Crown Royal Stoves RS7200 User manual

Installation, Operation & Maintenance Manual
RETAIN THIS MANUAL
CONSERVEZ CE MANUEL
UL 391, UL 726 & CSA B366.1
Mailing: PO Box 1237
Shipping: 2716 Crescent Dr
International Falls, MN 56649
Ph: 866-361-7355
Fax: [phone]
Web: www.crownroyalstoves.com
OWNER’ S MANUAL Models: RS7200 • RS7300 • RS7400

TABLE OF CONTENTS
INTRODUCTIONS/SPECIFICATIONS................................................................................................... 5
BEST BURN PRACTICES ......................................................................................................................... 7
SAFETY INSTRUCTIONS & PRECAUTIONS....................................................................................... 9
INSTALLATION ........................................................................................................................................10
CONCRETE PAD DIMENSIONS............................................................................................................11
CHIMNEY REQUIREMENTS.................................................................................................................12
TRANSFER LINES...................................................................................................................................13
WATER &ELECTRICAL CONNECTIONS...........................................................................................14
PIPING INSIDE BUILDINGS..................................................................................................................14
WIRING INSIDE BUILDINGS................................................................................................................14
ELECTRICAL REQUIREMENTS...........................................................................................................14
EXISTING HOT WATER HEAT .............................................................................................................15
WIRE DIAGRAM FOR GAS BOILER.....................................................................................................16
DOMESTIC HOT WATER &FORCED AIR...........................................................................................17
BRAZED PLATE......................................................................................................................................19
WATER TO AIR.......................................................................................................................................20
STOVE COMPONENTS ..........................................................................................................................21
CONTROL PANEL...................................................................................................................................23
START-UP & OPERATION......................................................................................................................24
FILLING WATER JACKET.....................................................................................................................24
FIRING THE FURNACE..........................................................................................................................24
DAILY FUELING &FIREING ................................................................................................................25
SAFETY....................................................................................................................................................25
POWER FAILURE ...................................................................................................................................25
STARTING ACOAL FIRE.......................................................................................................................26
MAINTENACE ...........................................................................................................................................27
DAILY, WEEKLY, MONTHLY ..............................................................................................................27
ANNUALLY.............................................................................................................................................27
OFF SEASON ...........................................................................................................................................27
ASH, ROTATION & DISPOSAL..............................................................................................................28
CREOSOTE FORMATION & REMOVAL.............................................................................................28
RUNAWAY CHIMNEY FIRE...................................................................................................................28
TROUBLESHOOTING..............................................................................................................................29
ELECTRICAL TROUBLESHOOTING...................................................................................................30
WIRING DIAGRAM..................................................................................................................................31
SMOKE TROUBLESHOOTING..............................................................................................................33
MANDATORY WATER TREATMENT..................................................................................................39
WATER TREATMENT............................................................................................................................39
START-UP DOSAGES.............................................................................................................................40
SYSTEM TESTING..................................................................................................................................41
EMERGENCY PROCEDURES................................................................................................................42
WARRANTY...............................................................................................................................................43
WARRANTY CLAIM FORM ...................................................................................................................45
ELECTRONIC CONTROL INSTALLATION MANUAL.....................................................................47
(ENCLOSED WARRANTY REGISTRATION AND DELIVERY FORM)

4

Greentech Manufacturing would like to thank you for your recent purchase of a Crown Royal Stove. We
sincerely appreciate the trust you have placed in us and we look forward to continuing to serve you. We
know that you will be pleased with our continued commitment to your satisfaction while you enjoy the
benefits of heating with a Crown Royal Stove. Crown Royal Stoves are manufactured with quality
workmanship and designed to offer you value now and years to come. We are so confident in the quality of
our stoves that each Crown Royal Stove comes with a 20 year limited warranty.
To ensure maximum benefits from your furnace, read complete manual prior to using or installing your
furnace.
Always keep this manual for future references.
Crown Royal Stoves - Outdoor Coal Series
The outdoor series furnaces are designed to be located next to your fuel storage for convenience and are
normally filled once or twice a day, depending on the temperature outside. Our outdoor series furnaces are
often used to heat homes, garages, shops, barns, businesses, greenhouses, swimming pools, spas,
domestic hot water, radiant in-floor heat and snow melt applications.
Specifications
RS7200
RS7300
RS7400
Estimated Btu’s*
165,000
240,000
365,000
Heating Capacity
2,000-3,000
4,000-5,000
8,000-10,000
Dimensions
53” x 55” x 80”
53” x 68” x 80”
65” x 83” x 86”
Weight
1250 lbs
1500 lbs
2140 lbs
Chimney Size
6”
6”
8”
Firebox Door Size
20” x 20”
20” x 20”
24” x 24”
Supply/Return Size
(2) 1-1/4
(2) 1-1/4
(2) 1-1/4
Water Capacity
150 Gallons
200 Gallons
380 Gallons
*Btu’s are estimated and will vary with the type of fuel burned. Check and comply with local and state
codes on approved fuels. Always comply with regulations associated with your area.
5

6

Learn how to get the best burn possible from your Crown Royal Stoves.
1. Instructions - Read and follow all operating instructions supplied by Greentech Manufacturing Inc.
2. Fuels - Only burn coal which is the only approved fuel for your Crown Royal Stove. Burning materials not
recommended play a major role in visible emissions. Never burn trash, plastics, gasoline, rubber, naphtha,
household garbage, materials treated with petroleum products particle board, railroad ties and pressure treated
wood, leaves, paper products or cardboard.
3. Loading - Burning coal creates visible emissions. In order to complete the combustion process, there is a
minimum amount of space needed. For instance, if a person were to load a relatively small firebox completely
and load a larger firebox with the same amount of fuel, with all of the other factors being the same, the larger
firebox would burn cleaner. In the smaller firebox, the combustion process does not have enough room to
expand, heat up and mix before exiting the firebox (insufficient time, temperature and turbulence). Just because
a firebox is large does not mean that it should be filled completely. This large volume is used in part for what
happens after it is loaded. Fireboxes should be loaded based on outdoor temperatures, and anticipated heat load
required maintaining sufficient levels to ensure the fire doesn’t go out before next fill.
4. Starting - Never use gasoline, lighter fluids, chemicals, or oils.
5. Furnace Sizing - The size of a furnace should be large enough to provide sufficient heat without constant
reloading. Targeted burn times are around 12 hours; an adequately sized furnace will provide enough heat for
90% of all heating days. Inadequate size of furnace will lead to unattended fires that leave colder fireboxes and
relighting will be dirtier because the flame quenching on the cool firebox walls. A good rule to follow is that if the
furnace cannot stay within 20% of its set temperature under regular reloading, then the unit is undersized and a
larger furnace is needed.
6. Operation - Improper combustion air can be associated with several factors. Air inlet and chimney may be
restricted by debris (creosote, ash, etc). A blower starts and stops properly and runs at proper speed. Door seal
is in satisfactory condition.
7. Maintenance - Excessive ash buildup in grates and frames can cause combustion fan blockage resulting in
restricting air flow. Excessive creosote buildup can be a result of restriction air flow from combustion fan, flame
baffle or chimney blockage.
8. Local and State Regulations - Always remember to comply with all applicable state and local codes.
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8

• All installation and operations must follow federal, provincial, state, and local codes for wire plumbing,
and installing chimney.
• All work must be performed by qualified personnel only.
• Read and understand all precautions before operating the furnace.
• Furnace not to be used as a standalone unit. It is recommended that a backup system be in place.
• Retain this manual as long as you own your Crown Royal Stove. Carefully read and follow these
directions. Regularly read over this manual to keep you informed.
WARNINGS!!
• All installations and operations of your furnace
must follow STATE, PROVINCIAL and LOCAL
LAWS pertaining to operations, wiring, plumbing,
and building codes. The installation must be
performed by a qualified installer.
• Only burn coal in this unit. (Check with
provincial, state, and local regulations that
obtain to banned fuels in designated locations)
• Do not install this unit on a combustible surface.
• All models operate at atmospheric pressure. DO
NOT obstruct, block or plug the overflow vent
tube in any way, which is located on top of the
furnace.
• You must open the chimney flue before opening
the furnace door.
• This unit cannot be hooked to a chimney already
serving another appliance. When installing a
chimney that is higher than twelve feet, guide
lines must be used.
• This unit must never be pressurized.
•Do not use an automatic stoker with this unit.
•Risk of Fire: Do not operate with fuel loading
and/or ash removal doors open. Do not store fuel
or other combustible materials within marked
installation clearances. Inspect and clean flues
and chimney regularly.
CAUTIONS!!!
• Hot Surfaces: Keep children away. Do not touch
during operation.
• Do not start or operate furnace without checking
heating fluid.
• Check for buried cables and utility lines before
digging trench.
• For safety and proper temperature control, keep
fuel door closed tightly during operation.
• Do not fire up boiler until filled with water.
• Do not to start the unit during a prolonged power
failure.
• Load fuel carefully to avoid injury to hands,
fingers and other body parts that may come in
contact with the unit’s loading door opening.
• Cleaning of the heat exchanger, flue pipe,
chimney and draft inducer if used, is especially
important at the end of the heating season to
minimize corrosion during the summer months
caused by accumulated ash.
• When installing the heat exchanger, be sure none
of the existing system safety controls are
disabled.
• When installing heat exchangers do not tamper
with existing controls. Wiring to existing blower
can be done with a line voltage or low voltage
thermostat.
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All installation and operations must follow federal, provincial, state, and local codes for wire plumbing, and
installing chimney. All work must be performed by qualified personnel only.
Location
When choosing the location of your furnace you should consider prevailing wind direction, distance from
home for refueling and storage, and give consideration for any effect of your neighbors. Check with your
homeowner’s insurance company to ensure they will approve the location relative to the distance from
building and combustibles. We recommend a minimum of 20 feet from any building being heated with this
unit.
Minimum Clearances to Combustibles
Sides
Front
Back
Top
Chimney Connection
36 Inches
60 Inches
36 Inches
12 Inches
60 Inches
• Adhere to minimal clearances to combustibles stated in manual and accordance with local, state,
provincial and federal building and fire codes.
• Prior to installation, contact you insurance provider to ensure that installation is in compliance to
regulations and all terms have been met.
Blocks or Concrete Pad
Inspect the ground conditions that you intend to install your furnace on. If the area is unstable or has a
history of staying wet, you may have to improve the soil with gravel as well as raising the elevation. A
cement pad of 4” - 6” inches should then be used. The furnace in most cases can be placed on four cement
blocks and they should not be less than 24 inches wide, 24 inches long, 3 inches thick. Obtain the footprint
of the model of furnace you have purchased. Place your blocks so that the legs will be in the center of
them.
For a pad, the width need not be greater than the outside width of furnace. The length of pad should be as
long as the outside length dimension and an added length is desirable as a work area at the loading door.
A four-foot extension is most commonly used.
Refer to the next page for concrete pad dimensions.
10

RS7100
RS7200
RS7300
RS7400
RS7500
A
47.5"
53"
53"
65"
82"
B
49"
56"
67"
83"
92"
C
18"
18"
18"
18"
14"
D
18"
18"
18"
14"
E
5.5"
9"
9"
12"
14"
F
-
9"
9"
12"
14"
G
-
-
-
-
28.75"
H
-
-
-
-
28.75"
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Chimneys
The size and height all depends on the unit you have purchased and where the unit will be located. If the
furnace is located within 300 feet of any residence, than the chimney stack must be at least two (2) feet
higher than the peak of the tallest roof. It is recommended that only a double insulated, stainless steel,
Class A chimney pipe to be used. The RS7200 & RS7300 use a six (6) inch diameter pipe, RS7400 uses an
eight (8) inch diameter pipe; RS7500 uses a ten (10) inch diameter pipe. Contact your local dealer or
Greentech Manufacturing, Inc for chimney purchase information.
• Installation of complete chimney flue is required.
• Adhere by local building codes and the National Fire Protection Association Rules Nos 31, 54 and 211.
• It is required to use Selkirk Chimney Systems; brand type is UT (Ultra Temp or Galva Temp).
Selkirk Chimney Systems is a double insulated, stainless steel, Class A Chimney Systems that meets
the requirements of UL103 and ULC-S629 and complies with the Chapter 11 of NFPA 211, Standard for
chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances.
Chimney termination caps are required; installation of spark arresters may be needed in high fire risk
areas.
Selkirk chimney comes in carious lengths, spanning from eighteen (18) inches to forty eight (48)
inches. Install each section of piping by placing male and female sections together then twisting them
to lock sections together. When installing your chimney piping, it is recommenced by many chimney
suppliers to brace every eight feet. The chimney manufacture also recommends that the height of the
piping does not exceed a total of forty 40 ft.
•When installing chimney please refer to manufactures recommendations and requirements for adequate
clearances.
•Furnaces come standard with the Selkirk brand, 6”, 8”, or 10” Anchor plate as well as an 18” chimney
length.
•Additional chimney components and lengths are available from your local dealer or can be purchased
direct from Greentech Manufacturing Inc. (Toll Free 866-361-7355)
•Do not attempt to fabricate your own adapters.
•Do not mix Selkirk Chimney with other manufactured brands.
•Do not use existing chimney that already connects to other appliances.
•A major cause of chimney-related fires is failure to maintain required clearances (air spaces) to
combustible material. It is of the utmost importance that the chimney be installed only in accordance
with the manufactures stated instructions. These instructions must be reviewed prior to installation of
venting components.
•Inspections of chimney need to be performed at least annual to ensure of any obstructions due to
creosote buildup. When necessary perform cleaning of chimney to prevent chimney fires.
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Underground insulated pipe is a crucial part of your installation. It is designed to transfer hot water from
your furnace to your home, garage or shop. Selecting the correct underground pipe depends on several
factors such as climate and distance. Choosing a pipe with the least possible heat loss is the most effective
way to ensure your furnaces efficiency.
• Ridged Insulated Underground Tubing –Ridged insulated pipe manufactured with the highest possible
R value ratings.
•Foam Filled Insulated Underground Tubing –Designed to respond to intensive environments and
climates. Insulated with high quality closed cell polyolefin or polyethylene foam and shelled in a virgin
plastic corrugated tile.
•Foil Wrapped Insulated Underground Tubing - Competitively priced closed cell polypropylene foil
wrapped Insulation and sleeved in Heavy Duty UV protected drain tile.
Make sure your insulated underground tubing is equipped with at least one supply and one return pipe.
This pipe should be at least one inch inside dimension; which is rated at 180 degrees F and 100 PSI
continuous flow. Pipe should have a construction of polyethylene and an oxygen barrier.
Insulated underground tubing must be without any splices, couplings and joints. Both tubing and piping
inside should be one continuous run. Underground insulated tubing needs to be free of damages or
punctures that which would allow ground water or soil to come in contact inside insulation and piping.
Allowing such contact will cause moisture to seep through the insulated pipe and result in extreme heat
loss. Insulated underground tubing must remain water tight or will be required to be replaced.
Installation Requirements:
• The trench must be 24” deep and 8” - 12” wide. If possible have a gradual slope in your trench to
allow drainage away from lines and out of the trench bottom. Place electrical supply in bottom of
trench and cover with 6” of gravel or dirt. At this point a water barrier is required. Several methods
are possible, but the most important factor is; if ground water comes in contact with your heating
lines, it will be the greatest heat loss to your system. A minimum of R10 insulation value is
recommended, and a water-tight vapor barrier such as a continuous poly tube of plastic PVC pipe to
encase your insulation is a must. NOTE: If you need to bury lines under an area where vehicles will
cross, you should increase the depth of trench to three feet or place planks over the trench in that
area to spread the load and reduce the pressure generated on the lines.
All wiring must conform to local codes. Use an electrical wire rated and approved for underground
installations. This wiring can be placed in the same trench below the water lines. Use 12-2 UF wire
with ground to provide power to the draft inducer blower, aqua stat, night light, etc. at the stove. This
is satisfactory for most applications but a state certified electrician must be consulted.
• The supply and return tubing and the power wire can be lowered in the trench, brought through the
buildings being heated, and extended a minimum of 36” out of the soil where the stove is to be
placed. Seal the openings around the tubing where it enters the building and seal the tubing where it
extends out of the ground at the location where the stove is to be placed.
Connections to the furnace are clearly marked. The installation of isolation valves at both ends of the
pump is recommended as well as a valve at the return line. This will allow you to shut off water supply
for repair or if additional heating components are added to the system. It is recommended that piping
used is able to withstand 100 PSI at 180 F, and is at least 1” (inch) in diameter. 1 1/4 “(Inch) piping is
recommended for larger systems. A single junction box at the rear of the furnace is included for your
power supply, and should be connected by a qualified person.
A hole large enough to accommodate two lines and insulation is required and attention to sealing this
point of entry is very important. Be sure to bring pipes, insulation and vapor barrier completely
through wall and seal from both sides.
13

Making Water and Electrical Connections at the Stove
After the stove has been placed on the concrete or pads, remove the panel at the back of the stove.
The return (cold water) pipe must be connected to the fitting at the upper position and the supply (hot
water) at the fitting toward the bottom of the stove. If multi-pole locations are to be heated, tees
must be added on both the supply (hot) and return (cold). It is necessary to use brass fittings
between the stainless and other metals.
The stove has been pre-wired at the factory; therefore it is only necessary to connect the common
from the wire from the trench to the common from the stove, neutral to neutral, ground to ground.
Ensure that the connections are water tight.
Return the panel to the back of the stove.
Piping Inside the Building
It is recommended that piping used is able to withstand 100 PSI at 180 F, and is at least 1” (inch) in
diameter.
1 1/4 “(Inch) piping is recommended for larger systems.
• For each building, a circulation pump is needed. The pump can be located on the supply side (hot
water).
• Before each pump, a filtering device must be installed. This filter will minimize the contaminants in
the water and maximize the life of the circulation pump.
• If the central heating system in the building is a forced air furnace, it is important to select the
appropriate water to air exchanger. Contact your heating contractor for proper size. The coil is to
be installed in the furnace plenum. If there is an air conditioning evaporator coil in the plenum,
install the water to air coil after the a/c coil.
• If the central heating system is a hot water boiler system, a water to water heat exchanger is
needed. The water from an open system will contaminate the closed system if the waters are mixed
together.
•It is advisable to install ball valves, isolation flanges, etc. to make the removal and the replacement
components easier.
Wiring Inside the Building
• The electrical wiring must be done by an experienced HVAC technician to ensure the system will
operate as desired and is safe.
• It is recommended that the circulation pump or pumps run continuously.
• The existing forced air circulation blower needs to be wired through the circuit board to a 24 volt wall
thermostat which is dedicated for this purpose. The other wall thermostat which is for the forced air
(Oil, LP, NG or Electric) is left intact. The new 24 volt wall thermostat will cause the circulation blower
to run without the burners coming on. An experienced HVAC technician needs to perform the wiring.
• The electrical for a boiler system is more complicated because the existing boiler wall thermostat is
used but the burners on the (Oil, LP, NG or Electric) boiler are not to operate when the water from
the water stove is to provide heat. It is necessary to have an experienced HVAC technician wire this
configuration.
•If air conditioning is used you must add a relay DPDT to prevent the condenser from turning on when
the fan is energized.
Electrical Requirements
•Electrical Rating: 120 AV Volts, 6 AMPS, 60 Hz. Wire must be rated and approved for direct burial if it
is to be buried in the same trench as the water lines. Boiler power connection box is located at rear of
boiler inside back cover. Minimum supply 15 AMPS. Maximum device 15 AMPS. USE COPPER
CONDUCTORS ONLY.
14

ALL INSTALLATIONS AND OPERATIONS MUST FOLLOW FEDERAL, PROVINCIAL, STATE, AND
LOCAL CODES FOR WIRING, PLUMBING AND INSTALLING CHIMNEY. ALL WORK MUST BE
PERFORMED BY QUALIFIED PERSONAL ONLY.
It is recommended that piping used is able to withstand 100 PSI at 180 F, and is at least 1” (inch) in
diameter. 1 1/4 “(Inch) piping is recommended for larger systems.
The Crown Royal Stove shall be installed without interfering with the normal delivery of heated water from
the original boiler.
The Crown Royal Stove shall be installed without affecting the operation of the electrical and mechanical
safety controls of the original boiler.
The Crown Royal Stove shall have provisions for preventing, or adequate water capacity within the boiler to
prevent damage from loss of circulation due to electrical power failure.
The Crown Royal Stove shall be installed without changing the function of the controls or rewiring the
original boiler. A wiring interconnection is permitted. The electrical system of both boilers shall be powered
from a single branch circuit without exception.
FOR UNITS USED IN CANADA THE FOLLOWING IS RECOMMENDED:
•Operate the existing boiler periodically to ensure that it will operate satisfactorily when needed.
•Do not relocate or bypass and of the safety controls in the existing boiler installation.
•The operation of the existing gas boiler must be verified for acceptable operation before and after
installation of the Crown Royal Stove by a gas fitter who is recognized by the regulatory authority.
•Do not connect to any chimney or vent serving a gas appliance.
•Ensure the installation complies with the requirements of CAN/CSA-B365. Any changes to the
installation should comply with CSA B139 (for oil-fire), C22.1 (for electric), or CAN/CGA-B149.1 or
CAN/CGA-B149.2 (for gas-fired).
15

Put ‘strap on Aqua stat on the supply side of the water-line from outdoor furnace. Run thermostat wire
from the ‘strap on Aqua stat to R and G of fan control center. Run 115V power to white and black wire of
fan center coil. Break one wire of gas boiler Aqua stat. Hook one side of wire to brown wire of fan control
center contact. Hook other side of gas boiler Aqua stat wire to black on fan control center contact. Set
‘strap on Aqua stat to close at 100-120 degree.
16

ALL INSTALLATIONS AND OPERATIONS MUST FOLLOW FEDERAL, PROVINCIAL, STATE, AND LOCAL CODES
FOR WIRING, PLUMBING AND INSTALLING CHIMNEY. ALL WORK MUST BE PERFORMED BY QUALIFIED
PERSONAL ONLY.
DOMESTIC HOT WATER
The Domestic Hot Water Flat plate Kit consists of a Water to Water Heat Transfer unit and the fittings
needed to hook it up. The unit goes on top of the domestic hot water heater and is connected as shown
below.
EXISTING FORCED AIR
A water to air heat exchanger is inserted in the existing plenum. In most cases the heat exchanger is
placed in a horizontal position, keeping all four sides level. The air must be forced through the finned area
of the heat exchanger evenly. The hot water line coming from the hot - water tube enters the bottom
fitting of the heat exchanger and exits the top fitting, which returns to the furnace. If the plenum is too
large or too small, it must be altered to fit the heat exchanger properly.
After installation of the add-on water to air exchanger, the air flow must be increased to fuel the furnaces,
electric furnaces, and electric/gas furnaces. Methods of doing this are:
BELT DRIVE SYSTEM: Blower pulleys and motor pulleys may be changed but the electric current flowing
through the motor shall not exceed the nameplate rating. (A blower motor or larger power may be used.)
DIRECT DRIVE SYSTEM: The motor shall not be changed, however the speed of the motor may be
increased.
Water return to
Crown Royal Stove
Hot Water
from
Crown Royal Stove
THE HEAT EXCHANGER: Air blows through the heat exchangers grill taking the heat from the water
heated grill and blowing it into your existing ductwork.
THE HEAT EXCHANGER: Air blows through the heat exchangers grill taking the heat from the water
heated grill and blowing it into your existing ductwork.
17

18

The Flat Plate Heater can be installed on either the cold side or the hot side of the hot water heater. If
installed on the cold side, the hot water heater needs to be left on to maintain the temperature in the hot
water heater. If installed on the hot side, the hot water heater needs to be turned off and the hot water
heater is now a reservoir.
19

Water to AirExchanger
Boiler Drain
Ball Valve
Fitting
20