Jack SUPER SJ125, Owner'S Manual

Page 1: ...ORTANT Installation must be made in accordance with State and Local Ordinances which may differ from this Installation Manual SUPER JACK MODEL SJ125 BIG JACK MODEL BJ90 SUPER JACK BIG JACK WOOD and COAL FIRED WARM AIR CENTRAL SUPPLEMENTARY FURNACES ALPHA AMERICAN CO 10 INDUSTRIAL BLVD PALISADE MN 56469 www yukon eagle com All furnaces in this owner s manual are UL Listed under UL FILE 11473 ...

Page 2: ...SURFACES ARE HOT Keep children away Do not touch Questions Visit www yukon eagle com or call 1 800 358 0060 For repair or replacement parts See back cover for details Before installing this furnace read and follow all instructions in this manual It is recommended that a heating professional installs or supervises the entire installation of the furnace ducts chimney and electrical connections FOR Y...

Page 3: ... INSTALLATION Place Furnace 22 Furnace Casing 22 23 Draft Inducer Motor 24 Junction Box 24 Fan and Limit Control 25 Mounting Thermostat 26 Electrical Wiring 27 Wiring Diagram 28 29 Connecting Smoke Pipe 30 Barometric Draft Regulator 31 33 Importance of Draft 34 OPERATING FURNACE Best Wood to Burn 35 Helpful Hints 36 Best Burn Practices 37 Wood Firing the Furnace 38 Burning Coal 39 40 MAINTENANCE A...

Page 4: ...ely of sheet metal Do Not use flammable liquids to start a fire Do Not attempt to light a wood fire when gas or oil vapors are present Do Not install on a combustible floor In the event of an electrical power failure be sure ash door and fire door remain closed Do Not install a power humidifier on warm air plenum Store all ashes in a metal container with a tight fitting lid Allow ashes to cool bef...

Page 5: ...ty DO NOT connect under any circumstances to the chimney or vent serving a gas furnace or gas appliance Operate the gas fired unit periodically to ensure that it will operate satisfactorily when needed DO NOT relocate or bypass any of the safety controls in the original furnace installation DO NOT use duct elbows having an inside radius of less than 150 mm 6 in Unit shall only be installed on a fu...

Page 6: ... result of a defect in material or workmanship at a cost to the purchaser of a proportion of the existing suggested retail prices as follows YEAR AFTER PURCHASE OF RETAIL COST TO PURCHASER YEAR AFTER PURCHASE OF RETAIL COST TO PURCHASER 2 3 40 7 10 60 4 6 50 11 30 80 HOW TO OBTAIN PERFORMANCE UNDER THIS WARRANTY Purchaser should first contact the dealer or contractor from whom the Yukon Furnace wa...

Page 7: ...Paper products cardboard plywood or particle board The prohibition against burning these materials does not prohibit the use of fire starters made from paper cardboard saw dust wax and similar substances for the purpose of starting a fire in this furnace NOTE Once the fire is established turn the thermostat up to call for the temperature that you want As long as there is the appropriate amount of ...

Page 8: ...rt a temperature measuring device Operate the primary furnace until the temperature rise TA TR across the primary furnace is equal to or less than 85 degrees F 29 C Should this temperature difference exceed 85 degrees 29 C increase the blower speed until the temperature rise TA TR is equal or less than 85 degrees F 29 C Shut off the primary furnace and build a fire in the Jack unit When the fire i...

Page 9: ... The furnace is shipped strapped to a pallet Inside the wood loading door is another carton This carton contains Barometric Draft Regulator Gasket Conduit Clip Wiring Harness Fan and Limit control Draft Inducer Motor Transformer Relay Interlock Relay Thermostat Owner s Manual Warranty Sheet Moisture Meter for measuring wood moisture Operating your furnace DVD Note If ordered the Circulating Blower...

Page 10: ...e flame It helps burn smoke and unburned gases that leave the flame thereby increasing efficiency FORCED DRAFT INDUCER BLOWER This furnace operates on a forced draft principle When the thermostat is calling for heat the draft blower will turn on to get the fire burning Draft blower air disc must be open HONEYWELL TRANSFORMER RELAY These Honeywell Transformers are the industry standard and made for...

Page 11: ...3 1 2 4 5 6 7 8 9 Furnace Features SJ125 ...

Page 12: ...r heat the Draft Blower will turn on to get the fire burning Draft blower disc must be open HONEYWELL TRANSFORMER RELAY These Honeywell Transformers are the industry standard and made for heating systems This 24V control circuit step down transformer is designed to power any 24V control system including ther mostats and relays EASY ACCESS ASH PAN Designed to allow for easy removal of ashes Pulls o...

Page 13: ...1 2 3 4 5 6 7 Furnace Features BJ90 13 ...

Page 14: ...th 24 Fire Box Dimensions 16 wide x 24 long x 23 high Smoke Collar 7 Weight 645 lbs Height 47 Width 26 25 Depth 34 5 Warm Air Plenum Opening 22 x 20 Fire Door Opening 13 x 13 Secondary Heat Exchanger Area 15 56 Sq Ft Circulating Blower Optional 1460 CFM SUPER JACK 125 MODEL SJ125 37 Specifications 14 ...

Page 15: ... Sq Ft Maximum Wood Length 24 Fire Box Dimensions 16 wide x 24 long x 23 high Smoke Collar 6 Weight 595 lbs Height 39 5 Width 24 25 Depth 34 5 Warm Air Plenum Opening 22 x 16 Fire Door Opening 13 x 13 Secondary Heat Exchanger Area None Circulating Blower Optional 1460 CFM 29 1 2 Specifications 15 ...

Page 16: ...ype HT All Fuel chimney Masonry Chimneys Connect this furnace to a chimney that complies with NFPA 211 A field constructed chimney of solid masonry units bricks stones listed masonry chimney units or reinforced portland cement concrete that is lined with suitable chimney flue liners and built in accordance with the provisions of Chapter 4 of this standard 5 Follow a regular service and maintenance...

Page 17: ...earance between combustible walls and chimney connector to furnace and ducts is allowed if insulated according to NFPA Standard 90B or your local building code This copyrighted book is available from the National Fire Protection Association Inc PO Box 9101 Quincy MA 02269 9101 It is a mistake to assume that sheet metal masonry or asbestos like board placed directly against a wall protects it Mater...

Page 18: ...TYPICAL INSTALLATIONS SERIES ADD ON PARALLEL ADD ON ƒ INDEPENDENT INSTALLATION ƒ DUCTS AND PLENUMS SHALL BE CONSTRUCTED ENTIRELY OF SHEET METAL IMPORTANT Plan Your Installation 18 ...

Page 19: ...11 1 5 217 4 as Type HT HT is an abbreviation meaning High Temperature Masonry Chimneys as referred to in NFPA 211 1 5 2 17 6 a field constructed chimney of solid masonry units bricks stones listed masonry chimney units or reinforced concrete that is lined with suitable chim ney flue liners and built with the provisions of Chapter 4 of this standard RIDGE More than 10 ft 3 1m 10 ft 3 1m 2 ft 0 61m...

Page 20: ...0 000 BTU per hour You need two grilles each with 180 square inches of free opening Metal grilles have about 60 free open area Therefore you need two metal grilles with 300 square inches each of louvered area The height should be about half the width SIZE 1 4 MESH SCREEN BTU WOOD LOUVERS BTU METAL LOUVERS BTU 3 1 4 X 12 INCH 8 INCH ROUND 8 X 12 INCH 8 X 16 INCH 144 000 200 000 382 000 512 000 36 0...

Page 21: ... by kitchen or bathroom fans It is also needed to replace air expelled by water heater chimneys or fans Failure to provide outside air to the furnace area will result in negative pressure or vacuum in the home Smoke from the wood fire may not be drawn up the chimney This causes creosote buildup and sometimes causes smoke to enter furnace room WARNING You must provide for enough fresh air to assure...

Page 22: ...tion Make sure the furnace is level Furnace Casing The furnace casing is shipped unassembled in a carton attached to the furnace Slide side panels down over angled edges of the black steel on the front and back of the furnace See Fig 1 Place top panel over the front edge of the furnace and set down over the side panels See Fig 2 FIG 1 FIG 2 Installation 22 Big Jack Model Shown ...

Page 23: ...furnace Secure with 3 screws furnished CANADIAN MODELS SJ125 C AND BJ90 C ONLY CANADIAN MODELS SJ125 C AND BJ90 C ONLY Super Jack SJ125 C Front panel installation With firing door open pull damper rod all the way out Slide panel casing on by tilting and maneuver ing all the way to the right and up taking care that the fire door hinges are missed Snug the left side to the furnace front line up the ...

Page 24: ... furnace See Fig 3 4x4 Junction Box Big Jack Attach the junction box with the transformer relay to the mount provided at the top right hand side of the front of the furnace See Fig 4 Note BJ90 C Canadian Model Attach by mounting the junction box onto insulated panel and place screws into two holes pre punched into panel casing Super Jack Attach the junction box with the transformer relay to the mo...

Page 25: ...Attach the fan and limit control mounting bracket to the top of the furnace using sheet metal screws 3 With the fan and limit control bracket up against the sheet metal plenum drill a 7 8 hole and two 1 8 holes through the holes in the bracket and through the sheet metal plenum using the bracket as a template 4 Screw the mounting bracket clamp onto the bracket and plenum with the 2 screws that are...

Page 26: ...ditioning if applicable If you have no plans for air conditioning you will need a 3 wire thermostat cable from your furnace to your thermostat If you intend to install air conditioning a 5 wire thermostat cable is required TYPICAL THERMOSTAT SETTINGS Set the thermostat above room temperature The draft inducer motor should now be running Be sure to load the wood according to the call for heat or th...

Page 27: ...ts 60 Cycle 1 Phase Alternating Current with a 20 amp circuit protector device WARNING Turn off electric power at circuit protector device before making any line voltage connections WIRING THE FURNACE The furnace wiring is provided in harness form Mount the 4 x 4 junction box to the mounting bracket on front of the furnace See Fig 4 5 page 24 Connect components as shown in wiring diagram on page 2...

Page 28: ...N FURNACE BLOWER EXISTING FURNACE BLOWER RED WHITE BLACK To Existing Furnace Blower POWER SUPPLY 115 V WITH GROUND AND FUSED SWITCH GROUND WHITE BLACK BLACK BLACK WHITE WHITE WHITE BLACK WHITE BROWN TRANSFORMER RED CONDUIT DRAFT BLOWER STANDARD BLACK GREEN BLACK R RC Y C W G R Y C W G EXISTING FURNACE EXISTING FURNACE THERMOSTAT 1 4 3 6 5 COIL 2 BLACK BLACK RED INTERLOCK Use Copper Conductors 28 W...

Page 29: ...COMMON L1 L2 GROUND INSULATE UNUSED SPEED TAP LEADS SEPARATELY BLACK WHITE BLACK WHITE WHITE BLACK BLACK WHITE CCW CW OPTIONAL 3 WIRE CONNECTION BROWN WHITE BROWN WHITE SPEED TAP L1 L2 CAP INSULATE CAP SIZE if Reqd 5MFD 370VAC Wiring for 4 SPEED 1 4 HP MOTOR OPTIONAL 29 Wiring Diagram CAPACITOR CAPACITOR ...

Page 30: ... must be at least one inch per linear foot of pipe Do not exceed 10 feet in length A clean out tee should be installed for removal of soot and fly ash Do not install smoke pipe longer than necessary to reach chimney This is for purposes of trapping heat The smoke outlet temperature is designed to carry by products of combustion out through chimney The smoke pipe must not pass through any combustib...

Page 31: ... on to gate again Flap can be removed by inserting small screw driver at the back side of the gate between the gate and the flap then pulling downward on flap HORIZONTAL FLUE Adjustment weight must be in LEFT HAND SLOT Marked H in bracket on gate See Fig 8 The arrow on flap at bottom of gate must line up with letter H on lower left part of gate If it does not remove flap turn over and snap on to g...

Page 32: ...l and plumb in the tee joint stub Using a carpenter s spirit level placed vertically across the ring position the draft regulator so it is plumb and does not lean forward or backward See Fig 10 Also place the spirit level horizontally across the front in line with the pivot pins and posi tion the regulator so it sets true level See Fig 11 Tighten locking screw to hold draft regulator in place FIG ...

Page 33: ...BLE CREOSOTE BUILD UP IS PERMIT TED ADVERSE CONDITIONS CONDUCIVE TO CREO SOTE BUILD UP Creosote condenses from the flue gases more rapidly when the temperature in the chim ney is cool The amount of creosote build up is dependent on Ÿ The amount of moisture in the flue gases Ÿ The temperature of the stack Ÿ The rate at which the wood is burned Ÿ The amount of draft in the stack Ÿ How completely the...

Page 34: ...is colorless odorless tasteless and non irritating If the early signs of CO exposure are ignored or the CO concentration is very high a per son may lose consciousness and be unable to escape the danger CO exposure is the leading cause of death due to poisoning in the United States However CO deaths are entirely preventable CO is produced by burning fuels such as wood oil natural gas propane kerose...

Page 35: ... per pound Hardwood such as oak or hard maple has nearly twice the BTU s per cord as pine or aspen because it is nearly twice as heavy Freshly cut wood has about 50 moisture content Wood that has been cut and split for 2 years has about 20 Wood must reach at least 435º to ignite High moisture content wood does not allow the gases in wood to get hot enough to provide complete combustion thereby cre...

Page 36: ... 4 to 6 hour burn In the spring and in the fall when the weather is mild burning large loads of wood for long periods may cause creosote Stack chimney temperature should be 300º for good burn ing Again depending on the weather you may not need a full load of wood for a good overnight burn You will get the best efficiency when you add only small amounts of wood Let the thermostat and draft inducer ...

Page 37: ... best efficiency from your wood stove or fireplace Season wood outdoors through the summer for at least 6 months before burning it Properly seasoned wood is darker has cracks in the end grain and sounds hollow when smacked against another piece of wood Wood burns best when the moisture content is less than 20 percent A wood moisture meter is included with your furnace to test the moisture content ...

Page 38: ...and chimney Leaving it open will increase the efficiency of the burning wood by up to 40 and reduce creosote buildup The wood fire will not last as long as secondary air while burning the unburned gases at the top of the flame tends to burn the wood a little faster 6 After substantial fire has been established for at least 30 minutes during installation set Barometric Draft Regulator to 03 using a...

Page 39: ...burns with little smoke when burning properly CAUTION Burn Anthracite or Bituminous coals only DO NOT BURN Petroleum Coke or Cannel Coals IGNITION TEMPERATURE OF COAL AND WOOD How hot does coal have to get to ignite Following are examples of the ignition points of various materials Paper ignites 350 F Wood ignites 435 F Western lignite ignites 630 F Low volatile bituminous ignites 765 F High volat...

Page 40: ...ls toward the back The grates must be protected from direct contact with the fire This is done by placing a layer of ash one 1 or two 2 inches thick on grates The ash left on the grate will help prevent overheating of the cast iron grates It also keeps coal from falling through the grate s opening IMPORTANT Never smother fire when adding fresh coal MAINTAINING A COAL FIRE Bituminous coal should be...

Page 41: ...ashes should be removed Never let ashes build up to grate level This will reduce the life of your grate To remove ashes simply pull out your ash pan But remem ber the ash pan can get very hot Dump ashes in a metal container with a lid that is placed on a non combustible surface Never use anything but a metal container to put your ashes in Every year fires are caused by emptying ashes into cardboar...

Page 42: ...sket material 1 rope gasket around the inside of the firing door and ash pan door to ensure proper sealing of the firebox The gasket material keeps added air from getting into the firebox which could lead to over firing of the furnace and causing excessive draft Fire Door Gasket Ash Door Gasket Maintenance 42 ...

Page 43: ...tinue brushing and sweeping downward until the full length of the chimney is cleaned Open the clean out door at the bottom of the chimney and sweep the debris into a plastic bag or container When clean ing the smoke pipe or the heat exchanger use a steel brush IN CASE OF CHIMNEY FIRE 1 Alert everyone in the house 2 Call Fire Department immediately 3 Shut any doors and air inlet dampers This should...

Page 44: ...s in the spring or fall or if you live in a mild climate your heat demands are small and your chimney just does not heat up enough to induce a natural exit up draft you may want to consider a power vent to force a draft up the chimney A Model D 3 or AD 1 power venter is available from Tjurnland Manufacturing Co in White Bear Lake Minnesota or Model D1 2 is available from Field Controls Co Kinston ...

Page 45: ...REMEDY CLOSE WITH CEMENT LOOSELY FITTED CLEAN OUT DOOR DISCLOSED BY SMOKE TEST REMEDY CLOSE LEAKS WITH CEMENT OPENING BETWEEN FLUES DISCLOSED BY SMOKE TEST REMEDY CLOSE OPENINGS TO MAKE A SMOKE TEST USE A SPECIAL SMOKE BOMB AND WITH TOP OF CHIMNEY CLOSED LOOK FOR LEAKS Home located on side of hill When the wind blows over a hill toward your home the wind will fall This could cause a down draft int...

Page 46: ...SUPER JACK SJ125 Exploded Views Parts Lists 46 ...

Page 47: ...ge Assembly 1 16 10090313 10104950 Door Bolts w Nuts 4 17 107 Door Handle Assembly 2 18 101 Ash Door w Hinge Assembly 1 19 102 Ash Door Gasket 1 20 104 Ash Pan 1 21 305 Fire Box Assembly 1 22 308 Jacket Side Left 1 23 10107000 Fan Limit Control Honeywell 1 24 118 Poker Assembly 1 25 122 Conduit Clips 2 26 10110001 Junction Box 1 27 121 Transformer Relay Honeywell 1 28 10111100 Conduit 2 29 1011320...

Page 48: ...BIG JACK BJ90 Exploded Views Parts Lists 48 ...

Page 49: ...13 107 Door Handle Assembly 2 14 101 Ash Door Ash Door Hinge 1 15 102 Ash Door Gasket 1 16 104 Ash Pan 1 17 201 Fire Box Assembly 1 18 203 Jacket Side Left 1 19 206 Two Piece Baffle 1 20 10107000 Fan Limit Control Honeywell 1 21 118 Poker Assembly 1 22 122 Conduit Clips 1 23 10110001 Junction Box 1 24 121 Transformer Relay 1 25 10113200 Straight Conduit Connector 2 26 10111100 Conduit 2 27 1011330...

Page 50: ...should turn on Smell an odor from the first fire in the home POSSIBLE CAUSE New steel small amounts of residue on steel SOLUTION Tighten the allen screw be sure squirrel cage did not move to one side or the other Return motor or blower for a replacement Try to adjust it or return blower for replacement SOLUTION Remove cover on fan limit control and set dials to the proper settings Recommended temp...

Page 51: ...uge Should be set at 03 Water Column Smaller and hotter fires Check page 21 of this manual for proper installation of outside combustion air to the furnace room The air that goes out the chimney in the form of smoke must be replaced with fresh outside air Smaller loads of wood and hotter fires Stack temps should maintain minimum of 300º Never use un insulated pipes for chimneys If installed on the...

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Page 56: ... JACK BIG JACK WOOD BURNING FURNACES ALPHA AMERICAN CO 10 INDUSTRIAL BLVD PALISADE MN 56469 www yukon eagle com MODEL BJ90 C MODEL SJ125 C HOW TO ORDER REPAIR PARTS WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE FOLLOWING INFORMATION Ÿ MODEL NUMBER Ÿ PART NUMBER Ÿ PART DESCRIPTION Ÿ NAME OF ITEM Our service technicians will help you Give us a call ALL PARTS MAY BE PURCHASED FROM ANY HEATING CONTRACTOR...