Klondike Manual RevisedApril2015 - Wood Furnace Companystore.yukon-eagle.com/content/Klondike_Manual... · 2015-05-19 · DS-103 DAMPER CONTROL This is the solid-state damper control

Yukon KlondikeEagle IV

Alpha American Co., 10 Industrial Blvd., Palisade, MN 56469www.yukon-eagle.com

OWNER’SMANUAL

• Assembly• Installation• Operation• Repair Parts• Maintenance Tips

Model No.LW-000 Series

CAUTION: Read rules and

instructions carefully for

s afe operation

IMPORTANT:Installation must be made inaccordance with state and localordinances which may differfrom this installation manual.

Wood and Coal FiredWarm Air Central Heating Furnace

All furnaces in this owner’s manualare UL Listed in UL File #MH11473

DANGERRISK OF FIRE OR EXPLOSION

Do not burn garbage, gasoline, drain oil, kerosene, thinners, etc.

WARNINGRISK OF FIRE

Tightly close the firing door and ash door during operation.

Do not operate with flue draft exceeding .03" W.C.

Do not store flammable materials within marked installation clearance.

Frequently inspect and clean soot and/or creosote from the heat exchanger,smoke pipe, and chimney.

Do not connect this unit to a chimney flue serving another appliance.

CAUTIONBLACK SURFACES ARE HOT

Keep children away. Do not touch.

Questions?Visit www.yukon-eagle.com

or call1-800-358-0060

For repair or replacement parts,See back cover for details.

Before installing thisfurnace, read and follow allinstructions in this manual.It is recommended that aheating professional installsor supervises the entireinstallation of the furnace,ducts, chimney andelectrical connections.

FOR YOUR SAFETY:If you smell gas:1. Open windows2. Do not touch electrical switches3. Extinguish any open flame4. Immediately call your gas supplier

FOR YOUR SAFETY:

Do not store or use gasoline orother flammable vapors andliquids in the vicinity of this orany other appliance.

2

TABLE OF CONTENTSINTRODUCTIONSafety Statements & EPA Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . .2, 4-7Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . …. . . . . . . . . ……10Unpack and Check Cartons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

PLAN YOUR INSTALLATIONPlan Your Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Clearance to Combustible Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Proper Chimney. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Furnace Located in Confined Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

INSTALLATIONPlace Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Secondary Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Door Handles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ….. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Draw Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19Yukontrol DS-103 Damper Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19Smoke Baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Installing the Fan and Limit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .22Mounting Thermostats and Settings . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Connecting Smoke Pipe ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Barometric Draft Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . . . . . . .25Testing for Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-28Importance of Draft………… . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2924 Volt Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .30Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-32

OPERATIONBest Wood To Burn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Best Burn Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Proper Use of DS-103 Damper Control and After Burner Jet System . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Hand Firing Wood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Coal Firing Unit. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Miscellaneous Coal Burning Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .37

MAINTENANCEGrate Care & Ash Removal & Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38Smoke Pipe, Chimney & Secondary Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Blower Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Duct Work and Blower Speed Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Fire Brick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Miscellaneous Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43-44Over Heating Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Exploded Views and Parts Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 46-48Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49-50

STOP FOR SAFETY!Safe assembly, operating and maintenance practices should always be

followed whenever using any equipment. Wherever you see the caution sign,extra safety precautions should be taken.

You must stop, read, and carefully follow the safety instructions before proceeding.

READ THROUGH THE ENTIRE MANUALIt is recommended to read through the entire manual before beginning your

installation and/or operating your furnace. Follow all steps exactly.

NFPA PRACTICESAreas of this manual refer to the National Fire Protection

Association (NFPA). NFPA is a non-profit organization.

This furnace must be installed according to NFPA codes.NFPA Codes, Standards, recommended practices, and guides referred to in this document are approved by

the American National Standards Institute. State and local codes are adopted from these standards.

DANGERS-CAUTION - FIRE HAZARDS(BURN WOOD LOGS OR COAL ONLY)

Ducts and Plenums shall be constructed entirely of sheet metal

Do Not use flammable liquids to start a fire.

Do Not attempt to light a wood fire when gas or oil vapors are present.

Do Not install on a combustible floor.

In the event of an electrical power failure, be sure ash door and fire door remain closed.

Do Not install a power humidifier on warm air plenum.

Store all ashes in a metal container with a tight fitting lid. Allow ashes to cool before disposing of them.

Be sure there is a sufficient supply of outside combustion air to the area where the furnace is located.

Keep smoke pipe connection as short as possible with a minimum of 1-inch rise per linear foot from thefurnace to the chimney opening. Smoke pipe shall be 24 gauge galvanized or black pipe.

Before servicing, allow furnace to cool. Shut off electricity.

Familiarize yourself with this wood burning furnace before leaving it unattended.

Follow a regular service and maintenance schedule of furnace and chimney.

IN THE EVENT OF A CHIMNEY FIRE, CALL FIRE DEPARTMENT, AND THEN BE SURE ALL FURNACEDOORS ARE CLOSED TIGHTLY. TURN OFF ELECTRIC POWER TO FURNACE.

SAVE THESE INSTRUCTIONS

Safety Statements

4

CAUTIONINSPECT FLUE PIPES, FLUE PIPE JOINTS, AND FLUE PIPE SEALS REGULARLY TO ENSURETHAT SMOKE AND FLUE GASES ARE NOT DRAWN INTO, AND CIRCULATED BY, THE AIRCIRCULATION SYSTEM.

ADD-ON to GAS FURNACE INSTALLATIONS

Installation shall comply with CAN/CSA-B365 and if changes are made to the central fur-nace, changes are to comply with CSA-B139 (add-on to oil furnaces), CSA C22.1 (add-onto electric furnaces), or CAN/CGA-B149.1 or B149.2 (add-on to gas furnaces).

When adding on to a gas furnace, the operation of the gas furnace must be verifiedfor acceptable operation before and after installation of the Klondike furnace by agas fitter who is recognized by the regulatory authority.

DO NOT connect, under any circumstances, to the chimney or vent serving a gasfurnace or gas appliance.

Operate the gas-fired unit periodically to ensure that it will operate satisfactorilywhen needed.

DO NOT relocate or bypass any of the safety controls in the original furnace installation.

DO NOT use duct elbows having an inside radius of less than 150 mm (6 in)

Unit shall only be installed on a furnace duct system and chimney that are in goodoperating condition.

External static pressure of the central furnace shall be measured before any chang-es are made for the Klondike furnace installation. These values shall be maintainedfollowing the add-on installation.

CAUTIONTHE WARM-AIR SUPPLY OF THE SUPPLEMENTARY FURNACE SHALL NOT BE CONNECTEDTO THE COLD-AIR RETURN DUCTING OF THE CENTRAL FURNACE.

Questions? Visit www.yukon-eagle.com or call 1-800-358-0060

Safety Statements

5

This manual describes the installation and operation of the Model SeriesLW-000 Klondike - Eagle IV wood and coal burning furnaces.

These furnace models meet the 2015 U.S. Environmental Protection Agency’s(EPA) requirements for central forced air furnaces sold after May 15, 2015.

Under specific testing done by Underwriter’s Laboratories (UL) these furnacemodels have been shown to deliver heat at the rates as follows:

●Model Series LW-000 has an output of 112,000 BTU

WARNING: The wood furnaces in this manual have a manufacturer-set minimumlow burn rate that must not be altered. It is against federal regulation to alter thissetting or otherwise operate this furnace in a manner inconsistent with operatinginstructions in this manual.

NOTE:The 30-YEAR LIMITED WARRANTY: Alpha American Company will repair or replace, at its option, any casing orheat exchanger which fails as a result of a defect in material or workmanship during the first year after purchaseor 18 months after date of manufacture, whichever comes first. Thereafter, replacement of any casing or heatexchanger which fails as a result of a defect in material or workmanship at a cost to the purchaser of a proportionof the existing suggested retail prices as follows:

YEAR AFTERPURCHASE

% OF RETAIL COST TOPURCHASER

YEAR AFTERPURCHASE

% OF RETAIL COST TOPURCHASER

2-3 40% 7-10 60%4-6 50% 11-30 80%

HOW TO OBTAIN PERFORMANCE UNDER THIS WARRANTYPurchaser should first contact the dealer or contractor from whom the Yukon Furnace was purchased, and notifythem of the defect or malfunction complained of, purchasers name, serial number and date of installation of theYukon Furnace. Parts to be replaced under this warranty should be delivered to the dealer or contractor, orshipped directly to Alpha American Co., 10 Industrial Blvd., Palisade, MN 56469, freight prepaid. If satisfactoryperformance of this warranty is not available through the dealer or contractor, the purchaser may contact AlphaAmerican Co., 10 Industrial Blvd., PO Box 20, Palisade, MN 56469 to obtain performance, but all such communi-cations must be in writing.

CONDITIONS OF THE WARRANTYRead the warranty sheet that is included with this furnace in its entirety! There are conditions that apply to theperformance of this warranty by Alpha American Company.

IMPORTANT! Operation of this furnace in a manner that is inconsistent with theowner’s manual would void the warranty!

EPA Compliance Requirements

6

This furnace is designed to burn natural wood and coal only. Higher efficiencies and lower emissions generallyresult when burning air dried seasoned hardwoods, as compared to softwoods or to green or freshly cut hard-woods.

DO NOT BURN:

(1) Garbage;

(2) Lawn clippings or yard waste

(3) Material containing rubber; including tires;

(4) Materials containing plastic;

(5) Waste petroleum products, paints or paint thinners, or asphalt products;

(6) Materials containing asbestos;

(7) Construction or demolition debris;

(8) Railroad ties or pressure-treated wood;

(9) Manure or animal remains;

(10) Salt water driftwood or other previously salt water saturated materials;

(11) Unseasoned wood; or

(12) Paper products, cardboard, plywood, or particle board. The prohibition against burning these materials does not prohibit the use of fire starters made from paper, cardboard, saw dust, wax and

similar substances for the purpose of starting a fire in this furnace.

NOTE: Once the fire is established, turn the thermostat up to call for the temperature that you want. Aslong as there is the appropriate amount of wood in the firebox the thermostat will cycle the YukontrolDS-103 damper control to keep the temperature in the house at the set temperature.

WARNING: Burning these materials may result in release of toxic fumes or renderthe furnace ineffective and cause smoke!

CAUTION: Do not turn wood thermostat down or off while the firebox is full. Thiswill cause the furnace to damper down and smolder, which could cause creosot-ing of the furnace or chimney pipe.

EPA Compliance Requirements

7

YUKONTROL SOLID-STATEDS-103 DAMPER CONTROLThis is the solid-state damper control thatcoordinates the thermostats with the wood/coaldamper so that your home is always comfortableusing your choice of fuels.

MORE HEAT EXCHANGE SURFACEMEANS LESS HEAT UP THE CHIMNEYThis 8-inch diameter type 304 Stainless Steelsecondary heat exchanger recovers heat that wouldnormally go out the chimney. This is added surfaceplus the large firebox and massive primary heatexchanger will produce a constant 112,000 BTU’s ofheat using 20% moisture content wood. (Wood splitand dried for 2 years.)

2-INCH THICK HI-TEMPERATUREFIREBRICK SURROUNDS THEWOOD/COAL FIREThe Klondike furnace features 180 pounds of 2-inchthick high-temperature firebrick, 18 inches high. Thefirebrick not only protects the steel from the extremecombustion temperatures, it retains a substantialamount of heat after the wood/coal fire burns down.

AFTER-BURNER JET SYSTEM GIVESMAXIMUM SOLID FUEL BURNINGEFFICIENCYTwenty percent of the air required for properwood/coal combustion is drawn in above thefirebox, and then distributed around the top of theflame to create an afterburner effect. Forty percentof the energy in wood/coal leaves the initial flame inthe form of an unburned gas (smoke). Thispatented system burns these gases, therebysubstantially increasing the efficiency of thewood or coal.

2 DIFFERENT STYLES OF HEAVY CASTIRON GRATESIt is imperative that 80 percent of the air forcombustion enters the firebox from below awood/coal grate to insure an efficient and cleanburning fire. Our standard heavy cast iron grate isadequate for a wood fire. A much heavier cast ironshaker grate is also available as an option for densecoal use.

AIR CIRCULATING BLOWER ANDMOTORThe Klondike is designed with 10 inch wide, teninch- diameter belt drive blower. This oversizedblower turns slower than ordinary furnaces becauseof its large size. It is therefore quieter than mostfurnaces. Each Klondike is equipped with apremium Class A motor with Class B insulation,which means it will operate in a highertemperature atmosphere. This motor also featuresa 1.35 service factor, which means it has 35% morepower than a standard motor of the same size. Upto four tons (48,000 BTU’s) of air conditioning canbe added to a Klondike furnace.

Furnace Features

8

Furnace Features

9

KLONDIKE MODEL Series LW-000

Output Rating .................................................................................................................................112,000 BTU/HRBlower Size (Belt Drive) ................................................................................................................................10" x 10"Blower C.F.M ............................................................................................................................................. 800 - 1800Motor Size ........................................................................................................................................1/3 - 1/2 - 3/4 HPFirebrick Lined.......................................................................................................… (18) 9 x 6 x 2” & (4) 9 x 4-½ x 2”Cast Iron Grates - Standard.......................................................................................................................(3) 16” x 8”Wood Fire Door .............................................................................................................................................11" x 10"Air Filter................................................................................................................................................. 20" x 25" x 1"Wood Combustion Chamber Size................................................................................................................ 24" x 16"

NOTE: It is recommended that a 2", non combustible, raised pad be used for the furnace.This will prevent moisture from getting under the furnace and causing corrosion.


Specifications

10

Unpack and Check Your CartonsINSPECT SHIPMENT

Your furnace is shipped complete in two cartons.Note any damage to the shipping cartons. Remove allitems from your shipping cartons. Check all itemsagainst the packing list below. Note any items lost ordamaged in shipment. Refer to the exploded view andparts list in the back of the manual for the part namesand numbers of missing or damaged items. Keep thesmall parts in the parts bag until you are ready toinstall them.

PACKING LIST1. Carton One: The basic furnace comes in the crate.

• The air filter lies on a frame inside the filter door,below the flue outlet.

• The blower cabinet below the filter door contains a pre-assembled circulating fan, motor, belt and drives.

Inside the furnace wood-firing door are:

• Three wood grates (installed)• Smoke pipe draw collar• Primary air draft tube• Door handle weldment and handle assembly for both

fire door and ash pan.

Remove these items and set aside for later installation.

2. Carton Two: This accessory package contains thefollowing items:

• Secondary air intake cover• Thermostat• Barometric draft regulator• Fan and limit control• Yukontrol DS-103 damper control• Transformer• Wiring harness• Owner's manual• Warranty sheet• Moisture Meter (for measuring the moisture in fire wood)• Operating the Furnace DVD

Remove these items and set aside for later installation.


FIG. 1

Unpack and Check your Cartons

11

FAN AND LIMITCONTROL

DS-103 DAMPERCONTROL

24 VOLTTRANSFORMER

SMOKEPIPE


PLAN YOUR INSTALLATIONIt is recommended to read through the entire manualbefore beginning your installation. Follow all steps exactly.Reading this manual will also help you get all the benefitsfrom your furnace.

CAUTION: Read these rules and theinstructions carefully. Failure to follow theserules and instructions could cause amalfunction of the furnace. This couldresult in death, serious bodily injury and/orproperty damage.

IMPORTANT!

CHECKING THE FURNACE INSTALLATION ANDMAKING ADJUSTMENTSIt is imperative that a heating professional, before startupand at the beginning of each heating season, inspects theentire installation and make any necessary adjustments.

RULES FOR SAFE INSTALLATION AND OPERATION1. Check your local codes. The installation must comply

with them.

2. Use only the type of fuel approved for this furnace.Over firing will result in failure of heat exchanger andcause dangerous operation.

3. Oil storage tanks, piping and valves should be installedand tested in accordance with NFPA 31.

4. You must have a sufficient supply of combustion air tothe area in which the furnace is located. (See page 16).

5. Factory Built Chimneys: Connect this furnace to achimney that complies with NFPA 211. Factory builtchimneys for use with wood-burning appliances shallcomply with the HT requirements of UL 103 orCAN/ULC-S629-M87. This means you must install whatis referred to as type HT all fuel chimney.

Masonry Chimneys: Connect this furnace to achimney that complies with NFPA 211. A fieldconstructed chimney of solid masonry units, bricks,stones, listed masonry chimney units, or reinforcedPortland cement concrete that is lined with suitablechimney flue liners and built in accordance with theprovisions of Chapter 4 of this standard.

6. Follow a regular service and maintenance schedule forefficient and safe operation.

7. Before servicing, allow furnace to cool. Always shut offelectricity to furnace when working on it. Thiswill prevent electrical shocks or burns.

LOCATING THE FURNACEThe furnace should be located no more than 10 feetaway from chimney. You will need 1” rise per linearfoot of pipe as a minimum.

The furnace should be located with respect to buildingconstruction and the placement of other equipment.Consideration should be given to sufficient clearance.Sufficient clearance provides adequate access for thecleaning of surfaces; the replacement of air filters,blowers, motors, controls and the chimney connector;and for the lubrication and servicing of moving parts.See Fig. 4 and 5.

UL Listed installation clearances from combustiblesurfaces are 48" in the front of this furnace.18" from the sides, rear and smoke pipe.See Fig. 4.

A 2-INCH PAD OR PAVERS IS RECOMMENDEDUNDER THE FURNACE.

FIG. 2

Unit Dimensions

Plan Your Installation

12

FIG. 4

ABOVE TOP OFWARM AIR PLENUM

FROM THEFRONT

FROM SIDESAND BACK

FROM CHIMNEYCONNECTOR

6 FT OFPLENUM

BEYOND6 FT OFPLENUM

CLEARANCES TO COMBUSTIBLES

6” 48” 18” * 18” 6” 1”

! !CAUTIONALL METAL DUCTING SHALL BE

USED AND INSTALLED WITHCLEARANCES SHOWN HERE

Floor Joist or Combustible Material

FURNACE

WARM AIRPLENUM

6 Inches

6 Feet

Heat SupplyDucts

1”

1” CLEARANCE TOCOMBUSTIBLESBEYOND 6’ TO APOINT WHERETHERE IS ACHANGE INDIRECTION OF90 DEGREES ORMORE.

Top View

Top View

Warm Air Plenum

Cold Air Plenum

18” MIN

18” MIN

8” Dia.Flue Pipe Combustible

Walls

NOTE:DUCT AND PLENUMS SHALL BECONSTRUCTED ENTIRELY OFSHEET METAL.

* Up to 50% less clearance between combustiblewalls and chimney connector to furnace andducts is allowed if insulated according to NFPAStandard 90B or your local building code. Thiscopyrighted book is available from the NationalFire Protection Association, Inc., PO Box 9101,Quincy, MA 02269-9101

SERVICE CLEARANCE OF 24 INCHES MINIMUM REQUIRED TO SERVICE BLOWER

FLOOR TO BE NON-COMBUSTIBLE MATERIAL

FIG. 3


13

FIG. 5

IMPORTANT!AIR CONDITIONING COIL MUSTBE INSTALLED WITH A METALCONDENSATE PAN.

DO NOT USE PLASTIC PAN

DUCTS SHOULD BE LARGE ENOUGHTO HANDLE GRAVITY AIR FLOW IN THEEVENT OF ELECTRIC POWER OR FURNACEFAN FAILURE.

IMPORTANT!DUCTS AND PLENUMS SHALL BECONSTRUCTED ENTIRELY OFSHEET METAL.

TYPICAL INSTALLATION


14

PROPER CHIMNEYS

The National Fire Protection Association (NFPA) requires that all factory built chimneys be Listed andinstalled in accordance with conditions of the Listing in the manufacturers instructions. NFPA alsorequires that your chimney extend at least three (3) feet above the highest point when it passes throughthe roof and at least two (2) feet higher than any portion of the building within ten (10) feet of thechimney.

Factory built chimneys must be what NFPA refers to in NFPA 211 1-5.217.4 as Type HT. HT is anabbreviation meaning high temperature.

Masonry Chimneys as referred to in NFPA 211 1-5.2.17.6, a field constructed chimney of solid masonryunits, bricks, stones, listed masonry chimney units, or reinforced concrete that is lined with suitable chim-ney flue liners and built with the provisions of Chapter 4 of this standard.

RIDGE

More than 10 ft.(3.1m)

10 ft. (3.1m)

2 ft. (0.61m)minimum

Chimney 3ft. (0.92m)minimum

RIDGE

Less than 10 feet(3.1m)

2 ft. (0.61m)minimum

Chimney 3 ft. (0.92m)minimum

CHIMNEY TERMINATION (LESS THAN 10 FEET)

CHIMNEY TERMINATION (MORE THAN 10 FEET)

WARNING: CHECK YOUR CHIMNEY.The chimney should be no less than8 inches inside diameter or equal. Thechimney is a very important part of your

heating system. It must be the right size, properlyconstructed and in good condition. No furnace canfunction properly with a bad chimney. The chimneymust supply a draft of at least -.03 Water Column.If possible, use a 15 foot or higher chimney. Addan additional foot to chimney for each 1000 feet ofelevation above sea level.


15

COMBUSTION AIRMake-up outside air must be provided to furnace forproper fuel combustion. This is provided by openingsto outside of building. These openings shall haveunobstructed areas not less than the areas of the fluepipe. See Figs. 6, 7 and 8

IMPORTANT:Outside air is needed to replace air used bythe wood or coal combustion process.Outside air is required to replace air used fortaking the by-products of combustion outthe chimney. Outside air is needed toreplace air expelled by kitchen or bathroomfans. It is also needed to replace air expelledby water heater chimneys, driyers or fans.See Figs. 6, 7 and 8

Failure to provide outside air to the furnace area willresult in negative pressure, or vacuum, in the home.Smoke from the wood/coal fire may not be drawn upthe chimney. This causes creosote buildup andsometimes causes smoke to enter furnace room.See Figs. 6, 7, and 8

WARNING: You must provide forenough fresh air to assure propercombustion. The fire in the furnace usesoxygen and must have a continuous

supply. The air in a house contains only enoughoxygen to supply the furnace for a short time.Outside air must enter the house to replace thatused by the furnace.

FIG. 7

FIG. 6

FIG. 8

Gooseneck Trap


16

FURNACE LOCATED IN CONFINED SPACE

When the furnace is in utility room, install two open grilles.Place them in a wall or door opening to the rest of thehouse. One grille will supply combustion air.

Locate it near the floor. The other grille is for ventilation.Locate it close to the ceiling. Each grille must have a freearea. It should be not less than one square inch for each1000 BTU/hr. of the total input rating of appliances inconfined space. See Fig. 9.

FOR EXAMPLE: Your furnace is rated at 150,000 BTUper hour. The water heater is rated 30,000 BTU per hour.The total is 180,000 BTU per hour. You need two grilles,each with 180 square inches of free opening. Metal grilleshave about 60% free (open) area. Therefore, you needtwo metal grilles with 300 square inches each of louveredarea. The height should be about half the width.

SIZE

1/4” MESHSCREEN

BTU

WOODLOUVERS

BTU

METALLOUVERS

BTU

3-1/4 X 12 INCH

8 INCH ROUND

8 X 12 INCH

8 X 16 INCH

144,000

200,000

382,000

512,000

36,000

50,000

96,000

128,000

108,000

150,000

288,000

384,000

BTU Per Hour Input*

* Based on opening covered by 1/4 inch mesh screen, wood or metal louvers.

FRESH AIR DUCT CAPACITIESFresh air duct capacities for duct supplying fresh air

FIG. 9


17

FIG. 11

PLACE FURNACEReview all instructions in the Planning YourInstallation section. Place the furnace in the pre-selected location.Refer to Figs. 4 & 5 (on pages 13 and 14 ) in thePlanning Your Installation section. Make sure thefurnace is level.

SECONDARY AIR INTAKE COVER

1. Remove secondary air intake cover fromaccessory package and align over mountingholes located above fire door assembly on faceof furnace. See Fig. 11.

2. Insert 12 ea. # 10 x 3/4 hex HD drill screws(furnished with cover) through mounting holesand tighten.

DOOR HANDLE

Install door handle as follows: See Fig. 12

1. Remove handle assembly, machine screw andwasher from plastic bag.

2. Place machine screw through handleassembly.

3. Place washer over machine screw and fastenthe handle assembly to the door.

ASH PAN HANDLES

Install ash pan handle as follows:

1. Remove pull handle and 10-24 x 2” screwsfrom plastic bag.

2. Insert 2 10-24 x 2” screws through pull handleinto threaded holes on ash pan and tighten.

3. Remove tapered handle from plastic bag andscrew to steel handle.

Questions? Visit www.yukon-eagle.com or call 1-800-358-0060FIG. 12

Secondary AirIntake Cover

DRAFT TUBE

FIG. 10

Installation

18

DS-103 DAMPER CONTROL

FIG. 13


DRAW COLLARFirmly attach the draw collar around the stainless steelsmoke pipe. Keep the field installed smoke pipe at least 2 "away from draw collar. This will insure that smoke leavingthe furnace will not be drawn into the circulating air stream.See Fig. 13.

NOTE: If barometric draft control is installedhorizontally as illustrated, it must be at least 8inches from furnace smoke outlet.

YUKONTROL DS-103 DAMPER CONTROL

NOTE: Refer to the wiring diagrams on pages 30-33.

Remove control from accessory box and install asfollows:

1. Remove the four screws that hold the gasket to theDS-103 damper control.

2. Mount the DS-103 damper control to the draft tube using screws removed above. Make sure gasket stays in place. See Fig. 11.

3. Loosen the two screws located at slotted end ofdraft tube, and remove remaining 12 screws. Makesure the draft tube gasket stays in place.

4. Mount DS-103 damper control and draft tubeassembly to furnace as shown. See Fig. 11 and 14.

The electrical connections will be completed laterin the Installation Instructions.

FIG. 14

Draft TubeAssembly

DS-103Damper Control

CHIMNEY DRAFTREGULATOR

DRAWCOLLAR FILTER

DOOR

SMOKEPIPE

Installation

19

SMOKE BAFFLESThe smoke baffles are factory installed. Theymust be checked to see that they have notbecome dislodged during shipping. See Fig. 15-A.Complete the following steps to check the baffles:

1. Hold the baffle in proper position. Tilt the rear up toclear baffle mounting brackets.

2. Push baffle up to top of combustion chamber aboveall three brackets, level off, slide left and lower ontomounting brackets.

3. Check to see that all three brackets are engaged.

4. Repeat with second baffle, making sure bafflesinterlock as shown. See Fig 15-B. When properlyinstalled, baffles will not move more than 1/4" in anydirection.

IMPORTANT! Failure to have baffles properlyinstalled will severely reduce combustionefficiency!


FIG. 15-B

FIG. 15-A

Installation

20

FIG. 17

Fan andLimit

Control

INSTALLING THE HONEYWELL FAN AND LIMITCONTROL

Included in the accessory carton is a white sheet metalbracket that is 8-1/4 inches high and 3-1/4 inches wide.It has a 7/8” hole in it 6 inches from the bottom. Rightbelow the 7/8” hole are 2 screw holes. This bracket alsohas 2 screw mounting holes on the bottom 1-1/4 inchflange. (Shown in Fig. 16)

1. Place the sheet metal plenum on top of the 24” X 24”warm air duct opening.

2. Attach the fan and limit control mounting bracket tothe top of the furnace using sheet metal screws to attachthe bracket into the screw holes (pre drilled) that are onthe furnace.

3. With the fan and limit control bracket up against thesheet metal plenum, either drill a 7/8” hole and two 1/8”holes through the holes into the sheet metal plenum oruse the bracket as a template.

4. Screw the mounting bracket onto the bracket with the2 screws that are furnished.

5. Install the fan and limit control through the mountingbracket and into the plenum.

6. Tighten the mounting bracket set screw into the fanand limit control.

WARNING:If you intend to install air conditioning, the airconditioning coil should be mounted above fanand limit control. Use metal water drain panonly. Do not use a plastic pan as high

temperatures resulting from electric power failure orfurnace fan failure could result in fire.

FIG. 16

Installation

21

FAN AND LIMIT CONTROL

ELECTRIC WIRINGAll electrical wiring must be done in accordance with theNational Electrical Code. The code needs to be legallyauthorized in the area where the installation is beingmade. The circuit protector device must be located in aconvenient place near the furnace. No lighter than14 AWG wire should be used in the furnace powersupply circuit. All furnaces covered by this manual andinstalled in the United States of America operate on115 Volts, 60 Cycle, 1-Phase Alternating Current with a20 amp circuit protector device.

WARNING: Turn off electric power atcircuit protector device before makingany line voltage connections.

WIRING THE FURNACEThe furnace wiring is provided in harness form.Mount the 4 x 4 junction box on 7/8” diameter openingon front of blower compartment. Secure with conduitconnector and locknut. For the blower motor, securewith lead conduit and at least one screw. Connectcomponents as shown in wiring diagrams. See Fig. 18.

CAUTION: This furnace is not approvedfor use with aluminum wire.

NOTE: 24 volt wires from the transformer to DS-103damper control and from thermostat toDS-103 damper control need not beenclosed in conduit unless required by localcodes.

DS-103 DAMPER CONTROLThe R terminal is not used.The C terminal is connected to the C terminal on the24-volt transformer. Terminal 1 is connected to thewood/coal thermostat (smaller stat). When Terminal 1is energized by the wood/coal thermostat, a relay on thecircuit board energizes a solenoid that opens a damperdoor that supplies air to the wood fire. See Fig. 20.

NOTE: Refer to the wiring diagrams onpages 30-32.

FIG. 18

FIG. 19


To “W” on Digital Thermostat

To “C” on 24 volt Transformer

DS-103 DamperControl

ElectricalJunction

Box

24 voltTransformer

WOOD

FIG. 20

Installation

22

DS-103 DamperControl Board


MOUNTING THE THERMOSTATS

The thermostats must be mounted on an interiorcentrally located wall. Place them away from directsunlight, drafts, and approximately 5 feet above thefloor. It is not required that they be level. Place themright next to each other. See Fig. 21.

A Honeywell digital thermostat is furnished with thisfurnace that controls the room temperature whenyou are burning wood/coal. This thermostat alsocontrols the air conditioning, if applicable.

If you have no plans for air conditioning you willneed a 3-wire thermostat cable from your furnace toyour thermostat. If you intend to install airconditioning a 5-wire thermostat cable is required.

TYPICAL THERMOSTAT SETTINGS

Set the thermostat above room temperature. Thedamper door to the firebox should now be open.

Be sure to load the wood or coal according to thecall for heat or the temperature outside so that thethermostat calls for heat and will cycle appropriatelyfor the amount of wood or coal in the firebox.

Once the thermostat is satisfied, the damper doorwill close off the air to the firebox until there isanother call for heat.

FIG. 21

HoneywellDigital

Thermostat

Installation

23

FIG. 22

CAUTION: Do not use any smokepipes less than 24 gauge betweenfurnace and chimney.

WARNING: No damper, heat saver, orautomatic vent damper device should beinstalled in or on smoke pipe. Except thebarometric draft regulator.

The smoke pipe entrance into a masonry chimney shouldbe at least 2 feet above the clean out. The smoke pipemust not extend into the chimney beyond the inner faceof the chimney liner.

LESSER CLEARANCES TO COMBUSTIBLEMATERIALS ALLOWEDThis furnace is UL Listed, requiring 18 inches from smokepipe to a combustible surface. A reduction of 9 inchesfrom a combustible ceiling and 12 inches from acombustible wall is allowed if the space is insulatedaccording to NFPA 90B, table 6-5.1.2.

WARNING: DO NOT CONNECT THISFURNACE TO A CHIMNEY SERVINGANOTHER APPLIANCE

CONNECTING SMOKE PIPESet the smoke pipe end of the furnace as close to thechimney as possible. The rise of the smoke pipetoward the chimney must be at least one inch perlinear foot of pipe. Do not exceed 10 feet in length.A clean out tee should be installed for removal of sootand fly ash.

NOTE: Service clearance of at least 24 inches isRequired to service blower and motor and clean outsecondary heat exchanger.

Do not install smoke pipe longer than necessary toreach chimney. This is for purposes of trapping heat.The smoke outlet temperature is designed to carry


WARNING

Check your chimney. The chimney is a very important part of yourheating system. It must be the right size, properly constructed and ingood condition. No furnace can function properly with a bad chimney.The chimney must supply a draft of .03 Water Column. If possible, usea 15 foot or higher chimney. Add an additional foot to the chimney foreach 1,000 feet of elevation above sea level.

Installation

24

BAROMETRIC DRAFTREGULATOR

INSTALLATION

Install barometric draft regulatorusing a 24 or 26 gauge 8” X 8” X 8”black sheet metal Tee.

DO NOT ATTACH DRAFTREGULATOR TO TOP ORBOTTOM OF FLUE PIPE,NOR IN ROOM SEPARATEDFROM APPLIANCE.BEST LOCATION IS ASCLOSE TO APPLIANCE ASPOSSIBLE.

IMPORTANT:MAKE THESE ADJUSTMENTS WHEN INSTALLING.

VERTICAL FLUE:Adjustment weight must be in RIGHT HAND SLOT(Marked “V”) in bracket on gate.

The arrow on flap at bottom of gate must line up with letter “V”on lower right part of gate. If it does not,remove flap, turn over and snap on to gate again.

Flap can be removed by inserting small screw driver at theback side of the gate between the gate and the flap, then pull-ing downward on flap.

HORIZONTAL FLUE:Adjustment weight must be in LEFT HAND SLOT(Marked “H”) in bracket on gate.

The arrow on flap at bottom of gate must line up with letter “H”on lower left part of gate. If it does not, remove flap, turn overand snap on to gate again.

IMPORTANTA MANOMETER MUST BE USED TO

ACCURATELY ADJUST FLUE DRAFT

Weight on Right Sideof Bracket (“V”)

Weight on Left Sideof Bracket (“H”)

Use Spirit Level to make sure that the draft regulator does notlean forward or backward but instead is plumb in both direc-tions, regardless of whether the flue is horizontal, vertical orsloping.

Installation

25

DRAFT REGULATOR

TO FUNCTION PROPERLY AND SAFELY, it is impera-tive that the draft regulator when installed in the Teestub, is pointing away from surrounding walls or obstruc-tions. (See Fig. 24) Placement of draft regulator pointingtoward nearby wall(s) or obstruction(s) could result in ahot spot on the exposed surface and subsequent firehazard.

REGARDLESS OF LOCATION AND POSITION, theTee stub opening MUST be plumb (perpendicular) forthe draft control to function properly.

AFTER THE TEE SECTION LOCATION HAS BEENDETERMINED, secure the section with both ends toadjacent sections of standard smoke pipe. Three sheetmetal screws placed at equal distance around each endof pipe will hold it firmly in place.

INITIAL SETTING OF BAROMETRIC DRAFTREGULATORBefore adjusting the draft regulator, be sure there is agood fire burning and the chimney temperature is stable.

Set the control at a maximum of -.03 to -.04 or as low adraft as will give good combustion and meet the require-ments for heat. Turn adjustment weight counter-clock-wise to loosen, then slide in slot to proper position andtighten. Bracket is marked 2, 4, 6, and 8, which indicatesdraft settings of .02, .04, etc. (These are draft in flueadjacent to control, not over-fire drafts.)

A manometer must be used to accurately adjust fluedraft.

SETTING THE DRAFT REGULATOR AND SOME INFORMATION ON CREOSOTECREOSOTE BUILD UP - Creosote, in a vaporized state,is present in the gases emitted by burning wood and ishighly combustible in its solid and semi-liquid states.Creosote may build up on the interior surface of thechimney and subsequently reduce the draft opening. ADANGEROUS CHIMNEY FIRE MAY RESULT IF ANYAPPRECIABLE CREOSOTE BUILD UP IS PERMIT-TED.

ADVERSE CONDITIONS CONDUCIVE TO CREO-SOTE BUILD UP - Creosote condenses from the fluegases more rapidly when the temperature in the chim-ney is cool. The amount of creosote build up isdependent on:� The amount of moisture in the flue gases� The temperature of the stack� The rate at which the wood is burned� The amount of draft in the stack� How completely the combustible elements in the

flue gases have been burned in the combustionchamber

Most problems with creosote are due to insufficiently dryor cured wood, inadequate chimneys with low draft andcold walls (below 250°F), and/or too low a rate of burn-ing when little heat is required during spring and fallmonths.

CONTROL OF CREOSOTE - Moisture in the fluegases may be controlled by:� Using properly seasoned fire wood� Mixing small pieces of air dried wood with every

load� Never using only large wood (usually less dry)

during mild weather when combustion is relativelyslow

The temperature in the stack may be controlled by:� Using as short a length of stove pipe as possible

between the appliance and the chimney� Using an insulated (double wall) smoke pipe to

connect the appliance to the chimney

The amount of draft in the stack may be improved by:� Having as few bends as possible� Insuring adequate chimney height and preventing

air leaks� Eliminating external obstructions in the chimney

outlet� Having only one appliance per flue (Code)

REMOVAL OF CREOSOTE - Accumulations ofcreosote in smoke pipe and chimney flue should beremoved on a regular basis by dismantling and scrapingconnector pipes and by scraping and brushing flue untilfree of deposits. In many areas there are professionalchimney cleaning services available to perform thiscleaning operation.

FIG. 24

Installation

26

Tee Stubwith DraftRegulator


TESTING INSTALLATIONS FOR EFFICIENCY

A Draft gauge must be used. Draft in smoke pipe mustbe set at -.03 Water Column updraft. Failure to setproperly will cause fuel to be wasted, heating will notbe satisfactory, fast buildup of creosote in heatexchanger and chimney may occur and cause damageto your heating system.

The draft regulator will afford the user maximum fuelefficiency, however, the finest draft regulator in theworld cannot increase the efficiency of a heatingsystem if the system as well as the regulator is not inproper adjustment.

Basically, stack temperature and percentage of CO2 area measure of stack losses for any fuel. Therefore,many of the basic principles can be and should beapplied to oil-fired furnaces as well as for those burningsolid fuels.

In preparation for these tests, the following should bechecked. The Draft Regulator installed should be:

• plumb and level

• in the same room as the unit

• on the side of a vertical, sloping or horizontal smokepipe

• located close to the furnace

Drill two holes approximately 1/4 inch in diameter in theflue pipe between the outlet from the furnace and thedraft regulator.

Insert a stack thermometer in one of the holes andleave it there continually during the test so that you canrefer to it at any time. See Fig. 23

FIG. 23

Installation

27

TEST PROCEDURE

Step 1.Set the thermostat high enough so that the unit will runfor at least 15 minutes, the maximum time that shouldbe required for the test. Let the unit operate enoughfor the stack temperature to stabilize.

Step 2.For your initial set of readings, set the draft regulatorso that there is -.03 Water Column Draft in the smokepipe between the flue outlet and draft regulator.A manometer must be used to properly set the draft to-.03” WC.

Step 3.Insert the sampling tube of the CO2 tester in the holethat you have drilled adjacent to the stackthermometer and find the percentage of CO2 in thesample of the products of combustion. Follow theinstructions of the manufacturer of the instrument youare using.

Step 4.Use efficiency finder chart or stack loss slide rule todetermine efficiency. Be sure to subtract roomtemperature from stack thermometer reading and usethis net stack temperature for determining theefficiency.

Step 5.Insert end of smoke tester into same hole as wasused to test for CO2 and perform the smoke test.

Step 6.The filter paper from the smoke test, when comparedto the standard, must be determined and be found tobe satisfactory. It should never be greater than #2,preferably #1 or zero, depending on localrequirements or your own service standard.

Repeat steps 3, 4, and 5 as needed, adjusting the airshutter on the burner and draft regulator until youobtain the highest possible efficiency. It is desirable tohave a high CO2 reading and low stack temperaturewith a minimum smoke reading.

FIG. 29


Installation

IMPORTANCE OF DRAFTDraft is the force which moves air from the applianceup through the chimney. The amount of draft in in yourchimney depends on the length of the chimney, localgeography, nearby obstructions and other factors.

Too much draft may cause excessive temperatures inthe appliance and damage the steel of the furnace.

Inadequate draft may cause back puffing into the roomand plugging of the secondary heat exchangers orchimney.

CONDITIONS INDICATING INADEQUATE DRAFTIn adequate draft will cause the appliance to leaksmoke into the room through appliance and chimneyconnector joints.

CONDITIONS INDICATING EXCESSIVE DRAFTAn uncontrollable burn or excessive temperatureindicates excessive draft.

PROPER CHIMNEY STACK HEIGHTThe chimney for this furnace should be a minimum of15 feet high and sized properly. Poor draft may becaused due to surrounding trees or if the home is builtin a valley or at the bottom of a hill. These conditionswill allow for wind to push down on the top of thechimney, causing poor draft.

NOTE: A Wind Directional Cap may help maintainproper drafting of a chimney if there are treessurrounding the building or if the home is locatedon the bottom of a hill.

CARBON MONOXIDE AND WHAT YOU NEED TO KNOW ABOUT ITCarbon monoxide (CO) is a gas that can kill you quickly. It is called the silent killer because it is colorless, odorless,tasteless and non-irritating. If the early signs of CO exposure are ignored or the CO concentration is very high, a per-son may lose consciousness and be unable to escape the danger. CO exposure is the leading cause of death due topoisoning in the United States. However, CO deaths are entirely preventable.

CO is produced by burning fuels such as wood, oil, natural gas, propane, kerosene, coal and gasoline. CO in indoorair is related to the presence of appliances which use CO-producing fuels. The normal background level of CO in ahome may vary depending on the presence of cigarette smoke and the types of heating and cooking fuels. TheWorld Health Organization recommends that the indoor air level for CO be below an average of nine parts per million(ppm) for any eight-hour period, and below 25 ppm for any one-hour period. One ppm means one part of CO permillion parts of air. Many people are treated for CO exposure in emergency rooms without further hospital care. MostCO exposures and poisonings occur when people are in the home.

IMPORTANT: It is recommended that a CO monitor is installed in your home. COmonitors should be located in areas that are expected to generate CO, especiallyin the utility room or where your furnace is located.

If you burn wood in your home, even occasionally, it is recommended that youinstall a smoke alarm to alert you and your family in the event of a fire. To beeffective, smoke alarms must be in the proper location and tested regularly.Batteries should be replaced regularly, too.

Installation

29

Terminal 1controls wooddamper andwoodthermostat

RC R Y C W G

C

R

1

2

T

T

R

C

Honeywell FocusPro 5000Thermostat

FanRelay

RC R Y C W G

C

R

1

2

T

T

R

C

Honeywell FocusPro 5000Thermostat

Terminal 1controls wooddamper andwoodthermostat

ACCondensing

Unit CompressorRelay

WOOD OR COAL HEATING ONLY

WOOD OR COAL HEATING WITH AIR CONDITIONING

24 voltTransformer

24 voltTransformer

DS-103 Circuit Board

24 Volt Field Wiring

30

DS

-103

Circ

uit B

oard


WOOD OR COAL HEATING ONLY

Wiring Diagram

31

HONEYWELLFOCUS PRO 5000

THERMOSTAT



Wiring Diagram

32

WOOD OR COAL HEATING WITH A/CHONEYWELL

FOCUS PRO 5000THERMOSTAT




BEST WOOD TO BURN

All solid fuel, whether it is coal, pine, oak or any grainhas about 12,000 BTU's per pound if its moisturecontent is zero. Wood that has been cut, split and airdried for 2 years has about 8,000 usable BTU's perpound. Hardwood such as oak or hard maple hasnearly twice the BTU's per cord as pine or aspenbecause it is nearly twice as heavy.

Freshly cut wood has about 50% moisture content.Wood that has been cut and split for 2 years has about20%. Wood must reach at least 435º to ignite. Highmoisture content wood does not allow the gases inwood to get hot enough to provide completecombustion, thereby creating smoke and creosote,which is usable energy, but wasted because ofincomplete combustion.

Yukon furnaces are designed to wring the most energypossible from each log. Your furnace is designed toallow the primary air under the grate to create theinitial burning. As the wood burns, gases, whichcontain 40% of the energy in the wood, escapeto the top of the flame. The patented secondary airsystem (the round tubes between the firebrick) drawsroom air into the tubes and provides oxygen to thefirebox to burn these gases. The result is you will useup to 75% less wood than stoves, furnaces or outdoorboilers without these features.

FIG. 25

FIG. 26Type

PoundWeight

per Cord

BTU’sper CordAir Dried

Wood

EquivalentValue #2Fuel OilGallons

White PineAspenSpruceAshTamarackSoft MapleYellow BirchRed OakHard MapleHickory

1800190021002900250025003000325030003600

17,000,00017,500,00018,000,00022,500,00024,000,00024,000,00026,000,00027,000,00029,000,00030,500,000

120125130160170170185195200215

Operating Instructions

33

BEST BURN PRACTICES

A properly installed, correctly used wood-burning appli-ance should be smoke free. If you see or smell smokethat means you may have a problem. Practice the fol-lowing guidelines to Burn Wise in your appliance andreduce smoke inside and outside your home.

Practical Tips for Building a Fire

Once your wood-burning appliance is properly in-stalled, building an effective fire requires good firewood(using the right wood in the right amount) and good firebuilding practices. The following practical steps willhelp you obtain the best efficiency from your woodstove or fireplace.

Season wood outdoors through the summer for at least6 months before burning it. Properly seasoned wood isdarker, has cracks in the end grain, and sounds hollowwhen smacked against another piece of wood.

Wood burns best when the moisture content is lessthan 20 percent. A wood moisture meter is includedwith your furnace to test the moisture content of yourwood before you burn it.

Store wood outdoors, stacked neatly off the groundwith the top covered.

Burn only dry, well-seasoned wood that has been splitproperly.

Burn hot fires.

To maintain proper airflow, regularly remove ashesfrom your wood-burning appliance into a metalcontainer with a cover and store outdoors.

PROPER USE OF YUKONTROL DS-103 DAMPERCONTROL

The DS-103 damper control system, that the furnaceis equipped with, is the thermostatically controlledcontrol that allows the primary combustion air in underthe fire when the thermostat is calling for heat. It isimperative that this control is wired in and workingproperly in order to maintain the right amount ofcombustion air to the solid fuel when there is a call forheat.

When “hand firing” the unit make sure the wood/coalthermostat is above room temperature to ensure thereis the right amount of air for clean combustion.

When the heat load on the home is low, usually duringdays with mild temperatures, it is important to notoverload the furnace. If the furnace is overloaded andthe thermostat is turned down the fire will go into avery low burn and smolder.

In the Spring and Fall it is important to burn smaller,hotter fires by using less wood or coal and still callingfor heat on the thermostat in order to keep the furnaceand chimney hot, thus keeping the system andchimney free from creosote and eliminating visibleemissions outside.

PROPER USE OF THE AFTER BURNER JETSYSTEM (SECONDARY AIR TUBE)

The Klondike is equipped with a air intake cover(above firing door) that allows the proper amount ofroom air into the secondary air tube. This secondaryburn is utilized 100 percent of the time.


34

IMPORTANT: Keep ash drawer empty.Primary air to the wood chambertravels under the grate. The grates willwarp and eventually burn out if ashesare permitted to build up above them.

CAUTION: RESTRICTED USE DURINGELECTRIC POWER FAILURE ORFURNACE FAN FAILURE

Furnace may be converted to a gravity system.The following directions must be followed carefullyto avoid an over-fire situation.

1. Remove access door to blower compartmentand remove air filter. Then replace access door.Keep ash drawer tightly closed. Do not tamperwith the DS-103 damper control. Loadwood/coal to half the recommended normalheight, approximately 4 inches above grate.

2. Do not overload, no furnace fan is available torapidly carry away the heat. Load smallamounts of wood/coal frequently until power isrestored.

3. Open all air registers and remove allobstructions near them. Keep children awayfrom air registers or burns could result.

4. DS-103 damper control will operateautomatically when electric power is restored.

HAND FIRING WOODSet the wood thermostat above room temperature toensure that the damper door in the DS-103 damper controlis open to allow air in under the grate for clean combustion.

Place paper and kindling in firebox as you would in afireplace or campfire. Add logs to top of fire oncekindling is burning. Reset small thermostat to desiredroom temperature.

Never leave ash drawer open, either to start fire or toprovide more heat. The furnace is designed to provideadequate heat with the ash drawer closed.

DO NOT FILL WOOD OR COAL HIGHER THAN THEBOTTOM ROW OF FIRE BRICK.

WARNING: Never operate furnace withash drawer open. It could cause fire toburn at extreme temperatures, causingmetal fatigue, firebox failure, and unsafeduct temperature.

WARNING: DO NOT OVER FIRE THISFURNACE! Attempts to achieve heatoutput rates that exceed furnacespecifications can result in permanentdamage to the furnace. Never allow thehot coals to build up above the lowerfirebricks.

DANGER: Never burn materials otherthan coal or wood logs, preferably splitand dried. A chimney fire or heatexchanger failure could result. This

includes large amounts of corrugated boxes, woodshavings, paper scraps, dried Christmas trees,coke, garbage, tires or other burnable products.

FIG. 27


35


WHAT SIZE COAL SHOULD I BURN?

The air space between the furnace grates is 1/2 inch.Therefore, coal smaller than 1/2 inch can fall throughthe grates into the ash pan.

• Pea size coal ranges from 9/16 to 11/16 inch.

• Nut size coal ranges from 1-3/16 to 1-5/8 inches.

• Stove size coal ranges from 1-5/8 to 2-7/16 inches.

Nut size is preferred by most people and isrecommended for use in this furnace.

Anthracite coal is hard and burns like charcoal that isused in your barbecue grill. The coals must toucheach other to ignite. Therefore, the smaller the coal,the easier to ignite. Stove coal is not likely to toucheach other because of its size.

Bituminous coal is soft and not as desirable as hardcoal. It creates dust when handled. It also produceslarge amounts of smoke and soot when burned at aslow rate. Soft coal from some areas of the countrycontains higher sulfur content. A large portion of itmay be removed if the coal is cleaned.

HOW TO START A COAL FIRE

Place a small amount of crumpled paper and kindlingwood on the ash-covered grates.

Ignite paper and after wood is burning briskly, coverwith a thin layer of coal. As first layer of coalbecomes ignited, add more coal gradually. Add coaluntil fire bed is built up to approximately 6 inchesdeep. As fresh coal is added always leave some ofthe glowing coal uncovered.

Draw the top red coals toward the front of the firebox.Pile the fresh coals toward the back.

The grates must be protected from direct contact withthe fire. This is done by placing a layer of ash, one(1) or two (2) inches thick on grates. The ash left onthe grate will help prevent overheating of the cast irongrates. It also keeps coal from falling through thegrate's opening.

MAINTAINING A COAL FIRE

Bituminous coal should be built into a cone shapeonce the fire has started. When re firing, break up thecone a little using a poker. Especially if it has cakedover to form a crust. Be careful not to mix the coal asthis increases the chance of forming clinkers.

Western lignite coal should be burned the same wayyou would burn wood. (Refer to wood burninginstruction on previous pages.)

SHAKING THE GRATES

Shaking a fire should only be done if room is neededfor fresh coal. Also, if the ash accumulation on thegrates is excessive. Generally, the grates need only beshaken once or twice a day.

Shake the grates using a few short strokes. Stop whenthe first red coals appear in the ash pan. Under-shaking restricts the amount of air that reaches thefire. Over-shaking may cause the fire to go out.

CAUTION: Do not use kerosene, gasoline,thinners, etc. to start a coal fire.

A coal fire should never be poked or broken up. Thiscauses ash to come to the surface of the coal bed.The ash may fuse into lumps or clinkers whichinterfere with proper burning.

Anthracite Coal - To bank the fire for the night, pile thecoal higher to the back of the firebox. Allow it to slopetoward the fire box door. Always leave some red orburning coals uncovered in the front of the firebox.

Bituminous Coal - To bank fire for the night, shake thefire and add coal, forming the center cone. Allowenough time for the volatiles to burn off before closingthe fire door.

FIG. 28


36


OPERATING INSTRUCTIONS FOR BURNING COALON 1/2-INCH OPENING GRATES (Optional)

The following instructions are for burning various typesof coal, storage of coal, and the cleaning of the furnace.

Some coal is oil-treated at the mine. Some users haveindicated that it tends to make the coal difficult to start.

Burning coal requires some patience and a regularprocedure. With improper tending, a coal fire can go outin a short time. Once the fire starts to go out, it is almostimpossible to reverse.

After a coal fire goes out, the coal must be removedfrom furnace. Then the starting process can berepeated.

Our coal burning instructions are general, as coalcomes in various sizes and types. Anthracite coal ismost recommended as it burns with little smoke whenburning properly.

CAUTION: Burn Anthracite, Bituminous, or Lignitecoals only. DO NOT BURN Petroleum,Coke, or Cannel Coals.

IGNITION TEMPERATURE OF COAL AND WOODHow hot does coal have to get to ignite? Following areexamples of the ignition points of variousmaterials:

• Paper ignites @: 350°F

• Wood ignites @: 435°F

• Western lignite ignites @: 630°F

• Low volatile bituminous ignites @: 765°F

• High volatile bituminous ignites @: 870°F

• Anthracite coal ignites @: 925°F

IMPORTANT:Never smother fire when adding fresh coal.


37

GRATE CARE - ASH REMOVALIt is necessary that ashes be removed from the ash panon a daily basis. The ashes should never be allowed toaccumulate high enough to come in contact with thegrates. Such a condition could cut off necessary aircirculation. It could also result in a warping or burnout ofgrates.

ASH DISPOSALUnlike wood ashes, coal ash should not be spread onthe garden. The minerals in coal ash contains severalchemicals which could be harmful to plant life.

RECOVERING UNBURNED COALScreen coal ashes through a piece of 1/4 inch or 3/8inch mesh hardware cloth. This helps recover anyunburned coal that has fallen though grates.

STORAGE OF COALCoal may be stored indoors or outdoors, with someprecautions:1. The storage area must be free of materials that are

easily burned. Examples are paper, wood, rags, andleaves.

2. Wetting and drying of coal should be avoided.Outside storage's should be protected from rain orsnow. Wet coal should not be piled on dry coal.

3. Locate the storage area in a place that is 75º F orlower.

4. Nut coal weighs approximately 58 lbs. per cu. ft. Astorage bin 4-feet square by 4-feet high will hold 2tons.

FIG. 29

CAUTION: Ashes should be placed in ametal container with a tight fitting lid. Theclosed container of ashes should beplaced on a noncombustible floor or on theground, away from all combustiblematerials, pending final disposal. Theashes should be retained in the closedcontainer until all cinders have thoroughlycooled.

MAINTAIN GASKET MATERIAL

As part of the annual maintenance of your furnace itis important to inspect the gasket material (1/2” ropegasket) around the firing door and ash pan door toensure proper sealing of the firebox.

The gasket material keeps added air from gettinginto the firebox, which could lead to over-firing of thefurnace and causing excessive draft.See Fig. 29 & 30.

Fire door gasket

Ash door gasket

FIG. 30

Maintenance

38

SMOKE PIPE, CHIMNEY AND SECONDARYHEAT EXCHANGER

Do not burn green or freshly felled wood. This maycause creosote and soot to build up in chimney,smoke pipe, and secondary heat exchanger. Theseshould be checked and cleaned several times eachheating season.

CLEANING FURNACE AND CHIMNEY FLUEPIPES

Frequently check and clean the furnace flue pipesand chimney. Soot and fly ash should not beallowed to build up on any of these surfaces.Chimneys are best cleaned professionally.

MORE IN DEPTH MAINTENANCE CANBE FOUND ON PAGE 43.

Secondary Heat Exchanger

Maintenance

39

FURNACE BLOWER ADJUSTMENT

Set adjustable motor pulley so blower will giveapproximately 80-90º F temperature rise through furnace.After pulley has been adjusted check bolt as follows:

The belt is drawn tight during shipment. Therefore bothbelt tension and sheave alignment must be rechecked bythe installer. This is done when the furnace is placed inservice.

Improper belt tension and pulley misalignment are themajor causes of furnace fan noise. It also causes failure ofbelts and bearings.

Sheave alignment is determined with a straight edge heldacross outer face of fan sheave. The face of motorsheave should be parallel to the straight edge at all points.See Figs. 31-33

Proper belt tension is more difficult to determineaccurately. Too little tension will permit slippage causingbelt wear. It may cause noise or squealing when the motorstarts. Excessive tension increases motor load. It maycause the oil film between shaft and bearing to fail. This,in turn, causes the bearing to seize or burn out.

The proper belt tension is the minimum which will drivethe blower without slippage. This varies with sheavediameter, fan size, and motor starting torquecharacteristics. The practical belt tension can best bedetermined by actual experience. When in doubt it isbetter to have the belt too loose rather than too tight. Belttension can be judged by grasping the belt as shown. Thebelt should be deflected approximately one inch, withoutthe motor moving, when moderate pressure is applied.See Fig. 34


FIG. 34

FIG. 33

FIG. 32

FIG. 31

Maintenance

40


DUCT WORK AND BLOWER SPEED ADJUSTMENT

Supply and return duct system should be sized properlyfor efficient operation. Normal air temperature risethrough the furnace should be adjusted toapproximately 80-90º F. Proper blower speedadjustment, in conjunction with adequate duct work arenecessary to achieve this.

A high temperature rise will result in excessive fuelusage. This is due to the high stack temperature thatalways accompanies a high air temperature rise. It canalso cause premature heat exchanger failure.

To perform temperature rise check, start furnace and letit run a minimum of 10 minutes. (Be sure all duct workis complete and furnace is in its normal operatingcondition). Place #1 thermometer in the return ductnear the furnace. Place #2 thermometer in the supplyduct near the furnace, but not in the plenum. After 10minutes or more operation, take thermometer readings.Supply air temperature should be no more than 80-90ºhigher than return air temperature.

Air temperature rise can be lowered by:

1. Increasing blower speed.

2. Additional supply or return outlets.

3. Lowering firing rate.

FIG. 35

Maintenance

41

FIG. 36

FIREBRICK REPLACEMENT

LOWER FIREBRICKRefer to Fig. 36 for proper installation. (Factoryinstalled)1. Remove grates.2. Place three 9” x 6” firebrick along lower rear of the

firebox. Center the end bricks.3. Next place four 9” x 6” brick in lower left and lower

right of firebox.4. Reinstall grates.

UPPER FIREBRICKRefer to Fig. 36 for proper installation. (Factoryinstalled)1. Loosen the upper brick retainers if necessary and install three 9 x 6 bricks along the upper rear of the firebox.2. Install two 9 x 6 bricks along the upper right and left sides of the back of the firebox.3. Install two 9” x 4-1/2” brick along the upper right and left sides of the front of the firebox.4. Tighten brick retainers to hold brick in place.5. See Fig. 36 for completed assembly.

NOTE: It is not necessary to remove thesecondary air tube when replacing firebrick.

Maintenance

42

SECONDARYAIR TUBE

HOW TO PREVENT RUST AND CORROSION

At the end of each heating season, clean both primaryand secondary heat exchangers. Also, clean the ash panthoroughly. Paint the inside of the heat exchanger withautomobile crankcase oil. This will decrease rustingcaused by summer moisture.

The black paint on firing door area may wear or burn off.It can be repainted with a high temperature, flat black,air-drying paint.

CLEANING THE CHIMNEY, SMOKE PIPE AND HEATEXCHANGER

Avoid chimney fires. On a regular schedule, check forcreosote and soot buildup in chimney, smoke pipe, andheat exchanger. They must be kept clean. Keep aprofessional chimney sweep in mind if you have accessto one.

Steel brushes are the safest for cleaning metal surfaces.Salt solutions and some chemicals may damage metalsurfaces. Do not over fire your furnace. Do not burnanything that combusts in seconds. Excessive fueltemperatures may result, thereby igniting creosote.

To clean the chimney, obtain a stiff brush with anextendible handle. Then insert the brush into chimneyfrom the top. Continue the brushing and sweepingdownward until entire length of chimney is cleaned.

After cleaning chimney, debris will be at the bottom ofchimney at the clean-out opening. Open clean-out doorand sweep debris into a metal container.

The smoke pipe, from furnace to chimney, can becleaned with an 8-inch diameter brush. A smaller brushcan also be used.For cleaning the secondary heat exchanger you can usea steel brush. Use a 3 x 8” brush with a flexible steelhandle. The primary heat exchanger can be cleanedwith any steel brush. A furnace vacuum cleaner maybe used.

NOTE: Soot will act as an insulator which causesless heat to be transferred into your ductsystem. It also causes more heat out yourchimney. Both reduce the efficiency of thewood and fuel being burned.

CAUTION: Before cleaning chimney,smoke pipe, and furnace, turn electricalpower off to furnace and other appliances

connected to chimney. Be sure wood/coal fire is out andinside of furnace is cool.

CAUTION: In case of chimneyfire, call the fire departmentimmediately!

CAUTION: Extinguish the fire in thefurnace. Do this by setting thewood/coal thermostat all the way down toclose the damper door in the DS-103damper control. Empty fire chamber andash pan into safe, fireproof container.

NOTE: Do not use your furnace until a professionalinspection has been made. They should inspectyour furnace, smoke pipe and chimney.

DISPOSAL OF ASHES

Ashes should be placed in a metal container with a tightfitting lid. The closed container of ashes should beplaced on a noncombustible floor or on the ground.Place the container well away from all combustiblematerials, pending final disposal. Ashes can bedisposed of by burial in soil or otherwise locallydispersed. First, the ashes should be retained in thecontainer until all cinders have thoroughly cooled.

CREOSOTE-FORMATION AND NEED FOR REMOVAL

When wood is burned slowly, it produces tar and otherorganic vapors. This combines with expelled moisture toform creosote. The creosote vapors condense in therelatively cool chimney flue of a slow-burning fire. As aresult, creosote residue accumulates on the flue lining.When ignited, this creosote makes an extremely hot fire.

The chimney connector and chimney should beinspected at least twice monthly during the heatingseason. This is to determine if a creosote buildup hasoccurred.

If creosote has accumulated it should be removed toreduce the risk of a chimney fire.

Maintenance

43

SMOKE IN THE FURNACE ROOM

This condition is usually caused because smokeis not being drawn up through the chimney. Othercauses could be a failed (firebox) heat exchanger.Check with your qualified furnace serviceprovider.

Chimney causes:

1. Fresh air for combustion must be supplied tothe furnace room.

2. Cold chimney. Warm air rises and cool air falls.Outside chimneys are cold, which can causedowndrafts until the chimney heats up. Thisusually happens in the spring and fall of the yearwhen outdoor temperatures are mild. Thesetemperatures do not produce enough heat towarm the chimney up.

3. Chimney not tall enough. It must terminate atleast 2 feet above the peak of the roof.

4. A downdraft can occur when the wind blows.This happens when your home is in a valley orhigh trees are near your home. Also, if yourhouse is on the east side of a hill or mountain.

See Fig. 37

One solution is to add a chimney cap with aweather vane. This often will turn a downdraftinto an updraft. Another solution is to addheight to your chimney. Another solution is toadd a power venter to the smoke pipe. Thepower venter operates when the thermostat iscalling for wood heat.

5. The barometric draft regulator must be set at-.03” WC (Water Column).

If set less, the chimney may not draw. If sethigher, the wood/coal fire may draw too muchcombustion air. This causes the room temperatureto exceed the thermostat setting.


FIG. 37

TOP OF CHIMNEY LOWER THAN SURROUND-ING OBJECTSREMEDY: EXTEND CHIMNEY ABOVE ALL OB-JECTS WITHIN 30 FEET.

CHIMNEY CAP PUSHED OVER FLUE OR FLUOBSTRUCTED BY A VENTILATORREMEDY: REMOVE OBSTRUCTION

ACCUMULATION OF SOOT OR DEBRIS INOFFSETREMEDY: REMOVE

AIR LEAKS THROUGH CRACKS IN FLUE ANDCHIMNEY DISCLOSED BY SMOKE TESTREMEDY: CLOSE LEAKS WITH CEMENT

FLUE CAP RUSTY AND LEAKYREMEDY: CLOSE LEAKS

VENT PIPE PUSHED INTO FLUEREMEDY: MAKE END FLUSH WITH INSIDE OFFLUE

LOOSELY FITTED VENT PIPE DISCLOSED BYSMOKE TESTREMEDY: CLOSE WITH CEMENT

LOOSELY FITTED CLEAN OUT DOOR DIS-CLOSED BY SMOKE TESTREMEDY: CLOSE LEAKS WITH CEMENT

OPENING BETWEEN FLUES DISCLOSED BYSMOKE TESTREMEDY: CLOSE OPENINGS

TO MAKE A SMOKE TEST, USE A SPECIAL SMOKE BOMBAND WITH TOP OF CHIMNEY CLOSED, LOOK FOR LEAKS.

Maintenance

44

OVER HEATING WHEN BURNING SOLID FUEL ASYOUR PRIMARY SOURCE OF HEAT

If your home is overheating, your furnace is providing heatwhen the thermostat is satisfied. One of these ideas willhelp with overheating.

1. The best answer is to use fewer logs or less coal at each filling. This provides the maximum amount of heat while conserving wood or coal.

2. There are 3 pegs in the fan and limit control. One pegis set at 250º F. Never change this setting. The middlepeg is set at 150º F. This is the temperature setting thatthe air circulating fan starts. You may want to set thissetting at 160º F or higher. The bottom peg is set at120º F. Reset this peg to 130º F or higher. These newsettings will not allow the fan to run as much. Thisreduces the amount of air provided to the rooms.

3. You may feel that the furnace is oversized for yourrequirements. If this is the case cover part of the gratewith a piece of heavy metal. This will retard the fire.This will cause some creosote buildup in firebox andchimney because it will not burn as clean.

IMPORTANT: During normal operation,firing door and ash drawer must be kepttightly closed. Air leakage will cause loss

of efficiency resulting in higher heating costs. If doorgaskets become worn, replace with 1/2" fiberglassrope available from local sources.

NOTE: The damper door will automatically close if there isan electric power failure. This can occur fromhigh limit cut-off or electrical power outage.This will prevent heat exchanger damage.

Maintenance

45

KLONDIKE - EAGLE IVMODEL SERIES LW-000

Exploded Views & Parts Lists

46

REPAIR PARTS-Combustion Chamber Assembly (Left Hand Shown)KLONDIKE - EAGLE IV SOLID FUEL FURNACE

Model Series LW-000Key No. Left Hand Right Hand Description

1 10110500 10110500 Fender Washer 5/16 I.D. x 1-inch O.D. (2 Req.)2 10104900 10104900 Screw Thread Cutting Hex Washed HD 1/4 20 x 3/4

(2 Req)3 20102200 20102200 Bracket, Baffle (3 Req.)4 10105300 10105300 Nut Hex 1/4-30 (14 Req.)5 20105900 20105900 Baffle, Smoke (2 Req.)6 20102640 20102640 Top Brick Retainer.7 20102650 20102650 Top Brick Retainer. Side (2 Req.)8 10100800 10100800 Fire Brick 9 x 4-½ x 2-inch (4 Req.)9 10100700 10100700 Fire Brick 9 x 6 x 2-inch (18 Req.)

10 10116200 10116200 Old configuration (not applicable)11 30103000 30103000 Air Tube Retainer12 10100900 10100900 Wood Grates (3 Req. )13 30103600 30103600 Secondary Air Tube14 10110700 10110700 Gasket, Secondary Air Tube15 20107003 20107003 Latch, Ash Pan16 10105000 10105000 Screw, Machine Rd HD 1/4-20 x 3/4 (4Req.)17 20107503 20107503 Ash Pan Assembly18 30300603 31300603 Base, Weldment19 20104903 20104903 Fire Door Assembly20 10139700 10139700 Door Latch21 30107003 31107003 Firebox Complete (Combustion Chamber)

20200700 20200700 Nut Retainer-Top & Bottom (22 1/2-inch (2 Req.)20200790 20200790 Nut Retainer-Side (7 3/4-inch (2Req.)10106100 10106100 Washer 1/2 X 20 SAE (16 Req.)10104800 10104800 Screw Thread Cutting Hex Washer HD 1/4-20 x 1-

inch (16 Req.)10103990 10103990 Gasket, Ash Pan 1/2 Thermo cord 42

10123200 Coal Grate Assembly Complete 10122400 Coal Grate (2 Req.) 20108400 Connecting Rod Assembly (Includes 2

Locknuts)10122500 Grate Frame (2 Req.)

10122900 Coal Grate, Handle

Not Shown

101232001012240010108400

1012250010122900


47

THIS CIRCULATING FAN PERFORMANCE CURVECHART IS FOR DETERMINING

MOTOR HORSEPOWER NEEDS

CIRCULATING FAN PERFORMANCE CURVE CHART

KLONDIKE MODEL SERIES LW-000


48

SERVICE HINTS & TROUBLESHOOTING

Main blower vibrating when in use...

POSSIBLE CAUSELoose allen screw on squirrel cage

Defective motor or blower bearings

Weight on squirrel cage wheel moved in shipment

Main blower or blowers continue to run...

POSSIBLE CAUSEFan and limit control on unit is set too low

Defective fan and limit control

Improper wiring

Main blower or blowers won’t turn on...

POSSIBLE CAUSEImproper wiring

Defective fan and limit control

Combustion blower staying on...

POSSIBLE CAUSEThermostat set higher than room temperature.

Short in thermostat wire

Home is not getting heat needed to satisfy wall thermostat

Combustion blower not turning on...

POSSIBLE CAUSEDefective wall thermostat;check by turning it above room temperature, damper doorshould open.

Smell an odor from the first fire in the home...

POSSIBLE CAUSENew steel, small amounts of residue on steel

SOLUTIONTighten the allen screw, be sure squirrel cage did notmove to one side or the other.

Return motor or blower for a replacement.

Try to adjust it or return blower for replacement.

SOLUTIONRemove cover on fan limit control and set dials to theproper settings. Recommended temps: 150º on — 130ºoff. NOTE: Never adjust fan limit by turning dial itself (pic-ture of fan limit dials.)

Check by turning one pointer down to where blowershould turn off, if they don’t, they need to be replaced.

Check wiring diagram.

SOLUTIONCheck wiring diagram.

Replace fan and limit control.

SOLUTIONSet thermostat to setting lower than room temperature.

Check all wiring or replace thermostat

Furnace may be undersized for the size of your home.

SOLUTIONReplace thermostat or check circuit board for propervoltage.

SOLUTIONThis will disappear in a matter of hours.

49

POSSIBLE CAUSEThe use of wet, frozen or unseasoned wood

The use of soft wood, particularly those of high resin con-tent such as plywood or blandex with glue

Poor natural draft or an obstruction in the stove pipe orchimney flue

Smoldering fire

Inadequate amount of oxygen supplied to the combustionchamber

Low fire or flue gas temperatures

Un-insulated stove pipe or chimney flues, especially ifconstruction is exterior to the house

Air leaks in the stove pipe or chimney

Not getting heat in the home...

POSSIBLE CAUSEImproper insulation in home, allowing heat to escape

Improper hook up to furnace

Fan and limit control set too low

Excessive amounts of smoke coming out of loadingdoor when loading...

POSSIBLE CAUSEImproper draft

Chimney cap too close to top of chimney

Too long of run of smoke pipe from Klondike to chimney

Negative pressure in home - lack of enough freshcombustion air.

SOLUTIONIf you have to use wet wood, make loads smaller and burnthem hotter.

Avoid using if possible.

Measure chimney draft with gauge. Should be set at .03Water Column.

Smaller and hotter fires.

Check page 16 of this manual for proper installation ofoutside combustion air to the furnace room. The air thatgoes out the chimney in the form of smoke must bereplaced with fresh outside air.

Smaller loads of wood and hotter fires. Stack tempsshould maintain minimum of 300º.

Never use un-insulated pipes for chimneys. If installed onthe outside of the house, INSULATE!

Check chimney top to bottom.

SOLUTIONRe-insulate!

Check installation drawings and/or consult your heatingservice provider.

Check settings; refer to operation on proper settings andadjust accordingly. If needed to set higher, never exceed180º on — 150º off.

SOLUTIONMeasure chimney draft with gauge. Should be set at .03Water Column.

Remove and discard chimney cap.

Relocate Klondike closer to chimney.

Install outside combustion air to furnace room.

Excessive creosote build-up. A small reminder, whatever kindof fuel you burn, there is some kind of residue build-up on thefurnace and chimney. Same with wood no matter how goodthe conditions...

50

Exploded Views & Parts List

51

Notes

Model Number: __________________________________ Serial Number:__________

Installation Date:_______________________Contractor_________________________

ServiceCalls:_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Notes:_____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Alpha American Co., 10 Industrial Blvd., Palisade, MN 56469www.yukon-eagle.com

EAGLE OWNER'S

MANUAL• Assembly• Installation• Operation• Repair Parts

ForModel Series

LW-000

CAUTION :Read Rules And

Instruct ionsCareful ly For

Safe Operat ion

HOW TO ORDERREPAIR PARTS

WHEN ORDERING REPAIR PARTS,ALWAYS GIVE THE FOLLOWING INFORMATION:

• PART NUMBER

• PART DESCRIPTION

• MODEL NUMBER

ALL PARTS MAY BE PURCHASEDFROM A YUKON DEALER OR

DIRECT FROM OUR FACTORY.

PHONE: 1-800-358-0060FAX: 1-800-440-1994E-MAIL: [email protected]: www.yukon-eagle.com

YUKON

IMPORTANT:Installation must be made in accordancewith state and local ordinances whichmay differ from this installation manual.

YUKON KLONDIKE

WOOD/COAL FIREDWARM AIR CENTRALHEATING FURNACES

Documents

Klondike Manual RevisedApril2015 - Wood Furnace Companystore.yukon-eagle.com/content/Klondike_Manual... · 2015-05-19 · DS-103 DAMPER CONTROL This is the solid-state damper control