ENERGY KING 360EK, 365EK, 480EK Installation, Operation & Maintenance Manual
ENERGY KING
Models 360EK/365EK and 480EK
®
Wood/Coal Furnaces
Installation, Operation & Maintenance Manual
RJM Manufacturing, Inc.
1875 Olson Drive
Chippewa Falls, WI 54729
(715) 720-1794 ♦ Fax (715) 720-1797
www.EnergyKing.com
ENERGY KING® Wood/Coal Furnaces
Installation and Operating Instructions
Models 360EK/365EK and 480EK
Congratulations on your purchase of an ENERGY KING solid fuel heating appliance!
Your ENERGY KING Wood/Coal Furnace is designed for a lifetime of durable, reliable
performance and easy operation. This manual describes the installation, operation and
maintenance of your ENERGY KING Wood/Coal Furnace.
Before installing your ENERGY KING Wood/Coal Furnace,
please read and be sure you understand the entire owner’s
manual and safety instructions.
Refer to markings on the appliance for additional
instructions.
ENERGY KING Wood/Coal Furnace has been designed to use independently or as an
add-on to an existing central heating system. The installation of any furnace is not a do-it-
yourself project. To ensure the ENERGY KING Wood/Coal Furnace will operate safely
and efficiently, the installation must be performed by a qualified installer with specific
knowledge of central heating systems.
With proper installation and maintenance, your ENERGY KING Wood/Coal Furnace will
give you years of trouble free service.
Thank you for choosing the ENERGY KING Wood/Coal Furnace.
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 registered trademark of RJM Manufacturing, Inc.
Save these instructions.
RJM Manufacturing, Inc
1875 Olson Drive
Chippewa Falls, WI 54729
(715) 720-1794 | Fax (715) 720-1797
www.energyking.com
Email: sales@energyking.com
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.
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.
▲
This Furnace is designed to burn air-dried
wood, or anthracite or bituminous coal
only. Burning of any other type of fuel will
void 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 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.
▲
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 strictly followed.
▲
This heating appliance 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 heating
appliance at the breaker box or service
panel before performing routine
maintenance and service. Allow the
heating appliance to cool before servicing.
▲
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.
▲
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.
Rev 05/05/11 ENERGY KING
®
360EK/365EK/480EK Wood/Coal Furnace Owner’s Manual U. S. i
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.
▲
A working smoke detector must be
installed in the same room as this product.
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.
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.
▲
Always keep a working fire extinguisher
on hand in case of fire.
Rev 05/05/11 ENERGY KING
®
360EK/365EK/480EK Wood/Coal Furnace Owner’s Manual U. S. ii
Table of Contents
SAFETY INSTRUCTIONS ................................................................................................................................................ i
TABLE OF CONTENTS ................................................................................................................................................... 1
SPECIFICATIONS ............................................................................................................................................................ 3
COMPONENT DESCRIPTION ....................................................................................................................................... 4
PREINSTALLATION CONSIDERATIONS .................................................................................................................. 6
FUEL REQUIREMENTS .................................................................................................................................................. 7
WOOD ............................................................................................................................................................................ 7
COAL .............................................................................................................................................................................. 8
INSTALLATION ................................................................................................................................................................ 9
G
ENERAL REQUIREMENTS
Placement ................................................................................................................................................................... 9
Floor Protection ................................................................................................................................................................. 9
As Primary Furnace .......................................................................................................................................................... 9
As Add-On Furnace: ....................................................................................................................................................... 10
A
SSEMBLING YOUR
C
OMBUSTION AIR REQUIREMENTS
V
ENTING SYSTEM
Masonry Chimney .................................................................................................................................................... 20
Chimney Connector ................................................................................................................................................. 20
Barometric Draft Control ........................................................................................................................................ 21
A
IR DUCT INSTALLATION
OPERATION .................................................................................................................................................................... 23
G
ENERAL INSTRUCTIONS
F
IRST FIRE
T
YPICAL OPERATION CYCLE
P
OWER FAILURE INSTRUCTIONS
B
URNING WOOD
Starting a Wood Fire ................................................................................................................................................ 25
Refueling .................................................................................................................................................................. 25
B
URNING COAL
Starting a Coal Fire ................................................................................................................................................. 27
Refueling / Recharging ............................................................................................................................................ 27
MAINTENANCE .............................................................................................................................................................. 29
C
REOSOTE – FORMATION AND NEED FOR REMOVAL
D
ISPOSAL OF ASHES
G
ASKET REPLACEMENT
R
OUTINE MAINTENANCE
TROUBLESHOOTING GUIDE ...................................................................................................................................... 32
D
ETAILED TROUBLESHOOTING
APPENDIX A: WIRING DIAGRAMS ......................................................................................................................... 37
A-1: A
UTOMATIC DRAFT WIRING DIAGRAM
A-2: F
ORCED AIR DRAFT WIRING DIAGRAM
A-3: M
APPENDIX B: FILTER BOX ASSEMBLY SCHEMATIC ........................................................................................ 41
APPENDIX C: PARTS LIST ........................................................................................................................................ 43
APPENDIX D: PURCHASE & SERVICE RECORD ................................................................................................ 47
APPENDIX E: WARRANTY CLAIM PROCEDURES ............................................................................................. 48
LIMITED WARRANTY ................................................................................................................................................. 51
SUPPLEMENT A: 24-V WALL THERMOSTAT ....................................................................................................... 53
SUPPLEMENT B: FAN/LIMIT CONTROL ............................................................................................................... 59
ANUAL DRAFT WIRING DIAGRAM
......................................................................................................................................................... 18
.................................................................................................................................................................... 23
............................................................................................................................................................ 25
............................................................................................................................................................. 26
............................................................................................................................................. 9
ENERGY KING W
............................................................................................................................................. 22
............................................................................................................................................. 23
....................................................................................................................................... 24
.................................................................................................................................. 24
...................................................................................................................................................... 29
............................................................................................................................................... 30
.............................................................................................................................................. 30
.................................................................................................................................... 33
OOD/COAL FURNACE
.............................................................................................................................. 17
................................................................................................. 29
.............................................................................................................. 37
.............................................................................................................. 38
.................................................................................................................... 39
.................................................................................. 11
Rev 03/12/14 ENERGY KING
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360EK/365EK/480EK Wood/Coal Furnace Owner’s Manual U. S. 1
Rev 03/12/14 ENERGY KING
®
360EK/365EK/480EK Wood/Coal Furnace Owner’s Manual U. S. 2
Specifications
Model Number 360EK/365EK 480EK
Dimensions (H x W x D) 48″ x 26″ x 53″ 51.5″ x 26″ x 60″
Leg Height 3.5″ 3.5″
Shipping Weight (Approx.) 650 lbs. 725 lbs.
Heating Capacity - BTU’s (Approx) 125,000 BTU 160,000 BTU
Heating Capacity – Sq Ft (Approx) 1,500 sq. ft. 2,000 sq. ft.
Burn chamber Volume 6.3 cu. ft. 9 cu. ft.
Flue Size (Rear Vent) 6″ 6″
Flue Collar Height (to top of flue) 45″ 48.25″
Log Length 21″ 26″
Cast Iron Fuel Loading Door Size (H x W) 15.5″ x 13.5″ 15.5″ x 13.5″
Cast Iron Ash Removal Door Size (H x W) 7.25″ x 11.5″ 7.25″ x 11.5″
Sliding Smoke Baffle Standard Standard
Insulated Cabinet Standard Standard
Wall Thermostat Standard Standard
Draft Controls Manual or Auto (Choice) Auto or Forced (Choice)
Pre-wired Electrical Components Standard Standard
Electrical Requirements
Cast Iron Hearth Plates
(Front & Rear)
115 Volts, 60HZ,
1 Phase, 15 Amps Circuit
Standard Standard
115 Volts, 60HZ,
1 Phase, 15 Amps Circuit
Removable Ash Pan Standard Standard
Cast Iron Stationary (Wood) Grates Standard Standard
Cast Iron Shaker Grates Optional Optional
Domestic Hot Water Tube Optional Optional
*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 03/12/14 ENERGY KING
®
360EK/365EK/480EK Wood/Coal Furnace Owner’s Manual U. S. 3
Component Description
1. 6″ Chimney Outlet. 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 Furnace. Draft is the force that
moves air from the burn chamber up through
the chimney. See Venting for further
instructions.
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
Figure 1: Components (Cutaway View)
flue gases are diverted around the sliding
smoke baffle, creating a longer path for the
heated air and allowing your furnace to
extract the maximum amount of heat from
the fire.
3. Plenum Opening. Allows you to connect the
Furnace into your home’s warm-air supply
duct. ENERGY KING 360EK/365EK Furnace
has a plenum opening of 18 inches by 18
inches. ENERGY KING 480EK Furnace has
a plenum opening of 20 inches by 20 inches.
Rev 03/12/14 ENERGY KING
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360EK/365EK/480EK Wood/Coal Furnace Owner’s Manual U. S. 4
Component Description
4. Cast Iron Doors. Heavy cast iron fuel
loading and ash removal doors are secured
to the Furnace 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
Furnace 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
Furnaces 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 Furnace, on the left
side of the ash removal door.
7. Firebrick. (9″ x 4-1/2″ x 1-1/4″) 2000-degree,
heat retentive firebrick protects the sides of
the Furnace’s burn chamber. ENERGY KING
360EK/365EK Furnace uses 10 firebricks (5
on each side), while ENERGY KING 480EK
Furnace uses 12 firebricks (6 on each side).
Ash Removal Pan. (Not pictured) Designed for
easy cleanup of fine ash accumulation. Do not
operate the Furnace 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. Circulation Blower. The three-speed
circulation blower, operated by the fan/limit
control, forces air on all sides of the burn
chamber, then into the home's duct system.
The blower can be manually adjusted to run
faster or slower to correspond to the amount
of heat being produced.
Rev 03/12/14 ENERGY KING
9. Filter Box (optional). Provides air filtration
for your cold-air return system. A noncombustible filter is required when using the
optional filter box.
10. Control Box. Controls the Furnace’s
electrical system. The control box is prewired for your preferred draft system.
Combustion Fan. (Not pictured) If you
selected Forced Air Draft, this fan will supply air
for combustion by forcing air into the burn
chamber when your wall thermostat calls for
heat.
11. 24-V Damper Control Motor. If you
selected Automatic Draft, this motor will
supply combustion air to the burn chamber
by automatically opening the draft damper
door when your wall thermostat calls for
heat.
Draft Dial. (Not pictured) If you selected
Manual Draft, this spin dial will allow you to
regulate the amount of combustion air being
pulled into the burn chamber.
24-V Wall Thermostat. (Not pictured) Tells
your Furnace when your home has cooled
below your preferred temperature. Your
automatic or forced air draft system is
controlled primarily by your wall thermostat.
12. Fan/Limit Control. This control
automatically starts and stops the
circulation blower. It also features a limit
switch which will cut power to the damper
control motor or combustion fan if the
temperature exceeds the set limit, while the
circulation blower continues to run to cool
the furnace.
13. Insulated Cabinet. The almond-colored
steel cabinet panels (sides and top) restrain
the foil-backed insulation, allowing
maximum heat from the Furnace to be
circulated through the home’s warm-air
supply duct system.
14. Legs. Raise the Furnace off the floor to
prevent the accumulation of moisture
between the floor and the bottom of the
Furnace.
Domestic Hot Water Tube (Optional).
(Not pictured) For heating domestic water.
®
360EK/365EK/480EK Wood/Coal Furnace Owner’s Manual U. S. 5
Preinstallation Considerations
This Furnace 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. This heating appliance must be installed in accordance with local, state and national
codes and regulations.
Before the position of the Furnace can be decided, a few questions should be considered.
1. Will this Furnace be used as a primary
(central) furnace, or will it be installed as an
add-on to your existing central heating
system?
2. Can the Furnace be vented properly?
a. Is your chimney appropriate for this
application? This Furnace requires
installation into a UL103 Type HT all-fuel
chimney. Do not connect this unit to a
chimney flue serving any other
appliance.
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 Furnace.
3. This Furnace may require an outside air
source for combustion air. Will this be
easily accessed in your desired location?
4. Are there any local, state or national codes
or regulations governing the use and
placement of the Furnace?
Finally, do you have a reliable, consistent source of fuel for your Furnace? Please see Fuel
Requirements for further information on fuel supply.
5. Can the Furnace be installed safely?
a. The Furnace 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.
6. How close is the electrical source? The
power source must conform to the
requirements shown in Specifications.
7. Will the Furnace be easily accessible for
cleaning, refueling, maintenance, and
repair?
8. Are there any structural reasons why the
Furnace cannot be placed where you
want?
Rev 03/12/14 ENERGY KING
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360EK/365EK/480EK Wood/Coal Furnace Owner’s Manual U. S. 6
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 Furnaces, such as your
ENERGY KING Wood/Coal Furnace, naturally produce ash as a byproduct of the burning process.
Even with the ENERGY KING Furnace’s efficient design, your Furnace 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 Furnace. 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.
This Furnace 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% 30% 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 Furnace. Burning wet or green wood
in your Furnace 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 Furnace, 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 and by adjusting your draft
controls.
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 Furnace.
Storage
Store all fuel in a dry location away from
the elements. Never burn wet or green
wood.
Do not store fuel within the Furnace
installation clearances or within the space
required for refueling, ash removal and
other routine maintenance operations.
Rev 03/12/14 ENERGY KING
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360EK/365EK/480EK Wood/Coal Furnace 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.
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.
This Furnace 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
your ENERGY KING solid-fuel heating
appliance and its components. Only burn
high-grade bituminous coal.
Coal Size: Your ENERGY KING
Wood/Coal Furnace 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 Furnace.
Storage
Store all fuel in a dry location away from
the elements. Never burn wet coal.
Do not store fuel within the Furnace
installation clearances or within the space
required for refueling, ash removal and
other routine maintenance operations.
Rev 03/12/14 ENERGY KING
®
360EK/365EK/480EK Wood/Coal Furnace Owner’s Manual U. S. 8
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 Furnace should be installed by a qualified installer with specific
knowledge of central heating systems. Check with your fire department and building inspector for
local, state, and national 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
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.
The ENERGY KING Wood/Coal Furnace is designed to be used in conjunction with a listed gas- or
oil-fired furnace, or as a central Furnace.
Placement
Do not connect the ENERGY KING heating appliance
to any chimney flue serving any other appliance.
General Requirements
be a part of every
Floor Protection
Floor protection must be provided because
of possible spillage of ashes and burning
fuel. The ENERGY KING Wood/Coal
Furnace must be installed on a noncombustible floor or 3/8-inch thick fireproof
millboard or equivalent.
The non-combustible material must be
placed underneath the furnace, and must
extend at least 18 inches on all sides of the
Furnace, and at least 8 inches on either
side of the fuel loading and ash removal
doors.
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
Furnace.
As Primary Furnace
Locate the ENERGY KING Wood/Coal
Furnace as close to the new or existing
chimney as possible and as central to the
heat distribution system as practical.
Additionally, the ENERGY KING
Wood/Coal Furnace should be placed so
that you can easily complete operation and
maintenance procedures.
Strictly adhere to all requirements
pertaining to clearances to combustibles,
combustion air, venting system, draft
control, and thermostat installation.
Rev 03/12/14 ENERGY KING
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360EK/365EK/480EK Wood/Coal Furnace Owner’s Manual U. S. 9
Installation
As Add-On Furnace:
The ENERGY KING Wood/Coal Furnace is
designed to be used in conjunction with a
listed gas- or oil-fired furnace, but not all
furnaces will accept an add-on application.
Some small furnaces, and especially
counter-flow or down-flow furnaces, may not
be used in an add-on installation.
The CFM (cubic feet per minute) capability
between the blower on the existing furnace
and the add-on furnace must be compatible.
If all of these conditions are met, then the
combined static pressure may not exceed
that established by the existing furnace.
Before installing your ENERGY KING
Wood/Coal Furnace, consult your
ENERGY KING dealer or heating contractor
and your local, state and national building
codes and regulations to determine if your
existing central heating system is compatible
with your ENERGY KING Wood/Coal
Furnace.
Clearances to Combustibles:
Sides: The ENERGY KING must have
clearances of 18 inches from the sidewall of
the ENERGY KING wood/coal Furnace to
combustibles.
Front: Leave a minimum clearance of 48
inches in front of your ENERGY KING
wood/coal Furnace. This is for safe, easy
loading and cleaning of your ENERGY KING.
Rear: The minimum clearance from the rear of
the ENERGY KING wood/coal Furnace to
combustibles is 28 inches
Top: The minimum clearance from the top of
the ENERGY KING Wood/Coal Furnace to
combustibles is 18 inches.
Stovepipe: Stovepipe must
have a minimum
of 18 inches from the rear to combustibles,
and a minimum of 20 inches from the sides to
combustibles.
Additionally, when using your ENERGY KING
wood/coal Furnace as an add-on, a 6-inch
minimum clearance is required between the
ENERGY KING Furnace and your existing
furnace.
Once it has been determined that your
existing furnace will accept an add-on
installation, RJM Manufacturing, Inc.
recommends a parallel installation, with a
direct (ducted) feed of return air to the
ENERGY KING Wood/Coal Furnace.
Install two backflow dampers to ensure that
when either furnace is operating
independently, hot air will not flow back
through the other furnace.
When using your ENERGY KING Wood/Coal
Furnace as an add-on, locate the
ENERGY KING as close to the new or
existing chimney as possible and as close to
your existing furnace as practical. However,
a minimum clearance of 6-inches is required
between your existing furnace and your
ENERGY KING Wood/Coal Furnace.
Figure 2: Clearances to Combustibles
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Installation
Assembling Your ENERGY KING Wood/Coal Furnace
The entire installation should be planned before putting the furnace in place to ensure compliance
with all the requirements outlined in the owner’s manual and any applicable markings on the
appliance.
Your new ENERGY KING Wood/Coal Furnace will have been shipped on a pallet with several
boxed components that will need to be assembled prior to installation. Please see Components for
a list of everything that was shipped along with your ENERGY KING Wood/Coal Furnace.
Once your furnace is placed in your desired location:
1. Remove the protective plastic coating from
the outer cabinet of the Furnace before
assembling.
2. Cast Iron Hearth Plates. Position front and
rear cast iron hearth plates in the burn
chamber. Your primary type of fuel (wood
or coal) will determine how to position the
hearth plates. The words “Wood” and
“Coal” are cast into the end plate on
opposite sides. 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.
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 Furnace 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.
The ENERGY KING 360EK/365EK
Wood/Coal Furnace uses 10 firebricks (5
on each side), while the ENERGY KING
480EK Wood/Coal Furnace uses 12
firebricks (6 on each side).
4. Cast Iron Doors. Mount the fuel loading
door and ash removal door on the front of
the Furnace and secure with the enclosed
door pins.
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Installation
5. Control Box.
a. Remove the control box cover. See Figure 3: Control Box for Automatic Draft, Figure 4: Control
Box for Forced Air Draft, or Figure 5: Control Box for Manual Draft.
b. Mount the pre-wired control box on the lower left side of the Furnace using the screws
provided.
Figure 3: Control Box for Automatic Draft
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Installation
Figure 4: Control Box for Forced Air Draft
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Figure 5: Control Box for Manual Draft
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Installation
6. Draft System.
a. Insert the conduit leading from your
chosen draft system into the control box
and tighten screw to secure.
b. For Automatic Draft. Mount the
automatic draft tube with the pre-wired
damper control motor to the draft
opening located next to the ash removal
door on the lower left front of the
Furnace, and secure using the bolts
found on the draft opening.
Figure 6: Automatic Draft Tube
with Damper Control Motor
c. For Forced Air Draft. Mount the prewired
forced air draft blower to the draft
opening located next to the ash removal
door on the lower left front of the
Furnace, and secure using the bolts
found on the draft opening.
Figure 7: Forced Air Draft Blower
d. For Manual Draft. Mount the manual
draft tube with attached spin dial to the
draft opening located next to the ash
removal door on the lower left front of
the Furnace and secure using the bolts
found on the draft opening.
Figure 8: Manual Draft Tube with Spin Dial
7. Fan/Limit Control.
a. Remove the cover of the fan/limit
control.
b. Mount the fan/limit control to the side of
the furnace directly above the control
box. Attach into the pre-punched holes
using the screws provided.
Figure 9: Fan/Limit Control, Mounted
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Installation
c. Set Pointers. Hold dial securely with one
hand and move the pointers with the
other hand. Do not force the pointers past
any stops on the dial even though the dial
may be graduated beyond the stops.
i. Limit. Verify that the right hand
pointer is set at 200-degrees F. This
is the temperature at which contacts
should open to prevent your Furnace
from overheating. Never set the Limit
pointer higher than 200-degrees F, as
recommended by the Fan/Limit
Control manufacturer.
ii. Fan. Move the “Fan On” pointer so
that its straight edge indicates the
temperature at which the fan contacts
should close to start the blower. Move
the “Fan Off” pointer so that its
straight edge indicates the
temperature at which the fan contacts
should open to stop the blower.
Recommended “Fan On” setting is
145-degrees F. Recommended “Fan
Off” setting is 90-degrees F.
Figure 10: Fan/limit Control Settings
Recommended “Fan Off” setting is 90 º F.
Recommended “Fan On” setting is 145º F.
8. Circulation Blower.
a. Mount circulation blower on rear of
b. If you selected the optional Filter Box kit,
furnace using the four bolts supplied.
proceed to step 9. Otherwise, attach the
conduit to Control Box and connect wire
ends as detailed in Appendix A: Wiring
Diagrams. Do not connect power to
your ENERGY KING Wood/Coal
Furnace until the installation is
complete.
9. Cold Air Return & Optional Filter Box.
a. Determine whether your cold air return
will enter on the left or right side of the
furnace.
b. Assemble the optional filter box per
Appendix B: Filter Box Assembly
Schematic.
c. Feed the conduit from your circulation
blower through the hole located on the
top of the filter box. Attach the conduit to
Control box and connect wire ends as
detailed in Appendix A: Wiring Diagrams.
Do not connect power to your
ENERGY KING Wood/Coal Furnace
until the installation is complete.
10. Domestic Hot Water Tube (Optional).
a. Your optional domestic hot water tube
may have been installed at the factory. If
so, your plumber can connect your
domestic hot water supply per the
installation instructions provided by the
hot water tube manufacturer.
b. If your optional domestic hot water tube
was not factory-installed, please follow
the installation instructions provided by
the hot water tube manufacturer.
11. Wiring. Do not connect power to your
ENERGY KING Wood/Coal Furnace until
the installation is complete.
Once you’ve completed the installation of
your ENERGY KING Wood/Coal Furnace,
you may connect your 110V power supply
to the left side of the control box. Wiring is
based on draft choice. Please see
Appendix A: Wiring Diagrams.
Risk of electric shock.
Disconnect power at the service
panel or breaker box before
servicing the ENERGY KING
Wood/Coal Furnace.
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Installation
Combustion Air Requirements
The ENERGY KING Furnace 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 Furnace does not draw steadily, smells, experiences smoke roll-out, burns
poorly, or back drafts whether or not there is combustion present.
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 Furnace installer to analyze whether the air supply in your installation
environment is adequate.
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.
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