Do Not
„с ME Discard
e RE
==) Manual
STOVES
KOZY-KING HOT AIR FURNACE
Models 100-14 . 300-09 . 400-09
OWNER'S MANUAL
This stove meets U.S. Test
Standard UL 391,ETLM78-1
CAN/CSA-366-1
Before you install or operate a D.S. furnace,
you must:
- Read all instructions carefully
- Install smoke and carbon monoxide
MADE IN USA
By detectors.
D.5. MACHINE SHOP - Connect return air to furnace
@padian's
YOU MUST INSTALL A SMOKE AND CARBON MONOXIDE DETECTOR BEFORE INSTALLING THIS UNIT —
meo a imp mega gate en e él ua dti 1; den сы чат in. LT
Safety Instructions ===—c2m me: om r NETO
1. Read ali Instructions before installing or operating any D.%. Furnace
2, You must install smoke and carbon monoxide detectors before you install or operate any fur-
nace. Check your local code, this installation must meet their rulings.
3. Do not open bottom ash door to increase draft. It is designed only fo empty ashes.
4. Never leave fumace doors open when Unattended.
5. Do not hook up a wood or coal furnace to an aluminum Type B gas vent. Use a code approved
Class A chimney with a 6” diameter (minimumyto 8” diameter (maximum),and minimum of 15" high.
6. Before you ignite your Furnace, be sure to inspect chimney for any cracks or leaking liners. This
will affect your draft.
7. Clean chimney before installing furnace. If there is creosote attached to the liner you could
create a serious chimney fire,
8. Never leave children unsupervised when they are in same room as furnace. Provide a sturdy
barrier to keep children and pets a safe distance from the furnace, or they could get burned.
9. Keep Furnace area clear from all combustible materials, gasoline, and other flammable vapors
and liquids.
10. Use the required floor protection as shown on the Safety listing on back of furnace.
11. Check the clearance to combustible walis and floors.
12. Do not allow anyone who is unfamiliar with furnace to operate i.
13. Spend some time with your furnace to become well acquainted with the different settings and
how each setting will affect its burning patterns. It is impossible to state how each setting will
affect your furnace.
14. Be extremely careful when removing the furnace ash pan. it may be extremely hot!
18. Make sure your stove pipe has at least 3 screws per joint.
16. Do not install this furnace in a mobile home or trailer.
17. Do not use a manual, barometric or automatic damper when burning wood.
18. ltis required to hook the return duct to the filter box.
Operational / Work Practice Standards
1. When burning wood, burn only seasoned, dry cord-wood that has been dried; then warmed be-
fore firing. (Warming cord-wood means placing near stove or furnace for 1 day before burning)
. Keep wood under cover: in a wood shed, or under a tam.
Right after delivery: stack cord-wood under cover
Split cord-wood before drying.
Do not burn green wood, it needs to have no more than 20% moisture.
All firewood must be seasoned at least 1 year.
Check cord-wood with moisture meter provided with your unit. Check wood moisture at least
ance a week!
Keep a 2" to 3" ash layer on top of your grates when burning wood. Note: Do not cover louvers.
The furnace is designed to burn air dried wood and coal at a predetermined firing rate. Over firing
occurs when the ash door is left open during operation or a highly volatile fuel, i.e. large amounts
of small kindling is used. Do not exceed 600° degrees on top of furnace.
10. When tending the firebox always open load door slowly to avoid a “flash back”.
11. With new steel there is a small amount of cil or dirt on the metal. You may smell an odor. This is
normal during the first operation. You may want to assemble the fumace out of doors and build a
small fire in it to "BURN OFF” this dirt and oil before installing unit.
12. Inspect air filters regularly. The air filter in the filter box should be changed at least every thirty (30)
days.
13. Be extremely careful when removing furnace ash pan. It can get very hot
14. Check the fit on the load door. It must fit tightly. If it does not, check for deterioration or wear of the
ceramic rope seal. Replace defective seals.
лотком
© wo
2
\ badiah's
OODSTOVES.NET
YOU MUST INSTALL A SMOKE AND CARBON MONOXIDE DETECTOR BEFORE INSTALLING THIS UNIT
15. inspect and clean your chimney and stove pipe regularly.
16. In the event of a chimney fire, shut all draft controls and blower off and call your fire department
immediately. Alert everyone in the house. If flue is still burning vigorously, throw baking soda into
firebox or discharge a fire extinguisher into fire box. After the chimney fire is over, have a certified
chimney sweep completely inspect your system for damage before farther use.
17. Slow Fires: It is not recommended to burn the Energy-Max Furnace any more than necessary
early in the fall and late in the spring, as you can not keep the fire box hot enough to burn gasses.
(without overheating your home) Slow fires can cause excessive creosote build-up in firebox,
stove pipe and chimney.
18. In the event of a power failure, all air filters must be removed, before operating fumace. Open
basement dump.
19. Equip your home with fire extinguishers, carbon monoxide and smoke detectors.
20. Do not burn garage, gasaling or any other flammable [liquids in this furnace.
21. This is a wood and coal-burning furnace and should not be altered in any way.
22. tis required to hook the return duct to the filter box.
NOTE: When burning coal, shake ashes every 12 hours if possible. You must Keep your ashes cleaned
out from under grating. This may require emptying your ash pan daily. If there is no air space under the
grates, the grates will warp and become inoperable.
Testing Furnace Before Lighting
To test your draft: Place a piece of newspaper inside of furnace and light it.
Starting A Coal Fire
1 = Shut off draft blower your body of fire should be & to 12”
2 « Remove wood plate on grates 8 - Close spinners on ash door. Keep fire door
3 - Put 80/20 handle on the out (coal) position spinners open 1/8"
4 - Use a good amount of kindling or charcoal 9 - Set thermostat
to start fire 10 - Open draft blower slide to about 1/2” or as
5 - Open spinners on ash door needed
6 - Add coal as necessary, 1" layer at a time 11 - Tum dratt blower on
7 - When you have an established coal fire, 12 - Shake ashes approximately every 12 hours
Starting A Wood Fire
1 - Install wood plate 6 - Once wood fire is established:
2 - Have draft blower in “off” position À - Close spinners on ash door and fire door
3 - Put 80/20 handle on the in (wood) position B - Load the furnace with wood
4 - Open spinners on ash door C - Set thermostat
5 - Open Fire Door, start fire with newspaper and D - Turn draft blower on
kindling. Fire starter blocks work also E - Reload as needed
Creosote — Formation and need for removal
When wood is burned slowly, it can produce tar or other organic vapors, which combined with
expelled moisture will form creosote. The creosote vapors condense in the relatively cool chimney flue
of a slow burning fire. As a result, creosote residue accumulates on the flue lining. When ignited, this
creosote makes an extremely hot fire.
The chimney connector and chimney should be inspected at least twice monthly during the heating
season to determine if a creosote build-up has occurred. If creosote has accumulated, it should be
removed to reduce the risk of a chimney fire.
3
(@padian's
YOU MUST INSTALL A SMOKE AND CARBON MONOXIDE DETECTOR BEFORE INSTALLING THIS UNIT
Locating Furnace
This furnace is to be installed maintaining clearances as shown in illustration.
1. Set the furnace on a solid noncombustible floor.
=, Use an approved fire retardant material for the floor mat.
3. The material must extend at least 16” in front of and 8” on either side, and underneath the
chimney connector and extending at least 2” on either side of the chimney connector.
1. The furnace should ba the only heat-
ing appliance using a chimney. One Caution: Do not store combustible or flammable
furnace per îlue. material near furnace.
2. A masonry chimney should be a | Gpecifications | 4100-14 1300-00 | £400-09
chimtek or lined with an insulated Sidea 19" ней 19“
stainless steel liner. = su TE =,
3. The masonty chimney should not че - -
have any missing mortar or loose Front Ls = ==
pricks. AA
4. There should be no mortar or parts E 18 1 №
о the chimney blocking the chimnay stove pipe
dE. Clearance
5. There should be a two inch clearance hetwaen flue &
between any chimney except o © 8” 8”
chimtek has zero clearance. stove pipe
6. The chimney should extend at least — Corner
2” above the highest point of the pe | * 18" | 18
house, or 2’ above the point at which
the chimney is 10’ from the roof.
%
ET ea de Te
PT RANIA AA
VE E AN Ta
TE ai В MC rR
Chimney Requi rements RTE ANETO
The minimum height of a chimney system for the D.S. Stove is 20 feet. The chimney must exceed
the roof of 2 house at a Minimum of 3 feet at any point of exit. In a pitched roof installation the chimney
must be 2 feet higher than anything within a 10 foot radius of the chimney. It is important to have a chim-
hey draft of 0,06 water column. It is required to abide by the manufacturer's instructions on Class A chim-
neys as well as local building codes. It is not recommended to build a chimney on an addition that is
lower than the main part of your house. Do Not extend the stovepipe past the inside of a masonry
chimney liner. Never connect this unit to a chimney serving another appliance.
Should you have a problem with inadequate draft you should see page 6.
20 feel minimum
4
¡Ovadians
Wood Plate
NOTE: Set on grates for
wood burning ONLY.
Remove when burning coal
YOU MUST INSTALL A SMOKE AND CARBON MONOXIDE DETECTOR BEFORE INSTALLING THIS UNIT
AT ET ET TI ET i
lea na Vaio PUNTA ” '
>
VC A A TOC) rl md pd
= + в
ат TETE DE MEE A CE PET nT TE ря
Wi I'l n G Di ag ra m 5 ad H DE TE rr aaa AA A eat ООН lea
Model #100-14
WIRING
DIAGRAM
All wiring must
SETTING
LIMIT CONTROL
be done by a qualified
FAN "OFF" LIMIT Electrician
INDICATOR INDICAFOR © = WIRE NUT
(200)
& = GROUND SCREW
(100)
FAN "ON"
INDICATOR
(150)
WALL THERMOSTAT
TOGGLE SWITCH
ral
Le
oy
La
“E FAN
CENTER
LIMIT
SWITCH
3-SPEED
SWITCH
Congult Conioblór Tp)
POWER
SUPPLY
BLOWER
MOTOR
X BE" Elbow
Suraght A
AT Eon ac
Models
#300-09
#400-09
WIRING
DIAGRAM
All wiring must
be done by a qualifiad
Electrician
SETTING
LIMIT CONTROL
" T
Napa INDICATOR clan
№ о 0) (200)
E GROUND SCREY
FL WALL THERMOSTAT
(150)
TOGGLE SWITCH
Eu
cami FAN
CENTER
LIPAFT
SWITCH
Roar View
O of
7
ge
Fan Limit Switch
Draft Blower
50 / 20 Control
Conduit Box
3-SPEED
SWITCH
a up]
MAN
POWER
SUPPLY
\ Цент
Боле © znengar
\ badiah's
MWODOSTOVES.NET
YOU MUST INSTALL A SMOKE AND CARBON MONOXIDE DETECTOR BEFORE INSTALLING THIS UNIT
= + À ,
| { { ATA ео пл eg SN TA deo, RY eT I NO TES TONER mT neu pers Te
С NA A Hh a RTE ER nd a hen PRT TE at ЕЕ La yt A aR Ea a TE Тай шв ноя Це BTL mp
y р! а n 5 d а 1 0 rl TEN dad BETA ET Ver dal UE dd dE Ed le rer har i fe oes Tam blab tem die EVE ha ADA CEE de A TES a
Below is a typical way to install a Kozy-King Add-On Furnace. In case of power outage you should
always run the hot air plenum up sa that it can circulate by gravity. The supply duct must be constructed
of material with a minimum 2509 temperature rating.
If you are using this unit as an add-on furnace, locate as close to the central fumace as possible.
NOTE: Do Not use a chimney serving another appliance!
T FI vet лая, а, Em NE RES EE 0 cat ee JF, vr
hp | af ÿ > TY kl rt Lot
M 180 TEL PA HEY
=." din mr ml ve ая nn aaa ea amen a Wow vn abet PT
we NC Sled Mh vaa A ThE Ted, ао re a ar at UE
| rp “aa, “ 21 1 a OPA e |,
dif Eat a iff "ope
+4 Bara 7 . "a
EE E TO PA ong aed '
LE Gun Ta EE an a TE Ne
|
HOT AIR TO HOUSE AS
! "an CT ma
In basement- |;
opens for :
heat dump >
when thereis | a.
a power outage [+4
8 Baffle
ot] ween Back Flow
Stop
|
KOZY-KING | = tale mie CENTRAL
FURNACE | FURNACE
[О_о] “RETURN AIR
+
| Ue TA I SL Tt dy RY, wR, a et ede qed El pe Wm орал Рана EL ed EU TARR AA IA ga
ou e 0 otin q da tee a TEE A at TRA Aaa? Tu Pala AAA RTH мобы а 1. male epa Neat nue a el ete не
1. Problem:
Smoke puffs from furnace
Solution:
Check chimney draft. Check for blocked chimney or flue pipe. Use mirror to check chimney clearance.
Check ash pit — if it is too full, empty.
Make sure furnace room is not too airtight.
Make sure all of chimney mortar connections are airtight,
Check ash door. Make sura it's airtight.
Check chimney for possible down-draft caused by taller surrounding trees or objects. Correct with proper
chimney vent cap.
Check the possibility of a cold chimney forcing cool gases backward. Remedied by properly insulating
chimney with non-combustible liner — non combustible insulation.
Fuel may be too green,
Make sure no other fuel buming devices are connected to the chimney impairing the draft.
Check ¿himney draft, it should be .06 inches of water column, This service is provided by a certified
chimnay sweep.
Make sure clean out door on the chimney is tight if you have one.
6
(@vadian's
YOU MUST INSTALL A SMOKE AND CARBON MONOXIDE DETECTOR BEFORE INSTALLING THIS UNIT
Trouble Shooting - continued
2. Problem:
Inadequate heat being delivered to your home.
Solution:
Check home insulation — is It adequate?
Check hook-up to furnace = is it installed correctly?
Cool air inlet may be inadequate or furnace room too airtight.
Your wood fuel may be too low grade. Hardwoods are recommended.
Make sure your hot air duct (and other duct work) is airtight.
If furnace room is warm but your home isnt, check back draft dampers
Is air to the blower available? It is required to hook the return air to the return filter box of the furnace.
Check filter. Change if necessary. Recommended every 30 days.
3. Problem:
Excess smoke or flames coming out door when refueling
Solution:
Wait 15 seconds and open door SLOWLY — then refuel.
Check length of flue pipe to chimney. Your unit should be within six (6) feet of your chimney.
Make sure chimney cap is not too close to the top of the chimney or it may be ciogged.
Check chimney draft ~ make sure chimney flue pipe is clean and chimney is of adequate height.
Make sure you're not suffocating the fire with excessive amounts of unburned wood.
Shut off draft blower before opening door. Return air must be hooked up to furnace.
Is cold air return hooked up to filter box? If not it will create negative pressure and draw smoke.
4. Problem:
Distribution blower vibrating
Solution:
Tighten blower wheel to motor shaft.
Check for bad fan bearings.
5. Problem:
Distribution blower continues to run or will not run
Solution:
Check fan limit or heat sensor and cable,
Check to see that blower is properly wired. (See Wiring and Assembly Instructions).
Check fuse box or power source.
Check power supply.
6. Problem:
Draft blower continues to run or will not run.
Solution:
Check wirlng, or check fandimit. If jumper is pulled it will not work,
Check thermostat or thermostat wire for short.
Make sure temperature is calling for heat. Replace filter in return box.
7. Problem:
Odor from first fire
Solution:
The odor from new steel should disappear in a few hours.
if the odor remains, call your dealer immediately. A bad weld can cause a fume leak.
8. Problem:
Excessive Creosote
Solution:
Check the grade of wood you are burning. Needs to be less than 20% moisture,
Make sure your unit is serviced by its own proper chimney
Check length of flue pipe and its connections.
Make sure you are burning the smallest, hottest fire to adequately heat your home.
Also see Solutions to Problem One.
Adjust draft control slide on draft blower to allow more air when not calling for heat. It is recommended to
have an insulated chimney no larger than 8” diameter.
;
(@padian's
IS
JD ho
STOVES
LIMITED WARRANTY
Kozy-King
Hot Air Furnace
Please read this warranty carefully!
0.3. Stoves warrants this Kozy-King Hot Air Furnace against premature failure of any com-
ponent due to workmanship[ quality or materials. So long as it is owned by the original pur-
chaser, subject to terms, limitations and conditions herein set out. Soft coal is prohibit-
ed in any DS Furnace or Boiler. This warranty is void if anything other than
Hard Goal or Dry Cord Wood is burned in this unit.
Time Period
1 = Firebox Five Years
2 - All doors - (fire and ash door) Five Years
3 - Cast Iron Components (grates, grate rails,
bypass baffle and firebox retainer) Five Years
4 - All Electrical Components One Year
D.S. Stoves will replace, at no charge to the owner, any defective part which 0.5. Stoves
determines affects the operation of the furnace.
The owner is responsible for labor and costs to complete the repair. The owner may at
his option and with D.S. Stoves approval, have the stove shipped to tha factory for repair.
All labor and material costs for repair at the factory will be borne by D.S. Stoves.
The owner is responsible for all shipping costs.
D.S. Stoves door glass, gaskets, paint or enameled parts, firebrick, and furnace cement
are not covered by this Limited Warranty.
Failure to follow installation and basic operation recommendations written in this
negligence abuse modifications to the furnace or over firing 6009 maximum, as determined
by D.S. Stoves or its authorized dealers.
This Limited Warranty is in lieu of all other warranties either expressed or implied.
D.S. Stoves is not responsible for accidents due to improper installation or failure to
follow instructions.
— D.5, Stoves
238-B Old Leacock Road
Gordonville, PA 17529
717-768-3853
@padian's
">
