Clayton 1600EF Installation & Operator'S Manual Download

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851846F-0704G

Installation/Operator’s Manual

External Furnace Model: 1600EF

COAL ONLY

United States Stove Company • 227 Industrial Park Road • South Pittsburg, TN 37380 • www.usstove.com

SAFETY NOTICE:

If this furnace is not properly installed, a house fire 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.

Safety Tested to UL 391

Tested & Listed

By:

Report #

215-S-13b-2

Portland

Oregon USA

U.S. Environmental Protection Agency

Certified to comply with 2015

particulate emissions standards.

Summary of Contents for 1600EF

Page 1: ... 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 Safety Tested to UL 391 Tested Listed By Report 215 S 13b 2 Portland Oregon USA U S Environmental Protection Agency Certified to...

Page 2: ... 31 5 8 12 COLD AIR RETURN 14 1 4 43 7 16 29 3 16 10 HOT AIR OUTLET HOT WATER COIL ACCESS OPTIONAL BLOWER SPEED SELECTOR SWITCH B D RINGS FOR GUY WIRE ATTACHMENT 17 5 16 55 5 8 5 3 16 45 3 4 65 1 2 2 9 16 29 1 2 24 1 4 6 FLUE GAS OUTLET LO MED HI ...

Page 3: ...ing heat loss type of construction amount of insulation type of air movement the location of the unit and more importantly the duct work and return air facility Warning Do not alter this appliance in any way other than specified in these instructions Doing so may void your warranty GENERAL INFORMATION Your 1600EF furnace comes ready for installation No assembly required Unpack your furnace and ins...

Page 4: ...uble Wall Black Pipe w Stainless Steel Inner wall 24 Gauge or Heavier 20 Single Wall Stainless Steel or Black Pipe The above clearances to combustibles must be maintained CHIMNEY REQUIREMENTS A Class A HT 2100 All Fuel 6 Chimney Pipe and Base Plate should be used for the installation See Illustration Place the Base Plate over the flue outlet of the furnace and drill eight 8 pilot holes into the Ca...

Page 5: ...pe wrapped with weather proof UV resistant insulation The 12 inch return may be galvanized pipe and attached to the home so as to not pressurize the home NEVER reduce the 10 hot air or the 12 return air as this will result in restricted air flow and cause the furnace to not operate properly NEVER draw cold outside air into the blower housing By doing so the furnace s heat chamber will not reach th...

Page 6: ...t you may run the hot air duct to the basement and pull the cold air return from the main floor This will create the perfect air flow since hot air rises CENTRAL DUCT CONNECTION When connecting to a central duct system avoid 90 degree elbows as this will reduce air flow delivery A duct run in excess of 40 feet is NOT RECOMMENDED The air flow and heat output will be greatly decreased Run 10 insulat...

Page 7: ...sting furnace plenum as practical INSTALLATION 2 The baffle on this system should be made the full width of the furnace plenum in order to properly direct the air into the distribution ducts INSTALLATION 3 Extending the hot air duct from the furnace into the existing plenum will help direct the flow of air from the furnace as well as the flow in the existing furnace Ducting entering the existing p...

Page 8: ...hten 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 Bolt 4 1 4 20 Kep Nut BRACKET SHAKER GRATE HANDLE Insert the Shaker Rod into the hole on the ash door frame as shown Then attach the Shaker Bracket to the front of the furnace using two 1 4 20 x 3 4 Hex Bolts and two...

Page 9: ...th weather resistant silicone 3 To remove the Distribution Blower E Unplug from power supply Remove items B and D as described above Unplug the blower from the top of the Fan Center G Remove the four 4 screws retaining the blower 4 To remove the Blower Motor Unplug from power supply Perform number 3 above Before removing the motor from the housing measure two things 1 The distance from the edge of...

Page 10: ...assembly from the furnace by loosening the two bolts retaining draw band 3 To remove the motor from the tubing assembly simply loosen the set screw in the collar on the motor and slide it off the tube 4 If replacing the Flipper remove the two 8 screws retaining the plate to the tube 5 Reverse the above steps for re assembly BAFFLE BRICK REPLACEMENT If baffle replacement is necessary slide the baff...

Page 11: ...ls 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 Clayton Furnace reacts together Adjusts ...

Page 12: ...king place at the given settings Visible smoke consist of unburned fuel and moisture leaving your stove Learn to adjust the air settings of your specific unit to produce the smallest amount of visible smoke EFFICIENCY Efficiencies can be based on either the lower heating value LHV or the higher heating value HHV of the fuel The lower heating value is when water leaves the combustion process as a v...

Page 13: ...t 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 OVER FIRING Attempts to achieve heat output rates that exceed heater design specifications can result in permanent damage to the heater Whenever ashes get 3 to 4 inches deep in your firebox or ash pan and when the fire has ...

Page 14: ...ake sure chimney flue pipe is clean and chimney is of adequate height Make sure you re not suffocating the fire with excessive amounts of unburned coal Slide baffle should be pulled out prior to load door opening 4 Distribution blower vibrating Tighten blower wheel to motor shaft Check for bad fan bearings 5 Distribution blower continues to run or will not run Check fan limit or heat sensor and ca...

Page 15: ... 15 Wiring Diagram SERVO MOTOR ...

Page 16: ... 16 Parts Diagram ...

Page 17: ... Painted 25726B 1 42 Insulation Top Front 88150 1 43 Insulation Top Middle 88151 1 44 Insulation Top Rear 88152 1 45 Mount Flue Outlet 25727 891916 1 46 Weldment Cabinet Top 69648 891910 1 47 D Ring Clip 83912 4 48 Bottom Intake Painted 25722B 1 49 Assembly Cabinet Door 69649 1 50 Latch Cabinet Door 891865 1 51 1800 CFM Blower Assembly 80590 1 N S 1 4 20 x 3 4 Self Tapping Screw 83236 4 N S Washer...

Page 18: ... void the warranty Key Description Part Qty 1 Weldment Draft Tube 68872 1 2 Spin Draft 40379 1 3 3 8 16 x 2 1 2 Carriage Bolt 83503 1 4 Lock Nut 3 8 16 83274 1 5 Actuator Motorized Draft 80592 1 6 Tube Flipper 23899 1 7 Flipper 23898 1 8 8 x 1 2 Tek Screw Hex Head 83455 2 9 Strain Relief 80154 1 10 Power Supply Cord 80593 17 in 11 Male Tyco Terminal 80382 2 Parts Diagrams And Lists Motorized Draft...

Page 19: ... Harness 6 Circuit Receptacle 80583 1 5 Harness 3 Circuit Receptacle 80584 1 6 Harness 2 Circuit Receptacle 80585 1 7 Transformer Fan Center 80130 1 8 Strain Relief 80154 1 9 Power Supply Cord 80232 1 10 10 x 1 2 Sheet Metal Screw 83172Z 13 11 Washer Internal tooth 10 83240 1 Parts Diagrams And Lists Fan Center Control ...

Page 20: ...emove the cover plate from the rear of the furnace firebox 4 Place one nut on each end of the water coil and thread each nut up to the end of the threads on the coil 5 Insert the coil through the holes from the inside of the firebox Install a gasket washer and nut onto each end of the water coil Tighten the nuts down securely to insure an air tight seal The installation is now ready to be plumbed ...

Page 21: ...ghest portion of your fire bed in the center of the firebox The first flames will be long and generally orange or yellow and produce quite a bit of smoke As the gases burn off the flames become shorter change color and produce less smoke Once the fire is WELL ESTABLISHED add coal to the center of the firebox forming the cone Burning in this fashion allows heat to drive off the volatile gases and t...

Page 22: ...stat open for a few minutes until the volatile gases have burned off It is not necessary to shake down the ashes each time you refuel the furnace Experience will be your best teacher BANKING THE FIRE For extended operation such as overnight the fire will need to be banked To do so heap coal up along the sides and back of the firebox so that the fire gradually burns it over a longer period of time ...

Page 23: ...e 07 Date _____________________ Engineer Name ________________________________ License No ____________________________________ Company _____________________________________ Telephone No _________________________________ Stove Inspected Chimney Swept Items Replaced ________________________________ Service 02 Date _____________________ Engineer Name ________________________________ License No ______...

Page 24: ... as a result of their breach of this written warranty or any implied warranty 2 Should the heater be replaced by United States Stove Company free of charge all further warranty obligations are thereby met 3 Parts and or service replacements made under the terms of this warranty are warranted only for the remaining period of the original heater warranty 4 Without speciﬁc written exclusionary waiver...

Page 25: ...e place for future reference When placing an order or for warranty claims please provide the following information found on the Certification Plate located inside the cabinet door Part Number____________________________________________________________ Part Description_________________________________________________________ Model Number__________________________________________________________ Ser...

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