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Installation/Operator’s Manual
Model: 1602G / 1802G
Wood or Coal Gravity Style (Up-Flow) Supplemental Furnace
SAFETY NOTICE:
If this furnace is not properly installed, a house fire may result! For your safety, follow these installation
instructions. Contact local building or fire officials about restrictions and installation requirements in your
area. This furnace must be installed by a qualified technician. Keep these instructions for future reference.
Safety T
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Do not place the furnace directly on a combustible floor. INTRODUCTION If you are placing it on a combustible floor, an approved Thank You for your purchase of a U.S. Stove Wood/Coal fire retardant material, equivalent to 3/8” UL Listed mill- Burning Gravity Style (Up-Flow) Furnace. Your decision to board, should be placed under the unit. The material must buy our Clayton Furnace was undoubtedly reached af- extend at least 16 inches beyond the front of the unit and ter much careful thought
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CHIMNEY REQUIREMENTS CREOSOTE - FORMATION AND NEED A fireclay lined masonry or Class A 103HT All-Fuel Metal FOR REMOVAL Insulated Chimney must be used in all airtight wood fur- When wood is burned slowly, it produces tar and other nace installations. The minimum recommended flue size organic vapors, which combine with expelled moisture to for the model 1602 is 6 inches, inside diameter and for the form creosote. The creosote vapors condense in the rela- 1802, the recommended flue size is 8
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Though United States Stove Company expressly Does Not IMPORTANT INFORMATION FOR ALL recommend the use of its furnaces to be installed and/or CONNECTOR PIPES used as a free-standing heater, it is possible to achieve a reasonably safe and functional installation IF certain stan- The connector pipe must be constructed and installed dard procedures are followed. The following are guidelines so that it maintains clearances, keeps condensation and creosote within the pipe, and is capable of w
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INSTALLATION #2 INSTALLATION #3 Extending the hot air duct from the furnace into the existing The baffle on this system should be made the full width of plenum will help direct the flow of air from the furnace as the furnace plenum in order to properly direct the air into well as the flow in the existing furnace. Ducting entering the distribution ducts. the existing plenum at an angle (approximately 45 degrees) will facilitate air flow from the furnace while diverting air from the existing
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FURNACE ASSEMBLY INSTRUCTIONS Unpack your Furnace and insure that there is no shipping SHAKER GRATE HANDLE damage. If damage exist, please contact your dealer im- Insert the Shaker Rod into the hole on the ash door frame mediately. as shown. Then attach the Shaker Bracket to the front of Your Clayton Furnace will require some assembly before the furnace using two 1/4-20 x 3/4” Hex Bolts and two 1/4- operation. All needed hardware and components for the 20 Lock Nuts. Next, insert the shaker
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SPRING HANDLES WIRING DIAGRAM Attach the four(4) spring handles to the Feed/Ash Doors, Baffle Rod, and Shaker Rod by twisting the springs counter- clockwise while applying pressure until you have screwed them approximately 3/4”-1” onto the rods. (4) Spring Handles DISTRIBUTION BLOWER & ACC. 1. Remove all contents and insure that all components are present for assembly. See the part list below 2. Begin by attaching the blowers to the unit. Insert a clip into each mounting hole in the furnace’
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FORCED DRAFT BLOWER - 69189 Using two 1/4-20 x 1” bolts and nuts, attach the draft blow- er adapter to the draft tube on the front of the furnace. Then mount and secure the draft blower to the adapter with the three 10-24 Kep nuts. Plug the blower into the out- let on the front of the furnace. (1) Draft Blower (1) Draft Blower Adapter (2) 1/4-20 x 1 Hex Bolt (2) 1/4-20 Lock Nut (3) 10-24 Kep Nut FIREBRICK AND BAFFLE REPLACEMENT FIREBOX BRICK REPLACEMENT BAFFLE/BRICK REPLACEMENT This furnace co
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TESTING AND OPERATING PROCEDURES 6. The forced air draft cycles on demand from the wall GENERAL FURNACE OPERATION thermostat. Setting the U.S. Stove thermostat four degrees After installation of the furnace is complete, it is ready for higher than your existing thermostat is recommended. In operation. The Honeywell Limit Control, in conjunction operation, the power draft blower will run until the U.S. with a wall thermostat, operates the distribution blowers Stove thermostat temperature s
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If the fire goes out or does not hold overnight, look for: Inspect and clean your chimney and stove pipe regularly. 1. Poor draft. In event of chimney fire, shut all draft controls and call your fire department immediately. Alert everyone in the 2. Incorrect damper settings. house. If the fire is still burning vigorously, throw baking 3. Improper firing methods for coal being used. soda into firebox or discharge a fire extinguisher into the firebox. After chimney fire is over, compl
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TROUBLE SHOOTING AND PROBLEM SOLVING 1. Problem: 4. Problem: Smoke puffs from furnace Distribution blower vibrating Solution: Solution: A. Tighten blower wheel to motor shaft. A. Check chimney draft. Check for blocked chimney or flue pipe. Use mirror to check chimney clearance. B. Check for bad fan bearings. B. Check ash pit — if it is too full, empty. 5. Problem: C. Make sure furnace room is not too airtight. Distribution blower continues to run or will not run D. Make sure all of
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PARTS DIAGRAM 23 35 34 28 29 30 34 22 33 36 21 20 18 3 19 16 4 17 3 2 27 1 25 37 26 3 24 8 9 7 6 10 14 17 16 15 2 3 5 31 32 13 12 11 12 USSC
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PARTS DIAGRAM AND LIST Key Description Part # Qty Key Description Part # Qty 1 Feed Door Assy. (w/Rope Gasket) 69091 1 36 Front Filler 23817 1 P Front Filler - 1800 24190 1 2 Door Handle 24179 2 37 Draft Cover 23818 1 N/S Lock Nut, 1/2-13 83444 2 P Draft Cover - 1800 24508 1 N/S Washer 83835 2 38 Room Blower - 800 CFM 80530 2 3 Spring Handle 89574 4 39 Blower Gasket 88127 2 4 Feed Door Latch 23786 1 40 Tinnerman Clip, 1/4-20 83340 8 5 Ash Door Assy. (w/Rope Gasket) 68880 1 41 Bolt, 1/4-20 x 3/4
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PARTS DIAGRAMS AND LISTS - 69189 1 2 4 3 5 Key Description Part # Qty 1 Drqft Blower Assembly 69190 1 2 FAD Bracket 69192 1 3 Bolt, 1/4-20 x 1” 83379 2 4 Lock Nut, 1/4-20 83261 2 5 Kep Nut, 10-24 83244 3 UFB908 COLD AIR RETURN / FILTER BOX - OPTIONAL KIT As mentioned earlier in this manual, a cold air return and/ or filter box should be incorporated into your furnace in- stallation. A cold air return or filter box will increase the life of your blowers and offer filtered distribution air for y
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DOMESTIC HOT WATER COIL KIT - OPTIONAL This Furnace will accept the installation of a Domestic Hot Water Coil Kit. The U.S. Stove kit is a 1124 Water Coil and it may be purchased from your local dealer. 2 1. Remove the access panel on the rear of the furnace enclosure. 2. With a utility knife, cut away a section of the insulation (if equipped) directly behind the access panel. 1 3. Remove the cover plate from the rear of the furnace firebox. ACCESS 4. Place one nut on each end of the water
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BULLETIN RC454 A GUIDE TO BURNING COAL IN YOUR FURNACE Furnaces that are capable of burning coal usually orange or yellow and produce quite a bit of smoke. will burn both Bituminous and Anthracite coal. An- As the gases burn off the flames become shorter, thracite is perhaps the best coal fuel because of its change color and produce less smoke. long even burn time, high heat output, and cleanli- Once the fire is WELL ESTABLISHED add coal to the ness which make it a good choice for the home.
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BULLETIN RC454 A GUIDE TO BURNING COAL IN YOUR FURNACE When the fire is well established and the room is be- BANKING THE FIRE: coming warm, partially close the dampers. Some For extended operation, such as overnight, the fire experimenting will have to take place with each will need to be banked. To do so heap coal up particular setting of all dampers and controls as the along the sides and back of the firebox so that the chimney provides the draft necessary to not only fire gradually bur
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NOTES 18 USSC
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NOTES USSC 19
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HOW TO ORDER REPAIR PARTS This manual will help you obtain efficient, dependable service from the fur- nace, and enable you to order repair parts correctly. Keep this manual in a safe place for future reference. When placing an order or for warranty claims, please provide the following information found on the Certification Plate located below the ash door. PART NUMBER PART DESCRIPTION MODEL NUMBER - 1602 / 1802 SERIAL NUMBER______________ United States Stove Company 227 Industrial Park Road P.
