heat

The trouble is that we can't see the big picture. From our point of view we see puzzle pieces and don't know just how they fit together. Could you sketch up a diagram of the whole system and label warm air and cold air ducts? Take a picture of the diagram or scan it and post. It would be a big help

If I understand the photo's and the verbiage, you had a hot air furnace with a standard return ducting with no modifications.
You had a jacket fabricated around the coal stove with a 10 inch duct coming off the top going to the cold air return.
You piped two 10 inch cold air returns from the first floor to the sides of the jacket around the coal stove which is what appears to be a loop on the top of the stove.
You piped the top of the jacket to your existing cold air return on the furnace.

I don't have to do any sq inch calculations to determine that your blower in the furnace is trying to pull air from a smaller system with restrictions ( your single 10 inch on the jacket) when it has a large area available with no restrictions which is your previous existing return ducting.

If you want the air to come from your smaller twin return system instead of the main return system, you have to block the main return system by either blocking cold air registers in the rooms or at the main ducting. Make it pull from where you want it to come from with no other paths available and it will work as you desire.

Freddy wrote:Picture 111.31 shows a duct pipe coming out the left side and going up, over the top and going in the right side. The heat doesn't go anywhere! You might as well remove all that pipe and cap the holes.

To move hot air you need a complete smooth circle of moving air..... cold air in from low parts of the rooms that you want to heat, it gets heated, then hot air out, going back to those same rooms, hopefully on the other side of the room from where you took the cold air.

Yeah, I'm kinda hoping there is something else going on there that we can't see in that picture

the two pipes you see coming from the sides are cold air returns coming from the main floor they are piped into the jacket.The pipe coming from the top is heat i tried to block off all other cold air going into the furnace . I also blocked off one of the pipes going into the jacket no better . is it possible that all my heat is going out the chimney or that my blower speed is too fast it is 1750RPM. I was told this was going to try taking it out of my chimney and hooking up the power vent and blowing it up the chimney .I live in up state NY

well have been using my coal stove for a week . I have blocked off all the cold air ducts to the plenum plus the two 10 cold air pipes going to the stove thinking i have too much cold air going to the stove . The only place it is getting any air is from the bottom of the jacket .Have the fan limit switch set for 150 to come on and 100 to go off . The blower is cycling but when it comes on the air coming from the registers on the main floor is cool the coal-trol is on min 5 max 85 FD 50 pictures 107.08 and 111.31 are not my stove it was a friend of mine stove. So i guess what iam saying is i know the stove is hot but dont know where the heat is going have it hooked into the cold side of the plenum as instructed the motor on the blower is 1750 rpms .Maybe going to fast???. Hope someone can help on this do not wish to waste coal as i see in my area it is going up in price . I live in upstate NY.

If the fan switch is set to 150 and the fan runs then it must have reached that heat. Try setting the fan switch higher.

Your probably moving too much air.

Your not going to get the blast of hot air that you get from an oil or natural gas hot air furnace. The heat from your coal stove will be continuous and at a lower temp. Your not wasting coal. If you can change out the furnace blower for a smaller one that moves less air, you will get the continuous heat your looking for.

Just remember to lock out your furnace burner so if your oil or gas furnace comes on with the smaller blower you may overheat it and it could trip on high air temp or damage the heat exchanger.

It's a tricky trial and error job to get the right size blower when you tie a coal stove into a system that was originally designed for a conventional hot air furnace system.

You can do it, you just have to be diligent and experiment.

got another question where does the coal- tro thermostat pickup the temp of the room ? the reason i ask is on the coal-tro it says its 80 but the thermostat from my oil furnace says its 72 i also have a thermometer on the wall in that room it is telling me it 70 . I have the temp on the coal-tro at 80 any thoughts on this? This is my first year with the stove still working out the bugs

i have opened up the two air ducts that are pulling air from the house and directing it to the jacket on the coal stove i have also slowed down the blower speed blower limit switch set at on 175 and off at 100 .But the air still feels cool to me .Any help with this ? would be greatly helpful . Thanks

Rather than guessing at the air temperature put a thermometer in the air stream.