Installation
OUTDOOR PRESSURIZED BOILER
Models: 6150, 6200, 6300, 6490
INDOOR PRESSURIZED BOILER
Models: 6130NS, 6150NS, 6200NS, 6300NS, 6490NS
www.royallfurnace.com
325 South Park Street Reedsburg, WI 53959
Phone 608-768-8508
Thank you for purchasing a ROYALL pressurized Solid Fuel appliance.
Boilers are a quality Solid Fuel Appliance designed to effectively heat structures.
Please read and follow all safety instructions to ensure optimal performance.
The installation and operation of the is quite simple. Nevertheless, we recommend
that the instructions be carefully read and followed. On INDOOR models, pay particular
attention to the chimney and chimney connector installations as they present a significant
fire danger.
If you have any questions on the installation or operation of your Solid Fuel
Appliance, please contact your local
representative.
Failure to install properly, or follow safety instructions could result in severe personal
injury, death or substantial property damage.
HAZARD DEFINITIONS
OBSERVE AND FOLLOW ALL SAFETY INSTRUCTIONS
The following defined terms are used throughout this manual to bring attention to the presence of hazards of serious
risk levels, or important information concerning the life of the product.
DANGER
Dictates presence of hazards that WILL CAUSE SERVER personal injury, death or substantial property damage.
WARNING
Indicates presence of hazards that CAN CAUSE SERVE personal injury, death or substantial property damage.
CAUTION
Indicates presence of hazards that WILL OR CAN CAUSE minor personal injury or property damage.
NOTICE
Indicates special instructions on installation, operation or maintenance that are important but not related
to personal injury or property damage.
VERIFY WITH YOUR INSURANCE COMPANY AND ALL LOCAL CODES AND ORDINANCES PRIOR TO INSTALLATION.
IT IS THE OWNER’S RESPONSIBILITY TO ENSURE THAT THE APPLIANCE MEETS ALL LOCAL CODES AND ORDINANCES.
September 2012
Page 2
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
EMAIL 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.
NAME
STREET ADDRESS
CITY
STATE
ZIP CODE
PHONE
EMAIL 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
OWNER’S REGISTRATION CARD MUST BE COMPLETED AND RETURNED T0 ROYALL AT TIME OF INSTALLATION.
Place
Stamp
Here
Brand Products
325 South Park Street
Reedsburg, WI 53959
Place
Stamp
Here
Brand Products
325 South Park Street
Reedsburg, WI 53959
CONTENT
GENERAL
SAFETY.................................................................................................................................................. Pg
4
PRESSURIZED BOILER SPECIFICATIONS.......................................................................................... Pg
5
PRODUCT DESCRIPTION.................................................................................................................... Pg
6
INSTALLATION
INSTALLATION TIPS............................................................................................................................. Pg
7
INSTALLATION PLACEMENT.............................................................................................................. Pg
8
CONTENTS............................................................................................................................................ Pg
9
SHROUD INSTALLATION.................................................................................................................... Pg 11
FIREBRICK INSTALLATION.................................................................................................................. Pg 12
INDOOR BOILER INSTALLATION: VENTING..................................................................................... Pg 13
PLUMBING CONNECTIONS................................................................................................................ Pg 15
COMPONENT ASSEMBLY.................................................................................................................... Pg 16
ELECTRICAL......................................................................................................................................... Pg 18
AQUASTAT CONTROL SETTING......................................................................................................... Pg 20
ELECTRICAL DIAGRAMS.................................................................................................................... Pg 21
SYSTEM PLUMBING............................................................................................................................ Pg 22
TYPICAL SYSTEM SCHEMATICS........................................................................................................ Pg 23
START UP
INITIAL SYSTEM FILL.......................................................................................................................... Pg 26
FIRST FIRE............................................................................................................................................ Pg 28
OPERATION
BOILER CONTROL............................................................................................................................... Pg 28
BURNING WITH WOOD...................................................................................................................... Pg 29
BURNING WITH COAL........................................................................................................................ Pg 30
EMERGENCY ACTIONS....................................................................................................................... Pg 32
MAINTENANCE.................................................................................................................................... Pg 33
TROUBLE SHOOTING................................................................................................................................... Pg 36
REPLACEMENT PARTS LISTING................................................................................................................. Pg 38
WARRANTY..................................................................................................................................................... Pg 42
September 2012
Page 3
SAFETY
NOTICE
ALL STATE or LOCAL CODES take precedence and MUST be observed.
These models have been certified compliant to UL 391-06 through independent testing. Additionally, some of
these recommendations align with the National Fire Protection Assign. Code 211. Before installing or starting
operation, read and familiarize yourself with all instructions. Installation is to be performed only by qualified
licensed heating professional.
DANGER
RISK OF EXPLOSION OR PERSONAL INJURY
DO NOT use chemicals, kerosene or other flammable liquids to start a fire; severe burns could result.
DO NOT store combustible liquids or materials near the appliance.
DO NOT store wood within the minimum clearance to combustibles.
DO NOT burn garbage, gasoline, naphtha or engine oil for any reason.
DO NOT burn tires, telephone poles, railroad ties or yard waste. In many areas this is illegal and will damage
the appliance. Burning anything other than approved fuels will void any warranties.
DO NOT start a fire if flammable vapors or dust are present. An explosion could result.
DO NOT use with an automatic stocker.
DO NOT operate with a flue draft exceeding .06 inches of water column pressure. Most anti-freeze is
glycol based. Never store glycol of any kind near the appliance or any potential ignition source. All glycol is
flammable when exposed to high temperatures. If glycol is allowed to accumulate in or around the appliance or any other potential ignition source, a fire can develop.
NEVER use automotive anti-freeze or ethylene glycol in the system. Using these glycols can destroy rubber
pump and valve seals leading to hazardous leakage and system damage. Monitor and inspect the system
and appliance regularly for leakage.
NEVER operate without a properly installed pressure relief valve (watts M335 or Apllo 407-1035) or equivalent) which discharge water and relieve pressure at 30 psi. Use only a boiler relief valve designed to lift at 30
psi. Failure to use proper valve could result in an explosion, injury or property damage.
WHEN SYSTEM IS COLD, CAREFULLY OPEN/TEST/INSPECT the pressure relief valve at least annually to
ensure waterways are clear. IF SYSTEM IS HOT, avoid contact with the scalding water that will be
released. Failure to check the valve could result in an over pressure condition. This provides risk of a
rupture in the system and significant risk of severe injury or damage.
DO NOT install in a garage due to routine presence of flammables.
DO NOT use petroleum-based cleaning or sealing compounds in the heating system. Pump and valve water
seal deterioration will occur. This can result in substantial property damage.
DO NOT use “homemade cures” or “boiler patent medicines”. Serious damage to the appliance, personal
injury and /or property may result. To avoid electric shock, disconnect electrical supply before performing
maintenance. To avoid server burns, allow the appliance to cool before performing maintenance. This appliance requires electricity whenever in operation. Operation without electricity could result in the
appliance overheating. If power outages are anticipated, a back-up electrical generator is recommended.
September 2012
Page 4
APPLIANCE OPERATION:
Before opening the fuel door to a fired system, ensure that the draft blower is OFF, the damper rod is pulled
out, wait 5-10 seconds, and ALWAYS hesitate momentarily between the first and second latches when
opening doors to allow unburned gases to ignite. Failure to do so could result in severe burns.
DO NOT
•
Block flow of combustion or ventilation air to the appliance.
•
Turn off the water circulation pump or prevent fluid flow during operation. An over pressurized
condition could result.
•
Restrict access to the rear of the unit for maintenance. Attempt to supply fuel to these units
with an automatic stoker device.
•
DO NOT attempt to supply fuel to these units with an automatic stoker device.
PRESSURIZED BOILER SPECIFICATIONS
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MODEL
NUMBER
6130
130,000
780
6.25 cubic ft
26”
10 X 14
6“
23 gal
24 X 44 X 38
N/A
N/A
6150
150,000
905
8.1 cubic ft
26”
10 X 14
6“
35 gal
26 X 51 X 38
45 X 60 X 77
1415
INDOOR & OUTDOOR
200,000
1250
13.0 cubic ft
26”
17 X 17
6“
90 gal
36 X 59 X 38
45 X 60 X 77
1760
6300
300,000
1650
17.7 cubic ft
43”
17 X 17
6”
135 gal
36 X 59 X 55
45 X 76 X 77
2530
490,000
2900
50. cubic ft
56”
24 X 32
10”
260 gal
50 X 74 X 74
60 X 90 X 85
4000
INDOOR & OUTDOOR
6200
INDOOR & OUTDOOR
6490
INDOOR & OUTDOOR
September 2012
Page
5
PRODUCT DESCRIPTION
The
Indoor/Outdoor Solid Fuel Boilers are designed to burn either seasoned, split cord wood or
coal. A water circulating pump moves the heated water to a heat exchanging device. This can be a base board
radiator, finned based board radiator, water to air exchanger, or existing boiler system; with the correct safety
apparatus installed to local codes.
The wood fire combustion process is controlled by an aqua stat that senses exiting water temperature. The aqua
stat is set to the desired high temperature set point and will energize the solid fuel draft fan when the water
temperature drops 10 degrees below the high temperature set point. When the water reaches the high
temperature set point the aqua stat shuts off the electrical power to the solid fuel draft blower. It is not necessary
to connect a thermostat wire from the heating structure to the boiler. The boiler will sustain the desired
temperature water so that is available to the heated structure when needed. The operator uses the high
temperature setting and fuel load size to match the unit’s heat output with the heated structures needs. If heat is
not needed by the structure, full temperature water returning to the unit should put it into a damping cycle until
heat is taken by the structure or lost in the system through normal heat loss related to the effectiveness of the
system insulation.
A master switch should be incorporated such that all power to unit can be controlled. A fan switch or light switch
should be incorporated to allow manual shut off during fuel loading and fire box maintenance.
A two position safety latch is installed on the fuel door and the ash pan door. Initial release of the latch should be
followed by a brief hesitation to allow ignition of unburned gases. Force from the unburned gases igniting can
cause the door to abruptly swing open to the 2nd position of the latch which stops further opening forcing the
ignition flame and gases to exit the flue instead of out the door.
These units should only be installed and operated as closed (pressurized) systems. An expansion tank is required to
provide safe changes in water volume related to system temperature change. A pressure relief valve is installed on
the unit to safely reduce system pressure if it ever exceeds 30 psi. The appliance is hydrostatically tested at the
factory to 60 psi.
The solid fuel boiler can deliver hot water to an existing gas, oil or electric boiler or can operate independently via a
bypass loop. Water must be continuously pumped through the appliance. The room thermostat cycles the existing boiler, starting the water pump. If the solid fuel boiler is out of wood, the primary boiler aquastat will signal the
primary firing system to take over and maintain system temperature.
An over temperature relief zone is required. To signal a relief zone exchanger a surface aquastat can be used as a
safety limit control. If the water temperature passing through the pipe where the surfaces aquastat is mounted rises
above the set point (should be the same or slightly above the high temperature setting of the boiler when attached
to the hot supply line). This signal will over ride the normal setting for the exchanger and relieve the system of
excess heat. This reduces risk of over pressurizing the system.
September 2012
Page 6
INSTALLATION TIPS
AVOIDING AIR LOCKS
All ROYALL Solid Fuel Boilers are designed not to exceed 30 psi, and will vent to the atmosphere if necessary.
Air trapped in the lines prevents circulation. Poor circulation is a common start up problem. Reduced flow can be
difficult to detect because the pipes will feel hot. It is essential to provide a means for the air in the lines to escape
as the system is being filled. Design piping to avoid high points where air can be trapped or install air bleeding
vents at these locations. Various vent fittings are available such as vented brass elbows or baseboard tees. Vents
should be open during the fill process. Close the vents when bubble-free water runs out. The auto air vents on top
of the air scoop should remain open at all times.
Improper venting can lead to risk of generating high temperatures or steam which can destroy
DANGER
hard and flexible plastic piping due to increased temperature.
BALL VALVES
Install ball valves in the lines to isolate various components or sections. The ball valves will eliminate the need to
drain and refill the entire system should joints need to be resoldered or plumbing modified. Normally, isolation
pump flanges are supplied with the pump. These have built in ball valves that can be opened or closed, allowing
the pump to be replaced without draining the system. It is recommended that isolation ball valves be installed at
the boiler to assist in maintenance.
WATER SUPPLY
A tee and additional drain valve installed in the system will assist in filling the appliance. Typically the existing boiler
system has a keep fill connection already installed. The boiler should be filled the first time according to the initial
fill manual section. Ensure that you can adequately monitor system pressure while filling. Ideally, system pressure
should be visible from the valve being used to fill the system. Unless a back flow preventer is used with a keep full
valve, you will need to disconnect the water supply. Normal routines should include inspecting the entire system
for leaks.
CORROSION INHIBITOR
It is recommended that the system water be tested and PH levels maintained between 8.5 & 11, Use of a corrosion
inhibitor is recommended. Treatment reduces premature failure due to corrosion and can help provide efficient
heat transfer by minimizing scale. Treatments should be designed for use in hydronic (boiler) systems. Individual
water conditions may require unique additives. Unit failure due to severe short term corrosion is not covered by
the warranty.
RELIEF VALVES
WARNING
A pressure relief valve must be piped into the appliance such that it can not be isolated from the
appliance. Open plumbing (no fitting at the end) should be added to the valve so that release
will safely discharge scalding water near the floor.
September 2012
Page 7
INSTALLATION PLACEMENT
IMPORTANT NOTE
•
•
CHECK WITH INSURANCE COMPANY PRIOR TO INSTALLATION. IT IS THE OWNER’S
RESPONSIBILITY TO ENSURE THAT THE APPLIANCE IS ACCEPTABLE TO THEIR INSURANCE
CARRIER.
VERIFY LOCAL CODES AND ORDINANCES PRIOR TO INSTALLATION. IT IS THE OWNERS
RESPONSIBILITY TO ENSURE THAT THE APPLIANCE MEETS ALL LOCAL CODES AND ORDINANCES
WHICH TAKE PREEDENCE AND MUST BE OBSERVED PROVIDING THEY ARE MORE RESTRICTIVE.
INSTALLATION MUST BE PERFORMED BY A QUALIFIED INSTALLER
1) When placing the Solid Fuel INDOOR Boiler, the following should be considered.
a) Review the minimum clearances to combustibles on page 9.
b) Review the recommended stack heights on page 13.
c) Do not locate near any combustible materials, gasoline or other flammable liquids or gases.
d) Check with insurance company and observe local codes and ordinances.
e) The unit requires 115V 15 Amp electrical service for operation.
DANGER
Failure to keep the solid fuel boiler area clear and free of combustible materials, gasoline or
other flammable liquids or 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. The Indoor boil is designed to be installed inside the building being heated
either as a stand alone unit or in combination with another boiler. All installations must be in accordance with local
and state codes which may differ from this manual.
FOUNDATION
The Indoor boiler must be located on a 2” minimum thickness concrete foundation pad. At a minimum, there must
be a non-combustible pad (concrete, brick, or paver) the width of the appliance extending out 48 inches from the
front of the unit.
Outdoor units should be set on a concrete pad capable of supporting the unit when it is filled. A 48” non-combustible surface is recommend in front of the fuel loading door.
DANGER
A non-combustible pad must be installed in front of the unit to contain any sparks or coals out of
the loading door or Ash pan door. Fire can result, causing severe personal injury, death or
substantial property damage.
FLOORING
DANGER
The Solid Fuel Boiler must be placed on a non-combustible floor which must extend a minimum
of 6 inches on sides and back. 48 inches are required in front. The unit should never be installed
on carpeting even if a foundation is used. Fire can result causing severe personal injury, death or
substantial property damage.
*** DO NOT INSTALL IN A GARAGE WHERE FLAMMABLES ARE STORED ***
September 2012
Page 8
CONTENTS
INSTALLATION: CLEARANCES – INDOOR MODELS
The Indoor boiler must be installed with these minimum clearances from NON-COMBUSTIBLE surface:
Front = 30”/ Back = 30” / Sides = 12”
The Indoor boiler must be installed with these minimum clearances from any COMBUSTIBLE surface:
Front = 48”/ Back = 30” / Smoke pipe / Sides = 18”
Recommended maintenance clearances = 18”
Back 30 / one side 36
DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE
SERVING ANOTHER APPLIANCE.
CHIMNEY TYPE: CLASS “A” ALL FUEL CHIMNEY 8” DIAMETER
CLEARANCES: UNIT TO BACKWALL
30”
UNIT TO SIDEWALL
18”
FLUE TO BACKWALL
18”
FLUE TO SIDEWALL
30’
FLOOR PROTECTION: FOR INSTALLATION ON NON-COMBUSTIBLE FLOOR ONLY.
MAXIMUM DRAFT: 0.06 IN WATER COLUMN.
ELECTRICAL RATING: 120 V., 0.5 AMP, 60 HZ.
OPERATION/MAINTENANCE
FUEL: BURN SOLID WOOD OR COAL ONLY. LOAD FUEL CAREFULLY OR DAMAGE
MAY RESULT. DO NOT STORE FUEL OR COMBUSTIBLES NEAR UNIT.
DO NOT USE CHEMICALS OR FLUIDS TO START FIRE, DO NOT BURN GARBAGE,
GASOLINE, NAPTHA OR ENGINE OIL. FOR SAFETY, KEEP FUEL AND ASH DOORS
TIGHTLY CLOSED. CLEAN HEAT EXCHANGER. FUEL PIPE AND CHIMNEY
FREQUENTLY TO PREVENT ACCUMULATION OF SOOT. THE APPLIANCE AND
FLUE PIPE MUST BE IN GOOD CONDITION. IN THE EVENT OF A RUN-AWAY FIRE,
STOP SUPPLY OF COMBUSTION AIR TO FIRE. SECURE FUEL AND ASH DOORS.
REFER TO OWNER’S MANUAL.
DO NOT OPERATE DURING POWER FAILURE.
September 2012
Page 9
CONTENTS (CONT.)
INSTALLATION: INSPECTING CONTENTS
BOXED COMPONENTS SHIPPED LOOSE INSIDE (component illustrations located in repair parts section)
ROYALL INDOOR BOILER

Fire Brick
Aquastat
Pressure and Temperature Gauge
Draft blower and gasket
Pressure Relief Valve
Spring Handles for doors, shaker grate and damper plate
Owners warranty / registration card
Installation and Operation Manual
BAFFLE PLATE (all boilers)
The unit comes with a cast iron baffle installed inside the fire box. Verify that the baffle is in place directly behind the
blower mounting opening.
GRATES (all boilers)
The unit comes with grates installed inside the fire box. Verify that the grates are in place and operate freely.
DOOR GASKETS (all boilers)
The unit comes with the door gaskets installed in both the fuel door and ash pan door. Verify that they are in place.
SMOKE DAMPER (all boilers)
The unit comes with the smoke damper assembly installed. Verify that the damper handle moves freely, opening
the smoke by pass plate.
ASH PAN
The unit comes with the ash pan stored in the ash pan trough. Open the ash door and remove the ash pan. The pan
should NOT be stored in the unit during operation, as it will warp and be to hot to handle.
September 2012
Page 10
SHROUD INSTALLATION
1.
Attach Shroud mount corners to Boiler using supplied hardware.
Each corner is designed to fit a specific corner of the unit.
2.
Attach Shroud side panels to corners.
Panels will fit inside the corners.
3.
Install Shroud top.
Top must be installed before aquastat is installed.
Attach with supplied hardware.
SHROUD TOP
SHROUD MOUNTING
CORNER
NOTE:
SHROUDS ORDERED AS A SET
SET INCLUDES:
4 CORNER
2 SIDES
1 TOP
HARDWARE SHROUDS ARE UNIQUE FOR EACH UNIT.
SHROUD SIDE
September 2012
Page 11
FIREBRICK INSTALLATION
The appliance comes with the firebrick packaged inside.
Brick size: 9” x 4-1/2” x 1-1/4” (Royall pin number firebrick standard split).
MODEL 6130 (6) Full Bricks & (2) Cut Brick
Starting in the BACK lay 3 full brick then 1 cut brick.
Repeat for 2nd side.
Model 6130
MODEL 6150 & 6200 (12) Full & (2) Cut Bricks
Starting in the BACK of the unit, place ½ brick on end,
then add 4 full brick on end. Last lay 2 full bricks side
down. Repeat for 2nd side.
Models
6150 & 6200
MODEL 6300 (18) Full Bricks & 2 Cut Bricks
Starting in the BACK stand 1 cut brick then 7 full brick
side by side. Then lay 2 bricks stacked side to side in the
front. Repeat for 2nd side.
Model 6300
MODEL 6490 (36) Full Bricks
Starting at the BACK stand 12 full brick side by side. Then
lay 6 full brick down on top of 12 lower ones. Repeat for
2nd side.
Model 6490
September 2012
Page 12
INDOOR BOILER INSTALLATION: VENTING
All single wall chimneys must be at least 18” from any combustible surface. Fire can
DANGER 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.
CHIMNEY MATERIAL
The Boiler must be connected to either a:
1) Class “A” masonry chimney
2) All Fuel metal insulated chimney (8”)
3) Listed type “HT” double wall chimney approved for temperatures up to 1400 °F (8”)
CHIMNEY CONNECTORS
Connectors will be required to attach appliance to chimney unless chimney is attached direct.
1) Chimney connector can either be:
A) 6” or 8” galvanized, black or blue steel, stove pipe with adapter only at the “T”
• Maintain 18” clearance to combustibles.
• Minimum thickness: .028 inches (24 gauge minimum)
B) 6” or 8” listed type “HT” double wall chimneys.
• Maintain 2” clearance to combustibles.
2)
Boiler must be the only heating appliance connected to a single chimney flue.
3)
Keep the connector as straight and short as possible.
A) Minimize elbows.
B) Maximum horizontal distance between boiler and chimney: 6 Ft.
C) “Male” end should point back to boiler.
D) Horizontal runs must be pitched back to the boiler in accordance with local Building Codes
(typically 1/4” pitch per Foot of horizontal run minimum).
E) Secure each connection with a minimum of 3 screws.
4)
Assemble in accordance with the vent manufacturers instructions. Additional sections may be required to
clear the peak of the structure. Do not install more than one appliance per flue.
When burning coal, a barometric draft damper MUST be installed between the boiler and the chimney to en
sure adequate draft.
5)
DANGER
DO NOT install more than one appliance per flue. Flue gas spillage and carbon
monoxide emissions can occur causing severe personal injury or death.
CHIMNEY MUST BE INSTALLED OR INSPECTED BY A PROFESSIONAL AND
MEET ALL LOCAL AND STATE REQUIREMENTS AND CODES FOR WOOD OR
COAL BURNING APPLIANCES OPERATING CONDITIONS.
September 2012
Page 13
INSTALLATION: VENTING
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.
Nearby structures, trees, or hills can cause downdraft conditions which force smoke to the ground. Chimney height
may have to be raised to overcome downdraft conditions.
NOTICE
Improper use or failure to maintain the boiler may cause nuisance conditions. Persons
operating this solid fuel boiler are responsible for operation so as not to cause nuisance
conditions. Even proper use and maintenance of the boiler, and meeting the distance
and stack height recommendations and requirements in State and local regulations may not
always be adequate to prevent nuisance conditions in some areas due to terrain or other factors.
ALL LOCAL AND STATE REGULATIONS OR CODES AND VENTING
SYSTEM MANUFACTURER’S INSTRUCTIONS TAKE PRECEDENCE OVER THESE INSTRUCTIONS.
ALL SOLID FUEL APPLIANCES CREATE VISIBLE SMOKE DURING SOME OPERATING CONDITIONS.
September 2012
Page 14
PLUMBING CONNECTIONS
SIZE OF BOILER FITTINGS
3
7
2
1
4
8
6
5
Front View
Back View
September 2012
Page 15
COMPONENT ASSEMBLY
INDOOR BOILER : CONNECTIONS
(OUT DOOR BOILERS ASSEMBLED AT FACTORY, INDOOR UNITS SHIPPED WITH COMPOTES BOXED AND STORED IN
FUEL CHAMBER FOR PROTECTION DURING SHIPPING)
INSTALL COMPONENTS AS FOLLOWS AND LOCATE PER REFERENCE CHART AND DIAGRAM ON PREVIOUS PAGE.
PRESSURE TEMPERATURE GAUGE (#2)
• Apply pipe sealer and Teflon tape to threads.
• Install in threaded coupling in upper left front of boiler.
• Tighten with proper wrench.
• Do not over tighten.
AQUASTAT WELL (#4) (WELL NORMALLY FACTORY INSTALLED)
• Apply pipe sealer and Teflon tape to threads.
• Install in threaded coupling in upper right front of boiler.
• Tighten with proper wrench.
• Install aquastat housing over the head of the aquastat well.
• Do not over tighten.
DRAFT BLOWER
• Mount the draft blower using the gasket to the front of the boiler with the three screws furnished.
• Ensure that the gasket seals tightly between the blower and the appliance flange.
BOILER DRAIN VALVES (#5 & #6):
• Apply pipe sealer and Teflon tape to threads.
• Install boiler drain valves in threaded flanges located in front #5 & 6 (steel plugs can be substituted).
• Tighten with proper wrench.
• Do not over tighten.
PRESSURE RELIEF VALVE (#3)
• A) Apply pipe sealer and Teflon tape to threads.
• B) Install in threaded coupling in upper center back of boiler.
• C) Tighten pressure relief valve with proper wrench.
• D) Do not over tighten.
DANGER
Before filling the system, ensure the pressure relief valve is installed. Use only a boiler relief valve
set to limit pressure to 30 psi. Failure to comply with these guidelines could result in failure of
the relief valve to operate, resulting in possibility of severe personal injury, death or substantial
property damage.
To avoid water damage or scalding due to relief valve operation:
• Discharge line must be connected to relief valve outlet and run to a safe place of disposal. Terminate the
discharge line to eliminate possibility of severe burns should the valve discharge.
• Discharge line must be as short as possible and be the same dimension as the valve discharge connection
throughout its entire length.
• Discharge line must pitch downward from the valve and terminate at least 6” above the floor drain where any
discharge will be clearly visible.
• The discharge line shall terminate plain (OPEN), not threaded, with a material serviceable for temperatures of
200°F or greater (copper, black pipe, galvanized or Pex-Al-Pex).
• Do not pipe the discharge to any place where freezing could occur.
PRESSURE RELIEF VALVE (#3) (CONT.)
September 2012
Page 16
PRESSURE RELIEF VALVE (#3) (CONT.)
• No shutoff valve shall be installed between the relief valve and boiler, or in the discharge line. Do not plug or
place any obstruction in the discharge line.
• Test the operation of the valve after filling and pressurizing system by lifting the lever. Ensure the valve
discharges freely. If the valve fails to operate correctly, replace it with a new relief valve.
WIRE HANDLES (4)
Turn the wire handles on to the levers in a clockwise direction.
LOW WATER CUT OFF (IF REQUIRED)
Some State and Local Codes and some Insurance Companies require a Low Water Cut Off device (LWCO)
when the heat source is installed above radiation. If required, the LWCO must be installed at a high point in the
system, in a Tee near the top of the boiler.
AUTOMATIC FILL VALVES
These devices help maintain water volume in the advent that the relief valve has a discharge event. It is more difficult to recognize a leak in a system with a valve continuously making up lost water. If an auto fill valve is installed,
it is recommended that a routine system check for leaks be established. Also careful monitoring of the relief valve
discharge area should be conducted.
WARNING
If a feed water line and valve are incorporated, a back flow preventer is required to preclude
heating system water from entering the domestic system.
INSTALLATION: ELECTRICALS BASIC ELECTRICALS
For your safety, turn off electrical power supply at service entrance panel before making any electrical
connections to avoid electric shock hazard. Failure to do so can cause severe personal injury or death.
DANGER
WARNING
Ensure power is shut off while making connections. Failure to do so may result in
severe personal injury or death.
To ensure that the appliance always has flow when operating, it is recommended that the pump
and the appliance receive power from the same breaker. This is most important if the pump is
located remote from the appliance in the structure being heated. DO NOT apply power to the
pump until system has been filled. The pump is water cooled and must never be run dry due to
risk of damage from overheating.
September 2012
Page 17
ELECTRICAL
ELECTRICAL INSTALLATION MUST COMPLY WITH
• National Electrical Code and any other national, state, provincial or local codes or regulations.
• In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.
Appliance must be electrically grounded as required by National Electrical Code ANSI/NFPA 70–latest edition.
Ensure ground wiring is installed per wiring diagram. Good grounding is extremely important for
proper operation.
OUTDOOR MODELS require power to be brought into the junction box on the rear of the unit and to the water
pump (not supplied). The low side of the Aquastat may be used to signal a safety heat relief zone.
INDOOR MODELS:
1) The following components are not included and must be provided by the installer:
• 4 x 4 junction box
• (2) SPST switches
2) Attach 4 x 4 junction box to the boiler.
3) Route power (115 V, 60 Hz, 15 Amp) to the junction box.
4) Connect the MASTER switch:
• Connect power “Hot” (Black) to one side
• Wire nut a lead from the other side to both the FAN switch and to the pump
5) Route power from the other side of the FAN switch to the aquastat, attach to “R”.
6) Route power from the aquastat (“B”) to the blower:
• Connect Black wire to Black wire on blower
• Connect White wire to one White wire on blower
• Connect Green wire to Green screw in blower junction box
7) Connect white common wires from the blower and pump to the White wire from the power supply.
The pump will operate when the MASTER switch is in the ON position. Operating the
NOTICE pump without water in the system will damage the pump.
8)
Route power to the pump.
9)
Connect pump using conduit with Black, White, and Green wire.
• Open pump junction box cover
• Remove one knockout and fasten conduit to pump junction box
• Connect Black wire to one White wire on pump
• Connect White wire to one White wire on pump
• Connect Green wire to pump grounding screw in pump junction box
September 2012
Page 18
ELECTRICAL (CONT.)
INSTALLATION: SETTING THE ANALOG AQUASTAT
ANALOG IMMERSION AQUASTAT
(Indoor units -Outdoor factory installed)
1) Loosen screw on right side of case and remove cover.
SET the high limit set point knob to the desired shut off
water temp (never above 195 degrees). NOTE these
units have a built in 10 degree drop differential.
2) Insert the sensing probe into the immersion well.
The sensing probe MUST touch the bottom of the well.
Sharp bends in sensing probe wire could impair operation.
3) Fasten aquastat to the well by tightening the adapter
clamp set screw in the top of the unit.
4) Replace cover.
ADDITIONAL SAFETY CONTROLS
HIGH TEMPERATURE LIMIT CONTROL
If installation is to comply with ASME or Canadian requirements, an additional high temperature limit is required.
Install control in supply piping close to the appliance. Set second control to approx. 20 °F above set point of first
control. Maximum set point should be established to protect weakest component in the system (such as plastic
piping). The boiler should be protected at no more than 240 degrees.
LOW WATER CUTOFF
A low water cutoff device (LWCO) is required when the heat source is installed above radiation level or by certain
state or local codes or insurance companies. If required, the LWCO must be installed code and manufacture’s instructions.
September 2012
Page 19
AQUASTAT CONTROL SETTING
September 2012
Page 20
ELECTRICAL DIAGRAMS
INSTALLATION: BOILER PIPING
1) BOILER DRAIN VALVES
A) Drain valves are recommended to assist in filling and purging air. See chart in
connection section in door and out door locations
B) Pipe in Tee at bottom of return (“Cold”) pipe.
C) Pipe in Tees at top of both return (“Cold”) and supply (“Hot”) pipes.
2) PUMP
A) A pump is required. If using isolation flanges, ensure that they are positioned
so that the shut off is accessible.
B) Pump motors are water lubricated and can burn out if incorrectly mounted.
The motor canister must be horizontal.
C) Body has an arrow on the casting that indicates direction of flow.
D) To rotate the motor canister, remove the four motor bolts, rotate 4-8” Max motor
and replace bolts. Ensure the junction box is NOT located underneath the circulator.
E) When boiler is operating, pump will feel hot to the touch. This is normal.
3) PRIMARY-SECONDARY PIPING
A) Primary-Secondary piping is recommended to ensure continuous flow through
the boiler.
B) Tees should be no more than 4-8 inches apart.
C) A full port ball valve may be installed between the Tees (as shown) to assist in
filling. It must not disturb the flow between the Tees when in the open position.
September 2012
Page 21
SYSTEM PLUMBING
INSTALLATION: GENERIC SYSTEMS
CAUTION
The system Diagrams provided are only suggested schematics for generic systems and do not
purport to show all required components necessary to meet all required codes. Complex
systems should be designed by a professional heating system.
GENERAL COMMENTS
PIPING AT THE APPLIANCE
Base Board
The piping at the appliance does not change with most
applications In the applications drawings on following
pages it is not shown but is assumed to be as shown on
this page.
PUMPS
Is recommended that a system pump be installed to ensure flow through the boiler at all times. If the system is
designed for continuous flow, then a system pump is not
necessary. All pumps must be sized properly based on
flow requiems.
EXPANSION TANK
Hydronic heating systems require an expansion tank to
allow water to expand/contract as it heats or cools
without adversely affecting system pressure. A diaphragm
type expansion tank is recommended. The tank must be
installed vertically. Typically it is attached to the bottom of
an air scoop. An existing hydronic system should already
have an expansion tank. Though it is not necessary to add
another expansion tank, ensure that the existing tank is
large enough to handle both the volume of the solid fuel
boiler and the volume of the existing system.
AIR ELIMINATION
Air will collect at the high points in the system, potentially
interrupting flow. An air vent should be located at points to
allow the system to be purged of air.
COMPLEX SYSTEMS SHOULD BE DESIGNED BY A HEATING PROFESSIONAL
September 2012
Page 22
TYPICAL SYSTEM SCHEMATICS
OPERATION
1) The solid boiler pump runs constantly, circulating
water through the solid fuel boiler via the primarysecondary Tees.
2)
If the thermostat calls for heat, the existing boiler will
start the boiler pump. The burner will not fire as long
as the start temperature is above the aquastat setting
on the existing boiler.
3)
If the temperature from the solid fuel boiler falls below
the existing boiler aquastat setting, the existing boiler
will fire as normal.
4)
A safety limit aquastat (recommended) attached to
the supply (“Hot”) line out of the solid fuel boiler turns
on a “dump” zone in the system that is able draw if heat
if the solid fuel boiler over temps.
PIPING INSTALLATION
1) Installing primary-secondary Tees (4” to 8” apart) in the return (“Cold”) line to the existing boiler.
2) Connect the solid fuel boiler supply and return lines as shown. Ensure that the supply (“Hot”) line is connected to
the Tee closest to the return of the existing boiler.
3) Ensure the neither the existing boiler nor the solid fuel boiler are isolated from the expansion tank.
DANGER
DO NOT remove or alter the relief valve on the existing boiler. Failure to do so could result in
explosion causing severe injury, death, or property damage.
DANGER
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 serve
personal injury or death.
SAFETY LIMIT AQUASTAT (RECOMMENDED)
1) Mount directly on the supply (“Hot”) line out of the solid fuel boiler.
2) Set 150 higher than aquastat on solid fuel boiler, but never over 2000 F.
3) Wiring installation:
a) Route low voltage wire from ‘R’ screw and ‘W’ spade on safety limit aquastat into the existing relay on boiler or
to the zone valve.
b) If you have several zones in your heating system, wire a safety aquastat to allow circulation through the largest
zone. Wire a safety limit in parallel with the thermostat of the designated “dump zone”.
September 2012
Page 23
TYPICAL SYSTEM (CONT.)
OPERATION
1) Water circulates continuously through the solid fuel boiler.
2) When the thermostat calls, either the zone pump turns on or the existing boiler turns on it’s pump, allowing water to
flow to the baseboard.
PIPING INSTALLATION
1) Ensure that the expansion tank is not isolated from the Boiler.
2) Position closely spaced Tees 4 to 8 inches apart.
3) For the zone pump use either a zoning circulator (with built-in relay) or a regular pump with a zone pump control panel.
WIRING A ZONING CIRCULATOR
1) Route wire from thermostat to ‘R’ on safety limit aquastat.
2) Route wire from ‘W’ on safety limit aquastat to ‘1’ on zoning circulator.
3) Route wire from ‘2’ on zoning circulator to thermostat.
SAFETY LIMIT AQUASTAT
1) Opens zone valve if boiler overheats. Set 15° higher than aquastat on solid fuel boiler, but not over 200°F.
September 2012
Page 24
TYPICAL SYSTEM SCHEMATICS (CONT.)
2) LOW TEMP RADIANT or MIXED TEMP SYSTEM
Low temperature radiant systems require some sort of
tempering device, most commonly a thermostatic
mixing valve. Low temperature and high temperature
applications can be easily accommodated by the solid
fuel boiler.
MIXING VALVE DETAILS
• The mixing valve MUST be piped such that a pump pulls
water through it.
• The best location for the pump is 10” to 12” down stream
of the “Mixed” port of the mixing valve.
Multiple pumps in parallel require check valves on the
outlet of each pump.
MIXED TEMPERATURE SYSTEMS
• Follow the instructions for high temperature systems as
modified by the diagrams below.
• Call Technical services with specific continuous flow
through Solid Fuel design questions.
September 2012
Page 25
INITIAL SYSTEM FILL
1) FILL, ISOLATE, AND PRESSURE TEST
Although the solid fuel boiler is factory pressure tested, it should
be tested in the field to ensure that no damage has occurred
during shipping. Isolate the solid fuel boiler from the system
prior to pressure testing.
A) Shut off isolation valves “B” and “C”.
B) Shut drain valve “G”.
C) Open drain valves “D” and “E”.
D) Keep fill valve or attach hose to drain valve “G”. (either side is
acceptable).
Connect the other end of the hose to a water source with
pressure between 30 and 40 psi.
E) Slowly open drain valve “G” to fill the boiler.
F) When water flows freely from both drain valves “D” and
“E”. Shut drain valves “G”, “D” and “E”.
G) Slowly open drain valve “D” and closely watch the
pressure gauge.
H) Shut drain valve “G” when test pressure on pressure gauge
reaches no more than 29 psi. The pressure relief valve will
discharge if pressure exceeds 30 psi.
The person pressurizing the appliance must
either be able to see the pressure gauge or must
be in direct communications with someone who
DANGER can see the pressure gauge. DO NOT EXCEED 45
PSI. Failure can result in severe personal injury,
death, or substantial property damage.
I) Test for no longer than 10 minutes at 29 psi. Ensure constant
gauge pressure has been maintained throughout test.
Check for leaks, Repair if necessary.
WARNING Leaks must be repaired at once. Failure to do
so can damage boiler, resulting in substantial
property damage. Do not leave Appliance
DANGER unattended. A cold water fill could expand as it
heats up and cause excessive pressure, resulting in
severe personal injury, death or substantial
property damage.
J) Disconnect hose from water source and slowly open drain valve
“H” to lower boiler pressure to 15 psi.
The Relief Valve must be Installed in the system
DANGER prior to operation. Failure can result in severe
personal injury, death, or substantial property
damage.
September 2012
Page 26
INITIAL SYSTEM FILL(CONT.)
2) TEST WATER QUALITY
Test system water pH to determine if water treatment is necessary. Heating system water pH of 8.5 to 11.0 is
recommended. Swimming pool pH test kits are readily available from other sources. Consult local water treatment
companies for unusually hard water areas (above 7 grains hardness) or low pH water conditions (below 7.0). Use only
water treatment designed for hydronic systems. For systems with poor water quality a corrosion inhibitor is required
to be maintained to stay within the warranty.
3) RE-FILL SYSTEM WITH WATER AND BLEED AIR
It is recommended to fill the system initially with water (even if non-toxic antifreeze will be used later) unless the
temperatures are below freezing temperature make it impractical. This will make it easier to drain and refill if it is
necessary to repair leaks or bleed out air. It is important to bleed air correctly when filling the appliance. Do not have
appliance pump running during filling and bleeding.
A) Re-attach garden hose to water supply and drain valve “G”.
B) Crack open drain valve “D” purging any air trapped at the top of the boiler.
C) Crack open drain valve “C” and repeat purging.
D) Slowly open Drain Valve “G” until Boiler pressure indicates 10 psi.
E) Open Isolation Valves “B” and “C”.
F) Verify that solid fuel boiler pump isolation flanges are open and start the solid fuel boiler pump. Verify that it is
running by placing the blade of a screw driver against the pump motor, and the butt against your ear.
G) Open (do not remove) small cap on auto air vent. The pump will circulate water and any air should escape out the
auto air vent. Pressure may drop from air escaping. Add more water with the garden hose or keep fill valve. When
adding more water, fill garden hose with water before attaching to the appliance to prevent from pushing more air
into system.
4) INSPECT SYSTEM FOR LEAKS
After filling the appliance and system with water, inspect all piping throughout the system for leaks. If found, repair
immediately. Repeat this inspection after the boiler has been started and the system has heated up.
LEAKS MUST BE REPAIRED AT ONCE. Failure to do so can damage the appliance, resulting in
WARNING substantial property damage. Do not use PETROLEUM-BASED CLEANING OR SEALING
COMPOUNDS in the heating system. Severe damage to the appliance can occur, resulting in
substantial property damage.
September 2012
Page 27
FIRST FIRE
OPERATION - FOLLOW ALL SAFETY PRECAUTIONS
BEFORE STARTING A FIRE
• ENSURE the isolation valves are open.
• Start the pump. The pump is lubricated with water. DO NOT run dry.
• 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. In most areas this is illegal. The unit is
designed to burn seasoned split cord wood or coal,
burning other materials can reduce the life of the
unit and will void the warranty.
BOILER CONTROL
FIRING THE SOLID FUEL BOILER
• NEVER start a fire without water in the system. Damage to the appliance and controls will result.
• Load the appliance with regard to the required heat load. On mild days, load less fuel in to the appliance. A small,
intense fire will burn cleaner, more efficiently and with less creosote formation than a large smoldering fire.
LIGHTING THE INITIAL FIRE (SAME FOR WOOD OR COAL)
1) Remove ash pan from unit store near by.
2) Place the FAN switch in the OFF position.
3) Pull smoke bypass damper rod out.
4) Build a SMALL fire using paper and kindling. Softwoods make good kindling due to the resin they contain and the
fact that they split easily. Hardwoods are better on top of the kindling to give a longer lasting fire.
5) When the fire is burning well add larger pieces of wood.
6) If burning coal,
A) After the wood fire is burning well, place larger pieces of wood to form a stable base for the coal. It will take ten
to twenty minutes before they are thoroughly ignited and ready for the coal. Adding the coal too soon could cut
the air supply and smother the fire.
B) Add a thin layer of coal, preferably smaller chunks to the wood fire, being careful not to disturb it too much or
cut off the draft.
C)After the coal is ignited and burning well, add a second heavier layer until it is even with the top to the firebrick.
Ensure that a red spot of glowing coals is visible after adding new coal. Do not smother the fire. This will also
help ignite the gases given off by the new charge. A deep charge will give more even heat and a longer burn
time. It may take one to two hours before the whole bed is fully ignited.
7) Allow the water temperature to rise. When the water temperature reaches 120°F, set the draft control aquastat to
110°F. The draft fan should stop and the shutter close. Reset to desired operating temperature. Note temps below
165°F may result in excessive creosote build up.
September 2012
Page 28
BOILER CONTROL (CONT.)
8) AUXILIARY “DUMP ZONE” A safety limit aquastat should be used. Set the safety limit aquastat below water
temperature. In a hot water base board system the zone valves should open and the circulating pump should start.
Reset to 15° above the solid fuel boiler aquastat setting. Never set safety limit aquastat above 200°F.
9) Monitor water pressure. Maintain about 15 psi (hot water pressure) by adding water as air is purged from the
system. It may take several days operation to purge all the air. ENSURE the vent opening on the automatic air vent
is clear and the cap is loose to allow air to escape. This vent always stays open with the cap halfway unthreaded.
Condensation in the fire box will occur for the first 3 or 4 days of operation resulting in water or water/ creosote
combination running out of the ash door. This should clear up in less than a week. You may want to place a pan
under ash door to keep concrete clean.
10) When firing boiler remove ash pan, place next to boiler for safety reasons.
BURNING WITH WOOD
Burn only split cordwood that has been seasoned for 12-18 months. Burning unseasoned wood is wasteful and inefficient it uses increased 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.
• 25% moisture content is optimum:
- Higher moisture content wastes energy boiling off water.
- Lower moisture content burns rapidly and inefficiently.
The type of wood will determine how often the unit will have to be refueled. It may take a week of close
attention to set up a time table for refueling. Generally eight to 10 hours between fillings can be expected, depending
on the heat loss of the building being heated. The best time for refueling is when the wood is burned down to about
4” to 6” bed of coals. It is important to maintain a 4” to 6” bed of coals for re-ignition of new wood when refueling.
REFUELING
1) Place the FAN switch in the OFF position.
2) Pull smoke bypass damper rod out and wait one minute.
3) Open the fuel loading door slowly. Pausing 3-5 sec at double latch point.
4) Work ashes down through the grate with a poker and shaker grate. Ensure that a 4”-6” deep coal bed remains.
5) Fill fire box “full” with wood. Do not load past the top of the loading door opening.
6) Close fuel loading door.
7) Open the ash door. Insert the ash pan and scoop out ashes.
8) Empty ashes into a safe container. DO NOT STORE THE ASH PAN IN THE UNIT DURING OPERATION.
9) Ensure that the ash door is tightly closed.
10) Place the FAN switch in the ON position.
11) Push the smoke bypass damper rod in.
*** DO NOT LOAD WOOD ABOVE THE LOADING DOOR OPENING ***
September 2012
Page 29
BURNING WITH COAL
BURNING COAL
A barometric draft damper MUST be installed between the solid fuel boiler and the chimney.
Determine and research what types of coal are commonly available in your area. You will get more heat and longer
burn periods if you are educated on how to burn the type of coal available to you. Number 3 “hard” coal tends to work
best. When burning any type of coal in the boiler do not fill the fire box above the firebrick. Some types of coal have a
high temperature and can cause damage to the boiler if filled above the brick. Most coal requires more air for combustion than wood. This is due to the higher kindling temperature needed to burn these types of coal. It usually takes
two or three days to determine the correct positioning of the blower damper to produced a satisfactory burn.
The type of coal and heat demand determine how often the unit will have to be refueled. It may take a week of close
attention to set up a time table for refueling. Generally 8 to 10 hours between fillings can be expected, depending on
the heat loss of the building being heated. The best time for refueling is when the fuel is burned down to about 6” to
8” bed of coals. It is important to maintain a 4” to 5” bed of coals for re-ignition of new coal when refueling.
REFUELING
1) Place the FAN switch in the 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.
6) After the new coal is well ignited add more coal to the front area that was left visible.
7) When refueling process is completed you should have a bed of coal even with the firebrick at both sides of the fire
box and heaped to the center of the fire box.
8) Close fuel loading door.
9) Gently move the shaker grate handle. A few short movements are better than a long movement of the Grate. The
object is to remove a small amount of the ashes without disturbing the fire. The fire should just be settled down
about a half an inch or an inch in the fire box until the first live coals start to fall. The fire may go out if you shake it
too much It is not necessary to sake down the ashes each time you refuel.
10) Open the ash door. Insert the ash pan and scoop out ashes.
11) Empty ashes into a safe container. Do not store the ash pan in the unit during operation.
12) Ensure that the ash door is tightly closed.
13) Place the FAN switch in the ON position.
14) Push the smoke bypass damper rod in.
*** DO NOT LOAD COAL ABOVE THE FIREBRICK***
September 2012
Page 30
BURNING WITH COAL (CONT.)
• The solid fuel boiler will maintain water temperature based on the aquastat settings.
• Room temperature is controlled by a thermostat in the room.
• The loading door and ash removal door must tightly shut and the seals maintained in good condition during
operation, otherwise overheating will occur.
WHEN LOADING
• Place FAN switch in OFF position.
• Open loading door – pausing momentarily between the first latch and the safety latch to allow any combustion
gases to burn off.
CAUTION
The solid fuel boiler will not operate without electrical power. The combustion air shutter
MUST NOT be manually opened or altered for any reason; overheating will result. Loading Door
and ash door must be closed and latched during operation. Failure to latch door will result in over
heating which could damage the appliance and controls.
CREOSOTE FORMATION
All solid fuel 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 inside the flue. Check daily to determine cleaning schedule.
4) When ignited this creosote makes an extremely hot fire.
5) The chimney connector and chimney should be inspected at least twice monthly during the heating season to
determine if a creosote buildup has occurred.
6) If creosote has accumulated it should be removed to reduce the risk of a chimney fire.
Note: hotter fires deposit less creosote. Creosote formation can be high during fall and spring, thus require more
frequent cleaning compared to the coldest months. Be prepared to handles a chimney fire (see emergency
action section)
“HEAT SAVERS” ADDED TO THE CHIMNEY ARE NOT RECOMMENDED AS THEY CAN INCREASE CREOSOTE PROBLEMS DISPOSAL OF ASHES
1) Ashes should be placed in a metal container with a tight fitting lid.
2) 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.
3) 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.
WARNING
DO NOT STORE THE ASH PAN IN THE UNIT DURING OPERATION
Improper use or failure to maintain a solid fuel boiler may cause nuisance conditions.
Persons operating this appliance are responsible for its operation, so as not to cause nuisance
conditions. Even proper use and maintenance of a solid fuel boiler, meeting the distance and
stack height recommendations and meeting all requirements in State and Local Regulations may
not always be adequate to prevent nuisance conditions in some areas due to terrain or other
factors.
September 2012
Page 31
EMERGENCY ACTIONS
OVER HEATING
1) Manually turn off the draft fan at the fan switch (place switch in OFF position).
2) The pump must have power to remove heat from the appliance.
3) Turn the thermostats fully up in the structure being heated by boiler to remove heat from the appliance as fast
as possible.
4) Allow the appliance to cool down.
5) Once the unit has cooled down:
• Determine and correct the cause of the overheating
• Refill the system if necessary
CHIMNEY FIRE
1) CALL 911 – INDOOR UNITS ONLY.
2) EVACUATE THE BUILDING. INDOOR UNITS ONLY
3) Manually turn off the draft fan at the FAN switch and close damper plate.
4) Leave the doors securely closed.
5) DO NOT TURNOFF THE SWITCH MASTER. The pump must have power to remove heat from the appliance.
LOSS OF ELECTRICAL POWER
1) Shut blower damper plate fully.
2) Restore Electrical Power.
3) If electrical power is off for a long duration, the appliance may over heat. Remove fuel and coals from the
fire box. Place removed fuel away from combustibles.
September 2012
Page 32
MAINTENANCE
Keeping the solid fuel boiler 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.
Failure to follow the directions in this manual and component literature could result in severe
personal injury, death, or substantial property damage.
DAILY
• Grates: For best performance level the wood/coal distribution on the grates prior to each loading. (A garden hoe
works well). There should be very little ashes on top of the grates. Ash build up will restrict air going through the
grate, promoting incomplete combustion and creosote formation.
• Remove ashes: Ashes should be removed with the ash pan daily. Excessive buildup of ashes in the ash trough will
eventually plug up the unit.
DURING HEATING SEASON
• Creosote: Formation and the need for removal. When wood is burned slowly, it produces tar and other organic
vapors, which combine with expelled moisture to form creosote. The vapors condense in the cool chimney
connector and chimney. As a result creosote residue accumulates on the flue lining. When ignited this creosote
makes an extremely hot fire. When burning wood, the chimney connector and chimney should be inspected every
2-4 weeks through out the season and build up removed.
MONTHLY
• Examine door gasket and draft fan shutter. Ensure airtight seal. Replace as required.
EVERY THREE MONTHS
• Clean heat exchanger and baseboard radiators. Dust and dirt buildup reduces heat transfer.
• 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. Do not use universal household oils.
WARNING Motor could be damaged, resulting in possible severe property damage.
END OF SEASON
• Power: Turn off power supply at the appropriate circuit breaker.
• Chimney: Clean and inspect chimney. Cap the chimney to keep rain water out.
• Fire box & Ash trough : Remove ashes, soot, and hardened deposits from the fire chamber by using putty knife or
wire brush. Coat inside of fire box with a light coat of motor oil to protect steel during the off season.
• Doors: Oil door hinges and latch guide.
• Plumbing: Shut all isolation valves. Ensure transfer line connections are tight.
Moisture from rain or condensation must not be allowed to accumulate in the fire box or ash pan
WARNING during the off season. Failure to perform preventive maintenance may result in corrosion
damaging the boiler resulting in possible severe property damage.
September 2012
Page 33
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).
• Plumbing: Open all isolation valves.
• Pump: The circulator shipped with the appliance is water-lubricated. No oiling is required. Check other circulators
in the system. Oil any circulators requiring oil, following circulator manufacturer’s instructions.
Over-oiling will damage the circulator.
DANGER
Use only S.A.E. 20 motor oil to lubricate the motor. Do not use universal household
oils. Motor could be damaged, resulting in possible severe property damage.
• Pressure: Verify cold pressure is approximately 5 psi. Fill if necessary.
• Water Chemistry: Verify heating system water pH of 8.5 to 11.0. Adjust as necessary. Add corrosion inhibitor
package to raise pH. Add scale inhibitor as testing indicates .
• Corrosion Inhibitor: Verify level per manufacturer’s instructions.
• Power: Turn on power supply at the appropriate circuit breaker. Ensure that the pump is running.
• Aquastat: Inspect and test the aquastat. Verify operation by turning aquastat temperature below the
appliance temperature. The boiler should cycle off. Return aquastat to original setting.
• Air Vents: Inspect automatic air vents . The cap must be unscrewed one turn to allow air to escape. If the air vent
is leaking, remove cap and briefly push valve and then release to clean the valve seat. Replace cap by twisting all
the way onto valve and then unscrewing one turn.
• Start-up: Review start-up Procedures.
• Safety: Review all safety Precautions.
• Housekeeping: Verify that area is free of any combustible materials , gasoline and other flammable vapors
and liquids or rags.
DANGER
Do not use petroleum-based cleaning or sealing compounds in the heating system. Severe dam
age to the heating system will occur, resulting in substantial property damage.
Eliminate all system leaks. Continual fresh makeup water will reduce appliance life. Minerals can
WARNING build up in the appliance, reducing heat transfer, overheating the metal. Leaking water may also
cause severe property damage.
DANGER
Electrical shock hazard: Turn off power to the appliance before any service operation on the
appliance except as noted otherwise in this instruction manual. Failure to turn off electrical power
could result in electrical shock, causing severe personal injury or death.
September 2012
Page 34
MAINTENANCE (CONT.)
**PRESSURE (SAFETY) RELIEF VALVE **
Failure to re-inspect the pressure relief valve as directed could result in unsafe pressure buildup, which can result in
severe personal injury, death or substantial property damage.
AT LEAST ONCE A YEAR: Pressure relief valves must be operated to ensure that waterways are clear. Certain naturally
occurring mineral deposits may adhere to the valve, rendering it inoperative. When manually operating the lever, water
will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage. Before operating lever, check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to
a proper place of disposal, otherwise severe personal injury may result.
IF NO WATER FLOWS, VALVE IS INOPERATIVE. SHUT DOWN THE APPLIANCE UNTIL A NEW RELIEF VALVE HAS BEEN INSTALLED.
AT LEAST ONCE EVERY THREE YEARS: Safety Relief Valves should be re-inspected by a licensed plumbing contractor
or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to
ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring
conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not
detectable unless the valve and its components are physically removed and inspected. This inspection must only be
conducted by a plumbing contractor or authorized inspection agency —not by the owner.
VERIFY SYSTEM PRESSURE FOLLOWING TESTING OF RELIEF VALVES. ADD WATER TO SYSTEM AS NECESSARY.
DANGER
Failure to inspect and repair the above conditions can result in severe personal injury or death.
September 2012
Page 35
TROUBLE SHOOTING
1) PROBLEM: LOSING PRESSURE IN SYSTEM.
A) Air bleeding out of system will cause pressure loss. When the appliance is first filled, it may take 3- 4 days to
purge all the air. Add water as needed until pressure stabilizes.
B) An undersized expansion tank will cause large pressure changes as the system water temperature changes.
C) If pressure consistently drops, it indicates a leak in system. Check joints, fittings, relief valves, etc.
2) PROBLEM: UNIT OVER HEATS.
A) Air leaks can cause appliance to overheat. Ensure loading and ash door are sealing properly.
B) Chimney may be creating a natural draw even when the draft blower is not running. Consider installing a shutter
on the draft blower.
C) Fan control aquastat or safety limit aquastat may be set too high. Fan control aquastat must not be set over
180°F. Maximum setting for safety limit aquastat is 190°F.
D) Water is not circulating. If pump is not running or an isolation valve is shut, or an air lock is stopping circulation,
appliance can overheat.
3) PROBLEM: NOT ENOUGH HEAT OUT OF THE APPLIANCE.
If the appliance reaches operating temperature and draft fan shuts off,
it is working properly. (If draft fan does not shut off, see Problem 4)
Check the following:
A) System water flow rate too low This can be caused by:
• The circulating pump may not have enough capacity.
• There could be an air lock in the system. (See Problem 5.)
B) The fan control aquastat may be set too low. Set aquastat up 10° but not over 180°F.
C) The house heating system may not be extracting enough heat from the water. Dust buildup on the baseboard
fins or forced air heat exchanger system will reduce heat output.
D) The house heating system may not have enough capacity. More baseboards may need to be added to a
hot water system. In a forced air system, more airflow through the heat exchanger will boost output.
E) The fuel quality might be poor. Split, seasoned, hardwoods are recommended.
Contact your installer or system designer for further resolution.
September 2012
Page 36
TROUBLE SHOOTING (CONT.)
4) PROBLEM: WATER TEMPERATURE DOES NOT REACH FAN CONTROL AQUASTAT SETTING. (DRAFT FAN RUNS CONTINUOUSLY.)
A)
B)
C)
D)
E)
F)
G)
Wood may be too wet or green. Try mixing woods.
Check for obstructions in draft fan.
A defective solenoid may cause flapper on fan not to open when fan comes on.
A partially clogged chimney or exhaust plenum may be restricting air flow in the appliance.
A buildup of ashes in the ash trough can restrict the exhaust of combustion air.
A buildup of ashes on top of the grates can restrict combustion air.
Heat is being lost through underground pipes. Temperature coming into house should be no more than 2-3°
different than temperature of water leaving the appliance.
H) Appliance is undersized for building being heated.
5) PROBLEM: NO WATER FLOW
A) Air could be trapped in the line.
• Repeat filling and venting procedure.
• Temporarily add more water to system to bring pressure to around 25 psi. This will compress any air
bubbles allowing them to more readily move to the air vents.
B) Pump is not running. You should be able to feel the vibration of pump when it’s running.
• Defective pump - check if installed properly. If installed incorrectly, pump will burn out. With 180° water
circulating through pump, it will be hot to the touch.
• Pump is not wired correctly. Refer to wiring diagram. (See page 20.)
C) Pump flanges are closed. Flanges are open when screw slot is parallel with the pipe.
D) The system is frozen somewhere.
6) PROBLEM: EXCESSIVE CREOSOTE IS BUILDING UP IN ASH TROUGH.
A) Ash build up above grates or in ash trough area will cause restrictions in combustion air.
B) Appliance may not be burning hot enough.
• Set fan control Aquastat to 180°F.
• Set differential on fan control Aquastat to 20° (if adjustable). This will let water temperature drop 20° before
fan is started, causing a longer burn cycle.
C) Verify that the fuel is properly seasoned (20-25% moisture content).
D) Try burning small pieces of extra dry wood for a few days. Large pieces of wood can cause creosote.
E) If problem persists call your installer or local ROYALL Representative
September 2012
Page 37
TROUBLE SHOOTING (CONT.)
7) PROBLEM: SMOKE “PUFFS” FROM THE UNIT
A) Wood may be too wet or green. Try mixing woods.
B) Check for obstructions in draft path (Blower, Chimney Connector, Chimney).
C) A partially clogged chimney or exhaust plenum may be restricting air flow in the appliance.
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 Boiler. Verify that the Chimney is properly
installed and insulated.
I) Check for possible Chimney “down draft” from taller surrounding trees, buildings or objects. It might
be possible to correct with a Chimney cap.
8) PROBLEM: EXCESSIVE SMOKE OR FLAMES COMING OUT OF LOADING DOOR DURING REFUELING
A) Fully open the smoke damper rod prior to opening the fuel loading door.
B) Open fuel door 1/2”, then wait 30 seconds for draft to increase prior to fully opening the door (SLOWLY).
C) Chimney could have insufficient draft:
1. Ensure that chimney draft is .06” w.c. or greater.
2. Check length of flue pipe to chimney. The appliance should be located within 6 feet of the chimney.
3. Ensure that the chimney cap is not too close to the top of the chimney, restricting air flow.
4. Clean chimney and chimney connector.
5. Raise chimney height to increase draft.
REFER TO WWW.ROYALLFURNACE.COM IN THE TOOL BOX SECTION FOR ADDITIONAL TROUBLE SHOOTING NEEDS.
REPLACEMENT PARTS LISTING
Parts listed on page 38 are not shown in Replacement Parts Listing Diagrams found on pages 39-40. Visit us
on the web at Royallfurnace.com for all other part related questions.
September 2012
Page 38
REPLACEMENT PARTS LISTING (CONT.)
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 Z-Bar
September 2012
Page 39
REPLACEMENT PARTS LISTING (CONT.)
Damper Plate
J
3/16x2 1/2 Cotter Pin
I
Damper Rod
H
Spring Handle
Ref.
Name
Royall Part Number
H
Spring Handle
HAR-HAN-Spring
I
Damper Rod
RB Damper Rod
LRG,MED,SML
J
Damper Plate
RB Damper Plate
Standard or Large (6490)
September 2012
Notes
Page 40
REPLACEMENT PARTS LISTING (CONT.)
P R E S S U R E R E L I E F VA LV E
PRESSURE/TEMP GAUGE
K
L
A Q U A S T AT W / W E L L
M
FUEL DOOR
N
Q
POSITIVE SHUT OFF
1/4-20x1 1/4 HHCS
1/4-20 NUT
P
DRAFT BLOWER W/H GASKET
O
ASH DOOR
G - L AT C H
R
G - L AT C H
A S H PA N
S
Ref.
Name
Royall Part Number
K
Pressure Relief Valve
RBPRESS/REL
L
Pressure/Temp Gauge
RBPRESS-Gauge
M
Aquastat
RBAQL4081
Aquastat Wall PIN-RB Aquastat Well
N
Fuel Door
Cas-Door
Specify size when ordering
10x14 17x17
O
Positive Shut Off
BL POS
Please specify stove model
P
Draft Blower W/H
Gasket
(Unit Specific)
B160, BL100, B1148, (Gasket)
Q
Ash Door
CAS-Door Ash
R
Ash Pan
(Unit Specific)
S
G-Latch
September 2012
Notes
Ash Pan 30, Ash Pan 45, Ash Pan 54
Page 41
20 YEAR LIMITED LIFETIME WARRANTY
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. This
warranty is extended only to the first retail purchaser of the product and only to a product that has not been moved from its original installation
site. Any warranty claims on Solid Fuel appliances or component parts should be reported to the ROYALL dealer from whom the product(s) were
purchased.
Steel Components and workmanship:
0-60 Months Owner Pays $0.00
After the 60th month, the warranty will follow a pro-rated schedule. The percentage applies toward manufacturer’s authorization of
warranty work or may be applied toward the purchase of a new ROYALL Solid Fuel Appliance.
•
•
•
•
•
61-72 months from date of purchase 50%
73-84 months from date of purchase 40%
85-96 months from date of purchase 30%
97-108 months from date of purchase 20%
109-240 months from date of purchase 10%
Cast Iron Components:
0-36 Months From Date of Purchase 100%
Component Parts:
0-12 Months-Manufactures Warranty Applies For The Following
fans, baffles, pumps, aquastats, relays, gauges, relief valves, expansion tanks, heat exchangers, etc. are warranted by their manufacturers.
In addition, ROYALL warrants the original factory installed components for 1 year from date of purchase.
In addition to the warranty above, the ROYALL warranty does not cover:
1. Components that are part of the heating system (products) but were not furnished by ROYALL as a part of the heating system (products).
2. The workmanship of any installer of ROYALL product(s). In addition, this warranty does not assume any liability of any nature for unsatisfactory
performance caused by improper installation.
3. Any costs for labor for removal and reinstallation of the alleged defective stove or part, transportation to, ROYALL if necessary, and any
other materials necessary to perform the exchange.
4. Any products that have a failure or malfunction resulting from improper or negligent operation, accident, abuse, freezing, over temping,
poor water quality, misuse, unauthorized alteration or improper repair or maintenance. Improper adjustments, control settings, care or
maintenance. Information is in the installation manual and other printed/technical information provided with the product or direct from ROYALL.
NOTE: THE WARRANTY DESCRIBED HEREIN IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY. ROYALL EXPRESSLY DISCLAIMS AND EXCLUDES ANY
LIABILITY FOR CONSEQUENTIAL, INCIDENTAL, INDIRECT OR PUNITIVE DAMAGES FOR BREACH OF ANY EXPRESS WARRANTY. For prompt product
warranty claims, notify the ROYALL dealer from whom the product was purchased. If this action does not result in warranty resolution, contact
ROYALL at 325 South Park Street Reedsburg, WI 53959, with details in support of the warranty claim. Alleged defective part(s) must be returned
through the same dealer channel in accordance with the ROYALL procedure currently in force for handling returned goods for the purpose of
inspection to determine cause of failure. ROYALL will furnish new part(s) to an authorized ROYALL dealer who, in turn will furnish the new part(s)
to the purchaser. If there are any questions about the coverage of this warranty, contact ROYALL at the address above.
Corrosion inhibitor / water conditioner is recommended . This necessitates annual testing (at least once yearly)
and adjust (if necessary) the corrosion inhibitor balance.
OWNER’S REGISTRATION CARD MUST BE COMPLETED AND RETURNED TO ROYALL AT TIME OF INSTALLATION.
September 2012
Page 42