USSC Clayton 1600, Installation & Operator'S Manual

Page 1: ...TY 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 UNITED STATES STOVE COMPANY KeepingAmericaWarmSince1869 ...

Page 2: ...ectrical installation 9 Draft Wiring Diagram 10 Testing and Operating Procedures 11 12 Trouble Shooting and Problem Solving 13 Parts Lists Model 1600 1800 14 16 Motorized Natural Draft 17 Forced Air Draft 18 Optional Electronic Control System Installation 19 Parts List Model 1600 19 Wiring Diagrams 20 23 Installation of Optional Equipment Domestic Hot Water Coil 24 Back Draft Damper 25 Filter Boxe...

Page 3: ...nd the location of the unit LOCATING YOUR FURNACE 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 in front of and 8 on eith...

Page 4: ...xpelled 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...

Page 5: ...should be cleaned at least once or twice during the heating season DO NOT CONNECT TWO HEATERS TO THE SAME CHIM NEY FLUE The National Fire Prevention Association recom mends 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 I...

Page 6: ...duct system or by tying into the cold air return of an existing gas or oil furnace The cold air return duct can be connected to the furnace with either a factory manufac tured U S Stove filter box or an equivalent fabricated from sheet metal See pages 21 23 When installing a cold air return the following minimum size should be maintained to insure proper furnace performance Model 1600 16 x 20 or e...

Page 7: ...teps to correct the problem 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 Four 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 Two Smoke Door Clips Rod Extension Manual Three 1 2 Lock Nuts One 1 2 x 2 1 2 Carriage Bolt Six 1 4 x 3 4...

Page 8: ... 1 4 x 3 4 hex bolts attach the door latch to the REAR OF FIREBOX TOP BAFFLE ROD EXTENSION HEX COUPLING BAFFLE ROD 6 1 1 2 2 1 3 5 4 6 1 2 BRICK MODEL 1600 41 2 BRICKS MODEL 1800 6 FULL BRICKS 7 1 3 4 5 6 2 THE MODELS 1600 AND 1800 HAVE BEEN EQUIPPED WITH DIFFERENT PLENUM OPENINGS THEY ARE AS FOLLOWS door latch mounting bracket on the left side of door frame as illustrated Adjust latch until door ...

Page 9: ...e cut brick in each back corner Place remaining brick in place 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 1 2 3 SPIN DRAFT CAP 1 2 X 2 1 2 CARRIAGE BOLT SMOKE DOOR SMOKE DOOR CLIPS 1 4 X 1 1 4 CARRIAGE BOLTS FRONT OF FURNACE FUEL LOADING DOOR FRAME 1 4 LOCK NUTS 7 1 2 LOCK NUT...

Page 10: ...s attach draft to furnace with draft tube clamp 2 Plug draft power cord into receptacle on front of furnace MOUNTING PROCEDURE FOR DRAFTS MODEL 1600 1800 KIT C60357M OPTIONAL MODEL 1600 1800 KIT 69189 FORCED AIR DRAFT SHIPPED WITH UNIT 1 Using 2 1 4 x 1 bolt lock washer and nut attach draft adapter bracket to furnace draft tube ...

Page 11: ... model 1800 This conduit may be cut shorter to provide a cleaner installation on model 1600 9 FAN CENTER HIGH LIMIT CONTROL THERMOSTAT TO THERMOSTAT TO R TO G FAN CENTER W W W W L1 1 3 WIRES TO BLOWER MOTOR PLASTIC KNOB SET SCREW NUT PUNCH GR FLEXIBLE CONDUIT TO HIGH LIMIT CONTROL BLK BLUE RED BLK BLK BLUE BLACK TO DRAFT RED BLK ELECTRICAL BOX 2 BLACK BLUE Wired to G on fan center front Wired to G...

Page 12: ...D SWITCH Two Models are available Model A and Model B Check your switch to see which model you have and wire accordingly RED RED RED RED RED WHITE WHITE WHITE WHITE BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLUE BLUE BLUE GREEN 1400 CFM 1250 CFM 1100 CFM TO R TO G BLOWER MOTOR SETTING LIMIT CONTROL WALL THERMOSTAT DRAFT MOTOR FAN CENTER ELECTRICAL BOX POWER SUPPLY WIRING DIAGRAM BACK VIEW FRONT VI...

Page 13: ...ause 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 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 hea...

Page 14: ...f the motor has sealed bearings no oiling is required If the motor is equipped with fill holes the motor should be oiled every 90 days with several 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 ...

Page 15: ...ming out door when refueling Solution A Wait 15 seconds and open door SLOWLY thenrefuel 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 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 ...

Page 16: ...tacle BOTH 80351 14 ITEM DESCRIPTION MODEL PART 11 Full Brick BOTH 89066 12 Full Brick 1600 23887 13 Slide Baffle Plate BOTH 24231 14 Grate Retainer 1600 40312 2 1800 40337 2 15 Baffle Rod S S 1600 C10871 1800 89704 16 Top Insulation 1600 C98871 1800 23979 2 17 Front Filler 1600 23817 1800 24190 18 Draft Cover 1600 23818 1800 24508 19 Top Flue Ring 1600 22761 1800 23958 20 Draft Cap BOTH 23859 21 ...

Page 17: ...52 88057 35 1 2 Rope for Ash Door 32 88057 36 Aqua Siphon Cover 23819 37 Shaker Grate Handle C000177 38 Hinge Bracket 24204 ITEM DESCRIPTION PART 39 1 4 x 3 4 Hex Bolt 83339 6 40 1 20 Kep Nuts 83250 8 41 1 4 x 1 Hex Bolt 83379 42 1 4 x 1 1 4 Carriage Bolt 83445 2 43 1 4 20 Kep Nut 83250 2 44 Smoke Door Curtain 23800 45 Smoke Door Clip 23787 2 46 1 2 x 1 1 2 Hex Connector C21899 47 Baffle Rod Exten...

Page 18: ...Limit Control 80145 2 3 Speed Switch 80361 3 Plastic Knob C9267M 4 Fan Center 80130 4 1 6 16 MODEL 1600 Blower Kit C60471 1400CFM MODEL 1800 Blower Kit C6137M 1800CFM ITEM DESCRIPTION PART 5 3 Speed Motor 1 3 hp C45799 6 Blower Housing 1600 C46799 Blower Housing 1800 C45899 3 5 2 ...

Page 19: ...and 23888 2 1 4 x 1 Bolt 83379 3 1 4 Lock Washer 83414 4 1 4 Hex Nut 83072 5 Erie Motor 120v C45099 6 Draft Cap 23859 7 Draft Tube Weldment 68872 8 Flipper Tube 23899 9 Flipper 23898 10 1 2 13 Hex Lock Nut 83444 11 8 x 1 2 Tek Screw 83455 12 1 2 x 2 1 2 Carriage Bolt C20599 Thermostat 80129 MODEL 1600 1800 MODEL 1600 1800 MND KIT C60357M 4 ...

Page 20: ...Draft Blower 80422 2 Power Supply Cord C40899 3 FAD Bracket 69192 4 10 24 Kep Nut 3ea 83244 5 1 4 20 x 1 Bolt 2ea 83379 6 1 4 20 Lock Nut 83261 FORCED AIR DRAFT PARTS LIST PRE ASSEMBLED AT FACTORY 18 MODEL 1600 1800 KIT 69189 ...

Page 21: ... behind back insulation and pull cable through hole on back of furnace 5 Attach control box to back of furnace and wire per instructions MOUNTING PINS L BRACKET PIN TABS 19 10 ITEM DESCRIPTION PART 1 Heat Sensor C47314 2 Heat Sensor Mounting Clip CL00084 3 3 8 Hex Nut C20699 4 Electronic Circuit Board 1988 C45599 5 Circuit Board Box CL00087 6 Box Cover CL00085 7 Utility Box Cover C40399 8 10 Amp F...

Page 22: ...e performed by a qualified electrician FUSE BOX TO THERMOSTAT PLUG IN CONNECTION FROM DRAFT RECEPTACLE PLUG IN CONNECTION FROM HEAT SENSOR SMALL BLACK PLUG ONCE ALL CONNECTIONS HAVE BEEN MADE REPLACE BOX COVER AND SECURE WITH 4 8 X 1 2 TEK SCREWS OPTIONAL 24V AC PLUG IN CONNECTOR FROM DISTRIBUTION BLOWER MATCH COLOR OF WIRES AND JOIN WITH WIRE NUTS TO 110 VAC POWER A C RED BLUE BLACK BLACK WHITE W...

Page 23: ... Refer to the following chart to select the blower speed options If you find the air from the heat registers is too cool turn Control 1 to a higher temperature setting The setting of Control 3 for two speed operation and Controls 2 and 3 for three speed operation may also be adjusted up or down to maintain a more constant temperature output 3 Speed Distribution Blower Operation when thermostat cal...

Page 24: ... BLACK RED BLOWER MOTOR AUX FAN R W Y G THERMOSTAT ELECTRONIC CONTROL BOARD PLENUM HEAT SENSOR W R WALL THERMOSTAT WOOD BLUE WHITE BLACK RED WALL THERMOSTAT WOOD CB CB CB ELECTRICAL SERVICE PANEL SEE TABLE 1 FOR CB SIZE SEE TABLE 1 FOR CONTACTOR SIZE OPTIONAL DOUBLE FEED METHOD 240V HEATER POWER INPUT ELECTRIC WALL THERMOSTAT MOUNT UNIT IN PLENUM DIRECTLY ABOVE WOOD WIRES MUST BE CONNECTED TO FURN...

Page 25: ...ETHOD WIRES MUST BE CONNECTED TO FURNACE FOR BLOWER CONTROL MOUNT UNIT IN PLENUM DIRECTLY ABOVE WOOD 240V HEATER POWER INPUT NOTE SEE PLENUM HEATER INSTRUCTIONS ELECTRIC WALL THERMOSTAT POWER SUPPLY BLUE WHITE BLACK RED BLOWER MOTOR AUX FAN R W Y G THERMOSTAT G IS FOR MANUAL FAN OPTION WALL THERMOSTAT WOOD DRAFT FAN OR MOTORIZED DRAFT PLENUM HEAT SENSOR ELECTRONIC CONTROL BOARD AC 24V 24V TRANSFOR...

Page 26: ...om pletely wrap a piece of hi temp fiberglass rope gasket provided with the kit around each threaded leg between the washer and the outside 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 R...

Page 27: ...f the back draft damper over Hotblast Furnace collar or male end of the duct pipe When properly placed the arrows on the air flow decal should point away from the furnace HORIZONTAL INSTALLATION NOTE POSITION SO THAT AIR FLOW WILL OPEN DAMPER IN DIRECTION OF DUCTWORK SEE PRODUCT LABEL NOTE POSITION SO THAT AIR FLOW WILL OPEN DAMPER FROM BOTTOM VERTICAL INSTALLATION MEDIUM BACKDRAFT DAMPER KIT C621...

Page 28: ...e illustration and secure with sheet metal screws provided 1 Assemble parts B and C to part E bottom 2 Attach to back of furnace 3 Assemble part D to parts B and C 4 Assemble part A top after you have attached filter box to furnace and blower is inside filter box on furnace NOTE The side with the 18 square hole can be used as the right or left side If you want filter on left side of furnace part B...

Page 29: ...X Model 1600 1800 see service bulletin 2 16 x 20 x 1 Filter Required 1 Attach sides of filter box to bottom with 4 sheet metal screws per side Be sure sides are inside bottom lips and positioned with predrilled holes as illustrated Side with no lip faces back of furnace 2 Position top so 2 wide lip is turned toward furnace Place top over sides and secure with 4 sheet metal screws per side 3 Center...

Page 30: ...N o t e s ...

Page 31: ...N o t e s ...

Page 32: ...ITING 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 PART NUMBER 2 The PART DESCRIPTION 3 The MODEL NUMBER 1600 1800 4 The SERIAL NUMBER ____________________ UNITED STATES STOVE COMPANY 227 Industrial Park Road P O Box 151 South Pittsburg TN 37380 423 837 210...