ROYALL 8095 User manual

Installation
INDOOR SOLID FUEL FURNACE
Models: 8095, 8130, 8130HD
www.royallfurnace.com 325 South Park Street, Reedsburg, WI 53959 Phone [phone]

Page 2 November 2013
OBSERVE AND FOLLOW ALL SAFETY INSTRUCTIONS
The following defined terms are used throughout this manual to bring attention to the presence of hazards of serious
risk levels, or important information concerning the life of the product. Failure to install properly or failure to follow
safety instructions could result in severe personal injury, death or substantial property damage.
HAZARD DEFINITIONS
DANGER Indictates presence of hazards that WILL CAUSE SERVE personal injury, death or substantial property damage.
WARNING Indicates presence of hazards that CAN CAUSE SERVE personal injury, death or substantial property damage.
CAUTION Indicates presence of hazards that WILL OR CAN CAUSE minor personal injury or property damage.
NOTICE Indicates special instructions on installation, operation or maintenance that are 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 structures.
Please read and follow all safety instructions to ensure optimal performance and safety.
The installation and operation of the is quite simple. Nevertheless, we recommend
installation to be completed by a qualified professional. The installation and operational
instructions should be carefully read and followed. Pay particular attention to the chimney and
chimney connector installation as they can present a significant fire danger. Refer to appliance
markings for additional instructions.
If you have any questions on the installation or operation of your Indoor Solid Fuel Appliance,
please contact your local representative.

PRODUCT REGISTRATION CARD
Warranty is in effect from the date of purchase upon receipt of this card.
NAME
STREETADDRESS
CITY STATE ZIP CODE
PHONE E-MAILADDRESS
DATE OF PURCHASE
MODEL NUMBER SERIAL NUMBER
DEALER CITY STATE
Reason for choosing Royall 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
STREETADDRESS
CITY STATE ZIP CODE
PHONE E-MAILADDRESS
DATE OF PURCHASE
MODEL NUMBER SERIAL NUMBER
DEALER CITY STATE
Reason for choosing Royall over other brands
__Price __Features __Safety __Previously owned Royall __Recommended to you
__Other

Place
Stamp
Here
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

November 2013 Page
3
CONTENT
GENERAL
SAFETY.................................................................................................................................................. Pg 4
SPECIFICATIONS................................................................................................................................. Pg 5
PRODUCT DESCRIPTION................................................................................................................... Pg 5-6
INSTALLATION
INSTALLATION PLACEMENT.............................................................................................................. Pg 6-7
CLEARANCES....................................................................................................................................... Pg 8
INSPECTING CONTENTS.................................................................................................................... Pg 9
FIREBRICK INSTALLATION................................................................................................................. Pg 10
INSTALLATION OF SHROUD.............................................................................................................. Pg 11
INSTALLATION 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
REPLACEMENT PARTS LISTING................................................................................................................ Pg 33-36
WARRANTY.................................................................................................................................................... Pg 37

Page 4 November 2013
SAFETY
ALL STATE or LOCAL CODES take precedence and MUST be observed.
These models have been constructed along U L391-99 parameters. Many of the recommendations
in this manual are also based on the National Fire Protection Association Code 211.
Before installing or starting operation, read and familiarize yourself with all instructions.
Installation is to be performed only by qualied heating professionals.
RISK OF EXPLOSION OR PERSONAL INJURY WHEN FUEL DOOR OR ASH DOOR ARE OPENED:
ALWAYS hesitate momentarily between the first and second latches when opening doors to allow
unburned gases to ignite. Failure to do so could result in severe burns.
DO NOT use chemicals, kerosene or other flammable liquids to start a fire; severe burns could result.
DO NOT store combustible liquids or materials 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. Burning anything other than approved fuels will void
any warranties.
MAINTENANCE:
To avoid electric shock, disconnect electrical supply before performing maintenance. To avoid severe burns,
allow the appliance to cool before performing maintenance.
APPLIANCE OPERATION:
DO NOT block flow of combustion or ventilation air to the appliance.
DO NOT restrict access to the rear of the unit for maintenance.
This appliance requires electricity whenever in operation. Operation without electricity could result in the
appliance overheating. If power outages are anticipated, a back-up electrical generator is recommended.
DANGER
NOTE:

November 2013 Page 5
NOTE:
Output values are based on theoretical 12 hour sustained burn rate under optimal conditions
and are provided as guideline only. Actual output will depend on a variety of factors beyond the
manufacturer’s control including: furnace location, wood species, wood moisture, wood size, ash
management and combustion air temperature.
SPECIFICATIONS
Features 8095 8130 8130HD
Dimensions: WxLxH (Inches) 22x32x38 24x32x48 24x32x48
Estimated BTU Output 95,000 130,000 150,000
Weight (LBS) 475 565 595
Fire Box Volume 5.6 cubic ft. 7.4 cubic ft. 7.4 cubic ft.
Log Length (Inches) 26” 26” 26”
Fuel Door Opening (Inches) 10” x 14” 10” x 14” 10” x 14”
Flu Size (Inches) 8” 8” 8”
INDOOR FORCED AIR FURNACE MODELS
PRODUCT DESCRIPTION
The Solid Fuel Furnace is designed to burn either seasoned, split cordwood or coal.
It is to be installed inside 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 that
is attached to the back of the solid fuel furnace. The hot air duct out of the solid fuel furnace attaches to the hot air
duct above the existing furnace. A pair of back draft dampers are required at the hot air outlet of each furnace.
Each furnace is controlled by a separate thermostat.
When installed in series with an existing furnace, the cold air ows rst through the existing furnace and then
through the solid fuel furnace. This application does not require a second circulation blower, but does require that
the existing furnace be a counter ow design. Each furnace is controlled by a separate thermostat.

Page 6 November 2013
PRODUCT DESCRIPTION (CONT.)
NOTE
CHECK WITH INSURANCE COMPANY PRIOR TO INSTALLATION. IT IS THE OWNER’S
RESPONSIBILITY TO ENSURE THAT THE APPLIANCE IS ACCEPTABLE TO THEIR INSURANCE
CARRIER. VERIFY ALL LOCAL CODES AND OR Distances PRIOR TO INSTALLATION.
IT IS THE OWNER’S RESPONSIBILITY TO ENSURE THAT THE APPLIANCE MEETS ALL LOCAL
CODES AND ORDINANCES.
LOCAL CODE OR ORDINANCE PLACEMENT REQUIREMENTS TAKE PRECEDENCE AND
MUST BE OBSERVED.
INSTALLATION MUST BE PERFORMED BY A QUALIFIED INSTALLER
1) When placing the solid fuel furnace, the following should be considered:
A) Review the minimum clearances to combustibles on page 8.
B) Review the recommended stack heights on page 17.
C) Do not locate near combustible materials, gasoline or other ammable liquids or gases.
D) Check with insurance company and local codes or ordinances.
E) The appliance requires 115 V 15 Amp electrical service to operate.
F) Refer to markings on appliance for additional instructions.
INSTALLATION PLACEMENT
NOTE
NOTE
The combustion process is driven by a draft blower mounted on the front of the appliance. When the room
thermostat calls for heat, the draft blower starts adding combustion air to increase the re 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/apper assembly is available for the
blower which ensures positive shutdown.
The circulation blower is controlled by an fan limit control that senses the exiting air temperature. The control starts
the circulation blower when air temperature is above 170° F. The circulation blower moves heated air through the
duct work and registers. If the air temperature falls below 130° F, the control turns the circulation blower o.
The blower will turn back on once air temperature rises back above 170° F.
It is recommend that A MASTER switch be installed to interrupt electrical power to the furnace.
A FAN switch is used to interrupt power to the draft blower reducing the re prior to opening the loading door.
A safety latch on both the loading door and the ash door allow unburned gases to combust prior to opening the
door. Always pause between the rst latch and the safety latch to minimize are backs.

November 2013 Page
7
Failure to keep furnace area clear and free of combustible materials, DANGER gasoline
and other ammable liquids and vapors can result in severe personal injury, death or
substantial property damage.
SOLID FUEL APPLIANCES SHALL NOT BE INSTALLED IN A LOCATION WHERE GASOLINE OR OTHER FLAMMABLE
VAPORS ARE LIKELY TO BE PRESENT. The solid fuel furnace is designed to be installed inside the building being
heated either as a stand alone unit or in combination with another furnace. All installations must be in accordance
with local and state codes which take precedence over this manual.
FOUNDATION
The solid fuel furnace must be located on 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 substantial property damage.
***DO NOT INSTALL IN A GARAGE WHERE FLAMMABLES ARE KEPT ***
FLOORING
The solid fuel furnace should be placed on a non-combustible oor which must extend a minimum of 6 inches
beyond the appliance on both sides and back and 48 inches in front.
Do not install appliance on carpeting even if foundation is used. Fire can result, causing
severe personal injury, death or substantial property damage.
INSTALLATION PLACEMENT (CONT.)
DANGER
DANGER
DANGER

Page 8 November 2013
NON-COMBUSTIBLE: Surfaces must have these clearances:
Front – 48” Back – underneath the chimney and Sides – 12”.
COMBUSTIBLE: Surfaces 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

November 2013 Page
9
INSPECTING CONTENTS
BAFFLE
The appliance comes with the cast iron blower bae installed. Inside the re box verify that the bae is in place
directly behind the blower mounting ange.
GRATES
The appliance comes with grates installed inside the re box. Verify that the grates are in place and operate freely.
DOOR GASKETS
The appliance comes with the door gaskets (loading and ash) installed. Verify that the gaskets are in place.
SMOKE DAMPER
The appliance comes with the smoke damper assembly installed. Verify that the damper handle moves freely,
opening the smoke bypass plate.
ASH PAN
The appliance comes with the ash pan stored in the ash trough. Open 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
COMPONENTS SHIPPED LOOSE INSIDE:
ROYALL INDOOR FURNACE
1. Fire Brick
2. Fan Limit Control
3. Fan Center Control
4. Draft Blower With Gasket
5. 4 x 4 Electric Box
6. BX Wire 72” of 14/2
7. BX Wire 60” of 14/3
8. BX Connector, 90 Elbow (1)
9. BX Connector, Straight (4)
10. Spring Handles (4)
11. Wire Strap
12. Bag With Door Locks & Fasteners W/H Instructions
13. Manual With Owner’s Registration Card Inside
14. Shroud Set
OPTIONAL COMPONENTS
15. Filter Box Assembly
16. Circulation Blower
17. Hot Water Loop

November 2013
Page 10
FIREBRICK INSTALLATION
The appliance comes with the rebrick boxpackaged inside appliance.
MODEL 8095 8130 8130HD (16) Full Bricks & (2) Cut Bricks
Install Bricks as follows:
1. Remove T-Bar from back of the re box.
2. Install (2) full bricks and (2) half bricks in the back of the re 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 re box. The (2) bricks closest to the front must be installed horizontally.
T-Bar

November 2013 Page
11
INSTALLATION OF SHROUD
SHROUD PREPARATION
1) For“Series” installation (see page 12):
A) Cover the lter box opening on the rear of the appliance.
Manufacture a cover from standard ducting material.
B) Cut an opening in shroud side for cold air return duct.
Opening should match duct dimensions out of the
existing furnace to maintain system balance.
Return duct can be located 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) Shroud sides are installed from the top. The“S”bent edges on the shroud sides grip the anges on the bottom of the furnace.
2) Then slide the sides front to back until the “S”bends grip the back of the furnace.
3) Shroud top ts snugly over the front, rear and sides per diagram.
4) Use 4 sheet metal screws (2 on each side) to fasten the top to the sides.

November 2013
Description of Operation
1) The circulation blower on the existing furnace draws air through the cold air return and the furnace.
2) The air passes into the bottom of the solid fuel furnace, which heats the air.
3) The heated air circulates through the heating ducts.
4) The existing furnace is controlled by a separate thermostat
5). If the existing furnace res, air ow remains the same through both units.
Required Additional Components
1) The existing furnace must be a “counter ow” design (“down ow”).
2) The existing furnace must be mounted on a ow direction base.
Installation
1) Place the counter ow (gas, LP, oil or electric) furnace on top of an air ow direction base.
2) Cut rectangular opening in the solid fuel furnace shroud to match the dimensions of the air ow direction base
3) The solid fuel furnace should be located approximately 8 inches from the existing furnace.
4) Connect the solid fuel furnace to the air ow direction base with sheet metal. Fasten the sheet
metal with screws and caulk.
INSTALLATION WITH AN EXISTING FURNACE (SERIES)
Page 12

November 2013 Page
13
FILTER BOX (0PTIONAL)
If installing the ROYALL furnace in Parallel with the
existing furnace (see page 14), construct and install the
lter box as follows:
1) Mount the Crculation Blower on the rear of the appliance
using 4-1/4” x 3/4” screws.
2) Assemble and mount the Filter Box over the Circulation
Blower using the 1/4”x 3/4”screws already in place.
A) The side panel with the 12” hole can be installed on
either side of the lter box for convenient installation
of the cold air return duct. For better air ow, 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 rmly 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 lter channel to the side panel with the
cold air return opening
F) Insert the lter.
3) Mount the fan control center on the side of the lter box
(see page18).
Filter Box
Top Panel
Bottom
Panel
Back Panel Side Panel
with Cold Air
Return Hole
6 Screw Holes
This Side Faces
Furnace
1” Slot for
Filter Filter BoxCirulation Blower

November 2013
TYPICAL SYSTEM SCHEMATICS
IN PARALLEL WITH EXISTING FURNACE
Page 14
DESCRIPTION OF OPERATION
1) The Circulation Blower (A) draws air through the “new” cold air return and moves it through the solid fuel
furnace, which connects to the hot air plenum above the existing furnace.
2) A back draft 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 res, back draft damper (2) will automatically open and back draft damper (1) will
automatically close.
REQUIRED ADDITIONAL COMPONENTS
1) Filter box
2) Circulation blower
3) (2 ) Back draft dampers (not available from Royall)
4) Water Loop

November 2013 Page
15
TYPICAL SYSTEM SCHEMATICS (CONT.)
INSTALLATION
1) Install a new cold air return from existing ducts to the solid fuel furnace.
2) Install a back draft damper (air flow baffle) between the solid fuel furnace hot air outlet and the existing furnace hot air plenum.
3) Install a back draft damper (air ow bae) between the 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 o electrical power supply at service entrance panel before
making any electrical connections to avoid possible electric shock hazard. Failure to do
so can cause severe personal injury or death.
***COMPLEX SYSTEMS SHOULD BE DESIGNED BY A HEATING PROFESSIONAL.***
DANGER

November 2013
VENTING INSTALLALLATION
Page 16
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.
A major cause of chimney-related res is failure to maintain required clearances
(air spaces) to combustible materials. It is of the utmost importance that all chimneys be
installed in accordance with the manufacturer’s instructions.
CHIMNEY MATERIAL
The Furnace must be connected to either a:
1) Class “A” masonry chimney.
2) All Fuel metal insulated chimney 6” or 8”
3) Listed type “HT” double wall chimney approved for temperatures up to 1400 °F 6” or 8”
CHIMNEY CONNECTORS
Connectors shall be installed to join unit to the vertical chimney unless chimney is attached direct.
1) Chimney connector can either be:
A) 6” or 8” solid fuel rated stove pipe with:
• Minimum thickness: 28 inches.
• Maintain 18” clearance to combustibles.
B) 8” listed type “HT” double wall chimneys
• Maintain 2” clearance to combustibles
2) Furnace must be the only heating appliance connected to a single chimney ue.
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 Building Codes
(typically 1/4” pitch per Ft of run). E) Secure each connection with a minimum of 3 screws.
4) Assemble in accordance with the vent manufacturers instructions. Additional sections may be required to clear
the peak of the structure. Do not install more than one appliance per ue.
5) When burning coal, a barometric draft damper MUST be installed between the furnace and the chimney to
ensure adequate draft.
DO NOT install more than one appliance per ue. Flue gas spillage and carbon monoxide
emissions can occur causing severe personal injury or death.
***CHIMNEY MUST BE INSTALLED OR INSPECTED BY A PROFESSIONAL AND MEET ALL LOCAL AND STATE
REQUIREMENTS AND CODES FOR WOOD OR COAL BURNING APPLIANCES.***
DANGER
DANGER
DANGER

November 2013 Page
17
VENTING INSTALLALLATION (CONT.)
CHIMNEY HEIGHT
To prevent downdrafts, chimney, or vent without a listed cap should extend at least 3 feet above the highest point
where it passes through a roof and at least 2 feet higher than any portion of a building within a horizontal distance
of 10 feet. A chimney or vent must not extend less than the distances stated above.
**Check local codes or ordinances for additional requirements**
Nearby structures, trees, or hills can cause downdraft conditions which force smoke to the ground. Chimney 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 regulations may not
always be adequate to prevent nuisance conditions in some areas due to terrain or other factors.
***ALL LOCAL AND STATE REGULATIONS OR CODES AND VENTING
SYSTEM MANUFACTURER’S INSTRUCTIONS TAKE PRECEDENCE OVER THESE INSTRUCTIONS.***
***ALL SOLID FUEL APPLIANCES CREATE VISIBLE SMOKE DURING SOME OPERATING CONDITIONS.***
NOTICE
3 FT.
2 FT.
10 FT.
2 FT.

November 2013
COMPONENT ASSEMBLY INSTALLALLATION
Page 18
1) FAN LIMIT CONTROL
A) The fan limit control may be installed on either side.
B) Drill a 3/4” diameter hole approximately 2-1/2” inches
down centered on the desired side.
C) Insert the sensor of the fan limit control and attach
the control with the provided sheet metal screws.
2) FAN CONTROL CENTER
A) The fan control center should be installed on the
same side as the fan limit control.
B) If installing the furnace in parallel with the existing
furnace, then mount the fan control center on the
lter 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 tightly between the
blower and the appliance ange.
Failure to mount fan properly will result in
the furnace overheating.
4) SPRING HANDLES (4)
A)Turn the spring handles on to the levers in a clock
wise direction.
WARNING
43
2
1
OPTIONAL FILTER BOX
3
2
1