Installation INDOOR SOLID FUEL FURNACE Models: 8095, 8130, 8130HD www.royallfurnace.
Thank you for purchasing a ROYALL Indoor Forced Air Solid Fuel Furnace. is a quality Indoor Solid Fuel Appliance designed to effectively heat structures. Please read and follow all safety instructions to ensure optimal performance and safety. The installation and operation of the is quite simple. Nevertheless, we recommend installation to be completed by a qualified professional. The installation and operational instructions should be carefully read and followed.
PRODUCT REGISTRATION CARD Warranty is in effect from the date of purchase upon receipt of this card. NAME STREET ADDRESS CITY STATE ZIP CODE PHONE E-MAIL ADDRESS DATE OF PURCHASE MODEL NUMBER SERIAL NUMBER DEALER CITY STATE Reason for choosing Royall over other brands __Price __Features __Safety __Previously owned Royall __Recommended to you __Other PRODUCT REGISTRATION CARD Warranty is in effect from the date of purchase upon receipt of this card.
OWNER’S REGISTRATION CARD MUST BE COMPLETED AND RETURNED T0 ROYALL AT TIME OF INSTALLATION.
CONTENT GENERAL SAFETY.................................................................................................................................................. Pg 4 SPECIFICATIONS................................................................................................................................. Pg 5 PRODUCT DESCRIPTION................................................................................................................... Pg 5-6 INSTALLATION INSTALLATION PLACEMENT......
SAFETY ALL STATE or LOCAL CODES take precedence and MUST be observed. These models have been constructed along U L391-99 parameters. Many of the recommendations in this manual are also based on the National Fire Protection Association Code 211. Before installing or starting operation, read and familiarize yourself with all instructions. NOTE: Installation is to be performed only by qualified heating professionals.
SPECIFICATIONS INDOOR FORCED AIR FURNACE MODELS Features Dimensions: WxLxH (Inches) Estimated BTU Output Weight (LBS) Fire Box Volume Log Length (Inches) Fuel Door Opening (Inches) Flu Size (Inches) NOTE: 8095 8130 8130HD 22x32x38 95,000 475 5.6 cubic ft. 26” 10” x 14” 8” 24x32x48 130,000 565 7.4 cubic ft. 26” 10” x 14” 8” 24x32x48 150,000 595 7.4 cubic ft. 26” 10” x 14” 8” Output values are based on theoretical 12 hour sustained burn rate under optimal conditions and are provided as guideline only.
PRODUCT DESCRIPTION (CONT.) The combustion process is driven by a draft blower mounted on the front of the appliance. When the room thermostat calls for heat, the draft blower starts adding combustion air to increase the fire intensity. If the exiting air temperature exceeds 200° F, the draft blower shuts down to prevent overheating. Standard models have manual damper on the draft blower that balances the draft rate.
INSTALLATION PLACEMENT (CONT.) DANGER Failure to keep furnace area clear and free of combustible materials, DANGER gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage. SOLID FUEL APPLIANCES SHALL NOT BE INSTALLED IN A LOCATION WHERE GASOLINE OR OTHER FLAMMABLE VAPORS ARE LIKELY TO BE PRESENT.
CLEARANCES NON-COMBUSTIBLE: Surfaces must have these clearances: Front – 48” Back – underneath the chimney and Sides – 12”. COMBUSTIBLE: Surfaces must have these clearances: Front – 48” Back – 30” Sides – 18” smoke pipe -27” (Side) 18” (Back). The following clearances are recommended for maintenance: Back –30” Sides –36”. DANGER Page 8 All single wall chimneys must be at least 18” from any combustible surface. Fire can result, causing severe personal injury, death or substantial property damage.
INSPECTING CONTENTS COMPONENTS SHIPPED LOOSE INSIDE: ROYALL INDOOR FURNACE 1. Fire Brick 2. Fan Limit Control 3. Fan Center Control 4. Draft Blower With Gasket 5. 4 x 4 Electric Box 6. BX Wire 72” of 14/2 7. BX Wire 60” of 14/3 8. BX Connector, 90 Elbow (1) 9. BX Connector, Straight (4) 10. Spring Handles (4) 11. Wire Strap 12. Bag With Door Locks & Fasteners W/H Instructions 13. Manual With Owner’s Registration Card Inside 14. Shroud Set OPTIONAL COMPONENTS 15. Filter Box Assembly 16.
FIREBRICK INSTALLATION The appliance comes with the firebrick boxpackaged inside appliance. MODEL 8095 8130 8130HD (16) Full Bricks & (2) Cut Bricks Install Bricks as follows: 1. Remove T-Bar from back of the fire box. 2. Install (2) full bricks and (2) half bricks in the back of the fire box. 3. Bolt the T-Bar back in place to hold the bricks (DO NOT tighten nuts at this point). 4. Install (2) bricks above the T-Bar and tighten nuts tightly. 5. Install the bricks on the sides of the fire box.
INSTALLATION OF SHROUD SHROUD PREPARATION 1) For “Series” installation (see page 12): A) Cover the filter box opening on the rear of the appliance. Manufacture a cover from standard ducting material. B) Cut an opening in shroud side for cold air return duct. Opening should match duct dimensions out of the existing furnace to maintain system balance. Return duct can be located on either side of the appliance. 2) For “Parallel” installation (see page 14): Nothing further is required.
INSTALLATION WITH AN EXISTING FURNACE (SERIES) Description of Operation 1) The circulation blower on the existing furnace draws air through the cold air return and the furnace. 2) The air passes into the bottom of the solid fuel furnace, which heats the air. 3) The heated air circulates through the heating ducts. 4) The existing furnace is controlled by a separate thermostat 5). If the existing furnace fires, air flow remains the same through both units.
FILTER BOX (0PTIONAL) If installing the ROYALL furnace in Parallel with the existing furnace (see page 14), construct and install the filter box as follows: 1) Mount the Crculation Blower on the rear of the appliance using 4-1/4” x 3/4” screws. 2) Assemble and mount the Filter Box over the Circulation Blower using the 1/4” x 3/4” screws already in place. A) The side panel with the 12” hole can be installed on either side of the filter box for convenient installation of the cold air return duct.
TYPICAL SYSTEM SCHEMATICS IN PARALLEL WITH EXISTING FURNACE DESCRIPTION OF OPERATION 1) The Circulation Blower (A) draws air through the “new” cold air return and moves it through the solid fuel furnace, which connects to the hot air plenum above the existing furnace. 2) A back draft damper (1) opens, allowing the heated air to circulate through the heating ducts. 3) A second back draft damper (2) closes, preventing the heated air from circulating through the existing furnace.
TYPICAL SYSTEM SCHEMATICS (CONT.) INSTALLATION 1) Install a new cold air return from existing ducts to the solid fuel furnace. 2) Install a back draft damper (air flow baffle) between the solid fuel furnace hot air outlet and the existing furnace hot air plenum. 3) Install a back draft damper (air flow baffle) between the existing furnace and the existing hot air plenum. A) The back draft damper MUST be installed above any air conditioning “A” coils.
VENTING INSTALLALLATION DANGER All single wall chimneys must be at least 18” from any combustible surface. Fire can result, causing severe personal injury, death or substantial property damage. DANGER A major cause of chimney-related fires is failure to maintain required clearances (air spaces) to combustible materials. It is of the utmost importance that all chimneys be installed in accordance with the manufacturer’s instructions.
VENTING INSTALLALLATION (CONT.) CHIMNEY HEIGHT To prevent downdrafts, chimney, or vent without a listed cap should extend at least 3 feet above the highest point where it passes through a roof and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet. A chimney or vent must not extend less than the distances stated above. **Check local codes or ordinances for additional requirements** 2 FT. 2 FT. 10 FT. 3 FT.
COMPONENT ASSEMBLY INSTALLALLATION 1) FAN LIMIT CONTROL A) The fan limit control may be installed on either side. B) Drill a 3/4” diameter hole approximately 2-1/2” inches down centered on the desired side. C) Insert the sensor of the fan limit control and attach the control with the provided sheet metal screws. 2) FAN CONTROL CENTER A) The fan control center should be installed on the same side as the fan limit control.
ELECTRICAL INSTALLALLATION BASIC ELECTRICALS For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. DANGER Thermostat Power shut off while making connections. Failure to do so may result in severe personal injury or death. eath h.
ELECTRICAL INSTALLALLATION (CONT.) 2) CONTROL CENTER JUNCTION BOX A) Install the “A” leg of the wring harness from the switch junction box. B) Install the “C” leg to the fan limit control. • “C” leg has (3) wires: Black, White and Red. C) Install the “D” Black to relay Red. D) Connect the wires as shown: • Wire nut the White wires from legs “A”, “D” and control transformer. • Wire nut leg “A” Red to transformer Black. • Wire nut leg “C” Red to relay Black. • Wire nut leg “D” Black to relay Red.
ELECTRICAL INSTALLALLATION (CONT.) 4) Room Thermostat A) Close the control center junction box. B) Attach thermostat wire to the heating contacts on the thermostat R+W (refer to thermostat manufacturer’s instructions). C) Attach other end of thermostat wire to “R” and “G” contacts on the control center. 5) FAN LIMIT CONTROL A) Attach wire “C” (3 wires: Black/Red/Blue) to the fan limit control. B) There should be a factory installed jumper between the top of the limit and fan switches.
ELECTRICAL INSTALLALLATION (CONT.
OPERATION FOLLOW ALL SAFETY PRECAUTIONS BEFORE STARTING A FIRE • Cycle the FAN switch to check for proper draft blower operation. • Inspect the loading door gasket before lighting the first fire and a few days after, looking for any indications of a poor seal. DANGER DO NOT use gasoline, kerosene, or other flammable liquids. These could cause a flash fire or explosion resulting in serious personal injury and property damage. DANGER DO NOT BURN GARBAGE, HOUSEHOLD WASTE, OR YARD WASTE.
SETTING THE FAN LIMIT CONTROL 1) Set the lower arm (left tab) to 130. This sets the temperature below which the circulation blower turns “OFF”. 2) Set the middle arm (middle tab) to 170. This sets the temperature above which the circulation blower turns “ON”. 3) Set the upper arm (right tab) to 200. This sets the temperature above which the draft blower turns “OFF”.
BURNING BURNING WOOD Burn only split cordwood that has been seasoned for 12-18 months. Burning unseasoned wood is wasteful and inefficient using much of the combustion energy to boil off the excess moisture. Ideally the wood should be split to aid in seasoning and should be around 25% moisture content by weight. The following are general guidelines for wood selection: • Hardwoods burn better than softwoods. • Larger pieces burn better than small pieces.
BURNING (CONT.) BURNING COAL (CONT.) REFUELING 1) Place FAN switch in OFF position. 2) Pull Smoke bypass damper rod out and wait one minute. 3) Open the fuel loading door slowly. 4) Pull the glowing coal to the front of the fire box. Try not to disturb the fire too much. 5) Add new coal to the back of the fire box, being careful not to seal off the top. It is important to leave a red spot of glowing coals visible after adding new coal to ensure that the fire has not been smothered.
BURNING (CONT.) CREOSOTE FORMATION All wood burning devices create some creosote. 1) When wood is burned slowly, it produces tar and other organic vapors, which combine with expelled moisture to form creosote. 2) Creosote vapors condense in the relatively cool chimney flue of a slow burning fire. 3) As a result, creosote residue accumulates on the flue lining. 4) When ignited this creosote makes an extremely hot fire.
EMERGENCY ACTIONS OVER HEATING 1) Manually turn off the draft fan at the fan switch (place switch in OFF position). 2) DO NOT TURN OFF THE MASTER SWITCH . The circulation blower must have power to remove heat from the appliance. 3) Turn the thermostats fully up in the structure being heated by furnace to remove heat from the appliance as fast as possible. 4) Allow the appliance to cool down. 5) If the furnace does not cool down then, with a shovel, remove as much of the wood and coals from the fire box.
MAINTENANCE Keeping the solid fuel furnace in good repair will result in more efficient operation and longer appliance life. You are responsible for safely maintaining the unit. Follow the Service and Maintenance procedures given throughout this manual and in component literature shipped with the appliance. DANGER Failure to perform the service and maintenance could result in damage to the boiler or system.
MAINTENANCE (CONT.) BEGINNING OF SEASON • Chimney: Remove cap from chimney. Inspect chimney. Ensure chimney is not blocked (check for animal or bird nests). • Loading door : Oil door hinges and latch. Inspect gaskets. Verify that door seals tightly (apply thin coat of lipstick to loading flange, shut door, reopen and inspect marking on the gasket). • Blower motor: Place a few drops of S.A.E. 20 motor oil in each of the two oil cups. Use only S.A.E. 20 motor oil to lubricate the motor.
TROUBLE SHOOTING 1) PROBLEM: NOT ENOUGH HEAT OUT OF THE APPLIANCE. A) If the appliance reaches operating temperature (200°F) and draft fan shuts off, it is working properly. (If draft fan does not shut off, see Problem 4). Possibly, the appliance is undersized for the required heat load. B) Ensure that the joints in the hot air duct are tight. C) Check and clean the return air duct. D) Replace the air filter. E) Check for furniture blocking the cold air return vents.
TROUBLE SHOOTING (CONT.) D) A buildup of ashes in the ash trough can restrict the exhaust of combustion air. E) A buildup of ashes on top of the grates can restrict combustion air. F) Ensure that the chimney has adequate draft (.06” w.c. minimum). G) Ensure that no other appliances are connected to the chimney. H) A “cold” chimney could force cooler exhaust gases back into the furnace. Verify that the chimney is properly installed and insulated.
REPLACEMENT PARTS LISTING 3/8-16x1 1/2 HHCS 3/8-16 Nut Cast Baffle Shaker Handle F Rocker Grate Front Grate Frame E G D C B Rear Grate Frame Rocker Flat Bar 1/4x1 1 3/4 Clevis Pin 1/6x1 1/4 Cotter Pin (SS) 3/8-16x1 1/2 HHCS 3/8-16 Nut A 1/4-20x1 HHCS 1/4-20 Center Lock Nut Cast S Hook Reference # A Item Name S HOOK Royall Part # CAS-S-HOOK B ROCKER FLAT BAR 4 GRATES RF-ROCKERFLTBR5HL C D E REAR GRATE FRONT GRATE ROCKER GRATE CAS-REAR-FRM CAS-FRONT-FRM CAS-ROCKER F CAST BAFFLE CAS-BA
REPLACEMENT PARTS LISTING (CONT.
REPLACEMENT PARTS LISTING (CONT.
REPLACEMENT PARTS LISTING (CONT.) Parts listed on page 36 are not shown in Replacement Parts Listing Diagrams found on pages 33-35. Visit us on the web at Royallfurnace.com for all other part related questions.
WARRANTY ON ROYALL SOLID FUEL APPLIANCES Warranty On Solid Fuel Appliances ROYALL Solid Fuel Appliances are warranted by ROYALL to the original user against defects in workmanship under normal use, from the date of purchase. This warranty is subject to the condition that the ROYALL Product(s) must have been installed in accordance with manufacturer’s instructions. The Purchaser’s warranty registration card must be on file at ROYALL to qualify for warranty.
800.944.2516 325 S. Park Street, Reedsburg, WI 53959 royallfurnace.
