page 9: Specifications
Specifications Model Number A40EK-D 35EK-D 45EK-D Dimensions (H x W x D) 54.5″ x 24″ x 43″ 54.5″ x 24″ x 38″ 54.5″ x 24″ x 43″ Shipping Weight (Approx.) 1,155 lbs. 1,055 lbs. 1,155 lbs. Heating Capacity* - BTU’s (Approx.) -
Page 10: Component Description
Component Description Figure 1: Components (Cutaway View) 1. 8″ Chimney Outlet. Top Vent. Venting must 2. Sliding Smoke Baffle. When open, the be provided using a lined masonry chimney sliding smoke baffle allows smoke and flue or a listed UL103 type HT chimney. The gases to flow into the chimney connector chimney exhausts smoke and flue gases that without restriction. - Page 11 The domestic hot water coil is not available ENERGY KING A40EK-D Boilers and on ENERGY KING A40EK-D Boilers. 35EK-D Boilers use 12 firebricks (6 on each side). The ENERGY KING 45EK-D Boiler uses 14 firebricks (7 on each side). Rev 08/24/10 ENERGY KING™...
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Page 12: What Is Asme-Certification
What is ASME-Certification? ENERGY KING Wood/Coal Boiler model A40EK-D is built and tested to the exacting standards of the American Society of Mechanical Engineers (ASME) Code Section 4, Construction of Heating Boilers, under the National Board ‘H’ stamp, and is independently inspected by a third party inspection agency. -
Page 13: Preinstallation Considerations
8″ UL103 Type HT all-fuel RJM Manufacturing, Inc. factory-built chimney. Do not connect 7. How close is the electrical source? The this unit to any chimney flue serving any other appliance. -
Page 14: Fuel Requirements
Fuel Requirements BURN AIR-DRIED WOOD, OR ANTHRACITE OR BITUMINOUS COAL ONLY Risk of Fire: Do not store fuel or other combustible material within the marked installation clearances. It is important to use fuel that is clean, dry and consistent. Solid-fuel boilers, such as your ENERGY KING Wood/Coal Boiler, naturally produce ash as a byproduct of the burning process. -
Page 15: Coal
Fuel Requirements BURN AIR-DRIED WOOD, OR ANTHRACITE OR BITUMINOUS COAL ONLY Risk of Fire: Do not store fuel or other combustible material within the marked installation clearances. 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. -
Page 16: Installation
A smoke detector in “working” condition must be a part of every ENERGY KING solid-fuel heating appliance installation—this is the most inexpensive insurance you can buy! 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. -
Page 17: As Primary Boiler
Installation • As Primary Boiler Before installing your ENERGY KING Wood/Coal Boiler, consult your heating Locate the ENERGY KING Wood/Coal contractor and local, state and national Boiler as close to the new or existing building codes and regulations to determine chimney as possible. -
Page 18: Assembling Your Energy King Wood/Coal Boiler
The purpose of proper location is to ENERGY KING A40EK-D and 35EK-D introduce the precise amount of combustion Boilers use 12 firebricks (6 on each side). air into the burn chamber to promote the ENERGY KING 45EK-D Boilers use 14 most efficient combustion for either fuel. - Page 19 Installation Figure 3: Control Box for Forced Air Draft Figure 4: Forced Air Draft Blower 6. Draft System. a. Insert the conduit leading from your draft system into the control box and tighten screw to secure. b. Mount the pre-wired forced air draft blower to the draft opening located next to the ash removal door on the lower left front of the Boiler and secure using the bolts found on the draft opening.
- Page 20 Unscrew & remove the 4″ plug located at Black the upper left on the back of the ENERGY KING Wood/Coal Boiler model 35EK-D or 45EK-D. 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
Installation Combustion Air Requirements Failure to provide adequate combustion air can lead to increased carbon monoxide production and increased emissions of combustion gases into the building, which may cause death or serious injury. The ENERGY KING Wood/Coal Boiler must have a minimum supply of 70 cubic feet of air per minute. -
Page 22: Venting System
10 feet of the chimney, measured horizontally. Please refer to Figure For best performance, RJM Manufacturing, Inc. 8: Venting Requirements. For best recommends using insulated chimney rather performance, RJM Manufacturing, Inc. - Page 23 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.
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Page 24: Masonry Chimney
Installation Masonry Chimney When connecting to an existing masonry chimney, an approved liner must be used in the 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″... -
Page 25: Barometric Draft Control
Installation Barometric Draft Control Risk of Fire: Do not operate with the flue draft exceeding .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. An auto-fill valve may be used for this purpose. If you include an auto-fill valve in your ENERGY KING 35EK-D/45EK-D Wood/Coal installation, be sure to choose one that is preset Boilers are equipped with: for 12 to 15 PSI. - Page 27 RJM Manufacturing, Inc. recommends installing a normally open zone valve and a strap-on (non-immersion, surface mounted) aquastat (not included) as part of every dump zone valve installation.
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Page 28: Operation
6 to 8 hours per load When plumbing into your existing heating of wood or coal. If the ENERGY KING heating system, RJM Manufacturing, Inc. recommends appliance is being fired hot constantly with full installing a series of three gate valves. The... -
Page 29: First Fire
Operation First Fire Before lighting your first fire, inspect your Next, make sure that the burn chamber is clear ENERGY KING Wood/Coal Boiler to ensure of all objects. that it has been properly installed and that all Do not fully load your ENERGY KING safety requirements have been met. -
Page 30: Overfire
Operation Overfire Do not overfire. Using too much wood or coal, As a safety feature, if your Boiler should burning trash in the Boiler, or operating with a overheat, it will trigger the pressure relief valve flue draft that exceeds .06 inches water and release water to relieve pressure. -
Page 31: Burning Wood
Operation BURN AIR-DRIED WOOD, OR ANTHRACITE OR BITUMINOUS COAL ONLY Burning Wood 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. 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. -
Page 32: Burning Coal
Operation BURN AIR-DRIED WOOD, OR ANTHRACITE OR BITUMINOUS COAL ONLY 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. A full load is not always the best solution for your needs. -
Page 33: Starting A Coal Fire
Operation Starting a Coal Fire Refueling / Recharging 1. Pull the sliding smoke baffle (located above To refuel/recharge the anthracite coal fire in the fuel loading door) out to open. your ENERGY KING Wood/Coal Boiler: 2. Place a small amount of crumpled paper in 1. - Page 34 Operation Bituminous Recharging Banking Because bituminous coal has higher sulfur Banking allows you to recharge your coal fire in content, bituminous recharging is slightly such a manner as to retain a hot coal bed different from anthracite recharging. throughout the night. To refuel/recharge the bituminous coal fire in Approximately one hour before retiring for the your ENERGY KING Wood/Coal Boiler:...
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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. To replace the gaskets you will need 3/4-inch, high temperature rope gasket, available from your ENERGY KING dealer or hardware store. - Page 37 Maintenance Monthly Annually The water level on your ENERGY KING At least once each year: • Verify the Pressure Relief Valve’s proper Wood/Coal Boiler should be monitored on a regular basis and refilled when necessary. functioning by manually opening the valve and releasing water into the floor drain.
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Page 38: Troubleshooting Guide
Troubleshooting Guide Risk of electric shock. Disconnect power at the service panel or breaker box before servicing the 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 check for these common problems: Fuel •... -
Page 39: Troubleshooting Guide
Troubleshooting Guide Detailed Troubleshooting 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. Problem(s) Cause(s) / Solution(s) •... - Page 40 Troubleshooting Guide Problem(s) Cause(s) / Solution(s) • Your ENERGY KING heating appliance may have been installed The ENERGY KING incorrectly. Please contact your ENERGY KING dealer or heating heating appliance is contractor. overheating or is burning without regard to the •...
- Page 41 Troubleshooting Guide Problem(s) Cause(s) / Solution(s) The ENERGY KING • Verify that the venting and draft control systems are clean and heating appliance will not free from obstruction. Verify that all heat delivery systems are heat the whole house or operating correctly.
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Page 43: Appendix A: Wiring Diagram
Appendix A: Wiring Diagram Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. - Page 44 This page is intentionally left blank. Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
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Page 45: Appendix B: Example Plumbing Diagram
Appendix B: Example Plumbing Diagram When plumbing into your existing heating system, RJM Manufacturing, Inc. recommends installing a series of three gate valves. The three gate valves are to be used in the event you do not use your ENERGY KING Wood/Coal Boiler for an extended period (one or more weeks). - Page 46 This page is intentionally left blank. Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
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Page 47: Appendix C: Parts List
4-ELE-PRESSRELIEF Pressure Relief Valve 4-ELE-PRESSTEMPGA Pressure Temperature Gauge 4-HOT-COIL 4” Hot Water Coil, Copper (optional) (models 35EK-D/45EK-D only) • 4-CAS-PLUG-COIL 4″ Square-Head Plug for Domestic Hot Water Coil receptacle (models 35EK-D/45EK-D only) Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual... - Page 48 4″ Square-Head Plug for Domestic Hot Water Coil receptacle (models 35EK-D/45EK-D only) 4-CAS-PLUG-TEMPRLF Plug for Temperature Relief receptacle 4-CAS-SHGR35SET Optional Shaker Grates Assembly (35EK-D & A40EK-D) • 4-CAS-LINKAGEBAR Linkage Bar for Optional Shaker Grates • 4-CAS-LINKAGEYOKE Linkage Yoke for Optional Shaker Grates •...
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Page 49: Boiler Components
A40EK-D Cabinet Panel (Shroud), Right Side • 4-CAB-A40-TOP A40EK-D Cabinet Panel (Shroud), Top Side 4-FIR-1-/4 Firebrick, 9″ x 4-1/2″ x 1-1/4″ • 35EK-D requires 12 (6 per side) • 45EK-D requires 14 (7 per side) • A40EK-D requires 12 (6 per side) 4-GAS-DOOR 3/4″... - Page 50 This page is intentionally left blank. Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
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Page 51: Appendix D: Purchase & Service Record
Appendix D: Purchase & Service Record NNUAL INSPECTION BY QUALIFIED PROFESSIONAL IS RECOMMENDED Purchase & Installation Record ODEL ERIAL UMBER URCHASE NSTALLATION EALER NSTALLER DDRESS DDRESS TATE TATE ONTACT ONTACT HONE UMBER HONE UMBER OMMENTS *Model and serial number are located on the label on the left side of the unit. Service &... -
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 &... - Page 53 Copies of invoices / receipts are required for all credits claimed on this form. 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 installation & operation manual.
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Page 55: Limited Warranty
ENERGY KING W OILER IMITED 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 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. directly. Provide your name, address, phone number, serial number and model number of the appliance, date of purchase, name and address of installer and a description of the problem.
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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 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. -
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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