ENERGY KING Wood/Coal Boilers Models 35EK-D/45EK-D & ASME-Certified Model A40EK-D Installation, Operation & Maintenance Manual RJM Manufacturing, Inc. 1875 Olson Drive Chippewa Falls, WI 54729 (715) 720-1794 ♦ Fax (715) 720-1797 www.EnergyKing.
ENERGY KING Wood/Coal Boilers Models 35EK-D/45EK-D & ASME-Certified Model A40EK-D 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. Save these instructions.
Safety Instructions Failure to follow these safety instructions may result in property damage, bodily injury or even death. ▲ ▲ Read this entire manual before installing, 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.
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 heating appliance. For additional safety, RJM Manufacturing, Inc.
Table of Contents SAFETY IN ST RUCTI ON S ................................................................................................................................................ i T A BLE OF CONT ENT S ................................................................................................................................................... 1 SP ECI FICA TI ON S ...................................................................................................................................
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Specifications Model Number A40EK-D 35EK-D 45EK-D 54.5″ x 24″ x 43″ 54.5″ x 24″ x 38″ 54.5″ x 24″ x 43″ 1,155 lbs. 1,055 lbs. 1,155 lbs. 140,000 BTU 140,000 BTU 160,000 BTU 1,500–2,500 sq. ft. 1,500–2,500 sq. ft. up to 4,000 sq. ft. 43 gallons 43 gallons 48 gallons Water Jacket (Sides, Front, Top, Back) 1/4″ SA516-70 Steel Plate 1/4″ A36 Steel Plate 1/4″ A36 Steel Plate Burn Chamber Dimensions (H x W x D) 30″ x 17″ x 30″ 30″ x 17″ x 30″ 30″ x 17″ x 35″ 8.5 cu. ft. 8.5 cu. ft.
Component Description Figure 1: Components (Cutaway View) 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. Rev 08/24/10 2. Sliding Smoke Baffle.
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. 4. Cold Water Inlet (Return). Cold water inlets return cooled water back to your Boiler. The ENERGY KING Model A40EKD Wood/Coal Boiler is equipped with one 11/2″ cold water inlet, located on the rear of the appliance.
What is ASME-Certification? ENERGY KING Wood/Coal Boiler model A40EK-D is built and tested to the exacting standards of the American Society of Mechanical Engineers (ASME) Code Section 4, Construction of Heating Boilers, under the National Board ‘H’ stamp, and is independently inspected by a third party inspection agency.
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.
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.
Fuel Requirements BURN AIR-DRIED WOOD, OR ANTHRACITE OR BITUMINOUS COAL ONLY Risk of Fire: Do not store fuel or other combustible material within the marked installation clearances. COAL One of the world’s most widely-used fuel sources, coal can provide the energy independence and low fuel prices sought by owners of solid-fuel heating appliances. • The ENERGY KING Wood/Coal Boiler has been tested for operation with anthracite (hard) or bituminous (soft) coal.
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. Do not connect the ENERGY KING heating appliance to any chimney flue serving any other appliance. General Requirements The installation of any solid fuel heating appliance is not a do-it-yourself project.
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.
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.
Installation Figure 3: Control Box for Forced Air Draft Figure 4: Forced Air Draft Blower 6. Draft System. a. Insert the conduit leading from your draft system into the control box and tighten screw to secure. b. Mount the pre-wired forced air draft blower to the draft opening located next to the ash removal door on the lower left front of the Boiler and secure using the bolts found on the draft opening. 7. Pressure-Temperature Gauge.
Installation 9. Aquastat-Immersion Control. a. Remove the cover of the prewired Aquastat-Immersion Control to adjust the High and Low temperature limits. Figure 7: Aquastat-Immersion Control, Mounted 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.
Installation Combustion Air Requirements Failure to provide adequate combustion air can lead to increased carbon monoxide production and increased emissions of combustion gases into the building, which may cause death or serious injury. The ENERGY KING Wood/Coal Boiler must have a minimum supply of 70 cubic feet of air per minute. All fuel-burning appliances must have air (oxygen) for proper combustion.
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.
Installation Figure 8: Venting Requirements 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. For best performance, RJM Manufacturing, Inc. recommends a chimney height of at least 12 feet. Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
Installation Masonry Chimney When connecting to an existing masonry chimney, an approved liner must be used in the chimney. An unlined chimney could remain cold and cause a downward pressure which creates the environment for poor burning, incomplete combustion, or backdraft. Chimney Connector The connection from the ENERGY KING Wood/Coal Boiler to the chimney must be made using 8″ black steel material with a minimum 24 gauge. Do not use galvanized steel.
Installation Barometric Draft Control Risk of Fire: Do not operate with the flue draft exceeding .06″ (14.95 Pa) water column. Proper draft must be provided for your ENERGY KING Wood/Coal Boiler. Draft is the force that moves air from the boiler up through the chimney. Draft is measured in inches of water column. The amount of draft in your chimney depends on the length of the chimney, local geography, nearby obstructions and other factors.
Installation Plumbing ENERGY KING A40EK-D Wood/Coal Boilers are equipped with: • One 2″ hot water outlet, located at the top of the Boiler • One 1-1/2″ cold water inlet, located on the rear of the Boiler. ENERGY KING 35EK-D/45EK-D Wood/Coal Boilers are equipped with: • One 2″ hot water outlet, located at the top of the Boiler • Two 1-1/4″ cold water inlets, located on the rear of the Boiler.
Installation 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.
Operation General Instructions Risk of Fire: ● Do not operate with flue draft exceeding .06″ (14.95 Pa) of 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. CAUTION – Hot Surfaces: Keep children away! Do not touch Boiler during operation. Please read this manual in its entirety prior to the first firing of your ENERGY KING Wood/Coal Boiler.
Operation First Fire Before lighting your first fire, inspect your ENERGY KING Wood/Coal Boiler to ensure that it has been properly installed and that all safety requirements have been met. During your inspection, pay particular attention to the clearances to combustibles, venting, and thermostat installation instructions. Verify the Pressure Relief Valve’s proper functioning by manually opening the valve and releasing water into the floor drain.
Operation Overfire Do not overfire. Using too much wood or coal, burning trash in the Boiler, or operating with a flue draft that exceeds .06 inches water column, may result in overfiring—a dangerous condition which could produce excessive heat and pressure within the ENERGY KING Wood/Coal Boiler, or could ignite creosote within the chimney or Boiler. Forced firing or abuse can be detected upon inspection and will void your warranty.
Operation BURN AIR-DRIED WOOD, OR ANTHRACITE OR BITUMINOUS COAL ONLY Burning Wood All home chimneys and hookups are different. After a few fires, you will find the best way to start a fire in your ENERGY KING Wood/Coal Boiler. Your ENERGY KING Wood/Coal Boiler is capable of holding very large logs. Do not try to add a log that is larger than what you can easily place in the ENERGY KING Wood/Coal Boiler. You will get the best efficiency when you add only the amount of wood needed for a 6 to 8 hour burn.
Operation BURN AIR-DRIED WOOD, OR ANTHRACITE OR BITUMINOUS COAL ONLY All home chimneys and hookups are different. After a few fires, you will find the best way to start a fire in your ENERGY KING Wood/Coal Boiler. You will get the best efficiency when you add only the amount of coal needed for a 6 to 8 hour burn. A full load is not always the best solution for your needs. Burning Coal Burning coal will provide a lesson in patience.
Operation Starting a Coal Fire 1. Pull the sliding smoke baffle (located above the fuel loading door) out to open. Refueling / Recharging To refuel/recharge the anthracite coal fire in your ENERGY KING Wood/Coal Boiler: 2. Place a small amount of crumpled paper in the center of your ENERGY KING Wood/Coal Boiler. Crisscross a couple of handfuls of dry, 3/4″ thick kindling wood, then several small pieces of firewood. Wait until the wood fire is established with hot, red embers before adding coal. 1.
Operation Bituminous Recharging Because bituminous coal has higher sulfur content, bituminous recharging is slightly different from anthracite recharging. Banking Banking allows you to recharge your coal fire in such a manner as to retain a hot coal bed throughout the night. To refuel/recharge the bituminous coal fire in your ENERGY KING Wood/Coal Boiler: 1. Pull the sliding smoke baffle out.
Maintenance Periodic maintenance is required to continue the performance of your ENERGY KING Wood/Coal Boiler. As with any solid-fuel heating appliance, the need for and frequency of cleaning depends on the amount and quality of fuel burned, the quality of the fire, and the length of time since the last cleaning. Weekly cleaning may be required in warmer weather, whereas monthly cleaning may be enough in colder weather.
Maintenance Gasket Replacement The cast iron fuel loading and ash removal doors of your ENERGY KING Wood/Coal Boiler are equipped with gaskets to ensure safe operation and an airtight seal. When these gaskets become worn or damaged, you will need to replace them. To replace the gaskets you will need 3/4-inch, high temperature rope gasket, available from your ENERGY KING dealer or hardware store. 1. Remove the door and lay it face down on a clean, flat surface. 2. Find the ends of the gasket and pull it off.
Maintenance Monthly Annually The water level on your ENERGY KING Wood/Coal Boiler should be monitored on a regular basis and refilled when necessary. Seasonally / Every 3 Months / After every 1 – 2 Tons of fuel burned Until you are familiar with how ash and creosote accumulate with your operating practices, we recommend inspecting your ENERGY KING Wood/Coal Boiler at least once per ton of fuel burned. Particular attention should be given to: • Draft Control system (blowers, etc.
Troubleshooting Guide Risk of electric shock. Disconnect power at the service panel or breaker box before servicing the ENERGY KING Wood/Coal Boiler. Many problems in the ENERGY KING Wood/Coal Boiler can be traced to a few commonplace causes and are easily fixed. Before making any repairs or replacing any components, be sure to check for these common problems: Fuel • Wet or Dirty fuel Solution: Empty and clean the burn chamber.
Troubleshooting Guide Detailed Troubleshooting Once you have exhausted the above common problems, if you are still experiencing trouble with your ENERGY KING Wood/Coal Boiler, you may wish to consult the following list of problems, or consult with your ENERGY KING dealer for further assistance. Problem(s) Cause(s) / Solution(s) Fire won’t start or starts but won’t stay lit, or does not hold out overnight • Make sure all doors are closed tightly and all gaskets are in good condition.
Troubleshooting Guide Problem(s) The ENERGY KING heating appliance is overheating or is burning without regard to the thermostat Cause(s) / Solution(s) • Your ENERGY KING heating appliance may have been installed incorrectly. Please contact your ENERGY KING dealer or heating contractor. • The thermostat or thermostat wiring may be faulty. Please contact your ENERGY KING dealer or heating contractor. • Your “heat dump” zone may have been closed off.
Troubleshooting Guide Problem(s) Cause(s) / Solution(s) The ENERGY KING heating appliance will not heat the whole house or doesn’t produce as much heat as when first installed • Verify that the venting and draft control systems are clean and free from obstruction. Verify that all heat delivery systems are operating correctly. The water level is low • Excessive pressure in your ENERGY KING Wood/Coal Boiler may have triggered your Pressure Relief Valve. Allow the Boiler to cool and refill as necessary.
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Appendix A: Wiring Diagram Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
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Appendix B: Example Plumbing Diagram When plumbing into your existing heating system, RJM Manufacturing, Inc. recommends installing a series of three gate valves. The three gate valves are to be used in the event you do not use your ENERGY KING Wood/Coal Boiler for an extended period (one or more weeks). When the ENERGY KING Wood/Coal Boiler is in use, Valves #1 and #2 are open and Valve #3 is closed.
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Appendix C: Parts List Electrical Components Part Number Part Description 4-ELE-24VTHERMOST 24-Volt Wall Thermostat 4-ELE-CTRLBXFD-B Control Box Assy (also includes Ctrl Box, Mtg Hardware, & Terminal Bars) • 4-ELE-24VRELAY 24 Volt Relay • 4-ELE-24VTRANSFOR 24 Volt Transformer 4-DRA-FDTUBEASSY Forced Draft Blower Assembly • 4-MOT-60CFMBLOWER 60CFM Forced Draft Blower • 4-MOT-60CFMROTARY Rotary switch for 60CFM Forced Draft Blower • 4-DRA-FORCEDTUBE Forced Draft Mounting Tube 4-ELE-AQUASTAT
Appendix C: Parts List Cast Components Part Number Part Description 4-CAS-CASTPLATE Cast Iron Hearth Plate, 2 required 4-CAS-DRAFTDIAL Cast Iron Draft Dial, located on Ash Removal Door 4-CAS-PLUG-COIL 4″ Square-Head Plug for Domestic Hot Water Coil receptacle (models 35EK-D/45EK-D only) 4-CAS-PLUG-TEMPRLF Plug for Temperature Relief receptacle 4-CAS-SHGR35SET Optional Shaker Grates Assembly (35EK-D & A40EK-D) • 4-CAS-LINKAGEBAR Linkage Bar for Optional Shaker Grates • 4-CAS-LINKAGEYOKE Linkag
Appendix C: Parts List Boiler Components Part Number 4-CAB-35-COMP Part Description 35EK-D Cabinet (Shroud) Assembly • 4-CAB-35-LT 35EK-D Cabinet Panel (Shroud), Left Side • 4-CAB-35-RT 35EK-D Cabinet Panel (Shroud), Right Side • 4-CAB-35-TOP 4-CAB-45-COMP 35EK-D Cabinet Panel (Shroud), Top Side 45EK-D Cabinet (Shroud) Assembly • 4-CAB-45-LT 45EK-D Cabinet Panel (Shroud), Left Side • 4-CAB-45-RT 45EK-D Cabinet Panel (Shroud), Right Side • 4-CAB-45-TOP 45EK-D Cabinet Panel (Shroud), Top Side 4-
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Appendix D: Purchase & Service Record ANNUAL INSPECTION BY QUALIFIED PROFESSIONAL IS RECOMMENDED. Purchase & Installation Record MODEL* SERIAL NUMBER* PURCHASE DATE DEALER INSTALLER ADDRESS ADDRESS CITY / STATE / ZIP CITY / STATE / ZIP CONTACT CONTACT PHONE NUMBER PHONE NUMBER INSTALLATION DATE COMMENTS *Model and serial number are located on the label on the left side of the unit.
Appendix E: Warranty Claim Procedures We make every effort to ensure that all ENERGY KING heating appliances and components adhere to our strict standards for quality and safety. However, should you receive a product or component that doesn't function as intended, please follow the instructions below for making a warranty claim.
Appendix E: Warranty Claim Procedures ENERGY KING™ Warranty Claim Form For all ENERGY KING heating appliance warranty claims, please complete this form IN FULL and return it to RJM Manufacturing, Inc., via fax at (715) 720-1797 or via postal mail at: RJM Manufacturing, Inc.
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ENERGY KING WOOD/COAL BOILER LIMITED WARRANTY Who is covered? You are covered under this warranty if you are the original purchaser of a new ENERGY KING solid-fuel heating appliance and your purchase was made through an authorized distributor/dealer of the ENERGY KING solid-fuel heating appliance. How long does the coverage last? The term of this warranty begins on the date of original purchase as evidenced by your purchase receipt, subject to the terms, conditions and restrictions of this agreement.
What will we do to correct problems? We will repair, or at our option, replace any ENERGY KING solid-fuel heating appliance or appliance part, which upon inspection shows a defect in materials or workmanship. How can you get service? If warranty service is needed during the warranty period, notify your authorized ENERGY KING dealer. If there is no ENERGY KING dealer in your area, contact RJM Manufacturing, Inc. directly.
Supplement A: Aquastat-Immersion Control The following document was prepared and published by Honeywell International for distribution with their models “L4081A,B and L6081A,C Multiple Aquastat Controllers.” It is reproduced here for reference purposes ONLY. Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S.
Supplement B: 24-V Wall Thermostat The following document was prepared and published by Honeywell International for distribution with their models “T822K,L & T827K” wall thermostats. It is reproduced here for reference purposes ONLY.
