ENERGY KING 35EKB, 45EKB, A40EKB Installation, Operation & Maintenance Manual

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

[phone] ♦ Fax [phone]

www.EnergyKing.com

ENERGY KING Wood/Coal Boilers

Models 35EKB/45EKB & ASME-Certified Model A40EKB

Installation and Operating Instructions

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

Your ENERGY KING Wood/Coal Boiler 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 Boiler.

Before installing your ENERGY KING Wood/Coal Boiler,
please read and be sure you understand this entire owner’s
manual and safety 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. To ensure the ENERGY KING Wood/Coal Boiler will operate safely

and efficiently, the installation must be performed by a qualified installer with specific
knowledge of hydronic heating systems. It is the owner’s responsibility to make certain
that both the appliance and installation are acceptable to their insurance company, as well
as ensuring compliance with all local, state and national codes and regulations.

With proper installation and maintenance, your ENERGY KING Wood/Coal Boiler will give
you years of trouble free service.

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.

ENERGY KING is a trademark of RJM Manufacturing, Inc.

Save these instructions.

RJM Manufacturing, Inc

1875 Olson Drive

Chippewa Falls, WI 54729

[phone] | Fax [phone]

www.energyking.com

Email: [e-mail]

Safety Instructions

▲ Read this entire manual before installing,

operating or maintaining this product.
Proper installation of this heating
appliance is crucial for safe and efficient
operation. Save these instructions for later
use.

▲ This heating appliance must be

installed in accordance with local,
state, and national codes and
regulations. Contact your local building

or fire officials about installation
restrictions and inspection requirements in
your area.

▲ Do not connect this heating appliance

to a chimney flue serving any other
appliance.

▲ 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.

Failure to follow these safety instructions may result
in property damage, bodily injury or even death.

▲ The fuel loading and ash removal doors

must be closed tightly during operation. All
seals must be maintained in good
condition.

▲ The ENERGY KING Wood/Coal Boiler is

designed to burn air-dried wood, or
anthracite or bituminous coal only.

Burning of any other type of fuel voids
your ENERGY KING warranty.

▲ 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 or fly ash. Burning treated wood,

colored paper, garbage, cardboard,
solvents or trash can be dangerous and
will void your ENERGY KING warranty.

▲ Do not place clothing or other flammable

materials on this heating appliance or
within marked clearances to combustibles.

▲ Do not use, store, or dispose of flammable

liquids near the heating appliance.

▲ Install in an area with adequate air for

combustion and ventilation. The use of
outside air may be required for safe
operation of this heating appliance.
Contact your local building or fire officials
about combustion air requirements in your
area.

▲ All minimum clearances to combustible

materials must be followed.

▲ This Boiler must be installed on a

non-combustible floor or 3/8-inch thick
fireproof millboard or equivalent. See

Installation for further instructions.

▲ Disconnect all power to the ENERGY

KING heating appliance at the breaker
box or service panel before performing
routine maintenance and service. Allow
the heating appliance to cool before
servicing.

▲ Never fire a boiler that is low on water.

Never add water to a hot boiler.

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. i

▲ DANGER – Risk of Fire or Explosion:

Do not burn garbage, gasoline, naphtha,
drain or engine oil, or other flammable
liquids or inappropriate materials in this
heating appliance.

▲ Do not use chemicals or fluids, such as

gasoline, gasoline-type lantern fuel,
kerosene, charcoal lighter fluid, or similar
liquids to start or freshen up a fire in this
heating appliance.

▲ Establish a routine for the storage of fuel,

care of the heating appliance and firing
techniques.

▲ CAUTION – Hot Surfaces: Keep children

away! Do not touch heating appliance
during operation.

▲ Use caution when opening fuel loading

door. Opening fuel loading door rapidly
can cause smoke or flame to flash out the

door. See Operation for further

instructions.

Safety Instructions

▲ Dispose of ashes with care. Ashes should

be placed in a metal container with a tight
fitting metal lid. The closed container of
ashes should be placed on a
noncombustible floor or on the ground,
well away from all combustible materials,
pending final disposal.

All coal contains small amounts of
dangerous elements. Therefore it is
essential that all coal ash be disposed of
in municipally designated areas.

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.

Failure to follow these safety instructions may result
in property damage, bodily injury or even death.

▲ A working smoke detector must be

installed in the same room as this heating
appliance. For additional safety, RJM
Manufacturing, Inc. 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.

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. ii

Table of Contents

SAFETY INSTRUCTIONS................................................................................................................................................i

TABLE OF CONTENTS ...................................................................................................................................................1

SPECIFICATIONS............................................................................................................................................................3

COMPONENT DESCRIPTION.......................................................................................................................................4

WHAT IS ASME-CERTIFICATION?.............................................................................................................................6

PREINSTALLATION CONSIDERATIONS ..................................................................................................................7

FUEL REQUIREMENTS ..................................................................................................................................................8

WOOD............................................................................................................................................................................ 8

COAL..............................................................................................................................................................................9

INSTALLATION ..............................................................................................................................................................10

GENERAL REQUIREMENTS ........................................................................................................................................... 10

Zones ........................................................................................................................................................................10

In-floor Heating.......................................................................................................................................................10

Placement.................................................................................................................................................................10

•Floor Protection................................................................................................................................................................... 10

•As Primary Boiler................................................................................................................................................................11

•As Add-On Boiler................................................................................................................................................................ 11

Clearances to Combustibles.................................................................................................................................................11

ASSEMBLING YOUR ENERGY KING WOOD/COAL BOILER..................................................................................... 12

COMBUSTION AIR REQUIREMENTS..............................................................................................................................15

VENTING SYSTEM ......................................................................................................................................................... 16

Masonry Chimney....................................................................................................................................................18

Chimney Connector .................................................................................................................................................18

Barometric Draft Control ........................................................................................................................................19

PLUMBING.....................................................................................................................................................................20

OPERATION ....................................................................................................................................................................22

GENERAL INSTRUCTIONS .............................................................................................................................................22

GATE VALVES ...............................................................................................................................................................22

FIRST FIRE .................................................................................................................................................................... 23

TYPICAL OPERATION CYCLE .......................................................................................................................................23

OVERFIRE...................................................................................................................................................................... 24

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..............................................................................................................................................30

TROUBLESHOOTING GUIDE......................................................................................................................................32

APPENDIX A: WIRING DIAGRAM ...........................................................................................................................37

APPENDIX B: EXAMPLE PLUMBING DIAGRAM.................................................................................................39

APPENDIX C: PARTS LIST ........................................................................................................................................41

APPENDIX D: PURCHASE & SERVICE RECORD................................................................................................45

APPENDIX E: WARRANTY CLAIM PROCEDURES .............................................................................................46

LIMITED WARRANTY.................................................................................................................................................49

SUPPLEMENT A: AQUASTAT-IMMERSION CONTROL......................................................................................51

SUPPLEMENT B: 24-V WALL THERMOSTAT.......................................................................................................64

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Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 2

Specifications

Model Number A40EKB 35EKB 45EKB

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.) 1,100 lbs. 1,000 lbs. 1,100 lbs.

Heating Capacity* - BTU’s (Approx.) 140,000 BTU 140,000 BTU 160,000 BTU

Heating Area* (Approx.) 1,500–2,500 sq. ft. 1,500–2,500 sq. ft. up to 4,000 sq. ft.

Water Capacity (Approx.) 40 gallons 35 gallons 45 gallons

Water Jacket (Sides, Top, Back)

Burn Chamber Dimensions (H x W x D) 30″ x 17″ x 30″ 30″ x 17″ x 30″ 30″ x 17″ x 35″

Burn Chamber Volume 8.5 cu. ft. 8.5 cu. ft. 10 cu. ft.

Log Length 26″ 26″ 32″

Sliding Smoke Baffle Standard Standard Standard

Cast Iron Fuel Loading Door Size
(H x W)

Cast Iron Ash Removal Door Size
(H x W)

Removable Ash Pan Standard Standard Standard

Flue Size 8″ 8″ 8″

Flue Collar Height 55.5″ 55.5″ 55.5″

Leg Height 4″ 4″ 4″

Insulated Cabinet Standard Standard Standard

Pre-wired Electrical Components Standard Standard Standard

1/4″ SA516-70

Steel Plate

15.5″ x 13.5″ 15.5″ x 13.5″ 15.5″ x 13.5″

7.25″ x 11.5″ 7.25″ x 11.5″ 7.25″ x 11.5″

1/4″ A36 Steel

Plate

1/4″ A36 Steel

Plate

Draft Controls Forced (60CFM) Forced (60CFM) Forced (60CFM)

Wall Thermostat Standard Standard Standard

Electrical Requirements

Cast Iron Stationary (Wood) Grates Standard Standard Standard

Cast Iron Shaker Grates Optional Optional Optional

Cast Iron Hearth Plates (Front & Rear) Standard Standard Standard

Domestic Hot Water Coil, 4″

Complies with Standards

*The heating capacity specifications are provided as guidelines only and in no way guarantee the output or
capacity of the units. 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. 3

115 Volts, 60HZ,

1 Phase, less than

12 Amp Circuit

N/A

ASME Code,

Section 4

115 Volts, 60HZ,

1 Phase, less than

12 Amp Circuit

Optional Optional

N/A N/A

115 Volts, 60HZ,

1 Phase, less than

12 Amp Circuit

Component Description

1. 8″ Chimney Outlet. Top Vent. Venting must
be provided using a lined masonry chimney
or a listed UL103 type HT chimney. The
chimney exhausts smoke and flue gases that
are a natural result of combustion and
provides “draft” to the Boiler. Draft is the
force that moves air from the burn chamber

up through the chimney. See Venting for

further instructions.

Figure 1: Components (Cutaway View)

2. 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 boiler to extract
the maximum amount of heat from the fire.

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 4

Component Description

3. 2″ Hot Water Outlet. Your ENERGY
KING Wood/Coal Boiler is equipped with
one hot water outlet, located at the top of
the appliance, which supplies heated
water to your heating system.

Cold Water Inlet (Return). (Not pictured)
Cold water inlets return cooled water back to
your Boiler. The ENERGY KING Model
A40EKB Wood/Coal Boiler is equipped with
one 1-1/2″ cold water inlet, located on the rear
of the appliance. ENERGY KING Models
35EKB/45EKB Wood/Coal Boiler are
equipped with two 1-1/4″ cold water inlets,
located on the rear of the appliance.

4. Cast Iron Doors. Heavy cast iron fuel
loading and ash removal doors are
secured to the ENERGY KING using door
pins (4 included). The door gaskets
provide an airtight seal and should be
inspected regularly to ensure that they are
in good condition at all times. The gasket
must be replaced if it becomes damaged
or worn. Do not operate the ENERGY
KING heating appliance with the fuel
loading or ash removal doors open.

5. Cast Iron Hearth Plates. Cast with the
words “Wood” and “Coal” on opposite
sides, these plates help to ensure the
precise amount of combustion air required
to promote the most efficient combustion
for either fuel. ENERGY KING Wood/Coal
Boilers use two cast iron hearth plates—
one at the front of the burn chamber, and
one at the rear (2 included).

Cast Iron Stationary (Wood) Grates. (Not
pictured) This is where you build your wood
fire. If you selected the Shaker Grate option,
the Wood Grates will have been replaced with
Shaker Grates at the factory.

6. Cast Iron Shaker Grates (Optional).
This is where you build your wood or coal
fire. The handle to control the Shaker
Grates is located at the front of the
ENERGY KING, on the left side of the ash
removal door.

7. Firebrick. (9″ x 4-1/2″ x 1-1/4″) 2000-
degree, heat retentive firebricks protect
the sides of the Boiler’s burn chamber.
ENERGY KING A40EKB Boilers and
35EKB Boilers use 12 firebricks (6 on
each side). The ENERGY KING 45EKB
Boiler uses 14 firebricks (7 on each side).

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 5

Ash Removal Pan. (Not Pictured) Designed
for easy cleanup of fine ash accumulation. Do
not operate the ENERGY KING heating
appliance with the ash removal door open;
keep it closed except to remove ashes. The
ash removal door gasket provides an airtight
seal and should be inspected to ensure that it
is in good condition at all times. The gasket
must be replaced if it becomes damaged or
worn.

8. Control Box. Controls the Boiler’s
electrical system. The control box is pre­wired for forced air draft.

9. Combustion Blower. This blower will
supply air for combustion by forcing air
into the burn chamber when your wall
thermostat calls for heat.

24-V Wall Thermostat. (Not Pictured) Tells
your ENERGY KING heating appliance when
your home has cooled below your preferred
temperature. Your draft system is controlled
primarily by your wall thermostat.

10. Aquastat-Immersion Control. Provides
boiler water regulation by controlling the
high and low water-temperature limits.

See Appendix D for further information.

11. Pressure-Temperature Gauge. Shows
the water pressure and water temperature
within your ENERGY KING Wood/Coal
Boiler.

12. Pressure Relief Valve. A safety feature,
the pressure relief valve will release
excess pressure within your ENERGY

KING Wood/Coal Boiler. See Plumbing for

further instructions.

13. Insulated Cabinet. The colored steel
cabinet panels (sides and top) restrain the
foil-backed insulation, allowing maximum
heat from the Boiler to be circulated
through the home’s hydronic heating
system.

14. Legs. Raise the ENERGY KING heating
appliance off the floor to prevent the
accumulation of moisture between the
floor and the bottom of the appliance.

Domestic Hot Water Coil, 4″ (Optional):

(Not Pictured) For heating domestic hot water.
The domestic hot water coil is not available
on ENERGY KING A40EKB Boilers.

What is ASME-Certification?

ENERGY KING Wood/Coal Boiler model A40EKB 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 Hartford Steam
Boiler Inspection & Insurance Company.

ENERGY KING Wood/Coal Boiler model A40EKB is constructed of certified, high-grade 1/4”

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.

The following information was taken from www.ASME.org and is reproduced here for informational
purposes only. Please visit www.ASME.org for more information about the ASME and codes and
standards.

Founded in 1880 as the American Society of Mechanical Engineers, ASME is a not-for-profit
professional organization that promotes the art, science and practice of mechanical and
multidisciplinary engineering and allied sciences throughout the world. The core values of
ASME are rooted in its mission to better enable mechanical engineering practitioners to
contribute to the well-being of humankind.

What is a standard?

A standard can be defined as a set of technical definitions and guidelines, “how to”
instructions for designers, manufacturers and users. Standards promote safety, reliability,
productivity and efficiency in almost every industry that relies on engineering components or
equipment. Standards can run from a few paragraphs to hundreds of pages, and are written
by experts with knowledge and expertise in a particular field who sit on many committees.

Are standards mandatory?

Standards are considered voluntary because they serve as guidelines, but do not of
themselves have the force of law. ASME cannot force any manufacturer, inspector, or
installer to follow ASME standards. Their use is voluntary.

Standards become mandatory when they have been incorporated into a business contract
or incorporated into regulations.

What is a code?

A code is a standard that has been adopted by one or more governmental bodies and has
the force of law.

Why are standards effective?

Standards are a vehicle of communication for producers and users. They serve as a
common language, defining quality and establishing safety criteria. Costs are lower if
procedures are standardized; training is also simplified.

Interchangeability is another reason. It is not uncommon for a consumer to buy a nut in
California for a bolt purchased in New Jersey.

ASME.org

. 2009. American Society of Mechanical Engineers.

19 May 2009 <http://www.asme.org>.

About Codes & Standards

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 6

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.

Always check with local authorities and obtain the necessary permits prior to installing this heating
appliance.

Before the position of the Boiler can be decided, a few questions should be considered.

1. Will this heating appliance be used as a
primary (central) boiler, or will it be installed
as an add-on to your existing hydronic
heating system?

2. Will your preferred heating system require
the use of storage tanks or mixing valves?
Some systems, such as in-floor heating,
cannot withstand the high water
temperatures produced by the ENERGY
KING Wood/Coal Boiler and may require
the heated water to be mixed with cool
water before it can be delivered into the
home.

3. Can the ENERGY KING heating appliance
be vented properly?

a. Is your chimney appropriate for this

application? This heating appliance
requires installation into a lined masonry
chimney or an 8″ UL103 Type HT all-fuel

factory-built chimney. Do not connect

this unit to any chimney flue serving
any other appliance. See Venting for

further instructions.

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 ENERGY KING
heating appliance.

4. This heating appliance may require an
outside air source for combustion air. Will
this be easily accessed in your desired
location?

Finally, do you have a reliable, consistent source of fuel for your ENERGY KING Wood/Coal Boiler?

Please see Fuel Requirements for further information on fuel supply.

5. Are there any local, state or national codes
or regulations governing the use and
placement of this heating appliance?

6. Can the heating appliance be installed
safely?

a. The heating appliance should not be

installed in a location where it could
come into contact with curtains, drapes,
walls, carpeting, or other combustible
surfaces, and must not be installed in a
sleeping room.

b. Will your desired location require floor

protection?

c. The clearances specified in this manual

are minimum clearances. Any reduction
must be approved by the regulatory
authority and is not recommended by
RJM Manufacturing, Inc.

7. How close is the electrical source? The
power source must conform to the

requirements shown in Specifications.

8. Will the heating appliance be easily
accessible for cleaning, refueling,
maintenance, and repair?

9. Are there any structural reasons why the
heating appliance cannot be placed where
you want?

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 7

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. 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. To
assist you in determining which fuel to use, here are some guidelines to consider:

Burning wood for heat is as old as civilization itself. More than any other major fuel, wood provides
us with energy independence – an easily available, locally produced and renewable source of heat
on which we can rely.

• The ENERGY KING Wood/Coal Boiler has
been tested for operation with air-dried
wood.

• Wood should be seasoned (dried) for at
least 12 months before burning. Properly
seasoned wood should have about 20% ­25% moisture content. To properly season
wood, split the logs as soon as possible
and loosely stack them in a dry spot for at
least 12 months.

You should not burn wet or green wood in
your Boiler. Burning wet or green wood in
your Boiler will not only reduce the
efficiency of your appliance, but also
increases 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 ENERGY KING Wood/Coal
Boiler, 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 and softwoods, using the hotter,
faster burning softwoods to start your fire,
and the denser hardwoods to maintain a
longer-lasting fire.

WOOD

• With this in mind, choosing the kind of
firewood that is best for you depends on
what is available in your area. If hardwoods
are unavailable in your area, you can
control the burn rate by using larger pieces
of wood.

• 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 or fly ash. Burning treated wood,

colored paper, garbage, cardboard,
solvents or trash can be dangerous and will
void your ENERGY KING warranty.

• DANGER – Risk of Fire or Explosion: Do
not burn garbage, gasoline, naphtha, drain
or engine oil, or other flammable liquids or
inappropriate materials in this heating
appliance.

Storage

• Store all fuel in a dry location away from
the elements. Never burn wet or green
wood.

• Do not store fuel within the heating
appliance installation clearances or within
the space required for refueling, ash
removal and other routine maintenance
operations.

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 8

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.

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
been tested for operation with anthracite
(hard) or bituminous (soft) coal.

• Anthracite: Also known as Hard Coal,
anthracite is a hard, lustrous coal with a
high carbon content that burns with a clean
blue, nearly smokeless, flame.

• Bituminous: Also known as Soft Coal,
bituminous coal is a soft type of coal that
has a high sulfur content and burns with a
yellow, smoky flame.

• Bituminous coal tends to contain more
impurities and sulfur than anthracite coal,
which may decrease the expected lifespan
of your ENERGY KING solid-fuel heating
appliance and its components. If you
choose to burn bituminous coal, be sure to
select only high-grade bituminous coal.

• Coal Size: Your ENERGY KING
Wood/Coal Boiler is designed to use coal
that is Nut size or larger.

COAL

• 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 or fly ash. Burning treated wood,

colored paper, garbage, cardboard,
solvents or trash can be dangerous and
will void your ENERGY KING warranty.

• DANGER – Risk of Fire or Explosion:
Do not burn garbage, gasoline, naphtha,
drain or engine oil, or other flammable
liquids or inappropriate materials in this
heating appliance.

Storage

• Store all fuel in a dry location away from

the elements. Never burn wet coal.

• Do not store fuel within the heating

appliance installation clearances or
within the space required for refueling,
ash removal and other routine
maintenance operations.

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 9

Installation

Risk of Fire:

• Do not operate with flue draft exceeding .06 in. (14.95 Pa)

water column.

• Do not operate with fuel loading or ash removal doors open.

• Do not store fuel or other combustible material within marked

installation clearances.

• Inspect and clean flues and chimney regularly.

The installation of any solid fuel heating appliance is not a do-it-yourself project. The

ENERGY KING Wood/Coal Boiler should be installed by a qualified installer with specific
knowledge of hydronic heating systems. Check with your fire department and building inspector for
local, state, and federal codes and regulations regarding installation.

Solid-fuel heating appliance related fires are caused almost exclusively by installation, operation, or
maintenance errors. A smoke detector in “working” condition must
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.

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.

Zones
A “heat dump” zone is required for all
installations. The purpose of this zone is to
circulate heated water away from the boiler
when no other zones are calling for heat. In
this way it will prevent your ENERGY KING
Wood/Coal Boiler from overheating. However,
as a safety feature, if your Boiler should
overheat or build up excess pressure, it will
trigger the pressure relief valve which will
release water, thus relieving pressure. See

Plumbing for further instructions.

In-floor Heating
Many newer homes feature in-floor heating.
The ENERGY KING Wood/Coal Boiler may not
be suitable for such applications as it produces
water temperatures in excess of 185-degrees,
which is much greater than can be withstood by
most standard in-floor heating installations.

To use the ENERGY KING Wood/Coal Boiler
with in-floor heating, a mixing valve may be
required to lower the water temperature before
it is delivered to your in-floor heating system.

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 10

Do not connect the ENERGY KING heating appliance
to any chimney flue serving any other appliance.

General Requirements

be a part of every ENERGY

Placement

• Floor Protection
Floor protection must be provided because
of possible spillage of ashes and burning
fuel. The ENERGY KING Wood/Coal Boiler
must be installed on a non-combustible floor
or 3/8-inch thick fireproof millboard or
equivalent.

The non-combustible material must be
placed underneath the heating appliance,
and must extend at least 18 inches on all
sides of the heating appliance.

Additionally, the non-combustible material
must extend at least 18 inches on either side
of the chimney connector.

Consult your local ENERGY KING dealer for
possible sources of non-combustible floor
protection material acceptable for use with
your ENERGY KING Wood/Coal Boiler.

Installation

• As Primary Boiler
Locate the ENERGY KING Wood/Coal
Boiler as close to the new or existing
chimney as possible. The ENERGY KING
heating appliance should be placed so that
you can easily complete operation and
maintenance procedures.

Locate the 24-V Wall Thermostat provided
with your ENERGY KING heating appliance
in the living area of the home. Your draft
system is controlled primarily by the wall
thermostat, so proper placement and
installation of the wall thermostat is crucial.

Strictly adhere to all requirements
pertaining to clearances to combustibles,
combustion air, venting system, draft
control, and thermostat installation.

• As Add-On Boiler
The ENERGY KING Wood/Coal Boiler is
designed to be used in conjunction with a
listed gas- or oil-fired boiler, but not all
boilers will accept an add-on application.
Some small boilers may not be used in an
add-on installation.

Clearances to Combustibles

• Sides: The ENERGY KING Wood/Coal

Boiler must have
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. This is for safe, easy
loading and cleaning of your ENERGY
KING heating appliance.

• Rear: The minimum clearance from the

rear of the ENERGY KING Wood/Coal
Boiler to combustibles is 20 inches.

• Top: The minimum clearance from the

top of the ENERGY KING Wood/Coal
Boiler to combustibles is 18 inches.

• Stovepipe: Stovepipe must

minimum of 18 inches to combustibles.

• Additionally, when using your ENERGY

KING Wood/Coal Boiler as an add-on, a
12-inch minimum clearance is required
between the ENERGY KING Wood/Coal
Boiler and your existing boiler.

clearances of 18 inches

have a

Before installing your ENERGY KING
Wood/Coal Boiler, consult your heating
contractor and local, state and national
building codes and regulations to determine
if your existing hydronic heating system is
compatible with the ENERGY KING
Wood/Coal Boiler.

When using your ENERGY KING
Wood/Coal Boiler in an add-on application,
locate the ENERGY KING Wood/Coal
Boiler as close to the new or existing
chimney as possible, and as close to your
existing boiler as practical. However a
minimum clearance of 12-inches is required
between your existing boiler and your
ENERGY KING Wood/Coal Boiler.

Locate the 24-V Wall Thermostat provided
with your ENERGY KING heating appliance
in the living area of the home, near your
existing thermostat. Your draft system is
controlled primarily by the wall thermostat,
so proper placement and installation of the
wall thermostat is crucial.

Figure 2: Clearances to Combustibles

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 11

Installation

Assembling Your ENERGY KING Wood/Coal Boiler

The entire installation should be planned before putting the Boiler in place to ensure compliance
with all the requirements outlined in the owner’s manual.

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.

Once your Boiler is placed in your desired location:

1. Remove the protective plastic coating from
the outer cabinet of the heating appliance
before assembling.

2. Cast Iron Hearth Plates. Position front and

rear cast iron hearth plates in burn chamber.
Your primary type of fuel (wood or coal) will
determine how to position the hearth plates.
The purpose of proper location is to
introduce the precise amount of combustion
air into the burn chamber to promote the
most efficient combustion for either fuel.

The words “Wood” and “Coal” are cast into
the hearth plates on opposite sides.

a. If you are going to burn wood, position

the hearth plates with the word “Wood”
facing out, not into the burn chamber.

b. If you plan to primarily burn coal,

position the hearth plates with the word
“Coal” facing out.

3. Firebrick. The firebrick in your ENERGY

KING heating appliance will have been
installed at the factory; however they may
have shifted during shipment. If adjustments
are needed, position the firebrick by standing
up on end on the left and right sides of the
burn chamber.

ENERGY KING A40EKB and 35EKB Boilers
use 12 firebricks (6 on each side). ENERGY
KING 45EKB Boilers use 14 firebricks (7 on
each side).

4. Cast Iron Doors. Mount the fuel loading

door and ash removal door on the front of
the heating appliance and secure with the
enclosed door pins (4 included).

5. Control Box.

a. Remove the control box cover. See

Figure 3: Control Box for Forced Air Draft.

b. Mount the control box on the lower left

side of the heating appliance using the
screws provided.

Do not connect power to your ENERGY
KING Wood/Coal Boiler until the
installation is complete.

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 12

Installation

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.

7. Pressure-Temperature Gauge. Insert the Pressure­Temperature Gauge into the right-front receptacle
located on top of the Boiler.

8. Pressure Relief Valve. Insert the Pressure Relief
Valve into either the left-middle or right-middle
receptacle located on the top of the boiler. The
Pressure Relief Valve must be plumbed with a
discharge tube that empties into a floor drain. See

Plumbing for further instructions.

Figure 3: Control Box for Forced Air Draft

Figure 4: Forced Air Draft Blower

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 13

Installation

9. Aquastat-Immersion Control.

a. Remove the cover of the prewired

Aquastat-Immersion Control to adjust the
High and Low temperature limits.

i. High Limit. Set the High Limit pointer to

the temperature at which contacts are
to open to prevent the boiler from
overheating. Normal setting for the High
Limit is 185º. Always set the high limit
20º or more above the low limit.

ii. Low Limit. Set the Low Limit pointer to

the lowest water temperature you would
like the boiler to maintain. Normal
setting is 160º. Always set the high limit
20º or more above the low limit.

Figure 5: Aquastat-Immersion Control

Blue

Black

b. Insert the probe well into the left-front

receptacle located on the top of the Boiler
and tighten to secure.

Figure 6: Probe Well

c. Squeeze the entire tube of heat-

conductive grease (included) into the
probe well, and then insert the Aquastat­Immersion Control probe into the probe
well, and secure.

Figure 7: Aquastat-Immersion Control,

10. 4″ Domestic Hot Water Coil (Optional).
a. Unscrew & remove the 4″ plug located at

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.

c. Insert the 4″ domestic hot water coil into

the opening at the upper left on the back of
the ENERGY KING Wood/Coal Boiler and
turn clockwise until tightened.

d. Connect your domestic water supply

according to the coil manufacturer’s
instructions.

11. 24-V Wall Thermostat. Locate the 24-V Wall
Thermostat provided with your ENERGY
KING heating appliance in the living area of
the home and install according to the
thermostat manufacturer’s installation

instructions (Supplement B).

12. Wiring. Do not connect power to your
ENERGY KING Wood/Coal Boiler until the
installation is complete. Once you’ve

completed the installation of your ENERGY
KING Wood/Coal Boiler, you may connect
your 110V power supply in to the left side of

the control box. Please see Appendix A:
Wiring Diagram.

panel or breaker box before servicing

ENERGY KING Wood/Coal Boiler.

Risk of electric shock.

Disconnect power at the service

Mounted

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 14

Installation

Combustion Air Requirements

The ENERGY KING Wood/Coal Boiler must have a minimum supply

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” causes carbon monoxide
(CO) production in quantities that can be dangerous inside a building. Combustion air from outside
may need to be brought in to prevent “air starvation”. Although an outside air source is strongly
recommended for all installations, it may be necessary if:

• The heating appliance does not draw steadily, smells, experiences smoke roll­out, burns poorly, or backdrafts, whether or not there is combustion present.

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.

of 70 cubic feet of air per minute.

• 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 air, such as clothes
dryers.

• A ventilation system is installed in the house.

Consult a qualified boiler installer to analyze whether the air supply in your installation environment
is adequate.

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 15

Installation

Venting System

• Failure to provide correct chimney venting can lead to increased

carbon monoxide production and increased emissions of
combustion gases into the building, which may cause death or
serious injury.

• 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.

• Risk of Fire: Do not operate with the flue draft exceeding .06″

(14.95 Pa) water column.

Consult a qualified boiler installer, your local building inspector and your fire
officials to make sure the chimney and all connections conform to all local, state and
national codes and regulations.

Your venting system is an extremely important
part of any solid-fuel heating appliance
installation and has two key functions:

1. To exhaust smoke and flue gases which
are the natural result of combustion.

2. To provide “draft.” The draft, along with
your combustion blower, provides a
continuous supply of fresh air for proper
combustion.

A chimney connector and chimney make up the
venting system and must be properly installed
and maintained to protect against a fire.
Consult a chimney and venting specialist.

The ENERGY KING Wood/Coal Boiler requires
installation into a lined masonry chimney or an
8-inch listed UL103 type HT all-fuel factory-built
chimney. Minimum 24 gauge black steel
chimney connector is required. An existing
chimney must be cleaned and inspected to be
sure it is clean and free from 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, RJM Manufacturing, Inc.
recommends using insulated chimney rather
than triple wall or air cooled chimney.

Important venting installation clearances and
points for proper operation and safety:

• 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. See Chimney Connector.

• A minimum distance of 18 inches must be
maintained between the chimney connector
and combustible ceiling surfaces.

• A minimum of 18 inches must be maintained
between the chimney connector and the
backwall, and 20 inches between the
connector and sidewalls.

• Secure all connector pipe joints with at least
three sheet metal screws.

• Avoid using more than two elbows in
connecting the heating appliance to the
chimney.

• Any horizontal runs of connector pipe should
have a minimum rise of 1/2-inch per linear
foot. Use extra 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.

• 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. Please refer to Figure
8: Venting Requirements.

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 16

Installation

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.

.

Figure 8: Venting Requirements

Rev 07/13/09 ENERGY KING™ Wood/Coal Boiler Owner’s Manual  U. S. 17