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Installation/Operator’s Manual
Model: 1602M
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 Tested to UL
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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. When mak- form creosote. The creosote vapors condense in the rela- ing new chimney installations, always
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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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7. If not already installed, snap the rocker switch into the SPIN DAMPER top of the junction box. Screw the spin draft onto the 3/8” x 2-1/2” carriage bolt 8. Attach the two longer conduit assemblies to the junc- followed by the 3/8”-16 lock nut. Then screw the spin draft tion box and to each blower. and bolt into the Combustion Air Inlet allowing approxi- 9. Provide a 110v power supply and secure it with the mately 1/2” of the bolt to stick through into the threaded cable clamp to the righ
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WIRING DIAGRAM All electrical connections should be done by a qualified electrician. NOTE: The extra brown wire on the fan center has no use. It should be capped off or removed. The conduit may be cut shorter to provide a cleaner installation FIREBRICK AND BAFFLE REPLACEMENT FIREBOX BRICK REPLACEMENT BAFFLE/BRICK REPLACEMENT This furnace comes from the factory with the firebrick in- If baffle replacement is necessary, slide the baffle out until stalled. However, if brick replacement is nece
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TESTING AND OPERATING PROCEDURES GENERAL FURNACE OPERATION STARTING A WOOD FIRE Using Forced Air Draft (optional) When you start a fire in the furnace and it reaches op- Shut off FAD when fuel door is open erating temperature, the blower(s) will come on auto- matically. The snap-disc is adjustable from 100°F(A) to 140°F(E), Each click on the switch is approximately 5°F. It 1. Start a fire inside the firebox as described above. comes from the factory, set at 120°F, setting C. The rocker 2. Th
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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, com
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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 33 32 28 22 31 34 21 20 18 3 19 16 4 17 3 2 27 1 25 35 26 3 24 8 9 7 6 10 14 17 16 15 2 3 5 30 29 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 42 Snap-disc Box 68234 1 2 Door Handle 24179 2 43 Conduit Assembly (1.5ft) 68231 1 N/S Lock Nut, 1/2-13 83444 2 44 Junction Box 25625 1 N/S Washer 83835 2 45 Insulation (5” x 5”) 25626 1 3 Spring Handle 89574 4 46 Junction Box Cover 80231 1 4 Feed Door Latch 23786 1 47 Rocker Switch C42373 1 5 Ash Door Assy. (w/Rope Gasket) 68880 1 48 Romex Cable Clamp 80362 1 6 Draft Cap 23859
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16DIKL FORCED DRAFT BLOWER - OPTIONAL KIT USSC offers a forced induced draft blower kit as an option to upgrade your Clayton furnace. Advantages of the forced draft are quicker recovery and greater turbulence inside the firebox for better mixing of fuel and oxygen. 6 And, it also allows you the furnace to be thermostatically controlled. You may purchase a forced draft kit from your local deal- er or direct from U.S. Stove. If installing a 16DIKL, follow the instructions supplied with the
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DOMESTIC HOT WATER COIL - OPTIONAL KIT 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 - 1602M SERIAL NUMBER______________ United States Stove Company 227 Industrial Park Road P.O. Box
