Clayton 1602G Owner'S Manual Download

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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.

851768C-1003G

Model: 1602G / 1802G OWNER’S

MANUAL

COAL ONLY

Gravity Style (Up-Flow) Supplemental Furnace

United States Stove Company • 227 Industrial Park Road, P.O. Box 151 • South Pittsburg, TN 37380 • www.usstove.com

Safety Tested to UL 391

U.S. Environmental Protection Agency

Certified to comply with 2015 particulate emissions standards.

Summary of Contents for 1602G

Page 1: ...area This furnace must be installed by a qualified technician Keep these instructions for future reference 851768C 1003G Model 1602G 1802G OWNER S MANUAL COAL ONLY Gravity Style Up Flow Supplemental Furnace United States Stove Company 227 Industrial Park Road P O Box 151 South Pittsburg TN 37380 www usstove com Safety Tested to UL 391 U S Environmental Protection Agency Certified to comply with 20...

Page 2: ...ctions Doing so may void your warranty LOCATING YOUR FURNACE The furnace is to be installed maintaining the clearances speci fied in the following illustrations Do not place the furnace di rectly on a combustible floor If you are placing it on a combus tible floor an approved fire retardant material equivalent to 3 8 UL Listed millboard should be placed under the unit The mate rial must extend at ...

Page 3: ... and other factors Too much draft may cause excessive tempera tures in the appliance Inadequate draft may cause backpuffing into the room and plugging of the chimney Inadequate draft will cause the appliance to leak smoke into the room through appliance and chimney connector joints An uncontrollable burn or excessive temperature indicates ex cessive draft Take into account the chimney s location t...

Page 4: ... 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 coal burning appliances vent into a separate flue 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 coal burner is required Use of a...

Page 5: ...e on this system should be made the full width of the furnace plenum in order to properly direct the air into the dis tribution ducts INSTALLATION 2 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 plenum at an angle approximately 45 degrees will facilitat...

Page 6: ... fire places and coal burning furnaces need enough oxygen for com plete combustion of their fuels The incomplete combustion that takes place when a furnace is air starved causes carbon mon oxide CO to be formed in quantities that can be dangerous in side a well sealed house Having a source of combustion air from outside the home will prevent air starvation of the furnace A simple positive air supp...

Page 7: ...ds 4 Spring Handles DISTRIBUTION BLOWER ACC 1 Remove all contents and insure that all components are present for assembly See the part list below 2 Begin by attaching the blowers to the unit Insert a clip into each mounting hole in the furnace s cabinet back Be sure to install the gasket between the blower and cabinet back Insert the eight bolts provided and tighten 3 Mount the Honeywell limit con...

Page 8: ...e a cleaner installation 2 800 CFM Blower 2 Gasket Blower 8 Tinnerman Clip 1 4 20 8 1 4 20 x 3 4 Bolt 2 Conduit Assembly 5ft 1 Honeywell Limit Control 1 Conduit Assembly 1ft 1 Junction Box 1 Insulation 5 x 5 1 Rocker Switch 1 Romex Cable Clamp 1 Fan Center Control 3 73B Wire Nut 1 74B Wire Nut 1 Female Term blue 1 Female Term red 8 10 x 1 2 Screw ...

Page 9: ...nt of the furnace Then mount and secure the draft blower to the adapter with the three 10 24 Kep nuts Plug the blower into the outlet on the front of the furnace 1 Draft Blower 1 Draft Blower Adapter 2 1 4 20 x 1 Hex Bolt 2 1 4 20 Lock Nut 3 10 24 Kep Nut FIREBRICK AND BAFFLE REPLACEMENT BAFFLE BRICK REPLACEMENT If baffle replacement is necessary slide the baffle out until you can access the nuts ...

Page 10: ...al NEVER USE Cannel or Channel coal or Brown Lignite Coal See our Bulletin RC454 on the following pages for the best infor mation available on burning coal 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 STARTING A COAL FIRE If y...

Page 11: ...he 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 all draft controls and call your fire department immediately Alert everyone in the house If the ...

Page 12: ...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 away from all combustible materials pending final disposal The ashes should be retained in the closed container until all cinders have thoroughly cooled SMOKE AND CO MONITORS Burning coal naturally produces smoke and carbon monoxide CO emissions CO is a...

Page 13: ...your chimney Make sure chimney cap is not too close to the top of the chimney Check chimney draft make 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 be...

Page 14: ...14 PARTS DIAGRAM 11 12 13 16 15 17 14 7 10 5 2 3 6 32 31 4 3 2 1 37 3 8 9 24 26 25 27 17 16 3 19 18 20 28 29 30 36 21 22 34 34 35 23 33 ...

Page 15: ...6607 1 1 20 Lock Nut 1 2 13 83444 2 21 Gasket Flue Collar 88032 1 22 Flue Collar 40246 1 23 P Flue Collar Ring Flue Collar Ring 1800 22761 23958 1 1 24 Smoke Curtain 23800 1 25 Smoke Door Clip 23787 2 26 Carriage Bolt 1 4 20 x 1 1 4 Long 83445 2 27 Kep Nut 1 4 20 83250 2 28 P Cabinet Side Left Cabinet Side Front Left 1800 68821 68962 1 1 29 P Insulation Side Insulation Side 1800 C98771 23977 2 2 3...

Page 16: ...n and or filter box should be incorporated into your furnace installation A cold air return or filter box will increase the life of your blow ers and offer filtered distribution air for your home U S Stove offers the model UFB908 as an option and can be purchased from your local dealer The UFB908 utilizes a standard 16 x 20 filter that can be purchased from your local dealer or any hardware duct w...

Page 17: ... The installation is now ready to be plumbed to your existing hot water system Choose one of the three methods described in the Hot Water Coil instructions 6 Remove knockouts from the access panel and re attach to the furnace enclosure Have a qualified plumber connect your domestic hot water pipe to the coil with the appropriate fittings DR6 6 DRAFT REGULATOR KIT OPTIONAL KIT In the unlikely event...

Page 18: ...cially if it has caked over or formed a crust But be careful not to mix the coal as this increas es the chances of forming clinkers When shaking the grate s be gentle Just a few short movements a couple of cranks is better than a lot of agitation The objective is to remove a small amount of the ashes without disturbing the fire Stop when you see a glow in the ashes or the first red coals fall into...

Page 19: ...use does not become too cold It is important that you begin banking early enough before retiring or leaving that you can make necessary adjustments after the fire is well established To revive a coal fire that is almost out 1 open the ash door and stove pipe damper and close the spin damper under the door to get a good draft through the grate 2 place a thin layer of dry coal over the entire top of...

Page 20: ...20 NOTES ...

Page 21: ...21 NOTES ...

Page 22: ... 07 Date _____________________ Engineer Name ________________________________ License No ____________________________________ Company _____________________________________ Telephone No _________________________________ Stove Inspected Chimney Swept Items Replaced ________________________________ Service 02 Date _____________________ Engineer Name ________________________________ License No _______...

Page 23: ... 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 24: ...ide the following information found on the Certification Plate located below the ash door PART NUMBER________________________________________________________ PART DESCRIPTION____________________________________________________ MODEL NUMBER______________________________________________________ SERIAL NUMBER______________________________________________________ United States Stove Company 227 Indust...

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