USSC Clayton 1600GC Installation & Operator'S Manual Download

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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

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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