TM
Model 1537G
OWNERS MANUAL
SOLID FUEL
WARM AIR FURNACE
*FOR PARALLEL INSTALLATION WITH EXISTING
FORCED AIR-GAS OR OIL FIRED FURNACE.
*FOR INSTALLATION AS A CENTRAL FURNACE
*THE 1537G CLAYTON FURNACE HAS BEEN
APPROVED FOR U.S. INSTALLATIONS ONLY.
IMPROPER INSTALLATION MAY VOID
YOUR WARRANTY
CAUTION:
READALLINSTRUCTIONSCARE-
FULLY BEFORE STARTING THE
INSTALLATION OR OPERATING
THE FURNACE
DO NOT USE THIS FURNACE
IN A MOBILE HOME OR TRAILER
UNITED STATES STOVE COMPANY
A
E
S
T
S
S
D
T
E
O
227 Industrial Park Road
P.O.Box 151
South Pittsburg, TN 37380
(423) 837-2100
T
VE
I
WARNOCK HERSEY
N
U
S
C
U
S
R
C
O
Y
N
M
P
A
851340 5/98
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CAUTION LABELS
Your Furnace has the following labels. Read and Obey all labels.
DANGER: RISK OF FIRE OR EXPLOSION.
DO NOT burn garbage, gasoline, drain oil, or other flammable liquids.
WARNING: FIRE HAZARD.
DO NOT operate with fire draft exceeding .06 inches w.c.
DO NOT operate with fuel loading or ash removal doors open.
DO NOT store fuels, paints, thinners, flammable liquids, or other highly
volatile substances in the furnace room.
CAUTION: HOT SURFACES
Keep children away.
Do not touch during operation.
CAUTION!
INSPECTFLUEPIPES, FLUEPIPEJOINTSANDFLUEPIPESEALSREGULARLY
TO ENSURE THAT SMOKE AND FLUE GASES ARE NOT DRAWN INTO, AND
CIRCULATED BY, THE AIR CIRCULATION SYSTEM.
CAUTION!
CLEANOUT OF THE HEAT EXCHANGER, FLUE PIPE, CHIMNEY, AND DRAFT
INDUCER (IF USED), IS ESPECIALLY IMPORTANT AT THE END OF THE
HEATINGSEASONTOMINIMIZECORROSIONDURINGTHESUMMERMONTHS,
CAUSED BY ACCUMULATED ASH.
SAFETY NOTICE: If this heater is not properly installed, a house fire
may result. For your safety, follow the installation
directions. Contact local building or fire officials
about restrictions and installation inspection
requirements in your area.
3
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RULES FOR SAFE INSTALLATION AND OPERATION
Read these rules and the instructions carefully. Failure to follow them will cause a
hazard that could result in death, serious bodily injury, and/or property damage.
1. Check your local codes. The installation must comply with their rulings.
2. Do not install this furnace in a mobile home or trailer.
3. Always connect this furnace to a chimney and vent to the outside. Never vent to another
room or inside a building.
4. Do not connect this furnace to an aluminum Type B gas vent. This is not safe and is
prohibited by the National Fire Protection Association Code. This furnace requires a
masonry or Listed Factory Built Chimney for residential type or Building Heating Appliance
Chimney. Usea6"diameter chimneyorlarger,thatishighenoughtogiveagooddraft.(See
page 7)
5. Besurethatifamasonrychimneyisused,itissafelyconstructedandin goodrepair. Have
the chimney inspected by the Fire Department or an inspector.
6. Inspectchimneyconnectorandchimneybeforeandfrequentlyduringthe heatingseason
for any deposit of creosote or soot which must be removed (See Chimney Maintenance,
page 15).
7. Provide air for combustion into the room where the furnace is located. If the intake is not
in the same room, air must have free access to the room.
8. CAST IRON PARTS MUST BE "SEASONED" TO AVOID CRACKING, BUILD ONLY
SMALL FIRES ON FIRST USE.
9. To prevent injury, do not allow anyone to use this furnace who is unfamiliar with the
correct operation of the furnace.
10. For further information on using your furnace safely, obtain a copy of the National Fire
Protection Association (NFPA) publication "Chimney's, Fireplaces and Solid Fuel Burning
Appliances"NFPA211. TheaddressoftheNFPAisBatterymarchPark,Quincy,MA02269.
11. Keep the ashpit section free of excess ashes. Do not allow ashes to stack higher than
the sides of the ash pan.
12. DISPOSAL OF ASHES- Place ashes in a metal container with a tight fitting lid. Keep
the closed container on a noncombustible floor or on the ground, well away from all
combustible materials. Keep the ashes in the closed container until all cinders have
thoroughlycooled. Theashesmaybeburiedinthegroundorpickedupbyarefusecollector.
13.CAUTION-Thespecialpaintsusedonyourfurnacemaygiveoffsome smokewhilethey
are curing during first few fires., Build small fires at first. The metal used in construction of
the furnace and duct work has a light coating of oil. This could give off smoke and/or odor
from registers when furnace is used for the first time. This should disappear after a short
period of time. Once this burn-off has occurred, it should not reoccur.
14. CARING FOR PAINTED PARTS- This furnace has a painted outside jacket, which is
durable, butitwillnotstandroughhandlingorabuse. Wheninstallingyourfurnace, usecare
in handling. Clean with soap and warm water when furnace in not hot. DO NOT use any
acids or scouring soap, as these wear and dull the finish. DISCOLORATION WILL OCCUR
IF THE FURNACE IS OVERHEATED. FOLLOW OPERATING INSTRUCTIONS
CAREFULLY.
Your Furnace is designed to be installed in a parallel air flow arrangement with a gas
or oil-fired forced air upflow-type central furnace, or it may be installed as a central
furnace.
4
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HOW THE FURNACE FUNCTIONS
PARALLEL INSTALLATION: (U.S. ONLY)
Your CLAYTON Furnace is designed
tobeasupplementalorcentralheatingsource
for your home. This Solid Fuel Furnace may
be installed in conjunction with a properly
operating central furnace that is listed or cer-
(See Optional Wiring Diagram, Page 13, Fig.
14) The design is such that when the blower
comes on, the blower on the central system
also comes on. The blower will only come on
when the temperature in the plenum has
reached the setting on the blower control.
Thisistoinsurethatthereissufficientwarmair
in the system to make it efficient for the unit to
operate. When the central system thermostat
calls for heat, the central system will operate
by the burner igniting and the blower coming
on. It is possible that both systems will op-
erate simultaneously. It is recommended that
for the most efficient use of your CLAYTON
Furnace, thatitbefiredasmuchaspossiblein
order to reduce the demand on your existing
central heating system. This unit has an op-
tional forced draft kit that operates from a wall
thermostat. Whenthetemperaturefallsbelow
the setting on the wall thermostat, the forced
draftwillcomeon(U.S.StoveOption11/DKU)
The warm air supply outlet of the CLAYTON
Furnace shall not be connected to the cold air
returnofthecentralfurnace,becausethepos-
sibility exists of components of the central
furnace overheating and causing the central
furnace to operate other than is intended.
tified in accordance with nationally
recog-
nized safety standards and equipped with the
required controls and other safety features
and which has been installed in accordance
with appropriate standards of the National
Fire Protection Association with installation
clearances specified in the
furnace name-
plate marking. The installation must be ac-
complished by a qualified agency (one who is
engaged in, and is responsible for, or is thor-
oughly familiar with the
installation and
operationofthegas, oil, andsolidfuelburning
heating appliances, who is experienced in
suchwork,familiarwithalltherequirementsof
the authority having
installation shall be in strict accordance with
themanufacturer's installationinstructions
jurisdiction.) The
furnished with the solid fuel furnace.
The chimney connector of the furnace is
to be installed to provide clearances to com-
bustible material not less than specified in the
individual classifications and marked on the
furnace. The chimney connector must be
connected to a chimney suitable for use with
residentialtypeorbuildingheatingappliances
which burn solid fuel.
The Furnace is designed to operate in
either parallel or series air flow arrangement
with the central furnace or as a central fur-
nace.
CENTRAL FURNACE INSTALLATION: As
a central furnace, the unit functions
inde-
pendently of any other system. The blower
willcomeonwhentheplenum temperature
reaches the setting on the blower control.
5
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DIMENSIONS OF FURNACE
49-1/8"
FIGURE 1
1537G
32-1/8"
24-1/16"
1-3/4"
33-7/8"
40-11/16"
9"
6
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LOCATING THE FURNACE
18"
6" CHIMNEY
1.The furnace should be located in the
same room as the central system
and as close as possible, but not
closer than 9". There should be no
wall between the furnace and the
warmairoutletductthatisconnected
directly to the warm air outlet plenum
of the central furnace. (See Fig. 2)
CENTRAL
FURNACE
12"
9"
48"
2.
The unit will require installation with
the following clearances:
Figure 2
Unittosidewall...............12"(305mm)
Unit to backwall............30"(760mm)
Chimney connector pipe to sidewall
.....................................21"(530mm)
Chimney connector pipe to backwall
.....................................18"(460mm)
Hot air ducts to combustibles
.......................................6"(150mm)
(Refer to Fig. 2 & 3)
18"
6" SOLID DAMPER
6" BAROMETRIC
DRAFT REGULATOR
(OPTIONAL)
18"
Place the furnace on a noncombus-
tible floor.
3.
4.
Check figures 2 and 3. Be sure you
have the clearances shown from the
furnace and the connector pipe to
combustible surfaces. If you have a
solid brick or stone wall behind your
furnace, you can place the furnace
ascloseasyouwishtothewall. Ifthe
wall is only faced with brick or stone,
treat it as a combustible wall.
NON-COMBUSTIBLE FLOOR
Figure 3
7
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THIMBLE
6" ELBOW
6" SOLID DAMPER
6" BAROMETRIC
DRAFT REGULATOR
(OPTIONAL)
6" CHIMNEY
CONNECTOR
NON-COMBUSTIBLE
WALL
6" ELBOW
CHIMNEY CONNECTION
Fig. 4
MASONRY CHIMNEY
Before using an existing masonry chimney, clean the chimney and inspect the flue liner to be sure
it is safe to use. Make repairs before attaching the furnace. See page 4, item 5. Look at Fig. 4.
The connector pipe and fittings you will need to connect directly to a masonry chimney are shown.
The chimney connection should be as short as possible.
If the connector pipe must go through a combustible wall before entering the masonry chimney,
consult a qualified mason or chimney dealer. The installation must conform to local fire codes, and
N.F.P.A. 211.
DO NOT CONNECT THIS FURNACE TO A CHIMNEY FLUE SERVING ANOTHER
APPLIANCE.
The chimney used for a furnace must not be used to ventilate the cellar or basement. If there is
a cleanout opening at the base of the chimney, close it tightly.
REFER TO CHIMNEY
2' MIN.
MANUFACTURER'S
INSTRUCTIONS AND
PARTS.
10'
3' MIN.
Fig. 5
6" SOLID DAMPER
6" BAROMETRIC
DRAFT REGULATOR
(OPTIONAL)
6" CHIMNEY CONNECTOR
6" ELBOW
LISTED FACTORY BUILT CHIMNEY
Carefully follow chimney manufacturer's instructions. Use only a Listed Residential Type or
Building Heating Appliance Chimney. If your chimney starts at the ceiling (Fig. 5), you will need
enough 6" pipe to reach the ceiling.
The top of the chimney must be at least 3 feet above the roof and be at least 2 feet higher than any
point of the roof within 10 feet (Fig. 5).
8
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RULES FOR CONNECTOR
PIPE INSTALLATION
1. The crimped end of the chimney connector fits
insidethefurnacefluecollar. Installadditional chim-
ney connectors and elbow with the CRIMPED END
TOWARD THE FURNACE. This will allow any
condensation in the flue to run back into the furnace.
Use 6" dia. steel pipe and elbows for connection to
chimney. Never use less than 24 gauge and
al-
though blued steel is satisfactory, high temp painted
black is much more desirable.
2. Slope any horizontal pipe upward toward the
chimney at least 1/4 inch for each foot of horizontal
run.
RIGHT
WRONG
WRONG
3. You must have at least 18 inches of clearance
between any horizontal piping and the ceiling.
(See Fig. 3)
Fig. 6
4. The chimney connector must not extend into the
chimney flue. (See Fig. 6)
5. Seal each chimney connector pipe joint with fur-
nace cement. Also seal the pipe at the chimney.
6. Use 3 sheet metal screws at each chimney pipe
joint to make the piping rigid.
7. The chimney connector may include a section for
abarometricdraftregulatorbetweenthefurnaceand
the chimney (Fig. 4,5, &7). The barometric draft
regulator must be installed in the same room (same
pressure zone) as the furnace.
8. Install the barometric draft regulator strictly in
accordance with the instructions that are provided
with the barometric draft regulator.
9. A solid damper must be used in the chimney
connecting pipes between the flue collar and the
chimney. When used in conjunction with a baromet-
ric draft regulator, the solid damper must be placed
between the barometric and the chimney. (See Fig.
4,5,7)
NON-COMBUSTIBLE
INSTALLATION PER
NFPA 211
6" SOLID DAMPER
6" BAROMETRIC
DRAFT REGULATOR
(OPTIONAL)
MEASURE FLUE
DRAFT HERE
Adjusting the Barometric Draft Regula-
tor
1. Drill a hole in the chimney connector within 18" of
the flue collar below the barometric draft regulator
just large enough for the tube of the manometer.
2. Build a fire after all chimney connections have
been made.
Fig. 7
3. Use a manometer to measure the draft in the flue.
4. Adjust the Barometric Draft Regulator to obtain a
draftof0.05-0.06"W.C. understablefireconditions.
9
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ASSEMBLY OF FURNACE
Your furnace requires the following items
to be assembled or installed by the service
person:
Feed Door Pull Handle
Feed Door Locking Handle
Blower(s) and Blower Controls
Electrical Connections
Remove all parts from inside the furnace
and inspect for damage, including the
firebrick as some breakage could occur
during shipment.
Assemble the feed door pull handle as
shown in Figure 8. Install thermostat
assembly and cover (complete with
handle) as illustrated in Figure 8.
Align thermostat control knob with flat on
thermostat control shaft and press onto
shaft. (See Fig. 8)
Attach feed door locking handle as in
Figure 9 with screws and nuts provided.
Note: Slotted holes are for adjustment of
handle. Adjust handle until some
pressure is required to lock feed door
during firing sequence.
1.
2.
Fig. 8
3.
4.
Fig. 9
Honeywell
FAN/LIMIT
CONTROL
Install Honeywell Fan/Limit Control on
rear of furnace cabinet as shown in
Figure 10.
Remove blower(s) from carton(s).
Remove junction box cover. Attach clip
nutsasinFigure10. Installblower(s)and
gasket(s) with 1/4"-20x3/4" bolts as
shown.
Wire right side blower first (See wiring
diagram, Fig. 11) and replace cover on
junction box on blower.
Wire left blower same as above and
replace cover.
5.
6.
4" ELECTRICAL
JUNCTION BOX
BLOWER
ASSEMBLY
7.
8.
Check operation of shaker grates with
grate handle before operating furnace.
CLIP NUTS
(DO NOT USE CLIP NUT
ON UPPER CENTER HOLE)
GASKET
(MODEL 1537G- 2 BLOWERS)
Fig. 10
10
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LOAD
FAN
LINE
LOAD
LIMIT
LINE
FAN "OFF"
INDICATOR
LIMIT
INDICATOR
BREAK OFF
JUMPER FOR
LOW VOLTAGE
FAN "ON"
INDICATOR
Honeywell
LIMIT SWITCH
WIRE COLOR CODE
G- GREEN- GROUND
B- BLACK- POWER SUPPLY
W- WHITE- POWER SUPPLY
R1- WHITE- FAN CONTROL
R2- BLACK- FAN CONTROL
M1- BLACK- BLOWER MOTOR
M2- WHITE- BLOWER MOTOR
R2
R1
GROUND
G
B
G
B
110
VAC,
60
W
HZ.
W
ELECTRICAL JUNCTION BOX
M2
M1
M1
M2
BLOWER
MOTOR
BLOWER
MOTOR
WIRE NUT
(7 PLACES)
FIGURE 11
IMPORTANT: POWER SUPPLY WIRING MUST NOT BE LESS THAN 90 CENTIGRADE.
11
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INSTALLATION
Please see all methods of Installation in
Appendix at the rear of this booklet.
Pipe to combustible:
Sides: 21"
Back: 18"
The installation must be made only on a
noncombustible floor.
This is a furnace, not a free standing stove.
Youmustdirectheatedairfrom8"outletsawayfrom
the furnace, or it will not function properly.
d) Install the smoke pipe connector to the
chimney with 26-gauge pipe and elbows (to be
purchased separately), maintaining the proper
clearances for the specific model. Seal the smoke
pipe in the chimney with furnace cement. (The
chimney connector shall be securely supported,
and joints fastened with sheet metal screws or
rivets.)
e) Install 8" diameter heat pipe to plenum of the
central hot air furnace. Use 26-gauge pipe and
connectors (to be purchased separately). (See
Fig. 15) If central air conditioning is installed in the
plenum, install heat pipe above the air conditioning
unit. Secure heat pipe connection with supports
and sheet metal screws.
1. This installation must be done by a qualified
heating equipment installer.
2. The installation is to be done in compliance with
National Fire Protection Association installation
standards: No. 89M, 90B, 211, 70 (National Elec-
tricalCode)andUniformMechanicalCode913,6-4,
in the states where applicable. (Their code offers
connecting smoke pipe connectors into chimney
with other fuel burning appliances.)
3. Rooms large in comparison with size of the
appliance:
a) Wood or Coal Burning Furnace needs air for
combustion and circulation to house.
f) Connect electrical supply in the electrical
junction box that is mounted on the back of the
Furnace. See Wiring Diagram (Fig. 11). Remove
the cover from electrical junction box and connect
power supply wires to wires designated, using wire
nuts. The power cord supplied may be used for
installation, if permitted by local codes and
regulations. If the power cord supplied cannot be
used, the power supply wiring must be 90 degrees
centigrade in a metal cable and should be
completed by a qualified installer complying with
NFPA Standard No. 70 and local codes.
g) Optional Plenum Fan Control Switch (Part
No. 11PCS) is available for installation on the
plenum of central hot air heating furnace. The
purpose of this switch is to activate the circulating
fan of the central hot air heating furnace when the
temperature in the plenum exceeds 120 degrees
F., and shut off the fan when the temperature in the
plenum is reduced to 100 degrees F. This avoids
overheating the plenum.
b) Provision must be made to make up this air
and not starve gas or oil furnace of combustion air.
c) Have "Authority Having Jurisdiction"
termine that air is of adequate makeup.
de-
(Refer-
ence N.F.P.A. Nos. 30&54, Code for
of Gas & Oil Equipment).
Installation
4. Have"AuthorityHavingJurisdiction"istoinspect
all chimneys and installations for adequate venting
and for compliance with standard and local codes
andregulationsregardinginstallationofwood burn-
ing appliances.
5. Installation for Supplemental Heat Application to
Existing Central System. (See Fig. 2 for typical
installation.)
a) Place Wood or Coal Burning Furnace so that
the chimney connector will be as short as practical
and avoiding unnecessary sharp turns in the smoke
pipe connector and the installation of devices that
would create excessive resistance to the flow of flue
gases.
b) Locate the Wood or Coal Burning Furnace as
close as practical to the existing central hot air
heating system, maintaining clearances as stated
on the label on the fuel door.
The electrical supply for operation of this fan
control switch is to be obtained from the same
electrical supply as the central hot air heating
system. Follow the instructions of the wiring
diagram (Fig. 11). Do not make connections across
Limit Control in the furnace.
c) Clearance from combustible materials must
comply with those stated on the label on the fire
door:
Make electrical wire connections in accordance
with NFPA Standard No. 70 and local codes in the
power supply junction box (See Fig. 13). The wiring
to complete the connections should be 18 AWG
minimum copper and 90 degrees centigrade in a
cable.
Unit to combustible:
Front: 48"
Back: 30"
Sides: 12"
Plenum to Ceiling: 6"
12
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Figure 12
6
"
MIN.
2" MIN. AIR SPACE
REQUIRED BY CODE
PLENUM
CENTRAL
FURNACE
TO GAS/OIL/ELECTRIC
TRANSFORMER AND
COMBUSTION FAN OF
SOLID FUEL UNIT
Figure 13
COMBINATION CONTROL
LIMIT
H
POWER
SUPPLY
JUMPER IN
N
FAN
GAS/OIL/ELECTRIC
POWER SUPPLY
JUNCTION BOX
CAUTION!
DO NOT CONNECT
PLENUM FAN CONTROL
SWITCH ACROSS FURNACE
LIMIT CONTROL.
FURNACE
BLOWER
MOTOR
POWER FAILURE INSTRUCTIONS:
Operation after loss of power--
1. Remove filter if provided
2. Do not expect to keep home at normal temperatures.
3. Do not load fuel above bottom of feed door.
13
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CAUTION
OPERATING INSTRUCTIONS
GASES THAT ARE DRIVEN FROM FRESH
COAL MUST BE BURNED OR THEY WILL
ACCUMULATE AND EXPLODE. NEVER
SMOTHER A FIRE WHEN ADDING FRESH
COAL.
FUEL, Model 1537G
A) Egg size (1-3/16" or larger) bituminous coal
for residential furnaces, or any of the specially
packed fireplace coals can be used. Coal with a
low ash content (2% to 6%) is recommended.
CAUTION
B) Hardwood, 18" to 26" should be split and air
dried (seasoned) for 6 months.
LIGHTING
DO NOT OPERATE WITH THE FEED AND/OR
ASH DOOR OPEN. THIS FURNACE IS DE-
SIGNED FOR THERMOSTATIC OPERATION.
OPERATION WITH ANY OF THESE DOORS
OPEN WILL OVERHEAT AND DAMAGE THE
FURNACE.
1.
Set the thermostat on "HIGH" for maximum
draft.
2.
Open the feed door and place paper and
kindling on the grate for starting the fire.
Light the fire and close the feed door.
Add wood or about 15 lbs. of coal (depending
on which model) after fire is burning briskly.
Set thermostat for desired temperature.
"MEDIUM" setting is normally satisfactory.
Set higher or lower for your comfort.
3.
4.
CAUTION
NEVER USE GASOLINE, GASOLINE-TYPE
LANTERN FUEL, KEROSENE, CHARCOAL
LIGHTER FLUID, OR FLAMMABLE LIQUIDS
TO START OR "FRESHEN UP" A FIRE IN THE
FURNACE.
5.
ADDING FUEL
WARNING
When starting a fire, add small amounts of fuel
instead of adding large quantities of fuel. This will
give more complete combustion and less build-up
of tars or soot in the chimney.
NEVER STORE FLAMMABLE LIQUIDS, ES-
PECIALLY GASOLINE, IN THE VICINITY OF
THE FURNACE.
ADJUSTING BLOWER LIMIT CONTROL SET-
TINGS.
1. Set thermostat to HIGH before opening feed
door.
The temperature in the plenum of the warm air
furnace at which the blower turns on or turns off,
is controlled by the setting of the pointers in the
blower limit control (See Fig. 12). These pointers
may be adjusted through their entire range of
settings to achieve the desired warm air output
from furnace. (See Fig. 15 below)
2. Wood fire -
Add wood to a convenient level.
3. Coal Fire -
a. Never smother the fire when adding coal (See
Caution). Gasaccumulationandamildsmoky
explosion will occur. Add fresh kindling if the
bed of coals has cooled.
b. Add up to 20 lbs. of coal per loading. Never
add coal above the bottom of feed door
opening.
Move both pointers towards the right (counter
clockwise) - this increases the temperature
setting at which the blower will turn on and off.
Move both pointers towards the left
(clockwise) - this decreases the temperature
setting at which the blower will turn on and off.
Move pointers away or apart from each other-
this increases the time that the blower will run
on each warm air cycle.
c. Stir the coal and watch the fire. Be sure the
new coal is burning briskly before you close
the doors and turn the thermostat down.
d. Shakegratesvigorously1/2"lefttorighttospill
ashes into the ash pan. Do this at least once
every 12 hours of operation. Empty ash pan
regularly. Do not allow ashes to build-up to
grate as grate will warp and burnout, and you
might spill the ashes when removing the pan.
Dispose of hot ashes properly (See note 12 on
page 4).
Fig. 14
BLOWER FAN
"OFF" POINTER
e. Rotation of the handle (5 o'clock to 7 o'clock)
position will agitate coals and spill ashes into
ash pan.
BLOWER FAN
"ON" POINTER
f. It is advisable for you to get familiar with the
shaker grate operation before firing.
BLOWER LIMIT
POINTER & STOP
14
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SERVICE HINTS
If the chimney is operating too cool, water
will condense in the chimney and run back
into the furnace. Creosote formation will be
rapid and may block the chimney. Operate
the furnace at a high enough fire to keep the
chimney warm, preventing this condensa-
tion.
Do not expect a furnace to draw. It is the
chimney that creates the draft. Smoke spillage
into the house or excessive build-up of water or
creosote in the chimney are warnings that the
chimneyisnotfunctioningproperly. Correctthe
problembeforeusingfurnace. Possiblecauses
are:
4.
5.
If the fire burns well, but sometimes smokes
or burns slowly, it may be caused by the
chimney top being lower than another part
of the house or a nearby tree. The wind
blowing over a house or a tree, falls on top
of the chimney like water over a dam,
beating down the smoke. The top of the
chimney should be at least 3 feet above the
roof and be at least 2 feet higher than any
point of the roof within 10 feet (Fig. 5).
1. The connector pipe may be pushed into the
chimney too far, stopping the draft (Fig. 6)
2. Do not connect two furnaces or a stove and
furnace into the same chimney flue.
3. The chimney used for a furnace must not be
used to ventilate the cellar or basement. If
there is a cleanout opening at the base of
the chimney, it must be closed tightly.
6.
See page 28 for list of trouble shooting tips.
A draft reading of .05 to .06 w.c. is suggested for proper burning of this unit when using
wood or bituminous coal as fuel. When using anthracite coal, this draft reading is a
minimum reading.
CHIMNEY MAINTENANCE
Creosote and Soot - Formation and Need for Removal
When wood is burned slowly, it produces tar
and other organic vapors, which combine with
expelled moisture to form creosote. The
creosote vapors condense in the relatively cool
chimney flue of a slow-burning fire. As a result,
creosote residue accumulates on the flue
lining. When ignited, this creosote makes an
extremely hot fire.
If creosote or soot has accumulated, it should
be removed to reduce the risk of a chimney fire.
Chimney fires burn very hot. If the chimney
catches fire, immediately call the fire
de-
partment, then reduce the fire by closing the
inlet air control. Pour a large quantity of coarse
salt, baking soda or cool ashes on top of the fire
in the firebox.
When coal is burned, the products of
combustion combine with moisture to form a
soot residue which accumulates on the flue
lining. When ignited, this soot makes an
extremely hot fire.
CAUTION
A chimney fire may cause ignition of
wall studs or rafters which you thought
were a safe distance from the chimney.
If you have a chimney fire, have your
chimney inspected by a qualified per-
son before using again.
The chimney should be inspected at least twice
monthly during the heating season to
determine if a creosote or soot build up has
occurred.
15
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PARTS LIST
MODEL 1537G
(SEE DIAGRAM, PAGE 16)
PART#
68215
40246
88032
23458
40258
40256
40257
89066
40269
68218
68218
22662
22824
23461
23457
23459
22761
22762
68229
24757
80145
80231
89520
23425
68234
22140
23787
68733
68732
68722
86318
24556
83461
83178
23445
40260
89319
23800
68228
68231
83445
83414
83250
89574
DESCRIPTION
QTY.
1
KEY
1
FIREBOX WELDMENT
FLUE COLLAR
1
2
FLUE COLLAR GASKET
CABINET BOTTOM
1
3
1
4
BACK LINER
1
5
SHAKER FRAME
2
6
SHAKER GRATE
2
7
FIREBRICK
12
1
8
FRONT LINER
9
ASH DOOR ASSEMBLY (INCLUDES DOOR & GASKET)
FEED DOOR ASSEMBLY (INCLUDES DOOR & GASKET)
FEED DOOR HINGE BRACKET
DRAFT KNOB
1
10
11
12
13
14
15
16
17
18
N/S
19
20
21
22
23
24
25
26
27
27a
27b
27c
28
29
30
31
32
N/S
33
34
N/S
35
N/S
36
37
1
1
1
CABINET SIDE (LEFT & RIGHT)
CABINET TOP
2
1
CABINET BACK
1
FLUE COLLAR RING
FORCED DRAFT RING
BLOWER ASSEMBLY
FEED DOOR HANDLE ASSEMBLY
LIMIT CONTROL
1
1
2
1
1
JUNCTION BOX
1
ROUND WOODEN HANDLE
HANDLE BRACKET
1
2
BLOWER THERMOSTAT BRACKET
RELAY BOX BRACKET
SMOKE DOOR CLIP
1
1
2
THERMOSTAT PANEL ASSEMBLY (INCLUDES A,B,C BELOW)
COVER WELDMENT
THERMOSTAT PANEL
16GA. WIRE LINK
-
1
1
.543FT
1
ASH DOOR HANDLE
HANDLE WASHER
1
3/8-16 JAMB NUT
2
DOOR LATCH
1
SHAKER HANDLE
1
BLOWER GASKET
2
SMOKE CURTAIN
1
ASH PAN WELDMENT
FAN CONTROL CORD ASSEMBLY
1/4-20 X 1-1/4 BOLT
1
2
2
1/4 ID LOCK WASHER
1/4-20 KEP NUT
2
2
SPRING HANDLE
2
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Central Installation
(U.S. ONLY)
COLD AIR DUCT
6" PIPE
90 ELBOW
DAMPER
OPTIONAL
11 RPT
PIPE
CONNECTOR
FURNACE
FIGURE 15-1
Add-On Installation
(U.S. ONLY)
COLD AIR DUCT
8" PIPE
6" PIPE
90 ELBOW
DAMPER
PIPE
CONNECTOR
FURNACE
EXISTING GAS/OIL/ELECTRIC FURNACE
FIGURE 15-1
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APPENDIX
INSTALLATION A
(U.S. ONLY)
TO EXISTING
DUCT WORK
COLD AIR
RETURN
WARM AIR
EXISTING
FURNACE
FILTER BOX
SOLID FUEL
FURNACE
19
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INSTALLATION B
(U.S. ONLY)
PLENUM
COLLECTOR BOX
TO EXISTING
DUCT WORK
COLD AIR
RETURN
WARM AIR
EXISTING
FURNACE
FILTER BOX
SOLID FUEL
FURNACE
INSTALLATION C
(U.S. ONLY)
PLENUM ELBOW
TO EXISTING
DUCT WORK
COLD AIR
RETURN
WARM AIR
PLENUM TOP
(OPTIONAL)
EXISTING
FURNACE
FILTER BOX
SOLID FUEL
FURNACE
20
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INSTALLATION D
(U.S. ONLY)
DUCT
WORK
2" MINIMUM
CLEARANCE
11 PCS
(OPTIONAL PLENUM
FAN CONTROL LOCATION)
COLD AIR
RETURN
FURNACE PLENUM
EXISTING FURNACE
ANTI-BACKDRAFT
FLAPPER
SOLID FUEL
FURNACE
INSTALLATION E
(U.S. ONLY)
DUCT
WORK
2" MINIMUM
CLEARANCE
BAFFLE
COLD AIR
RETURN
FURNACE PLENUM
EXISTING FURNACE
SOLID FUEL
FURNACE
21
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INSTALLATION F
DUCT
WORK
2" MINIMUM
CLEARANCE
COLD AIR
RETURN
FURNACE PLENUM
EXISTING FURNACE
SOLID FUEL
FURNACE
INSTALLATION G
DUCT
WORK
2" MINIMUM
CLEARANCE
CENTRAL
FURNACE
INSTALLATION
COLD AIR
RETURN TO
FILTER BOX
SOLID FUEL
FURNACE
22
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INSTALLATION H
EXISTING OIL,
ELECTRIC OR
GAS FURNACE
SOLID FUEL
FURNACE
(TOP VIEW)
2" MINIMUM
CLEARANCE
EXISTING OIL,
ELECTRIC OR
GAS FURNACE
SOLID FUEL
FURNACE
(FRONT VIEW)
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TROUBLE SHOOTING TIPS FOR WARM AIR FURNACE
LIST OF PROBLEMS
POSSIBLE CAUSE
SOLUTIONS
1. Smoking when feed door
is open.
a) Insufficient Draft.
b) Clogged chimney or chimney
connector.
a) Set Thermostat higher.
b) Clean Chimney.
c) Add raincap to chimney.
c) Down draft in chimney.
2. Furnace does not heat.
3. Blower Does not run.
a) Wood not seasoned and dry.
b) Blower control set too low.
c) Insufficient flue draft.
a) Allow wood to season in a
dry area for six months.
b) Set blower control to higher
temperatures. (See P. 14)
c) Set flue draft. (See P. 9)
a) Improperly wired.
b) Bad blower control.
c) Bad relay.
a) Wire unit properly.
b) Replace blower control.
c) Replace relay.
d) Bad blower motor
d) Replace blower.
4. No air from registers-
fan running.
a) Registers are closed.
a) Open registers.
b) Correct duct work install.
c) Wire unit properly.
b) Duct work improperly installed.
c) Improper wiring between central
furnace and this unit.
5. Air from Registers is not hot
6. Blower runs too long.
a) Blower control is set too low.
b) Bad blower control.
a) Adjust blower control to
higher setting. (See P. 14)
b) Replace blower control.
Blower control cut off set
too low.
Set blower control cut off to
higher setting. (See P. 14)
7. Blower does not run long
enough.
a) Blower control cut off set
too high.
b) Bad blower motor.
a) Set blower control cut off to
lower setting. (See P. 14)
b) Replace Blower.
8. Smoke and/or odor from
registers when furnace
is used for first time.
Oil from furnace and duct
work.
The metal used in constuc-
tion of the furnace and duct
work has a light coating of
oil. This should disappear
after a short period of time.
Once this burnoff has occur-
red, is should not reoccur.
9. Creosote build-up.
a) Burning green wood (not
seasoned or dry).
a) Burn only seasoned wood.
b) Thermostat setting too low
for type fuel.
b) Set thermostat higher to
attain higher flue tempera-
tures. This will aid in pre-
venting build-up of creosote.
10. Flame spillage when feed
door is open.
a) Insufficient draft.
b) Smothering fire when adding
fresh fuel.
a) Set thermostat higher.
b) Add fuel so as not to
smother fire.
24
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