ENERGY KING 35EK-D Instruction manual

ENERGY KING
Wood/Coal Boilers
Models 35EK-D/45EK-D &
ASME-Certified Model A40EK-D
Installation, Operation & Maintenance Manual
RJM Manufacturing, Inc.
1875 Olson Drive
Chippewa Falls, WI 54729
[phone] ♦Fax [phone]
www.EnergyKing.com

ENERGY KING Wood/Coal Boilers
Models 35EK-D/45EK-D & ASME-Certified Model A40EK-D
Installation and Operating Instructions
Congratulations on your purchase of an ENERGY KING solid fuel heating appliance!
Your ENERGY KING Wood/Coal Boiler is designed for a lifetime of durable, reliable
performance and easy operation. This manual describes the installation, operation and
maintenance of your ENERGY KING Wood/Coal Boiler.
ENERGY KING Wood/Coal Boilers have been designed to use independently or as an add-
on to an existing hydronic heating system. The installation of any furnace or boiler is not a
do-it-yourself project. To ensure the ENERGY KING Wood/Coal Boiler will operate safely
and efficiently, the installation must be performed by a qualified installer with specific
knowledge of hydronic heating systems. It is the owner’s responsibility to make certain
that both the appliance and installation are acceptable to their insurance company, as well
as ensuring compliance with all local, state and national codes and regulations.
With proper installation and maintenance, your ENERGY KING Wood/Coal Boiler will give
you years of trouble free service.
Thank you for choosing the ENERGY KING Wood/Coal Boiler.
We are constantly improving and updating our products in order to provide the highest quality and value
possible. RJM Manufacturing, Inc., the manufacturer of this product, reserves the right to alter its products,
their specifications and/or prices without notice.
RJM Manufacturing, Inc
1875 Olson Drive
Chippewa Falls, WI 54729
[phone] | Fax [phone]
www.energyking.com
Email: [email protected]
ENERGY KING is a trademark of RJM Manufacturing, Inc.
Save these instructions.
Before installing your ENERGY KING Wood/Coal Boiler,
please read and be sure you understand this entire owner’s
manual and safety instructions.

Rev 04/17/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. i
Safety Instructions
▲Read this entire manual before installing,
operating or maintaining this product.
Proper installation of this heating
appliance is crucial for safe and efficient
operation. Save these instructions for later
use.
▲This heating appliance must be
installed in accordance with local,
state, and national codes and
regulations. Contact your local building
or fire officials about installation
restrictions and inspection requirements in
your area.
▲Do not connect this heating appliance
to a chimney flue serving any other
appliance.
▲Do not install this heating appliance in
a mobile or manufactured home—this
can be dangerous and will void your
warranty. This heating appliance has not
been tested to meet the strict
requirements necessary for installation
into a mobile or manufactured home.
▲Install in an area with adequate air for
combustion and ventilation. The use of
outside air may be required for safe
operation of this heating appliance.
Contact your local building or fire officials
about combustion air requirements in your
area.
▲All minimum clearances to combustible
materials must be followed.
▲This Boiler must be installed on a
non-combustible floor or 3/8-inch thick
fireproof millboard or equivalent. See
Installation for further instructions.
▲Disconnect all power to the ENERGY
KING heating appliance at the breaker
box or service panel before performing
routine maintenance and service. Allow
the heating appliance to cool before
servicing.
▲Never fire a boiler that is low on water.
Never add water to a hot boiler.
▲The fuel loading and ash removal doors
must be closed tightly during operation. All
seals must be maintained in good
condition.
▲The ENERGY KING Wood/Coal Boiler is
designed to burn air-dried wood, or
anthracite or bituminous coal only.
Burning of any other type of fuel voids
your ENERGY KING warranty.
▲Do not burn: Treated wood, colored
paper, garbage, cardboard, solvents, or
trash—burning these may result in toxic
fumes, or produce soot and large flakes of
char or fly ash. Burning treated wood,
colored paper, garbage, cardboard,
solvents or trash can be dangerous and
will void your ENERGY KING warranty.
▲Do not place clothing or other flammable
materials on this heating appliance or
within marked clearances to combustibles.
▲Do not use, store, or dispose of flammable
liquids near the heating appliance.
▲DANGER – Risk of Fire or Explosion:
Do not burn garbage, gasoline, naphtha,
drain or engine oil, or other flammable
liquids or inappropriate materials in this
heating appliance.
▲Do not use chemicals or fluids, such as
gasoline, gasoline-type lantern fuel,
kerosene, charcoal lighter fluid, or similar
liquids to start or freshen up a fire in this
heating appliance.
▲Establish a routine for the storage of fuel,
care of the heating appliance and firing
techniques.
▲CAUTION – Hot Surfaces: Keep children
away! Do not touch heating appliance
during operation.
▲Use caution when opening fuel loading
door. Opening fuel loading door rapidly
can cause smoke or flame to flash out the
door. See Operation for further
instructions.
Failure to follow these safety instructions may result
in property damage, bodily injury or even death.

Rev 04/17/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. ii
Safety Instructions
▲Dispose of ashes with care. Ashes should
be placed in a metal container with a tight
fitting metal lid. 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.
All coal contains small amounts of
dangerous elements. Therefore it is
essential that all coal ash be disposed of
in municipally designated areas.
▲A working smoke detector must be
installed in the same room as this heating
appliance. For additional safety, RJM
Manufacturing, Inc. also recommends
installing working smoke detectors and a
listed carbon monoxide warning device in
the living areas of the home.
▲Always keep a working fire extinguisher
on hand in case of fire.
The National Fire Protection Association has information available on the safe use of solid-fuel
heating appliances. You can contact the NFPA at: National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02169-7471 or www.nfpa.org.
Failure to follow these safety instructions may result
in property damage, bodily injury or even death.

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 1
Table of Contents
SAFETY INSTRUCTIONS................................................................................................................................................i
TABLE OF CONTENTS ...................................................................................................................................................1
SPECIFICATIONS............................................................................................................................................................3
COMPONENT DESCRIPTION.......................................................................................................................................4
WHAT IS ASME-CERTIFICATION?.............................................................................................................................6
PREINSTALLATION CONSIDERATIONS ..................................................................................................................7
FUEL REQUIREMENTS ..................................................................................................................................................8
WOOD............................................................................................................................................................................ 8
COAL..............................................................................................................................................................................9
INSTALLATION ..............................................................................................................................................................10
GENERAL REQUIREMENTS ...........................................................................................................................................10
Zones ........................................................................................................................................................................10
In-floor Heating.......................................................................................................................................................10
Placement.................................................................................................................................................................10
•Floor Protection................................................................................................................................................................... 10
•As Primary Boiler................................................................................................................................................................ 11
•As Add-On Boiler................................................................................................................................................................ 11
Clearances to Combustibles ................................................................................................................................................. 11
ASSEMBLING YOUR ENERGY KING WOOD/COAL BOILER.....................................................................................12
COMBUSTION AIR REQUIREMENTS..............................................................................................................................15
VENTING SYSTEM .........................................................................................................................................................16
Masonry Chimney....................................................................................................................................................18
Chimney Connector .................................................................................................................................................18
Barometric Draft Control ........................................................................................................................................19
PLUMBING.....................................................................................................................................................................20
OPERATION ....................................................................................................................................................................22
GENERAL INSTRUCTIONS .............................................................................................................................................22
GATE VALVES ...............................................................................................................................................................22
FIRST FIRE ....................................................................................................................................................................23
TYPICAL OPERATION CYCLE .......................................................................................................................................23
OVERFIRE...................................................................................................................................................................... 24
POWER FAILURE INSTRUCTIONS..................................................................................................................................24
BURNING WOOD............................................................................................................................................................25
Starting a Wood Fire................................................................................................................................................25
Refueling..................................................................................................................................................................25
BURNING COAL.............................................................................................................................................................26
Starting a Coal Fire .................................................................................................................................................27
Refueling / Recharging............................................................................................................................................27
MAINTENANCE ..............................................................................................................................................................29
CREOSOTE –FORMATION AND NEED FOR REMOVAL .................................................................................................29
DISPOSAL OF ASHES...................................................................................................................................................... 29
GASKET REPLACEMENT ...............................................................................................................................................30
ROUTINE MAINTENANCE..............................................................................................................................................30
TROUBLESHOOTING GUIDE......................................................................................................................................32
APPENDIX A: WIRING DIAGRAM ...........................................................................................................................37
APPENDIX B: EXAMPLE PLUMBING DIAGRAM.................................................................................................39
APPENDIX C: PARTS LIST ........................................................................................................................................41
APPENDIX D: PURCHASE & SERVICE RECORD................................................................................................45
APPENDIX E: WARRANTY CLAIM PROCEDURES .............................................................................................46
LIMITED WARRANTY .................................................................................................................................................49
SUPPLEMENT A: AQUASTAT-IMMERSION CONTROL ......................................................................................51
SUPPLEMENT B: 24-V WALL THERMOSTAT.......................................................................................................64

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 2
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Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 3
Specifications
*The heating capacity specifications are provided as guidelines only and in no way guarantee the output or
capacity of the units. The actual BTU output depends on the type of fuel being burned and its condition, the
thermostat setting, the draft adjustments and the chimney into which the unit is installed.
Model Number A40EK-D 35EK-D 45EK-D
Dimensions (H x W x D) 54.5″x 24″x 43″54.5″x 24″x 38″54.5″x 24″x 43″
Shipping Weight (Approx.) 1,155 lbs. 1,055 lbs. 1,155 lbs.
Heating Capacity* - BTU’s (Approx.) 140,000 BTU 140,000 BTU 160,000 BTU
Heating Area* (Approx.) 1,500–2,500 sq. ft. 1,500–2,500 sq. ft. up to 4,000 sq. ft.
Water Capacity (Approx.) 43 gallons 43 gallons 48 gallons
Water Jacket (Sides, Front, Top, Back) 1/4″SA516-70
Steel Plate
1/4″A36 Steel
Plate
1/4″A36 Steel
Plate
Burn Chamber Dimensions (H x W x D) 30″x 17″x 30″30″x 17″x 30″30″x 17″x 35″
Burn Chamber Volume 8.5 cu. ft. 8.5 cu. ft. 10 cu. ft.
Log Length 26″26″32″
Sliding Smoke Baffle Standard Standard Standard
Cast Iron Fuel Loading Door Size
(H x W) 15.5″x 13.5″15.5″x 13.5″15.5″x 13.5″
Cast Iron Ash Removal Door Size
(H x W) 7.25″x 11.5″7.25″x 11.5″7.25″x 11.5″
Removable Ash Pan Standard Standard Standard
Flue Size 8″8″8″
Flue Collar Height 55.5″55.5″55.5″
Leg Height 4″4″4″
Insulated Cabinet Standard Standard Standard
Pre-wired Electrical Components Standard Standard Standard
Draft Controls Forced (60CFM) Forced (60CFM) Forced (60CFM)
Wall Thermostat Standard Standard Standard
Electrical Requirements 115 Volts, 60HZ,
1 Phase, less than
12 Amp Circuit
115 Volts, 60HZ,
1 Phase, less than
12 Amp Circuit
115 Volts, 60HZ,
1 Phase, less than
12 Amp Circuit
Cast Iron Stationary (Wood) Grates Standard Standard Standard
Cast Iron Shaker Grates Optional Optional Optional
Cast Iron Hearth Plates (Front & Rear) Standard Standard Standard
Domestic Hot Water Coil, 4″N/A Optional Optional
Complies with Standards ASME Code,
Section 4 N/A N/A

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 4
Component Description
1. 8″Chimney Outlet. Top Vent. Venting must
be provided using a lined masonry chimney
or a listed UL103 type HT chimney. The
chimney exhausts smoke and flue gases that
are a natural result of combustion and
provides “draft” to the Boiler. Draft is the
force that moves air from the burn chamber
up through the chimney. See Venting for
further instructions.
2. Sliding Smoke Baffle. When open, the
sliding smoke baffle allows smoke and flue
gases to flow into the chimney connector
without restriction. When closed, smoke and
flue gases are diverted around the sliding
smoke baffle, creating a longer path for the
heated air and allowing your boiler to extract
the maximum amount of heat from the fire.
Figure 1: Components (Cutaway View)

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 5
Component Description
3. 2″Hot Water Outlet. Your ENERGY KING
Wood/Coal Boiler is equipped with one hot
water outlet, located at the top of the
appliance, which supplies heated water to
your heating system.
4. Cold Water Inlet (Return). Cold water
inlets return cooled water back to your
Boiler. The ENERGY KING Model A40EK-
D Wood/Coal Boiler is equipped with one 1-
1/2″cold water inlet, located on the rear of
the appliance. ENERGY KING Models
35EK-D/45EK-D Wood/Coal Boiler are
equipped with two 1-1/4″cold water
inlets, located on the rear of the appliance.
5. Cast Iron Doors. Heavy cast iron fuel
loading and ash removal doors are secured
to the ENERGY KING using door pins (4
included). The door gaskets provide an
airtight seal and should be inspected
regularly to ensure that they are in good
condition at all times. The gasket must be
replaced if it becomes damaged or worn.
Do not operate the ENERGY KING heating
appliance with the fuel loading or ash
removal doors open.
6. Cast Iron Hearth Plates. Cast with the
words “Wood” and “Coal” on opposite
sides, these plates help to ensure the
precise amount of combustion air required
to promote the most efficient combustion
for either fuel. ENERGY KING Wood/Coal
Boilers use two cast iron hearth plates—
one at the front of the burn chamber, and
one at the rear (2 included).
7. Cast Iron Stationary (Wood) Grates. This
is where you build your wood fire. If you
selected the Shaker Grate option, the
Wood Grates will have been replaced with
Shaker Grates at the factory.
Cast Iron Shaker Grates (Optional). (Not
Pictured)This is where you build your wood or
coal fire. The handle to control the Shaker
Grates is located at the front of the ENERGY
KING, on the left side of the ash removal
door.
8. Firebrick. (9″x 4-1/2″x 1-1/4″) 2000-
degree, heat retentive firebricks protect the
sides of the Boiler’s burn chamber.
ENERGY KING A40EK-D Boilers and
35EK-D Boilers use 12 firebricks (6 on
each side). The ENERGY KING 45EK-D
Boiler uses 14 firebricks (7 on each side).
9. Ash Removal Pan. Designed for easy
cleanup of fine ash accumulation. Do not
operate the ENERGY KING heating
appliance with the ash removal door open;
keep it closed except to remove ashes. The
ash removal door gasket provides an
airtight seal and should be inspected to
ensure that it is in good condition at all
times. The gasket must be replaced if it
becomes damaged or worn.
Control Box. (Not Pictured) Controls the
Boiler’s electrical system. The control box is
pre-wired for forced air draft.
Combustion Blower. (Not Pictured) This
blower will supply air for combustion by
forcing air into the burn chamber when your
wall thermostat calls for heat.
24-V Wall Thermostat. (Not Pictured) Tells
your ENERGY KING heating appliance when
your home has cooled below your preferred
temperature. Your draft system is controlled
primarily by your wall thermostat.
Aquastat-Immersion Control. (Not Pictured)
Provides boiler water regulation by controlling
the high and low water-temperature limits.
See Appendix D for further information.
Pressure-Temperature Gauge. (Not
Pictured) Shows the water pressure and
water temperature within your ENERGY KING
Wood/Coal Boiler.
Pressure Relief Valve. (Not Pictured) A
safety feature, the pressure relief valve will
release excess pressure within your ENERGY
KING Wood/Coal Boiler. See Plumbing for
further instructions.
10. Insulated Cabinet. The colored steel
cabinet panels (sides and top) restrain the
foil-backed insulation, allowing maximum
heat from the Boiler to be circulated
through the home’s hydronic heating
system.
11. Legs. Raise the ENERGY KING heating
appliance off the floor to prevent the
accumulation of moisture between the floor
and the bottom of the appliance.
Domestic Hot Water Coil, 4″(Optional):
(Not Pictured) For heating domestic hot water.
The domestic hot water coil is not available
on ENERGY KING A40EK-D Boilers.

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 6
What is ASME-Certification?
ENERGY KING Wood/Coal Boiler model A40EK-D is built and tested to the exacting standards of
the American Society of Mechanical Engineers (ASME) Code Section 4, Construction of Heating
Boilers, under the National Board ‘H’ stamp, and is independently inspected by a third party
inspection agency.
ENERGY KING Wood/Coal Boiler model A40EK-D is constructed of certified, high-grade 1/4”
SA516-70 steel plate and is welded by experienced, ASME-certified welders, to ensure safety and
durability. For additional safety, a 30 PSI pressure relief valve is included with every Energy King
boiler. You can rest easy knowing that ENERGY KING A40EK-D boilers conform to an
internationally recognized standard for safety and quality.
The following information was taken from www.ASME.org and is reproduced here for informational
purposes only. Please visit www.ASME.org for more information about the ASME and codes and
standards.
ASME.org. 2009. American Society of Mechanical Engineers.
19 May 2009 <http://www.asme.org>.
Founded in 1880 as the American Society of Mechanical Engineers, ASME is a not-for-profit
professional organization that promotes the art, science and practice of mechanical and
multidisciplinary engineering and allied sciences throughout the world. The core values of
ASME are rooted in its mission to better enable mechanical engineering practitioners to
contribute to the well-being of humankind.
About Codes & Standards
What is a standard?
A standard can be defined as a set of technical definitions and guidelines, “how to”
instructions for designers, manufacturers and users. Standards promote safety, reliability,
productivity and efficiency in almost every industry that relies on engineering components or
equipment. Standards can run from a few paragraphs to hundreds of pages, and are written
by experts with knowledge and expertise in a particular field who sit on many committees.
Are standards mandatory?
Standards are considered voluntary because they serve as guidelines, but do not of
themselves have the force of law. ASME cannot force any manufacturer, inspector, or
installer to follow ASME standards. Their use is voluntary.
Standards become mandatory when they have been incorporated into a business contract
or incorporated into regulations.
What is a code?
A code is a standard that has been adopted by one or more governmental bodies and has
the force of law.
Why are standards effective?
Standards are a vehicle of communication for producers and users. They serve as a
common language, defining quality and establishing safety criteria. Costs are lower if
procedures are standardized; training is also simplified.
Interchangeability is another reason. It is not uncommon for a consumer to buy a nut in
California for a bolt purchased in New Jersey.

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 7
Preinstallation Considerations
The ENERGY KING Wood/Coal Boiler is intended for use in residential buildings. Do not install this
heating appliance in a mobile or manufactured home—this can be dangerous and will void your
warranty.This heating appliance has not been tested to meet the strict requirements necessary for
installation into a mobile or manufactured home.
Always check with local authorities and obtain the necessary permits prior to installing this heating
appliance.
Before the position of the Boiler can be decided, a few questions should be considered.
1. Will this heating appliance be used as a
primary (central) boiler, or will it be installed
as an add-on to your existing hydronic
heating system?
2. Will your preferred heating system require
the use of storage tanks or mixing valves?
Some systems, such as in-floor heating,
cannot withstand the high water
temperatures produced by the ENERGY
KING Wood/Coal Boiler and may require
the heated water to be mixed with cool
water before it can be delivered into the
home.
3. Can the ENERGY KING heating appliance
be vented properly?
a. Is your chimney appropriate for this
application? This heating appliance
requires installation into a lined masonry
chimney or an 8″UL103 Type HT all-fuel
factory-built chimney. Do not connect
this unit to any chimney flue serving
any other appliance. See Venting for
further instructions.
b. Has your chimney been inspected? For
your safety, it is important your chimney
be clean and free from defect or damage
prior to installing your ENERGY KING
heating appliance.
4. This heating appliance may require an
outside air source for combustion air. Will
this be easily accessed in your desired
location?
5. Are there any local, state or national codes
or regulations governing the use and
placement of this heating appliance?
6. Can the heating appliance be installed
safely?
a. The heating appliance should not be
installed in a location where it could
come into contact with curtains, drapes,
walls, carpeting, or other combustible
surfaces, and must not be installed in a
sleeping room.
b. Will your desired location require floor
protection?
c. The clearances specified in this manual
are minimum clearances. Any reduction
must be approved by the regulatory
authority and is not recommended by
RJM Manufacturing, Inc.
7. How close is the electrical source? The
power source must conform to the
requirements shown in Specifications.
8. Will the heating appliance be easily
accessible for cleaning, refueling,
maintenance, and repair?
9. Are there any structural reasons why the
heating appliance cannot be placed where
you want?
Finally, do you have a reliable, consistent source of fuel for your ENERGY KING Wood/Coal Boiler?
Please see Fuel Requirements for further information on fuel supply.

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 8
Fuel Requirements
BURN AIR-DRIED WOOD, OR ANTHRACITE OR BITUMINOUS COAL ONLY
It is important to use fuel that is clean, dry and consistent. Solid-fuel boilers, such as your ENERGY
KING Wood/Coal Boiler, naturally produce ash as a byproduct of the burning process. Even with
the ENERGY KING heating appliance’s highly efficient design, your heating appliance will still
produce some amount of ash which will need to be cleaned periodically. The type and quality of fuel
you burn affects the amount of ash produced and the performance of your heating appliance. To
assist you in determining which fuel to use, here are some guidelines to consider:
WOOD
Burning wood for heat is as old as civilization itself. More than any other major fuel, wood provides
us with energy independence – an easily available, locally produced and renewable source of heat
on which we can rely.
•The ENERGY KING Wood/Coal Boiler has
been tested for operation with air-dried
wood.
•Wood should be seasoned (dried) for at
least 12 months before burning. Properly
seasoned wood should have about 20% -
25% moisture content. To properly season
wood, split the logs as soon as possible
and loosely stack them in a dry spot for at
least 12 months.
You should not burn wet or green wood in
your Boiler. Burning wet or green wood in
your Boiler will not only reduce the
efficiency of your appliance, but also
increases the risk of dangerous creosote
build-up in your appliance and chimney.
•Softwoods, such as pine and fir, are easily
ignited and burn rapidly with hot flames.
With softwoods, you will spend more time
reloading your ENERGY KING Wood/Coal
Boiler, and will have much more difficulty
achieving an overnight burn. For a longer
lasting fire, it is best to use more dense
hardwoods.
•Ideally, you should burn a mixture of
hardwoods and softwoods, using the hotter,
faster burning softwoods to start your fire,
and the denser hardwoods to maintain a
longer-lasting fire.
•With this in mind, choosing the kind of
firewood that is best for you depends on
what is available in your area. If hardwoods
are unavailable in your area, you can
control the burn rate by using larger pieces
of wood.
•DO NOT BURN: Treated wood, colored
paper, garbage, cardboard, solvents, or
trash—burning these may result in toxic
fumes, or produce soot and large flakes of
char or fly ash. Burning treated wood,
colored paper, garbage, cardboard,
solvents or trash can be dangerous and will
void your ENERGY KING warranty.
•DANGER – Risk of Fire or Explosion: Do
not burn garbage, gasoline, naphtha, drain
or engine oil, or other flammable liquids or
inappropriate materials in this heating
appliance.
Storage
•Store all fuel in a dry location away from
the elements. Never burn wet or green
wood.
•Do not store fuel within the heating
appliance installation clearances or within
the space required for refueling, ash
removal and other routine maintenance
operations.
Risk of Fire: Do not store fuel or other combustible
material within the marked installation clearances.

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 9
Fuel Requirements
BURN AIR-DRIED WOOD, OR ANTHRACITE OR BITUMINOUS COAL ONLY
COAL
One of the world’s most widely-used fuel sources, coal can provide the energy independence and
low fuel prices sought by owners of solid-fuel heating appliances.
•The ENERGY KING Wood/Coal Boiler has
been tested for operation with anthracite
(hard) or bituminous (soft) coal.
•Anthracite: Also known as Hard Coal,
anthracite is a hard, lustrous coal with a
high carbon content that burns with a clean
blue, nearly smokeless, flame.
•Bituminous: Also known as Soft Coal,
bituminous coal is a soft type of coal that
has a high sulfur content and burns with a
yellow, smoky flame.
•Bituminous coal tends to contain more
impurities and sulfur than anthracite coal,
which may decrease the expected lifespan
of your ENERGY KING solid-fuel heating
appliance and its components. If you
choose to burn bituminous coal, be sure to
select only high-grade bituminous coal.
•Coal Size: Your ENERGY KING
Wood/Coal Boiler is designed to use coal
that is Nut size or larger.
•DO NOT BURN: Treated wood, colored
paper, garbage, cardboard, solvents, or
trash—burning these may result in toxic
fumes, or produce soot and large flakes
of char or fly ash. Burning treated wood,
colored paper, garbage, cardboard,
solvents or trash can be dangerous and
will void your ENERGY KING warranty.
•DANGER – Risk of Fire or Explosion:
Do not burn garbage, gasoline, naphtha,
drain or engine oil, or other flammable
liquids or inappropriate materials in this
heating appliance.
Storage
•Store all fuel in a dry location away from
the elements. Never burn wet coal.
•Do not store fuel within the heating
appliance installation clearances or
within the space required for refueling,
ash removal and other routine
maintenance operations.
Risk of Fire: Do not store fuel or other combustible
material within the marked installation clearances.

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 10
Installation
•Do not operate with flue draft exceeding .06 in. (14.95 Pa)
water column.
•Do not operate with fuel loading or ash removal doors open.
•Do not store fuel or other combustible material within marked
installation clearances.
•Inspect and clean flues and chimney regularly.
General Requirements
The installation of any solid fuel heating appliance is not a do-it-yourself project. The
ENERGY KING Wood/Coal Boiler should be installed by a qualified installer with specific
knowledge of hydronic heating systems. Check with your fire department and building inspector for
local, state, and federal codes and regulations regarding installation.
Solid-fuel heating appliance related fires are caused almost exclusively by installation, operation, or
maintenance errors. A smoke detector in “working” condition must be a part of every ENERGY
KING solid-fuel heating appliance installation—this is the most inexpensive insurance you can buy!
For additional safety, RJM Manufacturing, Inc. recommends installing working smoke detectors and
a listed carbon monoxide warning device in the living areas of the home.
The ENERGY KING Wood/Coal Boiler is designed to be used in conjunction with a listed gas- or
oil-fired boiler, or as a central boiler.
Zones
A “heat dump” zone is required for all
installations. The purpose of this zone is to
circulate heated water away from the boiler
when no other zones are calling for heat. In
this way it will prevent your ENERGY KING
Wood/Coal Boiler from overheating. However,
as a safety feature, if your Boiler should
overheat or build up excess pressure, it will
trigger the pressure relief valve which will
release water, thus relieving pressure. See
Plumbing for further instructions.
In-floor Heating
Many newer homes feature in-floor heating.
The ENERGY KING Wood/Coal Boiler may not
be suitable for such applications as it produces
water temperatures in excess of 185-degrees,
which is much greater than can be withstood by
most standard in-floor heating installations.
To use the ENERGY KING Wood/Coal Boiler
with in-floor heating, a mixing valve may be
required to lower the water temperature before
it is delivered to your in-floor heating system.
Placement
•Floor Protection
Floor protection must be provided because
of possible spillage of ashes and burning
fuel. The ENERGY KING Wood/Coal Boiler
must be installed on a non-combustible floor
or 3/8-inch thick fireproof millboard or
equivalent.
The non-combustible material must be
placed underneath the heating appliance,
and must extend at least 18 inches on all
sides of the heating appliance.
Additionally, the non-combustible material
must extend at least 18 inches on either side
of the chimney connector.
Consult your local ENERGY KING dealer for
possible sources of non-combustible floor
protection material acceptable for use with
your ENERGY KING Wood/Coal Boiler.
Risk of Fire:
Do not connect the ENERGY KING heating appliance
to any chimney flue serving any other appliance.

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 11
Installation
•As Primary Boiler
Locate the ENERGY KING Wood/Coal
Boiler as close to the new or existing
chimney as possible. The ENERGY KING
heating appliance should be placed so that
you can easily complete operation and
maintenance procedures.
Locate the 24-V Wall Thermostat provided
with your ENERGY KING heating appliance
in the living area of the home. Your draft
system is controlled primarily by the wall
thermostat, so proper placement and
installation of the wall thermostat is crucial.
Strictly adhere to all requirements
pertaining to clearances to combustibles,
combustion air, venting system, draft
control, and thermostat installation.
•As Add-On Boiler
The ENERGY KING Wood/Coal Boiler is
designed to be used in conjunction with a
listed gas- or oil-fired boiler, but not all
boilers will accept an add-on application.
Some small boilers may not be used in an
add-on installation.
Before installing your ENERGY KING
Wood/Coal Boiler, consult your heating
contractor and local, state and national
building codes and regulations to determine
if your existing hydronic heating system is
compatible with the ENERGY KING
Wood/Coal Boiler.
When using your ENERGY KING
Wood/Coal Boiler in an add-on application,
locate the ENERGY KING Wood/Coal
Boiler as close to the new or existing
chimney as possible, and as close to your
existing boiler as practical. However a
minimum clearance of 12-inches is required
between your existing boiler and your
ENERGY KING Wood/Coal Boiler.
Locate the 24-V Wall Thermostat provided
with your ENERGY KING heating appliance
in the living area of the home, near your
existing thermostat. Your draft system is
controlled primarily by the wall thermostat,
so proper placement and installation of the
wall thermostat is crucial.
Clearances to Combustibles
•Sides: The ENERGY KING Wood/Coal
Boiler must have clearances of 18 inches
from the sidewall of the ENERGY KING
Wood/Coal Boiler to combustibles.
•Front: Leave a minimum clearance of 48
inches in front of your ENERGY KING
heating appliance. This is for safe, easy
loading and cleaning of your ENERGY
KING heating appliance.
•Rear: The minimum clearance from the
rear of the ENERGY KING Wood/Coal
Boiler to combustibles is 20 inches.
•Top: The minimum clearance from the
top of the ENERGY KING Wood/Coal
Boiler to combustibles is 18 inches.
•Stovepipe: Stovepipe must have a
minimum of 18 inches to combustibles.
•Additionally, when using your ENERGY
KING Wood/Coal Boiler as an add-on, a
18-inch minimum clearance is required
between the ENERGY KING Wood/Coal
Boiler and your existing boiler.
Figure 2: Clearances to Combustibles

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 12
Installation
Assembling Your ENERGY KING Wood/Coal Boiler
The entire installation should be planned before putting the Boiler in place to ensure compliance
with all the requirements outlined in the owner’s manual.
Your new ENERGY KING Wood/Coal Boiler will have been shipped on a pallet with several boxed
components that will need to be assembled prior to installation. Please see “Components” for a list
of everything that was shipped along with your ENERGY KING Wood/Coal Boiler.
Once your Boiler is placed in your desired location:
1. Remove the protective plastic coating from
the outer cabinet of the heating appliance
before assembling.
2. Cast Iron Hearth Plates. Position front and
rear cast iron hearth plates in burn chamber.
Your primary type of fuel (wood or coal) will
determine how to position the hearth plates.
The purpose of proper location is to
introduce the precise amount of combustion
air into the burn chamber to promote the
most efficient combustion for either fuel.
The words “Wood” and “Coal” are cast into
the hearth plates on opposite sides.
a. If you are going to burn wood, position
the hearth plates with the word “Wood”
facing out, not into the burn chamber.
b. If you plan to primarily burn coal,
position the hearth plates with the word
“Coal” facing out.
3. Firebrick. The firebrick in your ENERGY
KING heating appliance will have been
installed at the factory; however they may
have shifted during shipment. If adjustments
are needed, position the firebrick by standing
up on end on the left and right sides of the
burn chamber.
ENERGY KING A40EK-D and 35EK-D
Boilers use 12 firebricks (6 on each side).
ENERGY KING 45EK-D Boilers use 14
firebricks (7 on each side).
4. Cast Iron Doors. Mount the fuel loading
door and ash removal door on the front of
the heating appliance and secure with the
enclosed door pins (4 included).
5. Control Box.
a. Remove the control box cover. See
Figure 3: Control Box for Forced Air Draft.
b. Mount the control box on the lower left
side of the heating appliance using the
screws provided.
Do not connect power to your ENERGY
KING Wood/Coal Boiler until the
installation is complete.

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 13
Installation
6. Draft System.
a. Insert the conduit leading from your draft system
into the control box and tighten screw to secure.
b. Mount the pre-wired forced air draft blower to the
draft opening located next to the ash removal door
on the lower left front of the Boiler and secure
using the bolts found on the draft opening.
7. Pressure-Temperature Gauge. Insert the Pressure-
Temperature Gauge into the right-front receptacle
located on top of the Boiler.
8. Pressure Relief Valve. Insert the Pressure Relief
Valve into either the left-middle or right-middle
receptacle located on the top of the boiler. The
Pressure Relief Valve must be plumbed with a
discharge tube that empties into a floor drain. See
Plumbing for further instructions.
Figure 4: Forced Air Draft Blower
Figure 3: Control Box for Forced Air Draft

Rev 08/24/10 ENERGY KING™ Wood/Coal Boiler Owner’s Manual U. S. 14
Installation
9. Aquastat-Immersion Control.
a. Remove the cover of the prewired
Aquastat-Immersion Control to adjust the
High and Low temperature limits.
i. High Limit. Set the High Limit pointer to
the temperature at which contacts are
to open to prevent the boiler from
overheating. Normal setting for the High
Limit is 185º. Always set the high limit
20º or more above the low limit.
ii. Low Limit. Set the Low Limit pointer to
the lowest water temperature you would
like the boiler to maintain. Normal
setting is 160º. Always set the high limit
20º or more above the low limit.
b. Insert the probe well into the left-front
receptacle located on the top of the Boiler
and tighten to secure.
c. Squeeze the entire tube of heat-
conductive grease (included) into the
probe well, and then insert the Aquastat-
Immersion Control probe into the probe
well, and secure.
10. 4″Domestic Hot Water Coil (Optional).
a. Unscrew & remove the 4″plug located at
the upper left on the back of the ENERGY
KING Wood/Coal Boiler model 35EK-D or
45EK-D.
b. Apply pipe joint compound (not included) to
the threads of the 4″domestic hot water
coil.
c. Insert the 4″domestic hot water coil into
the opening at the upper left on the back of
the ENERGY KING Wood/Coal Boiler and
turn clockwise until tightened.
d. Connect your domestic water supply
according to the coil manufacturer’s
instructions.
11. 24-V Wall Thermostat. Locate the 24-V Wall
Thermostat provided with your ENERGY
KING heating appliance in the living area of
the home and install according to the
thermostat manufacturer’s installation
instructions (Supplement B).
12. Wiring. Do not connect power to your
ENERGY KING Wood/Coal Boiler until the
installation is complete. Once you’ve
completed the installation of your ENERGY
KING Wood/Coal Boiler, you may connect
your 110V power supply in to the left side of
the control box. Please see Appendix A:
Wiring Diagram.
Blue
Black
Figure 5: Aquastat-Immersion Control
Figure 7: Aquastat-Immersion Control,
Mounted
Risk of electric shock.
Disconnect power at the service
panel or breaker box before servicing
ENERGY KING Wood/Coal Boiler.
Figure 6: Probe Well