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TESTING AND OPERA

TESTING AND OPERA

TESTING AND OPERA

TESTING AND OPERA

TESTING AND OPERATING PR

TING PR

TING PR

TING PR

TING PROCEDURES

OCEDURES

OCEDURES

OCEDURES

OCEDURES

TESTING:

TESTING:

TESTING:

TESTING:

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

STARTING A WOOD FIRE

STARTING A WOOD FIRE

STARTING A WOOD FIRE

STARTING A WOOD FIRE

Using Motorized Natural Draft

Using Motorized Natural Draft

Using Motorized Natural Draft

Using Motorized Natural Draft

Using Motorized Natural Draft

CAUTION: Never use gasoline, gasoline-type lantern fuel, kero-
sene, 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.

CAUTION: To avoid excessive temperatures, do not
operate with fuel door or ash pan open.

CAUTION: To avoid excessive temperatures, do not
operate with fuel door or ash pan open.

STARTING A COAL FIRE

STARTING A COAL FIRE

STARTING A COAL FIRE

STARTING A COAL FIRE

STARTING A COAL FIRE

If you burn coal a Forced Air Draft is required.

If you burn coal a Forced Air Draft is required.

If you burn coal a Forced Air Draft is required.

If you burn coal a Forced Air Draft is required.

If you burn coal a Forced Air Draft is required.

!

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

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.

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.

7. This furnace is not to be used with an automatic stoker

unless so certified.

OPERATING NOTES

OPERATING NOTES

OPERATING NOTES

OPERATING NOTES

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.)

!

Do not allow ashes to build up higher than 2" above grates.

!

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

Summary of Contents for Clayton 1600GC

Page 1: ...ONS MAY RESULT FOR YOUR SAFETY FOLLOW THE INSTALLATION DIRECTIONS MAY RESULT FOR YOUR SAFETY FOLLOW THE INSTALLATION DIRECTIONS MAY RESULT FOR YOUR SAFETY FOLLOW THE INSTALLATION DIRECTIONS MAY RESULT FOR YOUR SAFETY FOLLOW THE INSTALLATION DIRECTIONS CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND CONTACT LOCAL BUILDI...

Page 2: ... 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 ...

Page 3: ...you re placing it on a combustible floor an approved fire retardant material equivalent to 3 8 asbestos millboard should be placed underthefurnace Thematerialmustextendatleast16 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 CLEARANCES CLEARANCES ...

Page 4: ...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 SMOKE PIPE INSTALLATION SMOKE PIPE INSTALLATION SMOKE PIPE INSTALLATION SMOKE PIPE INSTALLATION Clearances to combustible materials i e paneling ceiling tile sheet rock plaster drape...

Page 5: ... 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 ADD ON SERIES ADD ON SERIES ADD ON SERIES ADD ON SERIES ADD ON SERIES INST INST INST INST INSTALLA ALLA ALLA ALLA ALLATION TION TION TION TION...

Page 6: ...ction 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 There are two methods of evaluating existing air flow the static pressure drop method and the temperature rise method HOTBLAST FURNACE MODIFICATIONS HOTBLAST FURNACE MODIFICATIONS HOTBLAST FURNACE MODIFICATIONS H...

Page 7: ...problem Parts List Parts List Parts List Parts List Parts List All models include the following Two Door Handles FAN LIMIT KIT FAN LIMIT KIT FAN LIMIT KIT FAN LIMIT KIT FAN LIMIT KIT One Fuel Door Latch Fan Limit Control One Ash Door Latch Fan Center One Shaker Grate Handle F A D Box Two 1 2 Washers 3 Speed Switch Six 1 4 Hex Nuts Knob Four Lock Washers Spin Draft Five 1 4 Lock Nuts One Pivot Brac...

Page 8: ... 8 BRICKS ON EACH SIDE BRICK RETAINING STRIP FIREBOX LEFT SIDE BRICK RETAINING STRIP SLIDE 4th BRICK BACK BEFORE INSTALLING 5th AND 6th BRICK 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 SMOKE CHAMBER 1 Place 1 firebrick in the back of smoke chamber 2 Slide baffle plate into smoke chamber fla...

Page 9: ...S THEY ARE AS FOLLOWS OPENINGS THEY ARE AS FOLLOWS OPENINGS THEY ARE AS FOLLOWS OPENINGS THEY ARE AS FOLLOWS MODEL 1800 MODEL 1800 MODEL 1800 MODEL 1800 MODEL 1800 18 x18 Sqaure Plenum Opening MODEL 1600 MODEL 1600 MODEL 1600 MODEL 1600 MODEL 1600 13 x18 Rectangle Plenum Opening SHAKER GRATE HANDLE INSTALLATION SHAKER GRATE HANDLE INSTALLATION SHAKER GRATE HANDLE INSTALLATION SHAKER GRATE HANDLE I...

Page 10: ...y 1 2 of the bolt to extend beyond the inside of the door 3 Secure bolt in place with 1 2 locking nut MOUNTING PROCEDURE FOR MOUNTING PROCEDURE FOR MOUNTING PROCEDURE FOR MOUNTING PROCEDURE FOR MOUNTING PROCEDURE FOR MOTORIZED NATURAL DRAFT MOTORIZED NATURAL DRAFT MOTORIZED NATURAL DRAFT MOTORIZED NATURAL DRAFT MOTORIZED NATURAL DRAFT DRAFT TUBE CLAMP MOTORIZED NATURAL DRAFT 1 Using 2 1 4 x 1 bolt...

Page 11: ...PER ELECTRIC FURNACE THERMOSTAT ELECTRIC FURNACE TO W1 TO R BLACK TO R RED TO G RED BLACK WIRE FROM DRAFT PLUG WHITE WIRE FROM DRAFT PLUG HOTBLAST COTROL CENTER PLUG IN ON THE FRONT OF HOTBLAST FOR DRAFT ALL ELECTRICAL WIRING SHOULD BE DONE BY A QUALIFIED ELECTRICIAN 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 lim...

Page 12: ...CENTER R WIREINTOGAS VALVECIRCUIT Ra TO GAS FURNACE FAN 110V POWER SUPPLY FROM GAS FURNACE RED BLACK BLUE BLACK RED BLACK BLACK BLACK WHITE GREEN TO R TO G OPTIONAL 120V RELAY MOUNTED IN GAS FURNACE ALL WIRING SHOULD BE DONE BY A QUALIFIED ELECTRICIAN ALL WIRING SHOULD BE DONE BY A QUALIFIED ELECTRICIAN ALL WIRING SHOULD BE DONE BY A QUALIFIED ELECTRICIAN ALL WIRING SHOULD BE DONE BY A QUALIFIED E...

Page 13: ...0 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 minutes until coal fire is established before adding more coal NOTE NEVER lo...

Page 14: ...d 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 ...

Page 15: ...lution Solution Solution Solution 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 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 exce...

Page 16: ... PART PART PART PART 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 Extension C000089 48 1 2 Hex Nut 83276 2 49 1 2 Coupling C21899 50 Brass Coil Knob 89574 4 Feed Door Assembled 68829 Ash Door...

Page 17: ... 1800 21 21 21 21 21 23 23 23 23 23 14 14 14 14 14 5 5 5 5 5 2 2 2 2 2 20 20 20 20 20 7 7 7 7 7 10 10 10 10 10 24 24 24 24 24 17 17 17 17 17 1 1 1 1 1 16 16 16 16 16 3 3 3 3 3 15 15 15 15 15 19 19 19 19 19 6 6 6 6 6 13 13 13 13 13 4 4 4 4 4 22 22 22 22 22 11 11 11 11 11 12 12 12 12 12 18 18 18 18 18 8 8 8 8 8 9 9 9 9 9 NOTE 1600 16 FULL BRICK 1 HALF BRICK 1800 22 FULL BRICK ITEM ITEM ITEM ITEM ITE...

Page 18: ... 1 11 11 11 11 11 5 5 5 5 5 7 7 7 7 7 6 6 6 6 6 12 12 12 12 12 8 8 8 8 8 10 10 10 10 10 9 9 9 9 9 3 3 3 3 3 4 4 4 4 4 3 3 3 3 3 4 4 4 4 4 11 11 11 11 11 ITEM ITEM ITEM ITEM ITEM DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION PART PART PART PART PART 1 Draw Band 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 Tub...

Page 19: ...ough 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 air tight installation The installation is now ready to ...

Page 20: ... REPAIR PARTS ALWAYS GIVE THE WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE FOLLOWING INFORMATION AS SHOWN IN THIS LIST FOLLOWING INFORMATION AS SHOWN IN THIS LIST FOLLOWING INFORMATION AS SHOWN IN THIS LIST FOLLOWING INFORMATION AS SHOWN IN THIS LIST FOLLOWING INFORMATION ...

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