Wood or Coal Furnaces
Models 360EK and 480EK
Installation, Operation & Maintenance Manual
RJM Manufacturing, Inc.
PO Box 27 ♦ 1875 Olson Drive
Chippewa Falls, WI 54729
(715) 720-1794 ♦ Fax (715) 720-1797
Energy King Wood/Coal Furnaces
Installation and Operating Instructions
Models 480EK and 360EK
BEFORE INSTALLING YOUR ENERGY KING
FURNACE, PLEASE READ ALL OF THE OWNER’S
MANUAL AND SAFETY NOTES
MANUAL FOR FUTURE REFERENCE
. PLEASE SAVE THIS
.
Congratulations on your purchase of an Energy King solid fuel heating appliance. Your 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 or Coal Furnace.
Energy King’s Furnace has been designed to use independently or as an add-on to an existing
heating system. The installation of any furnace is not a do-it-yourself project. To ensure the Furnace
will operate safely and efficiently, the installation must be performed by a qualified installer. With
proper installation and maintenance, your Furnace will give you years of trouble free service. Energy
King’s Furnace is designed to burn Air-Dried Hardwood, Anthracite or Bituminous Coal.
If your Furnace is not properly installed, a house fire may result. For your safety, follow the
manufacturer’s installation instructions. This Furnace maintains high temperatures when in use. Keep
combustible materials – such as clothing, paper, and furnishings – clear of the Furnace. Warn
children of the Furnace’s high temperature.
This Furnace is in compliance with UL 391 test standards.
Prior to installation, inspect your chimney to ensure it is in good condition and free of cracks. Contact
local building and fire officials regarding restrictions and installation inspection requirements for your
area. You also need to determine if you are required to obtain a permit from your local governing
authority.
TTaabbllee ooff CCoonntteennttss
SAFETY
PARTS
P
INSTALLATION
S
NOTES – IMPORTANT 1
LIST 2
ART NO. AND DESCRIPTION 2
3
PECIFICATIONS 3
GENERAL REQUIREMENTS 3
PLACEMENT – MINIMUM CLEARANCES 3
EDUCED CLEARANCES 4
R
A
DD-ON INSTALLATION 5
CHIMNEY 6
NIT ASSEMBLY 7
U
Wiring Diagram – Auto Draft
Wiring Diagram – Forced Draft
Wiring Diagram – Manual Draft
Filter Box Assembly Schematic
S
TOVEPIPE INSTALLATION 12
AROMETRIC DRAFT INSTALLATION 12
B
IR DUCT INSTALLATION 12
A
OPERATION
ENERAL INSTRUCTIONS 13
G
13
8
9
10
11
BURNING WOOD 14
TARTING A WOOD FIRE 14
S
URNING COAL 14
B
STARTING A COAL FIRE 15
Recharging
Bituminous Recharging
Banking
15
15
15
MAINTENANCE
REOSOTE – FORMATION AND NEED FOR REMOVAL 16
C
SH REMOVAL 16
A
TROUBLESHOOTING
REQUENTLY ASKED QUESTIONS 18
F
SIX
YEAR PRORATED WARRANTY 20
GUIDE 17
16
Safety Notes – Important
There are inherent hazards associated with the operation of Wood/Coal Furnaces. For your
safety, please read, understand and heed the following cautions. Failure to heed may result in
serious personal injury or death.
1. Do not burn garbage, gasoline, drain oil, or other flammable liquids.
2. Never use chemicals or fluids such as gasoline, charcoal lighter fluid, drain oil, fuel oil or
kerosene to start or “freshen” a fire in your furnace. Keep such liquids away from your furnace.
3. Do not operate with fuel loading or ash doors open.
4. The loading door, ash door and exposed firebox are extremely hot during operation. Never
touch these parts when hot. Warn children of the furnace’s high temperature.
5. Do not store fuel or other combustible material within marked installation clearances.
6. Comply with all minimum clearances to combustibles as they appear in this manual to prevent
fire.
7. All fuel-burning appliances require proper combustion air to operate and to avoid negative air
pressure in your home. Negative air pressure will cause safety and operation problems.
8. Do not connect your solid fuel appliance to a chimney flue already venting another appliance.
9. Do not let an accumulation of either soot or creosote build up in your chimney or inside the
firebox. Inspect and clean flues, chimney and firebox regularly.
10. Dispose of ashes with care. Never use anything but an airtight metal container to store your
ashes in. Ash can must be placed on a non-combustible surface. (See page 16 of this manual
for further information.)
11. Use caution when opening loading door. Wait 10 seconds on first latch before refueling.
Opening loading door rapidly can cause a flame to flash out the door.
12. Never burn wet or green wood. Store all wood in a dry location away from the elements.
13. Do not load coal above top of firebrick.
14. Disconnect appliance from electrical supply before servicing unit.
15. Equipment must be installed by a qualified heating person. Only “Class A” all-fuel or solid fuel
chimneys intended for use with your Energy King should be used. Check your chimney system
carefully before installation. If in doubt about its condition, contact a professional.
16. The furnace must be installed on a non-combustible floor or 3/8″ thick fireproof millboard or
equivalent.
1
Parts List
g
Please note that not all the
listed parts are shown on the
drawin
.
PART NO. AND DESCRIPTION
EK001-98 Circulation Blower: Sub-assembly EK019-98 Shaker Grate Bars
EK002-98 Filter Box: Sub-assembly 480EK → Quantity 5
EK003-98 Wiring Harness: Sub-assembly 360EK → Quantity 4
EK004-98 Cast Iron Feed Door EK020-98 Shaker Grate Frames – 2
EK005-98 Cast Iron Ash Door EK021-98 Shaker Grate Handle
EK006-98 Door Hinge Pins – 4 EK022-98 Cast Iron Hearth End Plates – 2
EK007-98 Ash Pan (removable) EK023-98 Shroud, Top
EK008-98 Self-Tapping Bolts – 3 EK024-98 Shroud, Left Side
EK009-98 ¼″ x ¾″ Bolts – 8 EK025-98 Shroud, Right Side
EK010-98 ¼″ Nuts – 4 EK026-98 Door Seal Rope Kit
EK011-98 ¼″ Washers – 4 EK027-98 Firebrick, 1 ¼″ x 4 ½″ x 9″
EK012-98 Fan Housing Mounts 480EK → Quantity 12
EK013-98 ½″ Jam Nut 360EK → Quantity 10
EK014-98 ½″ Acorn Nut EK028-98 Wood Grate
EK015-98 Sliding Smoke Baffle EK029-98 480EK Shaker Grate Bar Connector
EK016-98 Slider Rod EK030-98 Shaker Grate Control Handle
EK017-98 5/8″ Spring Handle EK031-98 360EK Shaker Grate Bar Connector
EK018-98 ½″ Spring Handle
2
Installation
Specifications
Model Number 480EK 360EK
H x W x D
Shipping Weight (approx.) 650 lbs. 530 lbs.
BTU Capacity (approx.) 160,000 125,000
Blower Capacity
3 Speed
Log Length 26″ 21″
Coal Capacity 190 lbs 130 lbs
Fire Chamber Capacity 9 Cu. Ft 6.3 Cu. Ft
Loading Door Size 13.5″ x 15.5″ 13.5″ x 15.5″
Ash Door Size 7.25″ x 11.5″ 7.25″ x 11.5″
Flue Size 6″ 6″
Flue Collar Height 48.25″ 45″
Plenum Outlet Size 20″ x 20″ 18″ x 18″
Efficiency (approx.) 78% 69%
Leg Height 3.5″ 3.5″
Combustion Air Diverter
Wood or Coal
Filter Box Left or Right Inlet Optional Optional
Draft Controls
Forced Draft Thermostatically Controlled
Automatic Draft Thermostatically Controlled
Manual Draft Control
Secondary Heat Exchanger Standard Standard
Insulated Cabinet Standard Standard
Shaker Grates Optional Optional
Wood Grates Standard Standard
Cast Iron Hearth Plates
Front and Rear
Prewired Electrical Components Standard Standard
Double Wall Back Standard No
Removable Ash Pan Standard Standard
Warranty
Complies with
Test Standards
General Requirements
The installation of any solid fuel heating
appliance is not a do-it-yourself project. The
Energy King should be installed by a
qualified heating specialist. Check with your
fire department and building inspector for
local, state and federal codes regulating
installation. Wood or coal related fires are
caused almost exclusively by installation,
operation or maintenance errors.
51.5″ x 26″ x 60″ 48″ x 26″ x 53″
1400-1600-1850 1400-1600-1850
Standard
Choice
Choice
N/A
Standard Standard
6 Year Prorated 6 Year Prorated
UL391 UL391
Standard
N/A
Optional
Standard
Only type HT or Residential type masonry
chimneys intended for use with your Energy
King should be used.
Do not connect this unit to a chimney flue
serving another appliance.
The Energy King is to be used in conjunction
with a listed gas or oil fired furnace or as a
central furnace.
Electrical supply:
115 volts, 60HZ, 1 phase, 15 amps.
Install system with 0.2 static pressu re.
Flue setting .06 in of W.C. minimum.
Smoke detectors in “working” condition
should be a part of every Energy King
furnace installation. This is the most
inexpensive insurance you can buy.
Placement – Minimum Clearances
The furnace must be installed on a noncombustible floor or 3/8 inch thick fireproof
millboard or equivalent. The non-combustible
material must extend at least 8 inches from
the sides and rear of the unit and 24 inches
in front of the unit.
One very important step in positioning your
wood/coal furnace is the distance from your
new or existing chimney. The unit should be
installed as close to the chimney as possible
with a minimum of elbows (no more than two)
and a run of no more than 6 feet horizontally
maintaining a ½ inch rise per linear foot.
3
Stovepipe must have a minimum of 18
inches from the rear and 20 inches from
the sides of the unit to combustibles.
The furnace must have clearances of 12
inches from the sides of the unit. Leave a
minimum clearance of 36 inches in front of
your unit. This is for safe, easy loading and
cleaning of your unit. The minimum
clearance to combustibles to the rear of the
unit is 28 inches.
If using your unit as an add-on, a 6-inch
minimum clearance is required between
the Energy King furnace and your existing
furnace.
Plenum clearances to combustibles – 2
inches.
Caution: Plenum must be installed in
accordance with NFPA 90-B, 1993, 2-1.3.
**Plenum 20″ x 20″ → 480EK Furnace
**Plenum 18″ x 18″ → 360EK Furnace
Reduced Clearances
NPFA guidelines and most codes permit
reduced clearances to combustible walls and
ceilings if adequate protection is added. A
common mistake is to assume that sheet
metal, masonry, or asbestos board placed
directly against a wall protects it. Materials
installed in this manner give very little
protection. These materials are good heat
conductors, so they will be almost as hot on
their backside as on the exposed side.
Therefore, the combustible wall behind is still
a fire hazard.
A wall can be kept cool using these items,
but only if they are mounted spaced out from
the wall by an inch or two to allow free
circulation of room air behind the protective
panel. Circulating air keeps the wall cool by
carrying the heat from the space between the
wall and panel. The protective panel should
start within a few inches of floor level.
The three rules to follow when constructing
wall protectors are as follows:
1. Non-combustibility of all materials
including mounting or supporting system.
2. A well ventilated air space between the
protector and the wall.
3. Sufficient strength and rigidity so that the
protector and air space will be durable.
4
Add-On Installation
A
Before installing your Energy King furnace,
consult your heating contractor and your
local and state building codes to determine
if your furnace will accept an add-on
application. Some small furnaces and
especially counterflow furnaces may not be
used in an add-on installation.
The CFM capabilities between the blower
on the existing unit and the supplemental
unit must be compatible.
If all these conditions are met, then the
combined static pressure may not exceed
that established by the existing furnace.
Once it has been determined that your
existing furnace will accept an add-on
installation, we recommend a parallel
installation, with a direct (ducted) feed of
return air to the Energy King furnace. The
two backflow dampers ensure that when
either unit is operating by itself the hot air will
flow into the home, and not flow back through
the other furnace.
MOST COMMON
DD-ON ARRANGEMENT
5
Chimney
The Energy King requires installation into an
all-fuel or a class “A” chimney only. Do not
connect the Energy King to any chimney flue
servicing any other heating appliance, as
recommended by the National Fire
Prevention Association. The chimney draft
should then be adjusted to .06 inch water
column.
All chimney connections must meet the
approval of the local building inspector and
fire marshall and conform to all local, state
and national codes.
It is also necessary to clean your chimney
of creosote or other causes of blockage
periodically to insure safe and trouble
free heating.
The chimney must extend not less than 3 feet above the highest point where it passes through
the roof of a building and not less than 2 feet above any portion of the building within 10 feet.
FACTORY BUILT CHIMNEYS
6
Unit Assembly
1. Remove the protective plastic coating
from the cabinetry of the unit.
2. Cast Iron End Plates. Position front and
rear cast iron end plates in firebox. The
type of fuel (wood or coal) you primarily
burn will determine how to locate the end
plates.
The words, “Wood” and “Coal,” are cast
into the end plate on opposite sides. If
you are going to burn wood, position end
plate with the word, “Wood,” facing out,
not into the firebox. If you are going to
primarily burn coal, position end plate
with the word, “Coal,” facing out. The
purpose of proper location is to introduce
the precise amount of combustion air into
the firebox to promote the most efficient
combustion for either fuel.
3. Firebrick. Position 6 firebricks for Model
480EK, or 5 firebricks for Model 360EK,
standing up on end on the left and right
side.
4. Control Box. Mount the 3-speed switch
control box on lower left side of furnace.
Four holes are pre-punched.
5. Fan Limit Control. Remove the cover of
the fan limit control by grasping the cover
at the top and bottom and pull outward.
(Grasping the cover by its side will make
removal more difficult.)
Attach the control directly above the
control box into the pre-punched holes
using the screws provided.
Normal fan limit settings are
For adjustment of these settings,
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.
Limit. Move the right hand pointer so
that its straight edge indicates the
140º ON
95º OFF
see drawing.
temperature at which the contacts should
open. The limit pointer should never be
set any higher than the setting
recommended by the furnace
manufacturer.
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.
6. Draft Blower or Tube. Mount forced
draft blower or natural draft tube on
front lower left side of ash pit door.
7. Circulation Blower. Mount circulation
blower on rear of the furnace using the
four bolts supplied.
8. Return Air. Determine whether your
return air will enter on the left or right
side of the furnace. Assemble the
optional filter box and mount on furnace
(see Assembly Schematic on page 11).
9. Wiring. Your Energy King is all prewired except for the circulation blower on
the rear of your furnace. Once the blower
and filter box are mounted on your
furnace, simply run conduit through the
hole on the filter box. Next, wire the four
lead wires onto the four spade
connectors in the junction box by
matching colors of wire and following the
applicable wiring diagram.
Black → High Speed
Blue → Medium Speed
Red → Low Speed
White → Neutral
7
Wiring Diagram – Auto Draft
8
9
9
Wiring Diagram – Manual Draft
10
Filter Box Assembly Schematic
THE AIR FILTER MUST BE
NON
-COMBUSTIBLE.
CAUTION
THE FILTER MUST BE
REMOVED IF THE FAN IS
INOPERABLE FOR ANY
REASON
PREVENT OVERHEATING
OF THE MOTOR
. THIS WILL
.
11
Stovepipe Installation
Install your wood/coal unit as close to the
chimney as possible with a minimum of
elbows (no more than two are
recommended) and a run of no more than 6
feet horizontally. The pipe should maintain a
½ inch rise per linear foot and never be
installed closer than 18 inches from
combustibles. Exceeding these
recommendations normally results in
creosote buildup, a smoking furnace or one
with a poor draft.
When connecting stovepipe, all joints should
be secured with at least three sheet metal
screws. If it is absolutely necessary to have a
run of more than 6 feet (which is not
recommended), use extra support hangers or
brackets every 3 feet.
The connection to the wood burner’s collar
must also be more than just a snug fit and
secured with sheet metal screws. Mark each
connection for cleaning. This will prevent
frustration when matching up your hole pattern
again.
Dampers in Stovepipes. Put a manual
damper at a safe, convenient place between
the chimney and your Energy King furnace.
In case of a chimney fire, it can quickly be
closed reducing draft to the chimney. Keep
the manual damper completely open during
normal operation.
When burning coal, a Barometric Draft
Damper must be installed at a safe,
convenient place between the chimney and
your Energy King. Setting at .06″ W.C.
Barometric Draft Installation
Some codes and the NFPA require draft
regulators in the chimney connector of wood
or coal furnaces and boilers.
Draft regulators limit the draft (the suction
pulling air into the appliance). A pivoted,
counterbalanced flap is pulled open by the
draft when the draft reaches a critical
amount. This permits air to enter the
chimney, thus preventing the draft in the
appliance from rising any higher.
Air Duct Installation
The ducts, fittings and registers should be
sized so that the total external static pressure
does not exceed 0.2.
The plenum on the Energy King 480EK
should be 20″ x 20″ and on the Energy King
360EK the plenum should be 18″ x 18″. The
plenum should be no closer than 2 inches
from the ceiling or any combustible material.
In a power outage situation, excessive heat
buildup in the plenum top may be dangerous;
so make sure clearances are maintained.
NEVER supply less than 150-square inches
of constant heated air outlet area.
DO NOT INSTALL THE ENERGY KING WARM AIR
SUPPLY INTO THE COLD AIR RETURN OF THE
CENTRAL FURNACE
CENTRAL AIR FURNACE COULD OVERHEAT
Cold air returns must be equal in size to the
heated air outlets and preferably 10% larger.
Every Energy King furnace MUST be
installed with a cold air return.
CAUTION
. THE COMPONENTS OF THE
.
12
Operation
General Instructions
Please read the following before firing your
furnace. It is very important that you follow
these suggestions and limitations in order to
maintain your warranty and to guarantee the
long life of your furnace.
This furnace is an airtight unit designed to
burn 6 to 8 hours per load of wood or coal. If
the furnace is being fired hot constantly with
full flames and operating at only a 2 to 4 hour
burn cycle, it is being overfired. Your home
heating needs may be too great for the size
of furnace you have purchased.
Sometimes you need to allow your existing
furnace to assist you in colder weather. Your
automobile engine works effectively at 55
mph, but can be damaged or destroyed at
constant speeds of 90 mph. Your furnace
can be damaged if it is constantly fired at
extremely high temperatures. Forced firing or
abuse can be detected upon inspection, and
will void your warranty.
PLEASE HEED THE FOLLOWING CAUTIONS
WHEN OPERATING YOUR
FURNACE
♦ N
♦ N
♦ U
:
EVER STAND IN FRONT OF THE LOADING
DOOR WHEN OPENING IT
SIDE OF THE DOOR
EVER OPERATE THE UNIT WITH THE ASH
DOOR OPEN
SE CAUTION WHEN OPENING THE
LOADING DOOR
LOADING DOOR RAPIDLY AS THIS CAN
CAUSE A FLAME TO FLASH OUT THE DOOR
THIS OCCURS WHEN THERE IS UNBURNT
FUEL AND A LARGE AMOUNT OF GASES ON
TOP OF THE FIREBOX
OPENED RAPIDLY
WITH THE GASES AND IGNITES
CAUTION
ENERGY KING
. STAND TO THE
.
.
. AVOID OPENING THE
.
. WHEN THE DOOR IS
, OXYGEN COMBINES
.
Check Blower Operation. Check to make
sure that your main blowers, or blower and
draft blower, are in proper working order
before lighting a fire.
♦ To check the main blowers, use the
manual switch on the fan limit control.
♦ To ensure the draft blower is working
properly, turn the thermostat upstairs to a
high temperature to turn the draft blower
on. Check to make sure your draft blower
is working and then set the thermostat to
the desired setting.
I
N THE EVENT OF A POWER FAILURE –
1. C
2. R
3. O
4. O
5. K
First Fire. The first fire in your Energy King
should be a small one. The unit may smoke
for a few minutes and there may be an odor
during the first firing as the paint and new
steel cure. Do not fully load your furnace or
open all draft controls completely until you
become familiar with the operation of your
furnace.
Manual Draft. The manual draft controls the
burn rate of your Energy King furnace. When
the manual draft is turned to the left, it will
burn at a higher rate. Turning the dial to the
right sets the burn rate to a slower burn. The
draft dial can be set to any position between
high and low to achieve the desired rate of
burn for your home. The chimney, hookups
and kind of wood used will also be factors in
determining the proper setting for your home.
IMPORTANT
LOSE DRAFT DIAL ON ASH DOOR.
EMOVE AIR FILTER (IF APPLICABLE).
PEN ALL HEAT REGISTERS
NLY LOAD THE UNIT HALF FULL.
EEP BYPASS DAMPER CLOSED.
13
Burning Wood
Burning wood can be fun as well as
economical if you are willing to expend the
personal energy required to reduce your fuel
dollar. More than any other major fuel, wood
provides us with independence – a source of
heat that we can rely on. Unlike fossil fuels,
wood is a renewable source of fuel when
harvested properly. When mature trees are
replaced with young trees, our forests and
woodlands can continue to supply an
excellent source of energy.
The most common unit of measure for wood
is the standard cord – a stacked pile of wood
that measures 4′ x 4′ x 8′. One of the most
important characteristics in selecting wood is
the energy content per cord. The more
weight in a cord of wood, the more heat it
can provide.
It is important to use air-dried wood. Although
all wood has some moisture content, the
drier the wood the better the burn. Different
wood certainly burns with different
characteristics. Because some woods are
denser than others, the amount of available
energy per cord will vary drastically. Dense
woods, such as hardwoods, burn for a longer
time than lighter woods, such as softwoods.
Be sure you know the type of wood and the
moisture content before you buy.
Your Energy King 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
furnace. You will get the best efficiency when
you add only the amount of wood needed for
an 8 to 10 hour burn.
Starting a Wood Fire
1. Pull the bypass damper (located above
the feed door) out.
2. Place a small amount of crumpled paper
in the center of your Energy King.
Crisscross a couple of handfuls of dry,
¾″ thick kindling wood, then several
small pieces of firewood.
Be sure the bypass damper is open.
3. It will take 5 to 10 minutes for the fire to
establish itself. Once you have some redhot burning embers, add larger pieces of
wood. All home chimneys and hookups
are different. After a few fires, you will
find the best way to start a fire in your
unit.
4. Push in the bypass damper after loading
your Energy King.
5. On airtight units, the burning time is
controlled totally by the draft controls on
the furnace.
6. To refuel your Energy King, pull the
bypass damper out. Open the door
slowly and rake the red-hot embers over
the grates evenly. Put a few smaller
pieces of wood on the coals first, and
then load the furnace with larger pieces
of wood. (A full load is not always the
best solution for your needs.) Close the
door and bypass damper.
Burning Coal
Burning coal will provide a lesson in
patience. Take the time necessary to
experiment and understand the operation of
your Energy King furnace. Please keep the
following points in mind when burning coal:
1. A barometric draft control in the smoke
pipe must be used when burning coal.
2. Never completely cover the live fire with
fresh coal. Always leave a generous area
of burning coal at the top and rear of the
fire.
3. Always keep the ash pit clean. Coal firing
produces much more ash than wood.
These ashes must be removed often
(possibly daily) in order to avoid piling up
too closely to the grates. Removal of the
coal ash will allow for passage of primary
air to the coal bed and prevent damage
or warpage to the grates.
Ash should always be put into an airtight
metal container that is placed on a noncombustible surface. All coal contains
small amounts of dangerous elements.
Therefore, it is essential that your coal
14
ash be disposed of in municipally
designated areas.
4. Too much draft air will cause clinkering of
coal and will waste heat up the chimney.
Shut the draft down to as low a point as
you can and still heat your home.
5. A coal fire should not be poked or broken
up, as this tends to bring ash to the
surface of the coal bed where it may
fuse. If the ash fuses, clinkers will form. It
may be necessary to remove all
unburned material and ash from the
firebox to remove the clinkers. These
should be carefully removed using tongs,
and as always, put into a metallic airtight
container.
6. If the fire goes out or does not hold
overnight, check for the following:
a) Poor draft.
b) Incorrect damper settings.
c) Improper firing methods for the coal
being used.
d) Coal is not sized to the furnace.
e) Ashes, if allowed to accumulate in
the ash pit, will not allow the passage
of required air for combustion. Keep
ash pit clean.
Starting a Coal Fire
1. Open the bypass damper (located above
the fuel door) by pulling out.
2. Build a fire using crumpled paper and a
small amount of dry kindling wood. Wait
until the wood fire is established before
adding coal.
3. Add several small shovels of coal over the
wood coals.
Never overload your firebox. Coal
should not cover the firebrick.
4. After the coal fire is established and
spread throughout the firebox, gently
shake the grate until ashes fall in the ash
pan area. Add larger amounts of coal to
build up the coal bed.
5. Allow your Energy King to operate with
drafts on for approximately 15 minutes or
until fresh coal ignites. When the coal is
properly ignited, adjust the thermostat
accordingly.
6. Check the fire periodically to be sure it is
spreading throughout the coal bed.
Recharging
Gently shake grates down. When recharging,
fresh coal tends to give off large quantities of
volatile gas. This gas may accumulate and
possibly ignite causing a backpuff. To reduce
backpuffing, partially open the fire door for 15
to 20 seconds before opening fully.
Spread fresh coal evenly over existing coal,
leaving some hot coals exposed in the center
of the firebox. Be careful not to smother your
existing coals. Never allow coal to build up
above the top of the firebrick. If the coal fire
dies down before recharging, a fresh supply
of kindling may have to be added.
Bituminous Recharging
Because bituminous coal has a higher
percentage of sulfur and a lower percentage
of fixed carbons than anthracite, recharging
should be as follows:
Gently shake down grates. Push the hot
coals to the rear of the firebox and
position fresh coal on the grate in front of
the banked coal. As the fresh coal begins
to burn, wood may be added to the top of
the coal.
Banking
Banking allows a person to recharge in such
a manner as to retain a hot coal bed
throughout the night. Approximately one hour
before retiring for the night, push the coals to
the rear of the firebox with the coal tapered
down in the front. Add a new layer of coal.
Always leave some hot coals exposed in the
front. This allows more coal to be added to
the firebox.
15
Before first firing each new heating season, check all installations and accessories to ensure a safe
burning process. The chimney and connectors should be free of any creo sote buildup prior to the
beginning of the heating season.
All ashes should be removed from the Energy King at the end of the heating season. Any ashes left
in the Energy King will draw moisture during the summer and have a corrosive effect on metal and
cast iron parts.
Maintenance
Creosote – Formation and Need for
Removal
When wood is burned slowly, it produces tar
and other organic vapors that combine with
expelled moisture to form creosote. The
creosote vapors condense in the relatively
cool chimney flue of a slow burning fire.
Consequently, creosote residue accumulates
on the flue lining. When ignited, this creosote
makes an extremely “hot hot” fire.
The chimney connector and chimney should
be inspected at least twice monthly during
the heating season to determine if a creosote
buildup has occurred. If creosote has
accumulated, it should be removed to reduce
the risk of a chimney fire.
Ash Removal
Check ashes daily. Remove ashes as
needed.
N
EVER LET ASHES BUILD UP TO
GRATE LEVEL
REDUCE THE LIFE SPAN OF YOUR
GRATE.
Ash pan can get very hot. Handle with
care.
Ashes should be placed in a metal
container with a tight fitting lid. The
closed container of ashes should be
placed on a non-combustible surface. If
the ashes are disposed of by burial in soil or
otherwise locally dispersed, they should be
retained in the closed container until all
cinders have thoroughly cooled. Coal ash
must be disposed of in a municipally
designated area.
Proven Fact: Small red embers buried in
ash cans stay red-hot for days. Ashes
are a good thermal insulator and keep
enough oxygen away so the embers do
not burn out.
CAUTION
. THIS WILL GREATLY
16
Troubleshooting Guide
Unit does not burn properly
1. Check the wood; it must be dry. If
moisture is sizzling out the end, the wood
is too wet.
2. Test the draft. It should be .05/.06
(inches of water column).
3. Check to make sure the flue is not
obstructed. Also, check the baffle area in
the unit for excessive ash buildup.
4. Check the ash drawer. Empty the
drawer if it has too much ash in it.
Combustion air needs to come up
through the grates on Energy King
heating appliances to feed the fire.
5. Check the airflow in the room. If it is too
airtight, the unit cannot get enough
combustion air to burn properly. You may
need to bring outside air to the furnace or
stove.
6. Check the chimney and stovepipe. They
need to be airtight to make the unit draft
properly.
7. Check that only one appliance is hooked
to the chimney.
8. Check the chimney for a downdraft. A
cold chimney will keep flue gases from
rising up the chimney. Proper insulation
of the chimney and/or installing a
stainless steel liner sized for the unit may
remedy the problem.
9. Check your chimney for downdraft
caused by taller surrounding trees or
buildings. The chimney may have to be
extended or a chimney vent cap
installed.
10. Check all gaskets for leaks: Door
gaskets, glass gaskets, ash drawer or
door gaskets (where applicable).
Unit does not give off enough heat
Is the unit installed correctly?
1. Check to see if the unit has an adequate
cold air return or inadequate hot air
outlet.
2. Furnace room may be too airtight,
inadequate combustion air or return air.
3. Flue draft may be inadequate or too
strong - .05/.06 (inches of water column)
recommended.
4. Door gaskets may be leaking. In
addition, glass gaskets, ash drawers or
door gasket should be checked for
leakage.
5. Check flue. Make sure it is not
obstructed.
6. Check ductwork for leaks, cold and hot
air ducts.
Unit is making noise/distribution
blower is vibrating
With electrical power disconnected,
check the following:
1. Check for loose parts.
2. Is the blower wheel contacting the
housing? If so, realign or replace as
required.
3. Is foreign material inside the housing?
4. Is there a leak in the ductwork or is there
loose ductwork?
5. Does the blower wheel/motor need to be
cleaned or serviced?
6. Is the blower wheel set screw loose? If
so, secure it properly.
Maintenance of blower assembly
After disconnecting the power source,
a) Remove dirt from blower wheel and
housing.
b) Check tightness of wheel set screw.
c) Check the wiring to see if it is secure
and well insulated.
d) Lubricate the motor according to the
manufacturer’s instructions. Remove
any excess lubricants.
17
Blower is not working
1. Check for a blown fuse or open circuit
breaker.
2. Insufficient air flow
a) Motor speed is too low (multi-speed
units only).
b) Leaks in ductwork.
c) Dampers and/or registers closed.
d) Obstruction in system.
e) Clogged filters.
3. Too much air flow
a) Filters not in place (where
applicable).
b) Motor speed too fast (multi-speed
units only).
c) Registers or grills not installed.
d) Insufficient static pressure (SP).
Check your static pressure (SP)
calculations and correct system
accordingly.
4. Motor overloaded – System static
pressure too low. Check and correct
system.
5. Thermostat is not opening damper (or
turning on forced draft fan)
a) Check wall thermostat.
b) Check the thermostat wires (possible
short or broken wire).
c) Check wire connections.
d) Make sure heated area is calling for
heat.
e) Check damper assembly so that all
parts move freely.
f) Damper motor or forced draft fan
improperly wired – compare wiring
on the unit to the schematic in the
manual.
6. Excessive creosote
a) Make sure the unit’s smoke pipe is
vented into its own proper chimney.
b) Check length of flue pipe and all
connections. Offsets in flue pipe will
slow flue gases down causing
buildup.
c) Slow fires with excessive amounts of
fuel can cause creosote buildup in
smoke pipe and chimney.
Coal fire goes out or does not hold
overnight
Check for the following conditions:
1. Poor draft
2. Incorrect damper settings.
3. Improper firing methods for coal being
used.
4. More combustion air needed.
5. Coal is not sized to the furnace.
6. Ashes, if allowed to accumulate in the
ash pit, will not allow the passage of air
for combustion. Keep ash pit clean.
Note: Never stand in front of loading door
when opening it. Stand to the side.
Too much draft air will cause clinkering of
coal and will waste heat up the chimney.
Shut draft down to as low a point as you can
and still heat your home.
Frequently asked questions
Q. “Do I operate my stove differently in cold
vs. warm weather conditions?”
R. Yes, during the warmer seasons of
spring and fall, control the total heat
output by limiting the amount of fuel
(wood) rather than by closing down the
air supply. Make shorter, hot fires using
more finely split wood. The actual air
supply setting will vary according to your
stove instructions, but the fuel loadings
will be consistently smaller. Let the fire
burn out rather than smolder at low air
supply settings. When your home
requires more heat, restart the fire with
kindling as always, but add smaller fuel
loads. This allows your stove to operate
at maximum efficiency and with minimum
emissions. Avoid the temptation of
building a big fire and then starving it for
air.
18
Q. “Is it important to have my stove and
chimney cleaned?”
R. Smoke rising through your chimney may
condense and build up on the cooler
inside walls forming a substance known
as creosote. This volatile substance can
ignite and burn in the chimney. Many
chimneys and installations are unable to
withstand these dangerous creosote
fires; the results can be tragic.
Q. “How often should I have my chimney
inspected and cleaned?”
R. A professional, certified chimney sweep
should inspect and clean your flue
system regularly. Frequent stove use
may require monthly chimney inspection
and cleaning, while even minimal use will
require annual servicing.
Woodstove connectors (stovepipes)
should be checked as often as every 2-4
weeks. Your chimney sweep can show
you the proper methods for these more
frequent inspections.
Q. “Does it matter what kind of wood I
use?”
R. Your fuel supply should consist of a
mixture of hardwoods, like maple or oak,
and softwoods, such as fir and pine.
When first starting your fire, use
softwoods. They ignite easily and burn
rapidly with a hot flame. Hardwoods
provide a longer lasting fire and are best
used after preheating the chimney. If
hardwoods are unavailable, you can
control your fire’s burn rate by using
larger pieces of wood.
Q. “Is it important to season wood before
burning it?”
R. The seasoning, or drying, p rocess allo ws
most of the natural moisture found in
wood to evaporate, making it easier to
burn. A properly seasoned log will have
20%-30% moisture content.
Wood only dries from the surface inward;
unsplit pieces dry very slowly. To
properly season wood, split the logs as
soon as possible and stack them in a dry
spot for 6-18 months. Pile the wood
loosely, allowing air to circulate through
the split logs. Hardwoods take longer to
dry than softwoods. Humidity and
temperature levels also will impact drying
time.
Q. “What’s the best way to load wood into
my stove?”
R. Avoid placing pieces of wood in parallel
directions, where they may stack too
closely. Vary the position of the wood in
the firebox to maximize the exposed
surface area of each piece of wood. Only
use wood properly sized for your stove’s
fire chamber. Complete wood
combustion requires wood (fuel),
temperature (heat) and oxygen (air) to
burn completely and cleanly.
Q. “Is there anything I shouldn’t burn?”
R. Never burn garbage, plastic, foil, or any
kind of chemically treated or painted
wood. They all produce noxious fumes
that are dangerous and highly polluting.
19
Six Year Prorated Warranty
RJM Manufacturing, Inc. warrants Energy King Wood/Coal Burning Furnaces to be free from
defects in workmanship and materials under normal use and service for a period of six (6) years
from the date of purchase, subject to the terms and conditions of this agreement.
Exceptions to the terms are firebrick and gaskets which are expendable and replaceable items;
electrical components, gauges, relief valves, and coils, which are covered by the original
manufacturer’s warranty; and castings in which Energy King warranties for one (1) year under
proper use.
An Energy King appliance or any parts or portion thereof, which in the judgment of
RJM Manufacturing, Inc., shows evidence of such defect will be repaired or replaced by
RJM Manufacturing, Inc., at our option through an authorized dealer provided that the defective
part is returned to the dealer, transportation prepaid, within six (6) years from the date of purchase
and registration of the warranty. This warranty does not apply to any part that has been altered,
tampered with, or has been subject to accident or misuse.
Warranty on an Energy King furnace will be prorated for a period of six (6) years from the date
of purchase with proof or purchase.
All transportation charges on warranty appliances and appliance parts submitted for repair or
replacement under this warranty shall be paid for the by purchaser; field analysis of condition,
removal, and/or replacement of any part or parts thereof are not covered under this warranty.
This warranty does not extend to any heating system or systems to which the appliance may be
attached. No warranty is extended to any of the smoke pipes, heat pipes, chimney, hardware,
ducting, vents, or other accessories used for installation.
This warranty does not cover part or parts modified, damaged in shipment, improper handling,
improper installation, improper operation, abuse, misuse, accident or unworkmanship repairs.
RJM Manufacturing, Inc., is not responsible for installation and will not be liable in any respect
under the terms of the warranty for injury or damage to the building structure in which the Energy
King has been installed, or to the person or persons and property therein, arising out of the use, or
installation of the Energy King appliance. The Energy King must be installed in compliance with
the local and state building and fire codes of the area and in strict adherence to the manufacturer’s
recommendations.
Warranty is limited to Energy King parts only. No other warranty is written, implied or
expressed.
RJM Manufacturing
PO Box 27 ♦ 1875 Olson Drive
Chippewa Falls, WI 54729
(715) 720-1794 ♦ Fax (715) 720-1797
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