Clayton 1602R, Installation & Operator'S Manual

Page 1: ...e 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 Installation Operator s Manual SAVE THESE INSTRUCTIONS Certified for installations in the USA and Canada Safety Tested to UL 39...

Page 2: ...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 It is better to keep a small intense fire as oppose to a large smol dering fire Be aware that the hotter the fire the less creosote is deposited Weekly cleanings may be necessary in mild weather even though monthly cleaning may be enough dur ing...

Page 3: ... is to be installed maintaining the clearances speci fied in the following illustrations Do not place the furnace directly on a combustible floor If you are placing it on a combustible floor an approved fire retar dant material equivalent to 3 8 UL Listed millboard should be placed under the unit The material must extend at least 16 inches beyond the front of the unit and 8 inches on either side o...

Page 4: ...ney 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 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 f...

Page 5: ...E This furnace is designed for use as a supplemental heating source When used as a supplementary furnace it is connected in conjunction with an oil gas or electric furnace to the existing duct work which distributes the heated air into several rooms and or areas Though United States Stove Company expressly Does Not rec ommend the use of its furnaces to be installed and or used as a free standing h...

Page 6: ...xisting 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 INSPECT FLUE PIPES FLUE PIPE JOINTS AND FLUE PIPE SEALS REGULARLY TO ENSURE THAT SMOKE AND FLUE GASES ARE NOT DRAWN INTO AND CIR ...

Page 7: ...ficiency of the furnace is de creased Without a return air system warm air will be drawn into your basement unnecessarily heating unused areas of the home In extreme cases if your basement or utility room is fairly airtight the blowers on the furnace could depressurize the room and pull toxic flue gases from the furnace a gas water heater or gas furnace The fumes could then be distributed througho...

Page 8: ... attach the door latches to the door latch mounting brackets on the left side of the door frames as illustrated The slots in the brackets and latches are for door seal adjustment Make the proper adjustments then tighten the nuts The door s gasket should be snug against the door frame on the furnace Feed Door Illustration Ash Door Illustration 1 Feed Door Latch 1 Ash Door Latch 4 1 4 20 x 3 4 Hex B...

Page 9: ...e junction box and insulation using two of the 10 x 1 2 screws provided Make a small slice in the 5 x 5 insulation to allow the wires from the draft blower to protrude then Install it between the cabinet back and junction box with the foil side to the cabinet back Attach the conduit assembly from the limit control to the junction box as shown 5 If not already installed snap the rocker switch into ...

Page 10: ...me three screws 1 Draft Blower 2 1 4 20 x 1 Hex Bolt 1 Draft Blower Adapter 2 1 4 20 Lock Nut 1 Draft Regulator Canada Only 3 10 24 Kep Nut For Canadian installations you must install the cover plate once you have completed the draft blower installation Using the two self drilling screws provided attach the cover plate to the draft cover located just below the Feed Door BAFFLE BRICK REPLACEMENT If...

Page 11: ...good indicator if wood is ready to burn is to check the piece ends If there are cracks radiating in all directions from the center then the wood should be dry enough to burn If your wood sizzles in the fire even though the surface is dry it may not be fully cured and should be seasoned longer There are ONLY two types of coal allowed for use in this furnace Bitu minous Coal soft coal and Anthracite...

Page 12: ...reful not to mix the coal as this increas es the chances of forming 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 disturbing 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 expo...

Page 13: ...lose the load door and push the slide Baffle rod to rear Close the spin draft cap on ash door leaving it cracked about the diameter of a dime The forced air draft cycles on demand from the wall thermostat Setting the U S Stove thermostat four degrees higher than your existing thermostat is recommended In operation the power draft blower will run until the U S Stove thermostat temperature setting i...

Page 14: ...escape the firebox so as not to damage any electrical components If the bypass damper is one that is designed to fall closed when the blowers are not running and there is no way to open the pas sage you will need to shut off all combustion air to the appli ance Observe the furnace operation closely and often until power is restored CAUTION To avoid excessive temperatures do not operate with fuel d...

Page 15: ... all cinders have thoroughly cooled SMOKE AND CO MONITORS Burning wood naturally produces smoke and carbon monoxide CO emissions CO is a poisonous gas when exposed to elevated concentrations for extended periods of time While the modern combustion systems in heaters drastically reduce the amount of CO emitted out the chimney exposure to the gases in closed or confined areas can be dangerous Make s...

Page 16: ...himney 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 Distribution blower vibrating Solution A Tighten blower wheel to motor shaft B Check for bad fan bearings 5 Problem Distribution blower continu...

Page 17: ...17 11 12 13 16 15 17 14 7 10 5 2 3 6 32 31 4 3 2 1 37 3 8 9 24 26 25 27 17 16 3 19 18 20 28 29 30 36 21 22 34 34 35 23 33 PARTS DIAGRAM ...

Page 18: ...Flue Collar Ring 22761 1 24 Smoke Curtain 23800 1 25 Smoke Door Clip 23787 2 26 Carriage Bolt 1 4 20 x 1 1 4 Long 83445 2 27 Kep Nut 1 4 20 83250 2 28 Cabinet Side Left 68821 1 29 Insulation Side C98771 2 30 Insulation Retainer 83884 41 31 Cabinet Side Right 68822 1 N S Cabinet Side Back 1800 69002 2 32 Receptacle Snap In 80351 1 33 Cabinet Back 69573 1 34 Insulation Panel C98871 2 35 Cabinet Top ...

Page 19: ...ld air return or filter box will increase the life of your blow ers and offer filtered distribution air for your home U S Stove offers the model UFB908 as an option and can be purchased from your local dealer The UFB908 utilizes a standard 16 x 20 filter that can be purchased from your local dealer or any hardware duct work supply store When installing a UFB908 follow the installation instructions...

Page 20: ...plumbed to your existing hot water system Choose one of the three methods described in the Hot Water Coil instructions 6 Remove knockouts from the access panel and re attach to the furnace enclosure Have a qualified plumber connect your domestic hot water pipe to the coil with the appropriate fittings In the unlikely event that your furnace overfires a condition evidenced by elbows stove pipes and...

Page 21: ...nual in a safe place for future reference When placing an order or for warranty claims please provide the following information found on the Certification Plate located below the ash door PART NUMBER PART DESCRIPTION MODEL NUMBER 1602R SERIAL NUMBER______________ United States Stove Company 227 Industrial Park Road P O Box 151 South Pittsburg TN 37380 80 750 2723 ...