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When constructing a single wall smoke pipe, the following

When constructing a single wall smoke pipe, the following

When constructing a single wall smoke pipe, the following

When constructing a single wall smoke pipe, the following

When constructing a single wall smoke pipe, the following
guidelines must be observed.

guidelines must be observed.

guidelines must be observed.

guidelines must be observed.

guidelines must be observed.

1. The smoke pipe should be 24 gauge or heavier stain less

steel or black pipe.

2. Secure all joints with three #8 screws.

3. If the smoke pipe must pass through a wall, an approved

insulated or ventilated thimble, at least three times the
diameter of the smoke pipe must be used. (i.e. a 6"
(15.24cm) diameter smoke pipe needs an 18" (45.72cm)
thimble).

4. The smoke pipe should not be used as a chimney.

IMPORTANT INFORMATION FOR

IMPORTANT INFORMATION FOR

IMPORTANT INFORMATION FOR

IMPORTANT INFORMATION FOR

IMPORTANT INFORMATION FOR

ALL SMOKE PIPES

ALL SMOKE PIPES

ALL SMOKE PIPES

ALL SMOKE PIPES

ALL SMOKE PIPES

The smoke pipe must be constructed and installed so that it
maintains clearances, keeps condensation and creosote
within the pipe, and is capable of withstanding a 2000°F to
3000°F (1093°C to 1649°C) chimney fire.

1. The smoke pipe should slant down toward the furnace a

minimum of 1/4" to the foot. At no time should the pipe
turn downward toward the chimney or run horizontal.

2. There should be no more than two 90 degree elbows.

3. The smoke pipe should never be longer than 6 feet.(1.83m)

If it is absolutely necessary to make a run of more than
six feet (not recommended) use extra support brackets
every 3 feet (.91m).

4. The smoke pipe should never be reduced to a smaller

size than flue opening on the furnace.

5. The smoke pipe should not block the flue of the

chimney or extend into it in any way.

6. A good airtight thimble should be used to hold the

smoke pipe in the chimney. It should be constructed so
the smoke pipe can be removed for cleaning.

7. The smoke pipe should not leave the heated portion of

the building to reach the chimney.

8. The smoke pipe should not pass from one story to the

next before entering the chimney, nor should it pass
through any closed or enclosed space.

9. Heat reclaimers should not be installed or used in the

smoke pipe.

     10. The smoke pipe should not be located near or in a walk

way or well traveled area.

    11. All male ends of smoke pipe should run or point towards

the furnace.

When you have installed the smoke pipe connecting your furnace
to the chimney, tap the pipe hard with your fingernail. Remember
the sound it makes - it will be a "ting" echoing inside the stove pipe.
If later you tap and hear a muffled thud, you are building up soot
in the pipe and should clean it. This pipe should be cleaned at
least once or twice during the heating season.

DO NOT CONNECT TWO HEATERS TO THE SAME CHIMNEY
FLUE. The National Fire Prevention Association recommends
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.

If codes allow, use extreme care in making such 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

standards allow same flue connection. Such installations can
cause severe problems. Gas hoods and barometric dampers
allow excess air into the chimney causing cooling of the flue
gases and a greater creosote build-up potential. If the same flue
connections are used, chimneys must be inspected more fre-
quently and the chimney should be cleaned any time the
creosote deposits exceed 1/4" thickness. A creosote fire in such
a chimney can burn out of control because of the air leak through
the barometric damper or gas hood. Keeping the chimney clean
and burning well-seasoned wood is absolutely necessary. This
type of installation does require more frequent inspection and
maintenance.

The  downstream series techniqueis the onlyapproved method
for using the 1600 and 1800 furnaces in combination with an
existing gas, oil or electric forced air furnace.  While it requires
reworking the main duct system, it typically results in a simpler,
less restrictive installation.

Certification testing establishes the minimum cross-sectional
area for the transfer duct permitted for a specific add-on.  A large
transfer duct will allow freer flow of air through the additional
elbows involved in the add-on installation.

Additional space will be required in the furnace room for an add-
on.  There must be a room beside the existing furnace for the add-
on and the transfer duct which runs from the hot air plenum of the
existing furnace down to the cold air inlet of the add-on.

While oil, gas and electric furnaces may be connected to
combustible return air ducts in the form of joist panning, wood
furnaces normally require noncombustible return air duct work.
Combustible return ducts connected to an existing oil, gas or
electric furnace need not to be replaced with noncombustible
ducts when an add-on is installed; the add-on connections make
reverse flow during a power failure very unlikely.

Major changes to the main distributionduct system are normally
required in order to route the existing duct over the new hot
plenum of the add-on. Any indivdual ducts connected directly to
registers from the existing plenum also have to be routed over to
the add-on plenum because all of the air must pass through the
add-on before reaching any distribution ductwork.

There are two options for managing the duct alternations.  In
some cases, it is more practical to move the existing furnace and
place the add-on in the location it previously occupied.  By
locating the add-on where the original furnace was, fewer supply
duct alterations will be needed.  On the other hand, alterations to
the return ducts will be needed to re-route them to the new
location of the cold air plenum.

The other option is to leave the existing furnace in its original
location and re-route the supply ducts to the new add-on plenum.

In your design of add-on installations, always choose the approach
that involves using the least elbows.  By keeping the number of
elbows to a minimum, duct restrictions and blower noise will be
reduced.

5

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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