United States Stove Furnace 1600EF User Manual

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Installation/Operator’s Manual  
Model: 1600EF  
Wood or Coal External 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 391  
USSC  
851846 rev 0
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WARRANTY INFORMATION CARD  
Name__________________________________________Telephone#:(_____)_____________  
City____________________________________________ State_______ Zip_________________  
Email Address __________________________________________________________________  
Model # of Unit________________________________ Serial #___________________________  
Fuel Type: qWood qCoal qPellet qGas qOther_________________________  
Place of Purchase (Retailer)______________________________________________________  
City____________________________________________ State_______ Zip_________________  
If internet purchase, please list website address___________________________________  
Date of Purchase _______________________________________________________________  
Reason for Purchase: qAlternative Heat qMain Heat Source  
qDecoration  
qCost  
qOther_________________________  
What was the determining factor for purchasing your new USSC appliance?_______  
I have read the owner’s manual that accompanies this unit and fully understand the:  
Installation  
q
Operation  
q
and Maintenance  
q
of my new USSC appliance.  
Print Name  
Signature  
Date  
Please attach a copy of your purchase receipt.  
Warranty not valid without a Proof of Purchase.  
Warranty information must be received within 30 days of original purchase.  
Detach this page from this manual, fold in half with this page to the inside and tape  
together. Apply a stamp and mail to the address provided. You may use an enve-  
lope if you choose.  
All information submitted will be kept strictly confidential. Information provided will not be sold for advertising purposes.  
Contact information will be used solely for the purpose of product notifications.  
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Fold Here  
Fold Here  
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PLACE  
STAMP  
HERE  
United States Stove Company  
P.O. Box 151  
South Pittsburg, TN 37380  
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INTRODUCTION  
GENERAL INFORMATION  
Thank You for your purchase of a U.S. Stove Wood/Coal  
Burning External Furnace. Your decision to buy our Clay-  
ton Furnace was undoubtedly reached after much care-  
ful thought and consideration. We are very proud you  
chose this furnace and trust you will receive the comfort  
and economy that others realize when heating with a U.S.  
Stove product.  
Your 1600EF furnace comes ready for installation. No as-  
sembly required. Unpack your furnace and insure that  
there is no shipping damage. If damage exist, please  
contact your dealer immediately. Review the items in-  
cluded with your furnace located inside the firebox.  
1 - 10” Starter Collar  
1 - 12” Starter Collar for Cold Air Return  
8 - #10 x 3/4 Screws w/ Sealing Washer  
1 - Literature Package  
Your dealer is important in your experience with the fur-  
nace not only with the purchase, but for recommen-  
dations for professional installation for your home. The  
qualified professional installer 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. They are specialist in this field.  
This furnace may be installed as a Stand-Alone Central  
Furnace or as a Supplementary Furnace. If installed as a  
Central Furnace, this unit will have it’s own central ducting  
system and will essentially be your primary heat source.  
If installed as a Supplementary Furnace, the 1600EF will  
assist an Electric, Gas or Oil Fired Furnace in heating your  
home by utilizing the existing furnace’s duct work system.  
The 1600EF must not be wired in conjunction with the exist-  
ing furnace. The outdoor furnace may be operated with  
the supplied wall thermostat or a 24 volt thermostat that  
you supply yourself.  
IMPORTANT  
Before installing and using your furnace, please read the  
following pages thoroughly and carefully. If you follow the  
instructions, your furnace will give you safe and more de-  
pendable service for years to come.  
• Check your local codes. This installation must  
comply with their rulings.  
• This is an outdoor hot air furnace and must NOT  
be installed inside the home or a building.  
• This furnace must be connected to a 110 volt  
Ground Fault Circuit Interrupter (GFCI) outlet suit-  
able for outdoor use.  
The furnace should be placed outdoors on a level non-  
combustible base, preferably a 4’ x 8’ concrete pad, as  
close to the home as clearances to combustibles will al-  
low. If locating the furnace more than 10 feet away from  
the home, a minimum of 6 feet of Class “A” HT 2100 All  
Fuel 6 inch chimney pipe is required - Do not place the  
furnace more than 40 feet away from the home. Maintain  
all clearances stated in this manual.  
• A back-up generator, 2,000 watts minimum, is  
recommended in case of a power failure.  
• Always have a properly functioning smoke or  
ionization detector and a CO detector installed  
in your home.  
• To prevent injury or damage, do not allow any-  
one who is unfamiliar with the furnace to operate  
it.  
• Spend adequate time with your furnace to be-  
come well acquainted with the 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.  
Class “A” HT 2100 All Fuel 6” Chimney Pipe is recommend-  
ed for optimum performance and can be purchased  
from your local dealer. A Chimney Base Plate should  
be installed over the flue outlet and sealed to maintain  
weather resistance. A 2” clearance to combustibles must  
be maintained from the pipe. We suggest using either  
Simpson Dura-Vent or Metal Fab chimney products for  
your installation.  
If you choose to use single wall stainless, the flue temper-  
atures will be reduced which promotes the formation of  
creosote, possibly creating a fire hazard. If you use single  
wall stainless pipe, the minimum clearance to combus-  
tibles is 20”.  
Attach the appropriate chimney pipe lengths to the cho-  
sen chimney base plate and finish with a rain cap. Secure  
the chimney with guy wires to each of the four anchors  
point on the furnace. Your furnace requires it’s own chim-  
ney system and can not share a flue with another appli-  
ance.  
DISCLAIMER NOTICE  
Once you have selected a location for the furnace and  
connected your furnace to a chimney and a 110 volt GFCI  
outlet, you will need to commence an initial firing. DO NOT  
connect the furnace to your duct work at this time. Your  
new furnace has a protective coating of oil and paint on  
the surface which could produce smoke or odors during  
the initial firing and will burn off. Build a small fire - DO NOT  
fill the firebox to it’s full capacity for the initial burn. This  
initial firing allows the metals and castings to cure.  
The BTU ranges and heating capacity specifications are  
provided as a guide and in no way guarantee the output  
or capacity of this unit. The actual BTU output depends  
on the type of fuel being burned and its conditions, the  
thermostat setting, the draft adjustment and the chimney  
to which the unit is attached. The actual area that this  
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, the location of the unit  
and more importantly the duct work and return air facility.  
After completing the firing and allowing it to cool, you are  
ready to finish the installation. Refer to the remainder of  
this manual for detailed instructions.  
Warning:  
Do not alter this appliance in any way other than speci-  
fied in these instructions. Doing so may void your warranty.  
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WOOD SUPPLY  
FLUE PIPE INSTALLATION  
Someimportantrulesforpreparinggoodrewoodare:Cut,  
split and stack the wood in the early spring and let it stand  
in the sun and wind all summer.  
Clearances to combustible materials will vary with the type  
of flue connection used. Be sure to maintain the specified  
clearances for your type of installation.  
TYPE OF FLUE  
CONNECTION  
REQUIRED  
Whether you purchase your wood or cut it yourself, spring  
is the best time to buy or cut your wood to insure it is good  
and dry come winter. If you live in a damper climate, it will  
take longer for the wood to season.  
CLEARANCE  
Class A 103HT All-Fuel or Equivalent .....2”  
Double Wall, Stainless Steel or ...............6”  
Double Wall, Black Pipe w/  
Stainless Steel Inner wall  
By far the most important characteristic of any firewood  
is its moisture content. Firewood with a moisture content  
higher than twenty percent will burn, but it will be hard to  
light and keep burning, will make a lot of smoke and will  
produce less efficient fires with lower sustained BTU output.  
Plus much of its energy content will be wasted right up the  
chimney. Firewood should be between 15 and 25 percent  
moisture to burn properly and to get that dry it must be split  
and stacked in the open for at least a full summer.  
24 Gauge or Heavier .............................20”  
Single Wall Stainless Steel  
or Black Pipe  
The above clearances to combustibles must be  
maintained.  
CHIMNEY REQUIREMENTS  
All wood burns, but wood that’s cut green (between 50  
and more than 100 percent moisture content) burns with  
more difficulty, because the water in the wood must be  
boiled off before the actual wood fiber can burn. Air-dried  
(“seasoned”) wood is generally between 20-30 percent.  
Kiln-dried firewood generally contains less than 20 percent  
moisture.  
A Class “A” HT 2100 All Fuel 6” Chimney Pipe and Base Plate  
should be used for the installation. See Illustration. Place  
the Base Plate over the flue outlet of the furnace and drill  
eight(8) pilot holes into the Cabinet Top. Apply a generous  
amount of high temperature sealant to the bottom of the  
base plate, and around the flue outlet. Position the base  
plate over the flue and secure with the eight(8) screws  
provided. Then attach the flue pipe sections.  
Green wood can produce more creosote--a black sooty  
liquid which deposits and hardens on the inside of your  
chimney and can ignite, causing a chimney fire.  
Aminimumchimneyheightof6feetisrequirednotincluding  
the rain cap. In order to determine proper chimney height  
above the roof, measure from the side of the chimney hori-  
zontally.Asyoumoveupthechimney,thelengthincreases.  
Once this measurement reaches 10 feet, this is the base  
height of the chimney. The chimney must be 2 feet taller  
than the base height. If the chimney is closer than 10 feet  
from the peak of the roof, the chimney must be 2 feet taller  
than the peak of the roof. The 2 feet measurement does  
not include the rain cap.  
When you stack your wood, you should stack it in an open  
location where the summer sun can warm it and breezes  
can help remove moisture. Be sure to cover the top of the  
wood pile to keep the rain out. It is important that you do  
not stack unseasoned wood in an unventilated area for  
it will not dry properly. You shouldn’t allow your firewood  
to lay on the ground for more than a couple days before  
stacking , or it will start to mold and rot quickly.  
Once your wood is seasoned, store it in a dry location  
before burning.  
Once correct chimney height is achieved, check the  
chimney draft. It should not exceed 0.06 inches of water  
column. Then secure with three screws at each joint and  
attach guy wires down to the rings located around the top  
of the furnace cabinet.  
CLEARANCES  
See illustration.  
COMBUSTIBLE WALL  
15”  
20”  
(TOP VIEW)  
22”  
MINIMUM CLEARANCES  
TO A COMBUSTIBLE  
FLUE  
WALL  
CAUTION:  
DO NOT store  
combustible or  
flammable materials or  
liquids near the  
furnace.  
12”  
Sides of furnace, 12”; Rear of furnace, 15” (allow approxi-  
mately 20” for the return box); Front of furnace, 36”; Heat  
Duct, 2” for the first 9 feet then 1” thereafter.  
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CONNECTING HOT AIR DUCT  
TO FURNACE  
We strongly recommend that the hot air duct work be  
developing air velocities of 600 to 1,000 feet per minute  
in the main trunk duct and 400 to 600 feet per minute at  
the registers. The heat outlet should never be less than ten  
inches (10”) round or 79 square inches.  
This furnace must be installed with a cold air return system.  
The system must be a minimum of twelve inches (12”) to  
readily transfer the cold air from the home back to the  
furnace. If desired, a cold air filter box may be constructed  
with a minimum opening of 225 square inches.  
installed by a home heating specialist. If doing the instal-  
lation yourself, before you decide which installation will  
best suit your needs, consult a qualified heating technician  
and follow his recommendations as to the safest and most  
efficient method of installation.  
The warm-air supply-duct system shall be constructed of  
metal in accordance with NFPA 90B, 2-1.1. The plenums  
installed to the furnace be constructed of metal in accor-  
dance with NFPA 90B, 2-1.3.  
The warm-air supply outlet of the outdoor furnace must  
not be connected to the cold-air-return inlet of an existing  
centralfurnacebecausethepossibilityexistofcomponents  
of the existing furnace overheating and may cause the  
central furnace to operate other than intended.  
Outside the house you must use 10 inch galvanized pipe,  
wrapped with weather proof, UV resistant insulation. The  
12 inch return may be galvanized pipe and attached to  
the home so as to not pressurize the home.  
NEVER reduce the 10” hot air or the 12” return air as this  
will result in restricted air flow and cause the furnace to not  
operate properly.  
NEVER draw cold outside air into the blower housing. By  
doing so, the furnace’s heat chamber will not reach the  
necessary temperature to heat the home.  
The duct work should be designed so the external static  
pressure does not exceed 0.2 inches water column while  
TYPES OF INSTALLATION  
NO DUCT WORK INSTALLATION  
Cold air return must be installed in all installations, even those without an air duct system. If you do not, the furnace will  
not be able to heat the home. A filter should be installed in the cold air return. Furnace filters should be checked and  
cleaned/replaced regularly.  
When there is no duct system to connect the furnace to, keep the following in mind:  
1. You must separate the hot air duct from the cold air  
return. Ideally, locate each at opposite ends of the  
home. This method will work well in homes that are built  
on concrete slabs and should create a good air flow. If  
you do not, air will not flow evenly through the home.  
2. In homes with a basement, you may run the hot air  
duct to the basement and pull the cold air return from  
the main floor. This will create the perfect air flow since  
hot air rises.  
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TYPES OF INSTALLATION continued...  
INSTALLATION #2  
CENTRAL DUCT CONNECTION  
The baffle on this system should be made the full width of  
the furnace plenum in order to properly direct the air into  
the distribution ducts.  
When connecting to a central duct system, avoid 90 de-  
gree elbows as this will reduce air flow delivery. A duct run  
in excess of 40 feet is NOT RECOMMENDED. The air flow  
and heat output will be greatly decreased.  
Run 10” insulated hot air duct from the outdoor furnace  
through a wall or window of the structure. Then attach a  
flexible hot air duct to the existing duct work. Connect the  
duct with a 45 degree elbow or at an angle so the hot air  
from the outdoor furnace is delivered downstream. This  
will insure proper air flow into the system.  
Avoid delivering hot air through an air conditioning coil as  
this will cause an obstruction reducing heat output.  
The following illustrations may be used as examples for  
your installation.  
INSTALLATION EXAMPLES  
INSTALLATION #1  
With this installation, a back draft damper (optional) is in-  
serted into the heat run before the plenum of the existing  
furnace to prevent air from the existing furnace to blow  
back into the furnace when it is not in use. When a back  
damper is employed, it should be located as close to the  
existing furnace plenum as practical.  
INSTALLATION #3  
Extending the hot air duct from the furnace into the existing  
plenum will help direct the flow of air from the furnace as  
well as the flow in the existing furnace. Ducting entering  
the existing plenum at an angle (approximately 45 degrees)  
will facilitate air flow from the furnace while diverting air  
from the existing furnace.  
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FURNACE ASSEMBLY INSTRUCTIONS  
Read and follow these instructions in the event you have  
to replace or re-assemble components of your furnace.  
SHAKER GRATE HANDLE  
Insert the Shaker Rod into the hole on the ash door frame  
as shown. Then attach the Shaker Bracket to the front of  
the furnace using two 1/4-20 x 3/4” Hex Bolts and two 1/4-  
20 Lock Nuts. Next, insert the shaker Rod into the bracket  
and attach to the shaker grate bar using the 1/4-20 x 1”  
Hex Bolt and a 1/4-20 Lock Nut. The bolt and nut retaining  
the shaker bar and rod should be left loose to allow free  
movement of the grates.  
DOOR HANDLES  
Insert door handle into door. From rear side of door, place  
a 1/2” washer over the threaded part of the handle, then  
attach the lock nut. Tighten the nut, then back off 1/4  
turn to allow free operation of the handle.  
Follow these same directions for the ash door handle as-  
sembly.  
(1) Shaker Rod  
(1) Shaker Bracket  
(1) 1/4-20 x 1” Hex Bolt  
(2) 1/4-20 x 3/4” Hex Bolt  
(3) 1/4-20 Lock Nut  
(2) Door Handle  
(2) 1/2” Washer  
(2) 1/2” Lock Nut  
BRACKET  
ASH DOOR SPIN DRAFT  
Screw the spin draft onto the 3/8” x 2-1/2” carriage bolt.  
Then screw the spin draft and bolt into the ash door al-  
lowing approximately 1/2” of the bolt to stick through the  
back side of the ash door. Secure the bolt in place with  
the 3/8”-16 lock nut.  
(1) Spin Draft  
(1) 3/8-16 Carriage Bolt  
(1) 3/8-16 Lock Nut  
FUEL & ASH DOOR LATCH  
With two 1/4-20 x 3/4 hex bolts each, attach the door  
latches to the door latch mounting brackets on the left  
side of the door frames as illustrated. The slots in the brack-  
ets and latches are for door seal adjustment. Make the  
proper adjustments, then tighten the nuts. The door’s gas-  
ket should be snug against the door frame on the furnace.  
SMOKE CURTAIN  
Using two 1/4-20 x 1-1/4” Carriage bolts, the smoke cur-  
tain clips and two nuts, attach the smoke curtain in place  
above the Fuel Feed Door as shown below. After installa-  
tion, the smoke curtain should swing freely back into the  
furnace.  
(1) Smoke Curtain  
(2) 1/4-20 x 1-1/4 Carriage Bolt  
1/4-20 NUT  
(2) Smoke Curtain Clips  
(2) 1/4-20 Kep Nut  
SMOKE CURTAIN  
CLIP  
Feed Door  
Illustration  
Ash Door  
Illustration  
1/4-20 x 1-1/4  
CARRIAGE BOLT  
(1) Feed Door Latch  
(1) Ash Door Latch  
(4) 1/4-20 x 3/4 Hex Bolt  
(4) 1/4-20 Kep Nut  
SMOKE CURTAIN  
NUT  
BOLT  
SMOKE CURTAIN  
CLIP  
SMOKE CURTAIN  
FRONT  
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DISTRIBUTION BLOWER & ACC.  
All electrical connections should be done by a  
qualified electrician.  
A
1. To replace the Honeywell Limit Control (A): Unplug from  
power supply  
The control may be removable thru the access panel on item  
“B”. However it may be easier to remove item “B” entirely for bet-  
ter access. Remove item “B” by means of the eight(8) screws. If  
siliconed, use a utility knife to score the silicone along the edges  
of the part. Take off the cover of the control (A), remove the  
three wires, and continue to remove the control by means of the  
two screws retaining it. Use the wiring diagram in the rear of this  
manual to re-connect the new control. Reattach item “B” and  
re-silicone all the seams with weather resistant silicone.  
B
C
2. To remove the return air box (D): Unplug from power supply.  
If siliconed, use a utility knife to score the silicone along the edges  
of the part. Remove item “B” as described above. Then remove  
the four(4) screws down each side and the four(4) across the top  
of the return air box. Pull the box back away from the unit enough  
that you can reach in to remove the snap-in plug (C) from the  
top of the box. The power supply cord will need to be feed back  
thru the plug in the bottom of the air box for complete removal.  
When re-attaching, make sure that the three plugs in the top of  
the Fan Center (G) are properly plugged in. Do not forget to put  
the snap-in plug (C) back in place. Re-silicone all the seams with  
weather resistant silicone.  
C
E
D
3. To remove the Distribution Blower (E): Unplug from power  
supply.  
Remove items”B” and “D” as described above. Unplug the blow-  
er from the top of the Fan Center (G). Remove the four(4) screws  
retaining the blower.  
F
H
G
4. To remove the Blower Motor: Unplug from power supply.  
Perform number 3 above. Before removing the motor from the  
housing, measure two things:  
1.) The distance from the edge of the motor to the edge of the  
motor bracket. Record (d1) _________________  
2.) The distance of the shaft remaining outside the coupling on  
the blower wheel. Record (d2) __________________  
d1  
These two measurements dictate the position of the blower in-  
side the housing and is critical in determining motor longevity.  
Repositioning of the blower motor, bracket, and wheel in respect  
to one another should keep as close to the factory position as  
possible.  
K
I
Remove the three(3) screws (I) from the blower housing. Then  
loosen the bolt (J) on the motor shaft. Next, loosen or remove the  
bolt (K) in the motor bracket to remove the motor.  
5. To remove the Blower Capacitor (F): Unplug from power supply.  
This may be accomplished by working thru the 12 inch diameter  
return duct hole in the Return Box. Otherwise, you must remove  
items”B” and “D” as described above. Unplug the blower from  
the top of the Fan Center (G). Using pliers with rubber coated  
handles, unplug the two connections on the capacitor. Remove  
the two screws and cap bracket.  
d2  
J
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MOTORIZED NATURAL DRAFT REPLACEMENT  
1. Make certain the unit has been unplugged from the  
2. Remove the draft assembly from the furnace by loos-  
ening the two bolts retaining draw band.  
power source. Remove the cover from the motor and  
remove the two wire nuts and grounding screw. With a  
pair of pliers, remove the strain relief and cord assem-  
bly from the motor.  
3. To remove the motor from the tubing assembly, simply  
loosen the set screw in the collar on the motor and slide  
it off the tube.  
If motor comes with the cord, the above step is not  
required. However, you will have to remove the panel  
on the inner cabinet side to rewire the motor. Do so by  
removing the rivets with a 3/16” drill bit. Screws may be  
used to replace the rivets.  
4. If replacing the Flipper, remove the two #8 screws re-  
taining the plate to the tube.  
Reverse the above steps for re-assembly  
(1) Draft Actuator  
(1) Spin Draft  
(1) 3/8-16 Carriage Bolt  
(1) 3/8-16 Lock Nut  
(1) Flipper Tube  
(1) Flipper  
(2) #8 Screw  
FIREBRICK AND BAFFLE REPLACEMENT  
FIREBOX BRICK REPLACEMENT  
BAFFLE/BRICK REPLACEMENT  
This furnace comes from the factory with the firebrick in-  
stalled. However, if brick replacement is necessary, follow  
these instructions. Before furnace operation, remove the  
brick retaining strip. This piece is used during shipping to  
reduce brick damage.  
If baffle replacement is necessary, slide the baffle out until  
you can access the nuts thru the flue outlet. Once the  
nuts have been removed, slide the baffle off the rod and  
thru the opening in the firebrick. You may have to remove  
one of the firebrick to make baffle removal easier.  
There are 6 full brick and 1 half brick per side. Install the  
half brick first by putting the bottom of the brick in first and  
let it rest against the firebox side and fire grates. Then slide  
it to the rear. After that, install the #2, #3, #4, #5 & #6 brick,  
sliding the 6th brick forward to allow for the 7th brick. Re-  
peat for opposite side.  
There are 4 full brick and 1 half brick in the top of the fur-  
nace. Install the brick by inserting one end of the brick an-  
gled upward and then allowing the opposite end to rest  
on the firebox lip. Lay the brick between the spacer and  
firebox back. Slide the baffle to the rear and let it rest on  
that half brick. After installing brick #2 in the front, install #3  
and slide it under the baffle. Finally install bricks #4 and #5.  
NOTE: Prior to operation, be sure to remove the brick  
retaining strips.  
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TESTING AND OPERATING PROCEDURES  
4. Load the furnace, close the load door and push the slide  
Baffle rod to rear.  
GENERAL FURNACE OPERATION  
After installation of the furnace is complete, it is ready for  
operation. The Honeywell Limit Control, in conjunction  
with a wall thermostat, operates the distribution blowers  
and the motorized draft on the front of the furnace. The  
limit control is located on the rear of the furnace in the  
upper left corner and is accessible by removing the two  
screws in the cover plate. DO NOT operate your furnace  
with this plate removed! The control can be adjusted to  
your desired blower On/Off times. The factory settings are  
100/150/200.  
5. Close the spin draft cap on ash door, leaving it cracked  
about the diameter of a dime.  
6.Themotorizeddraftcycles(opened&closed)ondemand  
from the wall thermostat. Setting the U.S. Stove thermo-  
stat four degrees higher than your existing thermostat is  
recommended. Inoperation, thepowerdraftwillremain  
openuntiltheU.S.Stovethermostattemperaturesettingis  
reached.Thenitwillclosetoreducecombustionair.Ifthe  
furnace looses power, the draft will automatically close.  
The wall thermostat setting operates the ON time of the  
motorized draft. If the temperature is below the setting on  
the wall thermostat, the motorized draft will come open.  
(Recommended setting at 5 to 10 degrees higher than  
other heating thermostats.)  
CAUTION: To avoid excessive temperatures, do not  
operate with fuel door or ash pan open.  
STARTING A COAL FIRE  
Shut off FAD when fuel door is open  
The first two set points on the limit control operates the  
distribution blower. When the furnace plenum reaches  
the second set point on the limit control, the distribution  
blower will come on. If the temperature falls to the first  
set point, the distribution blower will shut-off. The distribu-  
tion blower is a three speed blower and can be manually  
adjusted by means of the three position switch located  
behind the sliding access panel on the cold air return box.  
Open all draft controls on your furnace. Pull the slide  
baffle forward.  
Place about 10-15 lb. 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 crisscross a  
couple handfuls of dry kindling wood 3/4” in thickness  
on top of paper.  
When the furnace reaches the third set point on the limit  
control, the draft blower will shut-off. The draft blower will  
come back on if the temperature falls below the setting  
on the wall thermostat.  
Ignite the paper and close loading door. Wait about 30  
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 Clayton Furnace reacts  
together. Adjusts drafts accordingly.  
TESTING  
1. Check the motorized draft by turning the room thermo-  
stat up high enough so that the motorized draft opens.  
Then lower the thermostat setting to ensure it closes off.  
When loading with a good bed of coals in the morning  
- Open by-pass damper.  
2. Use a sheet of newspaper to test your draft by placing  
it inside the furnace and lighting it.  
1. Innormalshaking,onlyrockthegratesasmallamount  
to sift ash through. Do not agitate the fire bed too  
often. This practice will waste coal. If glowing coal is  
visible in the ash pan, you have shaken to much.  
With completion of the tests above, you are ready to light  
the furnace. Follow the operating steps.  
2. Remove all ashes every day from ash pit.  
STARTING A WOOD FIRE  
Using Motorized Natural Draft  
CAUTION:Ashesshouldbeplacedinametalcontainerwith  
a tight fitting lid. The closed container of ashes should be  
placed on a non-combustible floor or on the ground well  
awayfromallcombustiblematerialspendingnaldisposal.  
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.  
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. Open spin draft cap on ash door.  
3. 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.  
2. Pull the slide baffle rod to the front position.  
3. Open the fuel load door and light fire using kindling and  
severalsheetsofnewspaper,thenclosethefurnacedoor.  
Thefurnacedoorshouldremainclosedfor5to10minutes  
in order to establish the fire. If the fire has established, you  
are ready to load the furnace.  
4. 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.  
CAUTION: To prevent flame and smoke spillage, the slide  
bafflemustbepulledoutandthefueldoormustbecracked  
for ten seconds before being fully opened.  
1. NOTE: Never stand in front of loading door when  
opening it. Stand to the side.  
Do not over fire your furnace! After you have become  
familiar with its operating, you should know how much  
wood to use.  
2. NEVER completely cover the live fire with fresh coal.  
Always leave a generous area of glowing coal at the  
top of the fire and at the rear.  
3. Always keep the ash pit clean.  
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If the fire goes out or does not hold overnight, look for:  
1. Poor draft.  
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 danger-  
ous 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. If any portion of  
the connector pipe glows orange or red, you are in an  
over-firing situation. Close all dampers.  
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.  
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.  
6. Ashes, if allowed to accumulate in the ash pit, will  
not allow the passage of required air for combustion.  
Keep ash pit clean.  
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.  
7. Thisfurnaceisnottobeusedwithanautomaticstoker  
unless so certified.  
There are ONLY two types of coal allowed for use in this  
furnace: Bituminous Coal (soft coal) and Anthracite  
Coal (hard coal). NEVER USE Cannel (or Channel) coal  
or Brown (Lignite) Coal.  
NEVERthrowwateronthereoratthefurnace,asrapidly  
See our Bulletin RC454 at the rear of this manual for the  
expanding steam could result in a severe scalding.  
best information available on burning coal.  
Slow fires: It is not recommended burning the Clayton  
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.  
OPERATING NOTES  
DANGER: Risk of Fire or Explosion - Do not burn garbage,  
plastics, gasoline, drain oil or other flammable liquids.  
Plastics,whenburned,formhydrofluoricandhydrochloric  
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.  
Inspectairltersregularly.Theairltershouldbechanged  
at least every 30 days.  
Oil motors every 90 days with a few drops of 30 wt. oil.  
WARNING: Risk of Fire - Do not operate with flue draft  
exceeding .06 inches of water column and must be set  
withadraftgaugetomaintainasteadydraft.(Barometric  
Damper recommended.)  
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.  
In the event of a power failure, the furnace will not dis-  
tribute heat to the home. We recommend the use of a  
back-up generator, 2,000 watts minimum, for continued  
use until regular power is restored  
Do not operate with the fuel loading or ash removal  
doors open.  
Do not store fuel or other combustible material within  
marked installation clearances.  
Inspect and clean your flues and chimney regularly.  
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-8-1974. The address of the NFPA is 470 Atlantic  
Ave., Boston, Massachusetts 02210.  
CAUTION: Hot Surfaces - Keep children away. Do not  
touch during operation. Maximum draft marked on  
nameplate.  
Equip your home with fire extinguishers and smoke de-  
tectors appropriately located.  
Woodshouldbeplaceddirectlyontothecastironshaker  
grate of the Clayton furnace. Do not use additional  
grates and/or irons.  
THIS IS A WOOD AND COAL BURN-  
ING FURNACE AND SHOULD NOT BE  
ALTERED IN ANY WAY! DOING SO  
WILL VOID YOUR WARRANTY!  
Do not allow ashes to build up higher than 2” above  
grates.  
Never allow the ashes in the ash pan to touch the grate  
section. REMOVE ASHES FREQUENTLY!  
Be extremely careful when removing furnace ash pan;  
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 rela-  
tively 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.  
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 build a small fire in  
the furnace to “burn off” this dirt and oil before installing  
the duct work.  
The 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.  
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TROUBLE SHOOTING AND PROBLEM SOLVING  
4. Problem:  
1. Problem:  
Solution:  
Smoke puffs from furnace  
Distribution blower vibrating  
Solution:  
A. Tighten blower wheel to motor shaft.  
B. Check for bad fan bearings.  
A. Check chimney draft. Check for blocked chimney  
oruepipe.Usemirrortocheckchimneyclearance.  
B. Check ash pit — if it is too full, empty.  
5. Problem:  
C. Make sure all of chimney mortar connections are  
airtight.  
Distribution blower continues to run or will not run  
Solution:  
D. Check ash drawer. Make sure it’s airtight.  
A. Check fan limit or heat sensor and cable.  
E. Check chimney for possible down-draft caused  
by taller surrounding trees or objects. Correct with  
proper chimney vent cap.  
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.  
F. Check the possibility of a cold chimney forcing cool  
gases backward. Remedied by properly insulating  
chimneywithnon-combustiblelinernon-combus-  
tible insulation.  
6. Problem:  
Motorized draft stays open or will not close  
Solution:  
G. Fuel may be too green.  
H. Make sure no other fuel burning devices are con-  
nected to the chimney impairing the draft.  
A. Check wiring.  
B. Check thermostat or thermostat wire for short.  
C. Make sure temperature is calling for heat.  
I. Check chimney draft, it should be .06 inches of  
water column. This service is provided by a certified  
chimney sweep.  
7. Problem:  
Odor from first fire  
2. Problem:  
Solution:  
Inadequate heat being delivered to your home  
Solution:  
A. The odor from new steel should disappear in a few  
hours.  
A. Check home insulation — is it adequate?  
B. Checkhook-uptofurnaceisitinstalledcorrectly?  
C. Cool air inlet may be inadequate.  
B. If the odor remains, call you dealer immediately. A  
bad weld can cause a fume leak.  
8. Problem:  
D. Your wood fuel may be too low grade. Hardwoods  
are recommended.  
Excessive Creosote  
Solution:  
E. Make sure your hot air duct (and other duct work)  
is airtight.  
A. Check the grade of wood you are burning.  
B. Make sure your unit is serviced by its own proper  
chimney.  
F. Is air to the blower available?  
3. Problem:  
C. Check length of flue pipe and its connections.  
Excesssmokeoramescomingoutdoorwhenrefueling  
D. Make sure you are burning the smallest, hottest fire  
to adequately heat your home.  
Solution:  
A. Wait 15 seconds and open door SLOWLY — then  
refuel.  
E. Also see Solutions to Problem number 1.  
9. Problem:  
B. Check length of flue pipe to chimney.  
If the fire goes out or does not hold over night  
Solution:  
C. Make sure chimney cap is not too close to the top  
of the chimney.  
A. Poor Draft.  
D. Check chimney draft — make sure chimney flue  
pipe is clean and chimney is of adequate height.  
B. Incorrect damper settings.  
C. Improper firing methods if burning coal.  
D. More combustion air needed.  
E. Make sure you’renot suffocating therewith exces-  
sive amounts of unburned wood.  
F. Slide baffle should be pulled out prior to load door  
opening.  
E. Coal not sized to the furnace. We recommend 1”  
to 3” diameter pieces of coal.  
F. Ashes, if allowed to accumulate in the ash pit, will  
notallowpassageoftherequiredairforcombustion.  
Keep ash pit clean.  
G. This furnace is not to be used with an automatic  
stoker unless so certified.  
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WIRING DIAGRAM  
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PARTS DIAGRAM  
16  
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PARTS DIAGRAM AND LIST  
Key Description  
Part #  
40312  
891341  
40314  
40344  
40313  
89066  
891414  
24231  
86662  
24220  
C97999  
C23799  
83445  
23787  
83250  
23800  
891884  
83444  
83835  
23786  
69653  
69005  
24204  
23823  
68882  
24233  
68880  
23859  
25715  
25746  
25718  
25719  
25720  
88149  
25715  
25717  
80587  
25721  
25744  
69647  
88153  
83884  
Qty  
2
Key Description  
Part #  
25726  
88150  
88151  
88152  
25727  
69648  
83912  
25722  
69649  
891865  
80590  
83236  
83045  
80588  
69651  
80145  
80586  
83909  
25732  
88155  
25733  
25725  
25734  
83910  
25737  
69650  
25736  
25735  
25741  
69654  
80592  
23888  
83379  
83261  
25745  
80154  
25748  
891884  
89799  
891868  
83572  
Qty  
1
1
1
1
1
1
4
1
1
1
1
4
4
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
2
1
1
1
1
1
1
96  
1
2
Grate Retainer  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
Inner Top  
Shaker Bar  
1
Insulation, Top-Front  
Insulation, Top-Middle  
Insulation, Top-Rear  
Mount, Flue Outlet  
Weldment, Cabinet Top  
D-Ring Clip  
3
Shaker Grate Section  
Front Liner  
5
4
1
5
Back Liner  
1
6
Full Firebrick (4-1/2 wide x 9 tall x 1-1/4 thick)  
Half Firebrick (2-1/4 wide x 9 tall x 1-1/4 thick)  
Slide Baffle  
16  
3
7
8
1
Bottom Intake  
9
Baffle Rod  
1
Assembly, Cabinet Door  
Latch, Cabinet Door  
1800 CFM Blower Assembly  
10  
11  
12  
13  
14  
15  
16  
17  
Inside Cover Plate  
Gasket, Water Coil Cover  
#12 x 3/4: Tek Screw  
Carriage Bolt, 1/4-20 x 1-1/4 Long  
Smoke Door Clip  
1
1
3
N/S 1/4-20 x 3/4 Self Tapping Screw  
N/S Washer  
2
2
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
Blower Motor  
Kep Nut, 1/4-20  
2
Fan Center Assembly  
Honeywell Limit Control  
Harness, 3 Circuit Plug  
7/8” Snap Bushing-Heyco (BLK)  
Cable Chase  
Smoke Curtain  
1
Door Handle  
2
N/S Lock Nut, 1/2-13  
N/S Washer  
2
2
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
Feed Door Latch  
1
Gasket, Access Panel  
Probe Access Panel  
Cover, Water Coil  
Feed Door Assy. (w/Rope Gasket)  
Shaker Handle  
1
1
Bracket, Shaker Handle  
Ash Door Latch  
1
Bottom, Blower Box  
1
1-1/4” Bushing, Heyco  
Right Side, Blower Box  
Left Side Assy., Blower Box  
Back, Blower Box  
Ash Pan  
1
Carry Handle  
1
Ash Door Assy. (w/Rope Gasket)  
Draft Cap  
1
2
Top, Blower Box  
Outer Side Wall, Left  
Panel-L, inner Cabinet  
Clip, Outer Wall  
1
MTG. Bracket, Blower Box  
Motorized Natural Draft (MND) Assembly  
1
2
N/S MND Motor  
Bracket, Alignment  
Cabinet Door Stop  
Insulation, Cabinet Side  
Outer Side Wall, Right  
Panel-R, inner Cabinet  
Harness, 2 Circuit Plug  
Filler, Top  
2
69  
70  
71  
72  
73  
74  
75  
76  
77  
3” Draw Band  
1
1/4-20 x 1” Hex Bolt  
1/4-20 Lock Nut  
4
1
Plate, Electrical Connection  
Strain Relief Bushing  
Hook, Handle  
1
1
1
Handle, Separable  
12” Stub Collar  
Hood, Front  
1
Assembly, Cabinet Back  
Insulation, Back  
1
10” Stub Collar  
1
N/S #10 x 3/4 Tek Screw w/ Bonded Neoprene  
Washer  
Insulation Holder  
16  
N/S = Not Shown  
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PARTS DIAGRAMS AND LISTS - MOTORIZED DRAFT KIT  
4
Key Description  
Part #  
68872  
40379  
83503  
83274  
80592  
23899  
23898  
83455  
80154  
80593  
80382  
Qty  
1
2
Weldment, Draft Tube  
1
Spin Draft  
1
3
3/8-16 x 2-1/2 Carriage Bolt  
Lock Nut, 3/8-16  
1
4
1
5
Actuator, Motorized Draft  
Tube, Flipper  
1
6
1
7
Flipper  
1
8
#8 x 1/2 Tek Screw, Hex Head  
Strain Relief  
2
1
9
10  
11  
Power Supply Cord  
Male, Tyco Terminal  
17 in.  
2
18  
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PARTS DIAGRAMS AND LISTS - FAN CENTER CONTROL  
Key Description  
Part #  
25742  
25743  
80361  
80583  
80584  
80585  
80130  
80154  
80232  
83172Z  
83240  
Qty  
1
1
2
Electrical Box Cover  
Electrical Box Body  
1
3
Switch, 3-Position  
1
4
Harness, 6 Circuit Receptacle  
Harness, 3 Circuit Receptacle  
Harness, 2 Circuit Receptacle  
Transformer, Fan Center  
Strain Relief  
1
5
1
6
1
7
1
8
1
9
Power Supply Cord  
1
10  
11  
#10 x 1/2 Sheet Metal Screw  
Washer, Internal tooth, #10  
13  
1
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NOTES  
20  
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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  
directly behind the access panel.  
1
3. Remove the cover plate from the rear of the furnace  
firebox.  
ACCESS  
PANEL  
4. Place one nut on each end of the water coil and  
thread each nut up to the end of the threads on the  
coil.  
5. Insert the coil through the holes from the inside of the  
firebox. Install a gasket, washer and nut onto each end  
of the water coil. Tighten the nuts down securely to in-  
sure an air tight seal.  
The installation is now ready to be plumbed to your exist-  
ing hot water system. Choose one of the three methods  
described in the Hot Water Coil instructions.  
3
6. Remove knockouts from the access panel and re-attach  
to the furnace enclosure.  
REAR WALL OF  
FIREBOX  
Have a qualified plumber connect your domestic hot water  
pipe to the coil with the appropriate fittings.  
5
4
DOMESTIC HOT WATER  
COIL  
6
TURN INSIDE NUTS UP  
TO END OF THREADS  
1. NUT  
2. WASHER  
3. GASKET  
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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.  
As the gases burn off the flames become shorter,  
change color and produce less smoke.  
will burn both Bituminous and Anthracite coal. An-  
thracite is perhaps the best coal fuel because of its  
long even burn time, high heat output, and cleanli-  
ness which make it a good choice for the home.  
However, keep in mind it is a much more difficult  
fuel to use, requires more care and patience, is not  
so widely available, and is usually much more ex-  
pensive than Bituminous.  
Once the fire is WELL ESTABLISHED add coal to the  
center of the firebox forming the cone. Burning in  
this fashion allows heat to drive off the volatile gases,  
and turbulence created increases the burn efficien-  
cy. There will have to be some experimenting with  
the individual setup as no two chimney’s or instal-  
lations are going to be the same. Just remember to  
allow enough air to enter the firebox and keep the  
stove pipe damper open so that volatiles are prop-  
erly burned. Before refueling, take the time to break  
up the cone a little with a poker, especially if it has  
caked over or formed a crust. But, be careful not to  
mix the coal as this increases the chances of form-  
ing clinkers. When shaking the grate(s) be gentle.  
Just a few short movements - a couple of “cranks”  
- is better than a lot of agitation. The objective is to  
remove a small amount of the ashes without disturb-  
ing the fire. Stop when you see a glow in the ashes  
or the first red coals fall into the ash pan. Excessive  
shaking wastes fuel and can expose the grate(s) to  
very high temperatures which can cause warpage  
or burnout.  
SIZE OF COAL:  
Most sizes of Bituminous Coal will work in a coal fur-  
nace; for best results we recommend large “nut”  
coal to small “egg” coal (1-3/4” diameter to 4” di-  
ameter). When burning Anthracite, use “egg” or  
“broken” with sizes between 2-5/16” thru 4-3/8”.  
Note that it is important to the long life of your stove  
to buy coal which has been sized and cleaned.  
Cleaning insures removal of rocks and other miner-  
als. Never use coal smaller than 1” or larger than  
5” in diameter. Small sized coal will smother the fire.  
Too large a size of coal will not burn well.  
STOVE OPERATION:  
All coal fires should be started with wood which will  
allow the fire to get hot enough to ignite the coal.  
The best ignition fires utilize dry pine or other resinous  
soft woods as kindling, with hard wood (oak, hicko-  
ry, ash) added to increase the heat prior to addition  
of the coal.  
For overnight operation (long duration burn time)  
shake the fire and add coal, retaining the center  
cone. Once the volatiles are burned off, close the  
feed door and adjust the stove pipe damper, if  
equipped. Then adjust the thermostat to the desired  
heat level.  
Before starting the fire, open the stove pipe damp-  
er (if equipped), turn the thermostat to high, open  
the ash pit door and feed door, place newspaper  
and finely split kindling on the grate, light the paper,  
add larger hard wood after the kindling is burning  
brightly. CAUTION: Never use gasoline, lantern fuel,  
kerosene, charcoal lighter fluid, or other flammable  
liquids to start or freshen up a fire in any heater.  
Place the larger pieces of wood on the fire so that  
they are slightly separated and form a level for the  
addition of coal. It will take 10 to 20 minutes before  
this wood is thoroughly ignited. Adding coal too  
soon will cut the air supply and smother the fire.  
More MAINTENANCE will be needed with bituminous  
coal than with anthracite coal as more soot will  
collect on heating surfaces and in pipes, requiring  
more frequent cleaning.  
ANTHRACITE:  
Add a thin layer of coal (preferably smaller chunks)  
to the wood fire, being careful not to disturb it too  
much or cut off the draft. Then, add a second  
heavier layer after the coal is ignited and burning  
well. If necessary, add a third layer to bring the coal  
up to the top of the front liner (not above!). Be sure  
to close the ash door.  
BURNING BITUMINOUS:  
Once your kindling and wood fire has produced a  
bed of well established coals, start adding coal in  
layers allowing each to ignite before adding more.  
Bituminous has a high volatile content and, as a re-  
sult, should be fired with the “conical method” - with  
the highest portion of your fire bed in the center of  
the firebox. The first flames will be long and generally  
Before adding further fuel, be sure to leave a red  
spot of glowing coals in the center of the firebox to  
insure that the fire has not been smothered and to  
help ignite the gases given off by the new charge.  
A deep charge will give a more even heat and a  
longer fire, but it may take one to two hours before  
the whole bed is fully ignited.  
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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  
experimenting will have to take place with each  
particular setting of all dampers and controls as the  
chimney provides the draft necessary to not only  
exhaust the smoke, but to pull combustion air into  
the heater as well - and no two chimney’s perform  
the same. Under ideal draft conditions, one should  
be able to turn the secondary air supply below the  
feed door (some models) to a near closed position -  
but leave the ash pit damper at least partially open  
to prevent the fire from going out. Adjust the stove  
pipe damper to reduce the draft on the fire. With  
anthracite there will be short blue flames above  
the coal, except when the fire is started or a new  
charge is added. If, however, there is no flame then  
the fire needs more air from the bottom (unless it is  
near the end of its burn cycle and needs to be re-  
charged).  
For extended operation, such as overnight, the fire  
will need to be banked. To do so heap coal up  
along the sides and back of the firebox so that the  
fire gradually burns it over a longer period of time.  
The intensity of the fire will also be reduced without  
letting it go out. Follow the same procedure as for  
refueling. If possible, avoid shaking, as a heavier  
layer of ash will help reduce the intensity of the fire  
during this time. After loading, let the fire establish  
itself for about 30 minutes. Then close your damper  
and automatic control to the point where the house  
does not become too cold. It is important that you  
begin banking early enough before retiring or leav-  
ing that you can make necessary adjustments after  
the fire is well established.  
To revive a coal fire that is almost out, (1) open the  
ash door and stove pipe damper and close the spin  
damper under the door to get a good draft through  
the grate. (2) place a thin layer of dry coal over the  
entire top of the fire. DO NOT POKE OR SHAKE THE  
FIRE AT THIS TIME! (3) after the fresh coal has become  
well ignited shake the grate (just a little), refuel.  
Only when the coal is burned down to half its origi-  
nal depth it is time to add fresh coal. When doing so,  
open the stove pipe damper and turn the thermo-  
stat damper to high, which will allow the fire to burn  
off any accumulated gases. Open the feed door,  
and with a small rake, hoe, or hooked poker pull the  
glowing coals to the front of the firebox. Try not to  
disturb the fire too much. Next, add a fresh charge  
to the back being careful not to seal off the top.  
Close the feed door, but leave the spin damper (or  
thermostat) open for a few minutes until the volatile  
gases have burned off. It is not necessary to shake  
down the ashes each time you refuel the furnace.  
Experience will be your best teacher.  
DO NOT burn coke, charcoal, high volatile bitumi-  
nous coal, sub bituminous, lignite or cannel coal  
(sometimes called channel coal or candle coal).  
NEVER burn wax or chemically impregnated saw-  
dust logs - their intended use is for fireplaces only.  
NEVER fill the stove or furnace above the firebrick or  
cast iron liner.  
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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 inside the cabinet door.  
PART NUMBER  
PART DESCRIPTION  
MODEL NUMBER______________  
SERIAL NUMBER______________  
United States Stove Company  
227 Industrial Park Road  
P.O. Box 151  
South Pittsburg, TN 37380  
(423) 837-2100  
Customer Service: (800)-750-2723 • Repair Parts: (888) 299-1440  
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