ROYALL 8095, Installation Manual

Page 1: ...Installation INDOOR SOLID FUEL FURNACE Models 8095 8130 8130HD www royallfurnace com 325 South Park Street Reedsburg WI 53959 Phone 608 768 8508 ...

Page 2: ...re 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 Thank you for purchasing a ROYALL Indoor Forced Air Solid Fuel Furnace is a quality Indoor Solid Fuel Appliance designed to effectively heat s...

Page 3: ...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 E MAIL ADDRESS DATE OF PURCHASE MODEL NUMBER SERIAL NUMBER DEALER CITY STATE Reason for choosing Royall over other brands __Price __Features __Safety __P...

Page 4: ...325 South Park Street Reedsburg WI 53959 OWNER S REGISTRATION CARD MUST BE COMPLETED AND RETURNED T0 ROYALL AT TIME OF INSTALLATION Brand Products Place Stamp Here 325 South Park Street Reedsburg WI 53959 Brand Products ...

Page 5: ...ATION WITH AN EXISTING FURNACE SERIES Pg 12 FILTER BOX OPTIONAL Pg 13 TYPICAL SYSTEM SCHEMATICS Pg 14 15 VENTING ASSEMBLY Pg 16 17 COMPONENT ASSEMBLY INSTALLATION Pg 18 ELECTRICAL INSTALLATION Pg 19 22 OPERATION LIGHTING THE INITIAL FIRE Pg 23 SETTING THE FAN LIMIT CONTROL Pg 24 SETTING THE DAFT DAMPER Pg 24 BURNING Pg 25 27 EMERGENCY ACTIONS Pg 28 MAINTENANCE Pg 29 30 TROUBLE SHOOTING Pg 31 32 RE...

Page 6: ...ials near the appliance DO NOT store wood within the minimum clearance to combustibles DO NOT burn gasoline naphtha or engine oil DO NOT start a fire if flammable vapors or dust are present An explosion could result DO NOT install in garage where fuels are stored DO NOT burn garbage tires telephone poles railroad ties or yard waste In many areas this is illegal and will damage the appliance Burnin...

Page 7: ...nside the building that it is heating The furnace can be installed as a stand alone unit or can tie into an existing gas oil or electric furnace System If tying into an existing system the solid fuel furnace can be installed either in series or in parallel with the existing furnace When installed in parallel with the existing furnace a new cold air return duct is routed to a circulation blower tha...

Page 8: ...mounted on the front of the appliance When the room thermostat calls for heat the draft blower starts adding combustion air to increase the fire intensity If the exiting air temperature exceeds 200 F the draft blower shuts down to prevent overheating Standard models have manual damper on the draft blower that balances the draft rate An optional solenoid flapper assembly is available for the blower...

Page 9: ... a level 2 minimum thickness concrete foundation pad At a minimum there must be a non combustible pad concrete brick or paver 6 wider of the appliance extending out 48 inches from the front of the unit A non combustible pad must be installed in front of the unit to contain any sparks or coals falling out of the Loading door or Ash door Fire can result causing severe personal injury death or substa...

Page 10: ...urfaces must have these clearances Front 48 Back 30 Sides 18 smoke pipe 27 Side 18 Back The following clearances are recommended for maintenance Back 30 Sides 36 All single wall chimneys must be at least 18 from any combustible surface Fire can result causing severe personal injury death or substantial property damage CLEARANCES DANGER ...

Page 11: ...en the ash door and remove the ash pan The ash pan should not be stored inside the ash trough during operation as it will warp and be too hot to handle Store the ash pan near the appliance DO NOT store the ash pan in the UNIT during operation If the ash pan is stored inside the appliance during operation warping will occur Wear gloves when handling the ash pan to prevent burn injuries WARNING COMP...

Page 12: ...follows 1 Remove T Bar from back of the fire box 2 Install 2 full bricks and 2 half bricks in the back of the fire box 3 Bolt the T Bar back in place to hold the bricks DO NOT tighten nuts at this point 4 Install 2 bricks above the T Bar and tighten nuts tightly 5 Install the bricks on the sides of the fire box The 2 bricks closest to the front must be installed horizontally T Bar ...

Page 13: ...ocated on either side of the appliance 2 For Parallel installation see page 14 Nothing further is required SHROUD ASSEMBLY The appliance comes with the shroud installed The shroud must be removed to cut openings for duct work Re install shroud as follows 1 Shroudsidesareinstalledfromthetop The S bentedgesontheshroudsidesgriptheflangesonthebottomof thefurnace 2 Then slide the sides front to back un...

Page 14: ...nal Components 1 The existing furnace must be a counter flow design down flow 2 The existing furnace must be mounted on a flow direction base Installation 1 Place the counter flow gas LP oil or electric furnace on top of an air flow direction base 2 Cut rectangular opening in the solid fuel furnace shroud to match the dimensions of the air flow direction base 3 The solid fuel furnace should be loc...

Page 15: ... return duct For better air flow it is recommended that this panel be installed opposite of the motor of the circulation blower B Attach the bottom panel to the two side panels and tap until the panels lock firmly in place C Attach the top panel to the side panel opposite of the cold air return duct opening D Attach the back panel with sheet metal screws E Attach the filter channel to the side pan...

Page 16: ...damper 1 opens allowing the heated air to circulate through the heating ducts 3 A second back draft damper 2 closes preventing the heated air from circulating through the existing furnace 4 The existing furnace is controlled by a separate thermostat 5 If the existing furnace fires back draft damper 2 will automatically open and back draft damper 1 will automatically close REQUIRED ADDITIONAL COMPO...

Page 17: ... existing furnace and the existing hot air plenum A The back draft damper MUST be installed above any air conditioning A coils B The back draft damper MUST be installed below the connection to the solid fuel furnace back draft damper 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...

Page 18: ...pe HT double wall chimneys Maintain 2 clearance to combustibles 2 Furnace 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 furnace and chimney 6 Ft C Male end should point back to furnace D Horizontal runs must be pitched back to the furnace in accordance with local B...

Page 19: ...ney height may have to be raised to overcome downdraft conditions 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 regulat...

Page 20: ...alling the furnace in parallel with the existing furnace then mount the fan control center on the filter box PURCHASED SEPARATELY see page 13 C Attach the 4 x 4 junction box with sheet metal screws D Attach transformer relay plate to junction box 3 DRAFT BLOWER A Mount the draft blower using the gasket to the front of the furnace with the three screws furnished B Ensure that the gasket seals tight...

Page 21: ...t edition Ensure ground wiring is installed per wiring diagram Good grounding is extremely important for proper operation DANGER INSTALL WRING AS FOLLOWS 1 SWITCH JUNCTION BOX A The following components are not included and must be provided by the installer 4 x 4 junction box 2 SPST switches Double hang switch cover B Attach 4 x 4 junction box to the furnace C Route power 115 V 60 Hz 15 Amp to the...

Page 22: ...is installed in SERIES with the existing furnace Connect B wires to circulation blower on existing furnace Connect leg C white wire to either the blower Red or Black wire depending on the desired blower speed Connect the A White wire to the blower White wire B If the furnace is installed in PARALLEL with the existing furnace Connect C White wire to the blower Red Black wire depending on the desire...

Page 23: ... between the top of the limit and fan switches If not then install a jumper wire across these contacts C Attach Black wire to the top of the limit switch Left D Attach Red wire to the bottom of the limit switch Left E Attach Blue wire to the bottom of the Fan Switch Right 6 DRAFT BLOWER A Attach leg D 3 wires Black White Green to the draft blower B Wire nut leg D Black to one of the blower wires C...

Page 24: ...le WHT Blk HI YEL MED HI ORG MED LOW RED LOW R C W G Fan Limit Y ND NC RELAY H N BLK BLK BLK BLK BLK WHT WHT WHT WHT WHT BLK RED RED RED RED BWN WHT HIGH SPEED LOW SPEED LOW VOLTAGE THERMOSTAT WIRE CONTROL CENTER LIMIT OPENS 200 CLOSES 170 FAN SWITCH DRAFT BLOWER FAN LIMIT MASTER SWITCH CIRCULATION BLOWER FAN CLOSES 170 OPENS 130 120 VAC PURPLE THERMOSTAT N b 2013 R C W W G Fan Limit Y ND NC RELAY...

Page 25: ...al 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 the adding new coal Do not smother...

Page 26: ...amper plate can be moved to allow more air into the fire box increasing temperature quicker 1 Verify that the fan limit settings are proper 2 Adjust the room thermostat until the draft blower begins to operate 3 After the furnace plenum temperature reaches 170 as indicated on the fan limit control the circulation blower should start Adjust the draft damper dog ear shaped flap on the draft blower u...

Page 27: ...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 FAN switch in ON position 11 Push the smoke bypass damper rod in DO NOT LOAD WOOD ABOVE THE LOADING DOOR OPENING BURNING COAL A barometric draft damper MUST be installed bet...

Page 28: ...rt 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 FAN switch in ON position 14 Push the smoke bypass damper rod in The solid...

Page 29: ...OTE 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 cind...

Page 30: ...als from the fire box Place the removed wood and coals away from combustibles 6 Once the appliance has cooled down Determine and correct the cause of overheating CHIMNEY FIRE 1 CALL 911 2 EVACUATE THE BUILDING 3 Manually turn off the draft blower at the FAN switch place switch in OFF position 4 Leave the doors securely closed LOSS OF ELECTRICAL POWER 1 Shut Blower Damper fully 2 Remove the Filter ...

Page 31: ...ng 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 EVERY TWO WEEKS During Heating Season Examine chimney and chimney connector Clean any soot or creosote MONTHLY Examine door gasket and draft fan shutter Ensure airtight seal Replace as r...

Page 32: ...r Do not use universal household oils Motor could be damaged resulting in possible severe property damage Power Turn on power supply at the appropriate circuit breaker Ensure that the pump is running 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 Elec...

Page 33: ...ning small pieces of extra dry wood can cause creosote Try burning large pieces of wood for a few days D If problem persists call your installer or local ROYALL Representative 3 PROBLEM DRAFT BLOWER RUNS CONTINUOUSLY A Set the thermostat at the lowest setting The draft blower should stop if the room temperature is higher than the thermostat setting If the draft blower is still running go to step B...

Page 34: ...g trees buildings or objects It might be possible to correct with a chimney cap 6 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 i insufficient draft 1 Ensure that chimney ...

Page 35: ... 3 8 16 Nut 1 4 20x1 HHCS 1 4 20 Center Lock Nut Rocker Flat Bar A B C E F G Front Grate Frame D Reference Item Name Royall Part Notes A S HOOK CAS S HOOK B ROCKER FLAT BAR 4 GRATES RF ROCKERFLTBR5HL 5 HOLE FOR 4 ROCKER GRATE SYSTEM AND HARDWARE C REAR GRATE CAS REAR FRM D FRONT GRATE CAS FRONT FRM E ROCKER GRATE CAS ROCKER F CAST BAFFLE CAS BAFFLE 2 SIZES LARGE SMALL 8095 ONLY G SHAKER HANDLE RBS...

Page 36: ...PARTS LISTING CONT Damper Plate 3 16x2 1 2 Cotter Pin Damper Rod Spring Handle J I H Reference Item Name Royall Part Notes H SPRING HANDLE HAR HAN SPRING I DAMPER ROD RBDAMPERRODSML J DAMPER PLATE RFDAMPERPLATE STANDARD Page 34 ...

Page 37: ... NUT G LATCH ASH PAN N O November 2013 Page 35 REPLACEMENT PARTS LISTING CONT Reference Item Name Royall Part Notes K 10 x 14 FUEL DOOR CAS DOOR10x14 L DRAFT BLOWER W H GASKET BL60 5 HOLE M ASH DOOR CAS DOOR ASH N ASH PAN 30 ASH PAN 30 O G LATCH G LATCH DAMPER ROD ...

Page 38: ...or all other part related questions Reference Item Name Royall Part Notes P 5 8 GASKET ROPE GAS ROPE 5 8 FUEL DOOR ASH DOOR Q DRAFT BLOWER GASKET GAS DRAFTBLOWER R 4 SPEED CIRCULATION BLOWER RFCBOO1 S FIRE BRICK SPLIT FBSTANDARDSPLIT CUT ANGLE T T BAR CAS TBAR U FAN CONTROL RFFCT V FAN LIMIT SWITCH RFFLS W SPRING HANDLE HAR HAN SPRING X LEFT SHOURD Y RIGHT SHROUD Z TOP SHROUD Page 36 ...

Page 39: ...pair 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 MERCHANTABI...

Page 40: ...325 S Park Street Reedsburg WI 53959 royallfurnace com 800 944 2516 ...