United States Stove 1800GC Operator`s manual

United States Stove 1800GC Operator`s manual
STATES STO
D
E
T
VE
I
N
U
USSC
COMPANY
UNITED STATES
STOVE COMPANY
Keeping America Warm
Since 1869
MODEL: 1600GC / 1800GC
CANADA
ONLY
THE WOOD AND COAL FURNACE
SAFETY NOTICE: IF THIS FURNACE IS NOT PROPERLY INSTALLED, A HOUSE FIRE
MAY RESULT. FOR YOUR SAFETY, FOLLOW THE INSTALLATION DIRECTIONS.
CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND
INSTALLATION REQUIREMENTS IN YOUR AREA.
Installation/Operator's Manual # 851502
TABLE OF CONTENTS
Introduction ....................................................................................................... 3
Locating Your Furnace ...................................................................................... 3
Clearances ........................................................................................................ 3
Chimney Requirements ..................................................................................... 3-4
Smoke Pipe Installation ..................................................................................... 4-5
Add-on Series Installation ................................................................................. 5-7
Assembly Instructions ....................................................................................... 7-10
Wiring Diagram for Series Installation with Existing Electric Furnace ............... 11
Wiring Diagram for Series Installation with Existing Gas or Oil Furnace........... 12
Testing and Operating Procedures ................................................................... 13-14
Trouble Shooting and Problem Solving ............................................................. 15
Parts Lists
Model 1600/1800 .............................................................................................. 16-17
Motorized Natural Draft ..................................................................................... 18
Installation of Optional Equiptment ................................................................... 19
2
INTRODUCTION
CLEARANCES
Thank you for your purchase of a U.S. Stove Woodburning
furnace. Your decision to buy a Hotblast Furnace was undoubtedly reached after much careful thought and consideration. We
are very proud you chose the U.S. Stove furnace and trust you
will receive the comfort and economy that others realize when
heating with a U.S. Stove product.
Your dealer is important in your experience with the Furnace not
only in your purchase, but in his recommendations for professional installation in your home. The qualified professional
installer (as recommended by your dealer) has been expertly
trained in solid-fuel furnace installation to assure the safety and
comfort for your family while saving you money. Trust your
experienced installer. He is a specialist in his field.
FLAMMABLE WALL
MODEL 1600 - 20"(50.8cm)
MODEL 1800 - 25"(63.5cm)
(TOP VIEW)
MODEL
1600 - 22"(55.88cm)
1800 - 19"(48.26cm)
MODEL
1600 - 12"(30.48cm)
1800 - 8"(20.32cm)
IMPORTANT
Before installing and using your Hotblast Furnace, please
read the following pages thoroughly and carefully. If you
follow the instructions, your Hotblast furnace will give you safe
and more dependable service in the years to come.
MODEL 1600 - 15"(38.1cm)
MODEL 1800 - 18"(45.72cm)
FLUE
MINIMUM
CLEARANCE TO
FLAMMABLE WALLS
CAUTION: Do not
store combustible or
flammable material
near furnace.
REDUCED CLEARANCES
NFPA guidelines and most codes permit reduced clearances
to combustible walls and ceilings if adequate protection is
added. A common mistake is to assume that sheet metal,
masonry, or asbestos board placed directly against a wall
protects it. Materials installed in this manner give very little
protection. These materials are good heat conductors, so they
will be almost as hot on their back side as they are on the
exposed side. Therefore, the combustible wall behind is still a
fire hazard.
A wall can be kept cool using these items but only if they're
mounted and spaced out from the wall by an inch or two to
allow free circulation of room air behind the protective panel.
The protective panel should start within a few inches of floor
level.
The three rules to follow when constructing wall protectors:
1. Non-combustibility of all materials including mounting
or supporting.
2. A well ventilated air space between protector or wall.
3. Sufficient strength and rigidity so that the protector and
air space will be durable.
! First step; check your local codes. This installation must
comply with their rulings.
! Do not install this furnace in a mobile home or trailer.
! Always have a smoke or ionization detector installed in
your home.
! To prevent injury or damage, do not allow anyone who is
unfamiliar with the furnace to operate it.
! Spend some time with your furnace to become well
acquainted with different settings and how each will
affect its burning patterns. It is impossible to state just
how each setting will affect your furnace because of
the variations in each installation.
DISCLAIMER NOTICE
The BTU ranges and heating capacity specifications are
provided as a guide only and in no way guarantee the output
or capacity of the units. The actual BTU output depends on the
type of fuel being burned and its conditions, the thermostat
setting, the draft adjustment and the chimney that the unit is
hooked up to. The actual area that the unit will heat depends
on factors such as the conditions of the building, heat loss,
type of construction, amount of insulation, type of air movement, and the location of the unit.
2" FROM CEILING
CONSTRUCTING
NON-FLAMMABLE
WALLS
PROTECTIVE COVERING
AND ALL SUPPORTS MUST
BE NON-COMBUSTIBLE.
1" AIR SPACE
LOCATING YOUR FURNACE
2" FROM FLOOR
CHIMNEY REQUIREMENTS
The furnace is to be installed maintaining clearances as shown
in illustration.
Do not place the furnace directly on a combustible floor. If you're
placing it on a combustible floor, an approved fire retardant
material equivalent to 3/8" asbestos millboard should be placed
under the furnace. The material must extend at least 16" (40.64cm)
in front of and 8" (20.32cm) on either side of the fuel-loading and
ash-removal doors, and underneath the chimney connector and
extending at least 2" (5.05cm) on either side of the chimney
connector.
A masonry or Class A All-Fuel Metal Insulated Chimney must be
used in all airtight wood furnace installations. The minimum
recommended flue size for the U.S. Stove Hotblast Furnace is 6"
(15.24cm) (inside diameter) for round flues, and 7" x 7" (17.78cm)
for square flues. When making new chimney installations,
always follow the chimney manufacturers instructions.
3
NOTE: Type of chimney: Class A All-Fuel also referred to as
Low-Heat appliance type chimney per Uniform Mechanical
Code:
Chimney, low-heat appliance type is a factory built, masonry
or metal chimney suitable for removing the products of
combustion from fuel-burning low-heat appliances producing combustion gases not in excess of 1000°F (538°C) under
normal operating conditions but capable of producing com
bustion gases of 1400°F (760°C) during intermittent forced
firing for periods up to one hour. All temperatures are
measured at the appliance flue outlet.
TOP OF CHIMNEY MUST BE
2 FT. (60.96cm) ABOVE
HIGHEST POINT OF ROOF
8. The portion of an all-fuel metal chimney that extends
above the roof should be well secured.
9. A masonry chimney should be built on footings and not
attached to the house.
10. A rain cap, complete with an animal or bird screen,
should be installed on top of the chimney.
CREOSOTE — FORMATION AND NEED
FOR REMOVAL
When wood is burned slowly, it produces tar and other
organic vapors, which combine with expelled moisture to form
creosote. The creosote vapors condense in the relatively cool
chimney flue of a slow-burning fire. As a result, creosote
residue accumulates on the flue lining. When ignited, this
creosote makes an extremely hot fire.
The chimney connector and chimney should be inspected at
least twice monthly during the heating season to determine if a
creosote build-up has occurred. If creosote has accumulated, it
should be removed to reduce the risk of a chimney fire.
CAP SHOULD HELP
PREVENT DOWNDRAFT
WHILE STILL PROVIDING
ADEQUATE EXHAUST.
2 FT. (60.96cm) MINIMUM
3 FT. (91.44cm)
MINIMUM
RECOMMENDED
MINIMAL 20 FT.
(6.10m) HEIGHT
MINIMAL 3 FT.
(91.44cm) FROM TOP
OF CHIMNEY TO
POINT AT WHICH IT
PASSES THROUGH
THE ROOF.
CHIMNEY FLUE
SHOULD BE
CONSTANT DIAMETER
THROUGHOUT ITS
ENTIRE HEIGHT.
APPROVED
CHIMNEY
SMOKE PIPE INSTALLATION
Clearances to combustible materials (i.e. paneling, ceiling tile,
sheet rock, plaster, draperies, casements or wood trim, etc.)
will vary with the type of flue connection used. Be sure to
maintain the specified clearances for your type of installation.
TYPE OF FLUE
REQUIRED
CONNECTION
CLEARANCE
24 Gauge or Heavier
18" (45.72cm)
Single Wall Stainless Steel
or Black Pipe
Double Wall Stainless Steel
6" (15.24cm) Model 1600
8" (20.32cm) Model 1800
CHIMNEY FLUE
MUST BE AS
LARGE OR
LARGER THAN
FURNACE FLUE
PIPE
Class A All-Fuel or Equivalent
2" (5.08cm)
COMBUSTIBLES
CLEANOUT DOOR
SHOULD HAVE
AIRTIGHT FIT. DO
NOT LEAVE OPEN
WHEN FURANCE IS
IN OPERATION.
SMOKE PIPE
CHIMNEY THIMBLE SHOULD BE
CONSTRUCTED OF FIRE CLAY, AND
SHOULD FIT TIGHTLY TO FLUE PIPE.
1. The wood furnace should be the only heating appliance
using a chimney flue. One furnace per flue.
2. A masonry chimney should have a tile or stainless steel
liner.
3. The masonry chimney should not have any missing
mortar or loose bricks.
4. There should be no mortar or parts of the chimney
blocking the chimney flue.
5. There should be a two inch clearance between any
chimney (masonry or metal) and combustibles (such
as the house).
6. The chimney should extend at least 2' above the
highest point of the house, or 2' above the point at
which the chimney is 10' from the roof.
7. The chimney should be relatively straight and vertical.
According to NFPA standards, single wall stove pipes can be
within 9" (22.86cm) of combustibles provided an approved fire
retardant material covered with 28 gauge sheet metal, spaced
out 1" (2.54cm) on non-combustible spacers, is utilized. See
illustration.
18" (45.72cm)
9" (22.86cm)
18" (45.72cm)
CEILING OR WALL
When using a Class A or double wall flue pipe connection,
follow the manufacturer's instructions.
4
When constructing a single wall smoke pipe, the following
guidelines must be observed.
1. The smoke pipe should be 24 gauge or heavier stain less
steel or black pipe.
standards allow same flue connection. Such installations can
cause severe problems. Gas hoods and barometric dampers
allow excess air into the chimney causing cooling of the flue
gases and a greater creosote build-up potential. If the same flue
connections are used, chimneys must be inspected more frequently and the chimney should be cleaned any time the
creosote deposits exceed 1/4" thickness. A creosote fire in such
a chimney can burn out of control because of the air leak through
the barometric damper or gas hood. Keeping the chimney clean
and burning well-seasoned wood is absolutely necessary. This
type of installation does require more frequent inspection and
maintenance.
2. Secure all joints with three #8 screws.
3. If the smoke pipe must pass through a wall, an approved
insulated or ventilated thimble, at least three times the
diameter of the smoke pipe must be used. (i.e. a 6"
(15.24cm) diameter smoke pipe needs an 18" (45.72cm)
thimble).
4. The smoke pipe should not be used as a chimney.
ADD-ON SERIES
INST
ALLA
TION
INSTALLA
ALLATION
IMPORTANT INFORMATION FOR
ALL SMOKE PIPES
The smoke pipe must be constructed and installed so that it
maintains clearances, keeps condensation and creosote
within the pipe, and is capable of withstanding a 2000°F to
3000°F (1093°C to 1649°C) chimney fire.
1. The smoke pipe should slant down toward the furnace a
minimum of 1/4" to the foot. At no time should the pipe
turn downward toward the chimney or run horizontal.
The downstream series techniqueis the onlyapproved method
for using the 1600 and 1800 furnaces in combination with an
existing gas, oil or electric forced air furnace. While it requires
reworking the main duct system, it typically results in a simpler,
less restrictive installation.
Certification testing establishes the minimum cross-sectional
area for the transfer duct permitted for a specific add-on. A large
transfer duct will allow freer flow of air through the additional
elbows involved in the add-on installation.
2. There should be no more than two 90 degree elbows.
3. The smoke pipe should never be longer than 6 feet.(1.83m)
If it is absolutely necessary to make a run of more than
six feet (not recommended) use extra support brackets
every 3 feet (.91m).
Additional space will be required in the furnace room for an addon. There must be a room beside the existing furnace for the addon and the transfer duct which runs from the hot air plenum of the
existing furnace down to the cold air inlet of the add-on.
4. The smoke pipe should never be reduced to a smaller
size than flue opening on the furnace.
5. The smoke pipe should not block the flue of the
chimney or extend into it in any way.
While oil, gas and electric furnaces may be connected to
combustible return air ducts in the form of joist panning, wood
furnaces normally require noncombustible return air duct work.
Combustible return ducts connected to an existing oil, gas or
electric furnace need not to be replaced with noncombustible
ducts when an add-on is installed; the add-on connections make
reverse flow during a power failure very unlikely.
6. A good airtight thimble should be used to hold the
smoke pipe in the chimney. It should be constructed so
the smoke pipe can be removed for cleaning.
7. The smoke pipe should not leave the heated portion of
the building to reach the chimney.
8. The smoke pipe should not pass from one story to the
next before entering the chimney, nor should it pass
through any closed or enclosed space.
Major changes to the main distributionduct system are normally
required in order to route the existing duct over the new hot
plenum of the add-on. Any indivdual ducts connected directly to
registers from the existing plenum also have to be routed over to
the add-on plenum because all of the air must pass through the
add-on before reaching any distribution ductwork.
9. Heat reclaimers should not be installed or used in the
smoke pipe.
10. The smoke pipe should not be located near or in a walk
way or well traveled area.
11. All male ends of smoke pipe should run or point towards
the furnace.
There are two options for managing the duct alternations. In
some cases, it is more practical to move the existing furnace and
place the add-on in the location it previously occupied. By
locating the add-on where the original furnace was, fewer supply
duct alterations will be needed. On the other hand, alterations to
the return ducts will be needed to re-route them to the new
location of the cold air plenum.
When you have installed the smoke pipe connecting your furnace
to the chimney, tap the pipe hard with your fingernail. Remember
the sound it makes - it will be a "ting" echoing inside the stove pipe.
If later you tap and hear a muffled thud, you are building up soot
in the pipe and should clean it. This pipe should be cleaned at
least once or twice during the heating season.
DO NOT CONNECT TWO HEATERS TO THE SAME CHIMNEY
FLUE. The National Fire Prevention Association recommends
that woodburning appliances vent into a separate chimney from
gas or oil furnaces. If such an installation is contemplated, first
check with a local building inspector to find out if a separate flue
for a woodburner is required.
If codes allow, use extreme care in making such installations. Be
sure that one pipe is higher than the other so that the two openings
will not be opposite each other. Also, when connecting two
heaters into the same chimney flue, the flue size should be large
enough to handle both heaters. Very few codes and
The other option is to leave the existing furnace in its original
location and re-route the supply ducts to the new add-on plenum.
In your design of add-on installations, always choose the approach
that involves using the least elbows. By keeping the number of
elbows to a minimum, duct restrictions and blower noise will be
reduced.
5
The connection of the add-on to an existing furnace imposes a
greater work-load on the air-circulating blower. Unless
compensating adjustments are made, the additional restriction
will reduse air flow, and overheating of the existing furnace can
result. To provide a reference point for later adjustments,you
must test air flow before any installation work begins.
2. Cut an opening in the side of the Hotblast furnace that will face
your existing furnace. (see illustration)
There are two methods of evaluating existing air flow: the static
pressure drop method and the temperature rise method.
HOTBLAST FURNACE MODIFICATIONS
1. Cut and insert a piece of sheet metal of sufficient thickness to
provide a tight fit over the opening on the back of the Hotblast
furnace.
6"
(15.24 cm)
FINISHED
OPENING
10" x 16"
BEND BACK
FLANGE
1" (2.54 cm)
CUTOUT
8" H x 14" W
(20.32 x 35.56 cm)
10" (25.4 cm)
16" (40.64 cm)
CONNECTING HOT AIR DUCT TO FURNACE
We strongly recommend that the hot airduct work be installed by a home
heating specialist. If doing the installation yourself, before you decide
which installation will best suit your needs, we recommend that you consult
a qualified heating technician and follow his recommendations as to the
most safe and efficient method of installation.
2" MIN. (5.08 cm)
1" MIN.
(2.54 cm)
6' (182.88cm)
6' (182.88cm)
HOT AIR
PLENUM
EXISTING
FURNACE
(if used)
HOTBLAST
FURNACE
DUCTWORK
INSTALLATION
HOT AIR
DUCT
And Minimum
MINIMUM CLEARANCES
Clearances
TO COMBUSTIBLES
6
1" MIN.
(2.54 cm)
HOT AIR
PLENUM
FAN LIMIT
CONTROL ON
PLENUM
7/8" HOLE
COMBUSTION AIR
3-1/2"
(8.9 cm)
All fires need air (specifically oxygen) to burn. Furnaces, fireplaces, and wood-burning furnaces need enough oxygen for
complete combustion of their fuels. The incomplete combustion
that takes place when a furnace is "air starved" causes carbon
monoxide (CO) to be formed in quantities that can be dangerous
inside a well-sealed house. Having a source of combustion air
from outside prevents this "air starvation" of the furnace.
6" (15.24cm)
SIDE OF HOTBLAST FURNACE
Drill one 7/8" hole as illustrated for placement of the Hotblast fan
limit control.
ASSEMBL
Y INSTR
UCTIONS
ASSEMBLY
INSTRUCTIONS
Your furnace is shipped from the factory in four (3) packages.
1) the furnace, 2) fan limit kit, 3) draft kit. Before assembling
the furnace, check to make sure there is no shipping damage,
and that all necessary parts are located in the firebox. See parts
list below.
If you find shipping damage or any of the parts missing, contact
the dealer immediately. He will take the necessary steps to
correct the problem.
DOOR HANDLE INSTALLATION
Insert door handle into door. From rear side of door place
1/2" washer over threaded part of door handle. Then attach
1/2" lock nut, being careful not to over tighten. Handle should
turn freely.
Parts List
All models include the following:
Two Door Handles
One Fuel Door Latch
One Ash Door Latch
One Shaker Grate Handle
Two 1/2" Washers
Six 1/4" Hex Nuts
Four Lock Washers
Spin Draft
Five 1/4" Lock Nuts
One Pivot Bracket
Four Brass Coil Knobs
One 1/4" x 1" Hex Bolt
Three 1/2"-13 Lock Nuts
One 1/2" x 2 1/2" Carriage Bolt
Six 1/4" x 3/4" Hex Bolts
Smoke Door
Two 1/4" x 1-1/4" Carriage Bolts
Two Smoke Door Clips
Rod Extension
FAN LIMIT KIT
Fan Limit Control
Fan Center
F.A.D. Box
3-Speed Switch
Knob
FUEL & ASH DOOR LATCH INSTALLATION
With two 1/4" x 3/4" hex bolts, attach the door latch to the
door latch mounting bracket on the left side of door frame as
illustrated. Adjust latch until door closes securely.
FUEL DOOR
ILLUSTRATION
ASH DOOR
ILLUSTRATION
LOCK
WASHER
HEX
NUTS
7
SMOKE CHAMBER:
1. Place #1 firebrick in the back of smoke chamber.
2. Slide baffle plate into smoke chamber, flat side down.
3. Place remaining firebrick in smoke chamber as
numbered below. (in placing the firebrick in the smoke
chamber, lift the left side of firebrick first and drop into
place.) See Illustrations below.
BRICK INSTALLATION
(PRE-INSTALLED AT FACTORY)
NOTE: Prior to operation, be sure to remove brick
retaining strips.
MODEL 1600 - (6) BRICKS ON EACH SIDE
FIREBOX LEFT SIDE
2
MODEL 1600
(41/2) BRICKS
1
1/2 BRICK
3
5
4
BRICK RETAINING STRIP
6
SLIDE 4th BRICK BACK
BEFORE INSTALLING 5th
AND 6th BRICK
2
MODEL 1800
(6) FULL BRICKS
MODEL 1800 - (8) BRICKS ON EACH SIDE
1
4
5
FIREBOX LEFT SIDE
6
7
BRICK RETAINING STRIP
TOP
FIREBOX:
The firebrick must be inserted on each side resting on the
grate frame. First, place cut brick in each back corner. Place
remaining brick in place.
REAR OF
FIREBOX
8
3
ATTACHING SLIDE BAFFLE ROD EXTENSION
THE MODELS 1600 AND 1800 HAVE BEEN
EQUIPPED WITH DIFFERENT PLENUM
OPENINGS, THEY ARE AS FOLLOWS:
BAFFLE
ROD
EXTENSION
MODEL 1600
BAFFLE
ROD
13"x18" Rectangle Plenum Opening
1-1/2"
HEX COUPLING
MODEL 1800
18"x18" Sqaure Plenum Opening
SMOKE DOOR INSTALLATION
SHAKER GRATE HANDLE INSTALLATION
1. Attach angle with two 1/4" x 3/4" hex bolts and two 1/4"
lock nuts.
2. Attach handle with 1/4" x 1" hex bolt and 1/4" lock nut.
3. Put brass knob onto end of handle.
1
SMOKE DOOR CLIPS
1/4" LOCK
NUTS
1/4" X 1-1/4"
CARRIAGE BOLTS
2
FRONT
OF
FURNACE
SMOKE DOOR
FUEL
LOADING
DOOR
FRAME
3
9
INSTALLING ASH DOOR SPIN DRAFT
MOUNTING PROCEDURE FOR
MOTORIZED NATURAL DRAFT
1. Screw spin draft onto 1/2" x 2-1/2" carriage bolt.
2. Screw spin draft and bolt assembly into ash door allowing
approximately 1/2" of the bolt to extend beyond the inside
of the door.
3. Secure bolt in place with 1/2" locking nut.
SPIN DRAFT CAP
1/2" X 2-1/2"
CARRIAGE
BOLT
DRAFT
TUBE
CLAMP
MOTORIZED NATURAL DRAFT
1. Using (2) 1/4" x 1" bolts, lock washers and nuts,
attach draft to furnace with draft tube clamp.
2. Plug draft power cord into receptacle on front of
furnace.
1/2" LOCK NUT
10
WIRING DIAGRAM FOR SERIES INSTALLATION WITH EXISTING ELECTRIC FURNACE
MAIN POWER
110 VOLT
BLACK
TO BE ADDED
WHITE
BLACK
BLUE FROM LIMIT
BLUE
HOTBLAST
LIMIT CONTROL
HOTBLAST
COTROL
CENTER
MUST PULL OUT
THE JUMPER
BLACK
BLACK
BLACK
TO BE
ADDED
ELECTRIC
FURNACE
THERMOSTAT
RED
WHITE WIRE
FROM DRAFT PLUG
BLACK WIRE
FROM DRAFT PLUG
ELECTRIC FURNACE
PLUG IN ON THE FRONT
OF HOTBLAST FOR DRAFT
TO "W1"
BLACK TO "R"
ALL ELECTRICAL WIRING SHOULD BE DONE
BY A QUALIFIED ELECTRICIAN.
RED TO "G"
NOTE: Must cut yellow end off draft wires.
NOTE: DO NOT use three (3) speed switch supplied.
NOTE: The jumper must be pulled out of the limit
control.
NOTE: Thermostat wires for the hotblast furnace go
to the front of the control center attach to "R"
and "G".
11
TO "R"
WIRING DIAGRAM FOR SERIES INSTALLATION WITH EXISTING GAS OR OIL FURNACE
SETTING LIMIT CONTROL
HIGH
LIMIT
CONTROL
LIMIT
FAN
250
50
100
200
150
BLUE
SAFETY
STOP
RH POINTER
(LIMIT OPENS)
200
BLACK
CENTER
POINTER
(FAN ON)
150
RED
LH POINTER
(FAN OFF)
100
WALL
THERMOSTAT
TO
"R"
ELECTRICAL BOX
TO
"G"
BLACK
DRAFT
RED
FAN
CENTER
BLACK
GREEN
BLACK
WHITE
WHITE
R*
TO GAS
FURNACE
FAN
BLACK
110V POWER SUPPLY
FROM GAS FURNACE
Ra
* OPTIONAL 120V RELAY MOUNTED IN GAS FURNACE
ALL WIRING SHOULD BE DONE BY A QUALIFIED ELECTRICIAN
12
WIRE INTO GAS
VALVE CIRCUIT
TESTING AND OPERA
TING PR
OCEDURES
OPERATING
PROCEDURES
minutes until coal fire is established before adding more coal.
NOTE: NEVER load coal over the level of firebrick.
! Close by-pass damper and set all draft controls to your own
needs. It may take 3 to 4 coal fires to determine how your
local coal and the Hotblast Furance reacts together —
adjusts drafts accordingly.
! Loading with a good bed of coals in the morning — open
by-pass damper.
• In normal shaking, only rock the grates a small amount to
sift ash through.
• Remove all ashes every day from ash pit.
CAUTION: Ashes should be placed in a metal container with
a tight fitting lid. The closed container of ashes should be
placed on a non-combustible floor or on the ground well away
from all combustible materials pending final disposal. If the
ashes are disposed of by burial in soil or otherwise locally
dispersed, they should be retained in the closed container
until all coals have thoroughly cooled.
• With your poker, push hot burning embers to the rear of
the unit and add green coal in front. NEVER load over
height of firebrick. This can result in damage to your
furnace and home.
• Close by-pass damper.
! Too much draft air will cause clinkering of coal and will waste
heat up the chimney. Shut draft down to as low a point as you
can and still heat your home.
1. NOTE: Never stand in front of loading door when opening
it. Stand to the side.
2. NEVER completely cover the live fire with fresh coal.
Always leave a generous area of burning coal at the top
of the fire and at the rear.
TESTING:
1. If using an optional power draft, check the draft blower
by turning the room thermostat up high enough so that
the draft blower turns on. Then lower the thermostat
setting until you hear it shut off.
2. Use a sheet of newspaper to test your draft by placing it
inside the furnace and lighting it.
With completion of the tests above, you are ready to light the
furnace. Follow the operating steps.
STARTING A WOOD FIRE
Using Motorized Natural Draft
CAUTION: Never use gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter fluid, or similar liquids to start or "freshen
up" a fire in the furnace. Keep all such liquids well away from the
furnace while it is in use.
1. Turn up thermostat to open motorized damper.
2. Open spin draft cap on ash door.
3. Pull the slide baffle rod to the front position.
4. Open the fuel load door and light fire using kindling and
several sheets of newspaper, then close the furnace
door. The furnace door should remain closed for 5 to
10 minutes in order to establish the fire. If the fire has
established, you are ready to load the furnace.
CAUTION: To prevent flame and smoke spillage, the slide baffle
must be pulled out and the fuel door must be cracked for ten
seconds before being fully opened.
Do not over fire your furnace! After you have become familiar with
its operation, you should know how much wood to use.
5. Load the furnace, close the load door and push the slide
baffle rod to rear.
6. Close the spin draft cap on ash door.
7. The motorized natural draft cycles on demand from the
U.S. Stove wall thermostat. Setting the thermostat
four degrees higher that your existing thermostat is
recommended.
During operation, the motorized natural draft remains
open until the thermostat temperature setting is reached.
3. Always keep the ash pit clean.
!If the fire goes out or does not hold overnight, look for:
1. Poor draft.
2. Incorrect damper settings.
3. Improper firing methods for coal being used.
4. More combustion air needed.
5. Coal not sized to the furnace. We recommend 1" to 3"
diameter pieces of coal.
6. Ashes, if allowed to accumulate in the ash pit, will not
allow the passage of required air for combustion. Keep
ash pit clean.
CAUTION: To avoid excessive temperatures, do not
operate with fuel door or ash pan open.
7. This furnace is not to be used with an automatic stoker
unless so certified.
CAUTION: To avoid excessive temperatures, do not
operate with fuel door or ash pan open.
OPERATING NOTES
! Do not over draft the furnace! It is designed to operate at .06
inches of water column and must be set with a draft gauge to
maintain a steady draft. (Barometric Damper recommended.)
STARTING A COAL FIRE
If you burn coal a Forced Air Draft is required.
! Do not allow ashes to build up higher than 2" above grates.
! Open smoke pipe damper all the way. Open all draft
controls on your 1600/1800. Pull the slide baffle forward.
! Place about 10-15 lbs. of coal in on the shaker grates.
It should come up to about half of the first firebrick level.
! Place crumpled paper over the coal and criss-cross a
couple handfuls of dry kindling wood 3/4" in thickness on
top of paper.
! Ignite the paper and close loading door. Wait about 30
! Be extremely careful when removing furnace ash pan; it can
get very hot.
! With new steel, there is a small amount of oil or dirt on the
metal. You may smell an odor. This is normal during the first
operation. You may want to assemble the furnace out of
doors and build a small fire in it to "burn off" this dirt and oil
before installing the unit.
13
! The furnace is designed to burn air dried wood and coal at a
predetermined firing rate. Over firing could result in damage
to the heat exchanger and cause dangerous operation. Over
firing occurs when the ash door is left open during operation
or a highly volatile fuel, i.e. large amounts of small kindling, is
used.
THIS IS A WOOD AND CO
AL
COAL
BURNING FURNA
CE AND
FURNACE
SHOULD NO
T BE AL
TERED
NOT
ALTERED
IN ANY WAY!
! When tending the firebox always pull the baffle slide rod out
prior to opening load door. Open load door slowly to avoid a
"flash back". After closing load door, push the baffle slide rod
to the rear.
! Equip your home with fire extinguishers and smoke detectors
appropriately located.
! Oil motor on forced air draft every 90 days with a few drops of
30 wt. oil.
! Check the fit on the load door. It must fit tightly. If it does not,
check for deterioration or wear of the ceramic rope seal.
Replace defective seals.
! Inspect and clean your chimney and stove pipe regularly.
! In event of chimney fire, shut all draft controls and call your
fire department immediately. Alert everyone in the house. If
the fire is still burning vigorously, throw baking soda into firebox
or discharge a fire extinguisher into the firebox. After chimney
fire is over, completely inspect system for damage before
further use.
! Slow fires: It is not recommended burning the U.S. Stove
furnace any more than necessary early in the fall and late
spring, as you cannot keep the firebox hot enough (without
overheating your home) to burn gases. Slow fires can cause
excessive creosote build-up in smoke pipe, chimney and
firebox.
! Wood should be placed directly onto the cast iron shaker grate
of the U.S. Stove furnace. Do not use additional grates and/or
irons.
! In the event of a power failure, you may operate the 1600/1800
furnace provided the following instructions are followed:
1. Any air filter should be removed.
2. If the motorized natural draft is used, the draft cap is to be
set at a 1/2 inch opening. If the forced air draft is used, the
damper on the built-in draft regulator will automatically
open to the preset factory spacing.
3. Do not burn garbage, plastics, gasoline, drain oil or other
flammable liquids. Plastics, when burned, form hydrofluoric and hydrochloric acids which will damage and destroy
your furnace pipe and chimney. The burning of trash or oil
can result in an extremely hot fire and is sometimes a
cause of chimney fires.
NEVER BURN GREEN WOOD OR TIRES.
! Do not store fuel or other combustible material within marked
installation clearances.
NOTE: For further information on using your furnace safely,
obtain a copy of the National Fire Protection Association publication "Using Coal and Wood Stoves Safely." NFPA NO. NW-81974. The address of the NFPA is 470 Atlantic Ave., Boston,
Massachusetts 02210.
14
TR
OUBLE SHOO
TING AND PR
OBLEM SOL
VING
TROUBLE
SHOOTING
PROBLEM
SOLVING
1. Problem:
Smoke puffs from furnace
Solution:
A. Check chimney draft. Check for blocked chimney
or flue pipe. Use mirror to check chimney
clearance.
B. Check ash pit — if it is too full, empty.
C. Make sure furnace room is not too airtight.
D. Make sure all of chimney mortar connections are
airtight.
E. Check ash drawer. Make sure it's airtight.
F. Check chimney for possible down-draft caused by
taller surrounding trees or objects. Correct with
proper chimney vent cap.
G. Check the possibility of a cold chimney forcing cool
gases backward. Remedied by properly insulating
chimney with non-combustible liner —
non-combustible insulation.
H. Fuel may be too green.
I. Make sure no other fuel burning devices are
connected to the chimney impairing the draft.
J. Check chimney draft, it should be .06 inches of
water column.
D. Check chimney draft — make sure chimney flue
pipe is clean and chimney is of adequate height.
E. Make sure you're not suffocating the fire with
excessive amounts of unburned wood.
F. Slide baffle should be pulled out prior to load door
opening.
4.
Problem:
4.Problem:
Distribution blower vibrating
Solution:
A. Tighten blower wheel to motor shaft.
B. Check for bad fan bearings.
5. Problem:
Distribution blower continues to run or will not run
Solution:
A. Check fan limit or heat sensor and cable.
B. Check to see that blower is properly wired.
(See Wiring and Assembly Instructions).
C. Check fuse box or power source.
D. Check power supply.
6. Problem:
Draft blower continues to run or will not run
Solution:
A. Check wiring.
B. Check thermostat or thermostat wire for short.
C. Make sure temperature is calling for heat.
2. Problem:
Inadequate heat being delivered to your home
Solution:
A. Check home insulation — is it adequate?
B. Check hook-up to furnace — is it installed
correctly?
C. Cool air inlet may be inadequate or furnace room
too airtight.
D. Your wood fuel may be too low grade. Hardwoods
are recommended.
E. Make sure your hot air duct (and other duct work)
is airtight.
F. If furnace room is warm but your home isn't, check
back draft dampers.
G. Is air to the blower available?
7. Problem:
Odor from first fire
Solution:
A. The odor from new steel should disappear in a
few hours.
B. If the odor remains, call you dealer immediately.
A bad weld can cause a fume leak.
8. Problem:
Excessive Creosote
Solution:
A. Check the grade of wood you are burning.
B. Make sure your unit is serviced by its own proper
chimney.
C. Check length of flue pipe and its connections.
D. Make sure you are burning the smallest, hottest fire
to adequately heat your home.
E. Also see Solutions to Problem one.
3. Problem:
Excess smoke or flames coming out door when
refueling
Solution:
A. Wait 15 seconds and open door SLOWLY —
then refuel.
B. Check length of flue pipe to chimney. Your unit
should be within six (6) feet of your chimney.
C. Make sure chimney cap is not too close to the top
of the chimney.
15
PAR
TS LIST
ARTS
MODEL 1600/1800
43
45
33
42
27
34
26
32
33 31
44
29
50
37
28
30
35
40
38
36
39
50
47
46
49
48
ITEM
26
27
28
29
30
31
32
33
34
35
36
37
38
DESCRIPTION
Top Safety Latch
Feed Door (Drilled)
Ash Door (Drilled)
Door Latch Handle
Ash Door Latch
1/2" Flat Washer
1/2" Lock Nut
5/16" x 1" Hinge Pin
1/2" Rope for Fire Door 52"
1/2" Rope for Ash Door 32"
Aqua-Siphon Cover
Shaker Grate Handle
Hinge Bracket
PART#
23786
69091
68880
24179(2)
23823
83835(2)
83444(3)
C21399(4)
88057
88057
23819
C000177
24204
ITEM
39
40
41
42
43
44
45
46
47
48
49
50
16
DESCRIPTION
1/4" x 3/4" Hex Bolt
1/-20 Kep Nuts
1/4" x 1" Hex Bolt
1/4" x 1-1/4" Carriage Bolt
1/4-20 Kep Nut
Smoke Door Curtain
Smoke Door Clip
1/2" x 1-1/2" Hex Connector
Baffle Rod Extension
1/2" Hex Nut
1/2" Coupling
Brass Coil Knob
Feed Door Assembled
Ash Door Assembled
40
41
PART#
83339(6)
83250(8)
83379
83445(2)
83250(2)
23800
23787(2)
C21899
C000089
83276(2)
C21899
89574(4)
68829
68880
PAR
TS LIST
ARTS
15
3 16
19 6
MODEL 1600/1800
13
17
4
1
11
12
22
9
18
10
8
24
7
21
20
ITEM
1
DESCRIPTION
Left Side Front Assy.
2
Right Side Front Assy.
3
Top Wrapper
4
Back Weldment
5
6
Side Insulation (2ea.)
Back Insulation
7
Ash Pan Weldment
8
9
Carrying Handle
Shaker Grate Section
10
Shaker Bar
*
Snap in Receptacle
MODEL
1600
1800
1600
1800
1600
1800
1600
1800
1600
1800
1600
1800
1600
1800
1800
1600
1800
1600
1800
BOTH
23
5
14
PART#
68821
68962
68822
68961
69088
68964
68823
68963
C98771
23977
C98971
23978(2)
68882
68919
24233
23852
68914
C000047
23961
80351
* = NOT SHOWN
17
NOTE:
1600 = 16 - FULL BRICK
1- HALF BRICK
1800 = 22 - FULL BRICK
2
ITEM
11
12
13
14
DESCRIPTION
Full Brick
Full Brick
Slide Baffle Plate
Grate Retainer
15
Baffle Rod S/S
16
Top Insulation
17
Front Filler
18
Draft Cover
19
Top Flue Ring
20
21
22
Draft Cap
1/2" x 2-1/2" Bolt
Back Liner
23
Front Liner
24
Cabinet Side Back
MODEL
BOTH
1600
BOTH
1600
1800
1600
1800
1600
1800
1600
1800
1600
1800
1600
1800
BOTH
BOTH
1600
1800
1600
1800
1800
PART#
89066
23887
24231
40312(2)
40337(2)
C10871
89704
C98871
23979(2)
23817
24190
23818
24508
22761
23958
23859
C20599
40313
40339
40344
40338
69002
MO
TORIZED NA
TURAL DRAFT P
AR
TS LIST
MOT
NATURAL
PAR
ARTS
PRE-ASSEMBLED AT FACTORY
(OPTIONAL KIT)
6
7
5
1
12
11
2 2
10
9
8
11
3
MODEL 1600 / 1800
4
3
ITEM DESCRIPTION
1
Draw Band
4
MODEL 1600/1800
MND KIT #C60357M
2
3
4
5
6
1/4" x 1" Bolt
1/4" Lock Washer
1/4" Hex Nut
Erie Motor-120v
Draft Cap
83379
83414
83072
C45099
23859
7
Draft Tube Weldment
68872
8
Flipper Tube
23899
9
Flipper
23898
1/2" - 13 Hex Lock Nut
#8 x 1/2" Tek Screw
1/2 x 2-1/2 Carriage Bolt
Thermostat
83444
83455
C20599
80129
10
11
12
*
18
PART#
23888
INST
ALLA
TION OF OPTIONAL EQ
UIPMENT
INSTALLA
ALLATION
EQUIPMENT
INSTALLING DOMESTIC HOT WATER COIL
1. Remove access panel at rear of enclosure.
2. With a utility knife cut out the section of fiberglass insulation
directly behind the access panel.
3. Remove cover plate from rear of firebox.
4. Place one nut on each end of the coil and thread each as
far as they will go.
5. Place the coil through the holes from the inside of the firebox
and run a washer and nut down each leg on the outside of the
stove. Before tightening the nuts down completely, wrap a
piece of hi-temp fiberglass rope gasket, provided with the kit,
around each threaded leg between the washer and the outisde
of the firebox. Tighten the nuts down securely to insure an airtight installation. The installation is now ready to be plumbed
to your existing domestic hot water system. Choose one of the
three methods described in the Hot Water Kit Installation
Instructions.
6. Remove knockouts from access panel and attach to furnace
enclosure.
7. Have a qualified plumber connect your domestic hot water
pipe to the coil with appropriate fittings.
2
ACCESS
PANEL
1
3
4
REAR WALL OF FIREBOX
5
DOMESTIC HOT
WATER COIL
1. NUT
2. WASHER
3. GASKET
19
TURN INSIDE NUTS UP
TO END OF THREADS
6
HO
W TO ORDER REP
AIR P
AR
TS
HOW
REPAIR
PAR
ARTS
THIS MANUAL WILL HELP YOU OBTAIN EFFICIENT, DEPENDABLE SERVICE FROM THE
HEATER, AND ENABLE YOU TO ORDER REPAIR PARTS CORRECTLY.
KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
WHEN WRITING, ALWAYS GIVE THE FULL MODEL NUMBER WHICH IS ON THE NAMEPLATE
ATTACHED TO THE BACK OF THE HEATER.
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION AS SHOWN IN THIS LIST:
1. The
2. The
3. The
4. The
PART NUMBER
PART DESCRIPTION
MODEL NUMBER: 1600GC / 1800GC
SERIAL NUMBER: ____________________
UNITED STATES STOVE COMPANY
227 Industrial Park Road
P.O. Box 151
South Pittsburg, TN 37380
(423) 837-2100
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