United States Stove Furnace 1600M User Manual

UNITED STATES  
STOVE COMPANY  
Keeping North America Warm  
Since 1869  
MODEL: 1600M  
WOOD and COAL FURNACE  
SAFETY NOTICE: IF THIS FURNACE IS NOT PROPERLY INSTALLED, A HOUSE  
FIREMAYRESULT. FORYOURSAFETY,FOLLOWTHEINSTALLATIONDIRECTIONS.  
CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND  
INSTALLATION REQUIREMENTS IN YOUR AREA. REFER TO MARKINGS ON  
APPLIANCE FOR ADDITIONAL INFORMATION.  
Installation/Operator's Manual #851547A  
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NOTE: Type of chimney: Class A All-Fuel UL 103HT  
on the flue lining. When ignited, this creosotemakesan extremely  
hot fire.  
The chimney connector and chimney should be 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.  
TOP OF CHIMNEY MUST  
BE 2 FT. ABOVE HIGHEST  
POINT OF ROOF WITHIN  
10 FEET  
CAP SHOULD HELP  
PREVENT DOWNDRAFT  
WHILE STILL PROVIDING  
ADEQUATE EXHAUST.  
SMOKE PIPE INSTALLATION  
2 FT.  
MINIMUMS  
3 FT.  
MINIMUM  
Clearances to combustible materials (i.e. paneling, ceiling tile,  
sheet rock, plaster, draperies, casements or wood trim, etc.)  
will vary with the type of flue connection used. Be sure to  
maintain the specified clearances for your type of installation.  
RECOMMENDED  
MINIMAL  
20 FT. HEIGHT  
MINIMAL 3 FT.  
FROM TOP OF  
CHIMNEY TO POINT  
AT WHICH IT PASSES  
THROUGH THE ROOF.  
TYPE OF FLUE  
CONNECTION  
REQUIRED  
CLEARANCE  
24 Gauge or Heavier  
Single Wall Stainless Steel  
or Black Pipe  
18"  
CHIMNEY FLUE  
SHOULD BE  
CHIMNEY FLUE  
MUST BE AS  
LARGE OR 20%  
LARGER THAN  
FURNACE FLUE  
PIPE  
Double Wall Stainless Steel  
6"  
CONSTANT DIAMETER  
THROUGHOUT ITS  
ENTIRE HEIGHT.  
Class A 103HT All-Fuel or Equivalent  
2"  
APPROVED  
CHIMNEY  
CLEANOUT DOOR  
SHOULD HAVE  
AIRTIGHT FIT. DO  
NOT LEAVE OPEN  
WHEN FURNACE IS  
IN OPERATION.  
CHIMNEY THIMBLE SHOULD BE  
CONSTRUCTED OF FIRE CLAY, AND  
SHOULD FIT TIGHTLY TO FLUE PIPE.  
According to NFPA standards, single wall stove pipes can be  
within 9" of combustibles provided an approved fire retardant  
material covered with 28 gauge sheet metal, spaced out 1" on  
non-combustible spacers, is utilized. See illustration.  
1. The furnace should be the only heating appliance using  
a chimney flue. One furnace per flue.  
2. A masonry chimney should have a tile or stainless steel  
liner.  
3. The masonry chimney should not have any missing  
mortar or loose bricks.  
9"  
18"  
18"  
CEILING OR WALL  
4. There should be no mortar or parts of the chimney  
blocking the chimney flue.  
5. There should be a two inch clearance between any  
chimney (masonry or metal) and combustibles (such  
as the house).  
When using a Class A or double wall flue pipe connection,  
follow the manufacturer's instructions.  
6. The chimney should extend at least 2' above the  
highest point of the house, or 2' above the point at  
which the chimney is 10' from the roof.  
When constructing a single wall smoke pipe, the following  
guidelines must be observed.  
7. The chimney should be relatively straight and vertical.  
1. The connector pipe should be 24 gauge or heavier  
stainless steel or black pipe.  
8. The portion of an all-fuel metal chimney that extends  
above the roof should be well secured.  
2. Secure all joints with three #8 screws.  
9. A masonry chimney should be built on footings and not  
attached to the house.  
3. If the connector pipe must pass through a wall, an ap-  
proved insulated or ventilated thimble, at least three  
times the diameter of the smoke pipe must be used. (i.e.  
a 6" diameter smoke pipe needs an 18" thimble).  
10. A rain cap, complete with an animal or bird screen,  
should be installed on top of the chimney.  
CREOSOTE — 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  
4. The connector pipe should never be used as a chimney.  
IMPORTANT INFORMATION FOR  
ALL CONNECTOR PIPES  
The connector pipe must be constructed and installed so that it  
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maintains clearances, keeps condensation and creosote within  
the pipe, and is capable of withstanding a two to three thousand  
degree chimney fire.  
HEATED AIR DISCHARGE  
The Clayton furnace is designed for use as a supplemental  
heating source. When used as a supplementary furnace, the  
1600M is connected in conjunction with an oil, gas, or electric  
furnace to the existing duct work which distributes the heated air  
into several rooms and/or areas.  
1. The connector 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.  
Though United States Stove Company expressly Does Not  
recommend the use of its furnaces to be installed and/or used as  
a free-standing heater, it is possible to achieve a reasonably safe  
and functional installation IF certain standard procedures are  
followed. The following are guidlines only and are intended to  
enable the furnace user to obtain resonable efficiency from his  
furnace, and with due respect to safety when installing as a "free-  
standing heater". If installed correctly, and in accordance with  
the instructions found in this manual, your warm air furnace may  
be installed as a "space heater" within living quarters, cabins,  
garage, or workshop. Please adhere to the following:  
2. There should be no more than two 90 degree elbows.  
3. The connector pipe should never be longer than six  
feet. If it is absolutely necessary to make a run of more  
than six feet (not recommended) use extra support  
brackets every 3 feet.  
4. The connector pipe should never be reduced to a  
smaller size than flue opening on the furnace.  
5. The connector 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  
connector pipe in the chimney. It should be constructed  
so the connector pipe can be removed for cleaning.  
1) The use of a cold air return and/or filter box is mandatory. This  
will not only inscrease your blower life and provide filtered air, it  
will also help prevent the blower or blowers from "capturing"  
heated air exiting from the top of the furnace heat outlets.  
7. The connector pipe should not leave the heated portion  
of the building to reach the chimney.  
2) If installed as purchased , without directing the heat away from  
the furnace itself, it will simply sit and cycle, turning the blowers  
off and on. The thermostat may not function properly.  
8. The connector pipe should not pass from one story to  
the next before entering the chimney, nor should it pass  
through any closed or enclosed space.  
3) All larger furnaces (or those with multi-speed blowers)  
absolutely require BACK PRESSURE to prevent premature  
winding failure. If allowed to operate at high RPM (As in "FREE  
AIR" mode - no ductwork or flow restrictions) the windings  
overheat, insulation melts and the motor simply burns up - not  
covered under warranty.  
9. The connector pipe and any elbows must be of 24 ga.  
or greater.  
10. The connector pipe should not be located near or in a  
walk way or well traveled area.  
11. All male ends of connector pipe should run or point  
towards the furnace.  
CONNECTING HOT AIR DUCT TO  
FURNACE  
We strongly recommend that the warm air duct work be installed  
by a home heating specialist. If doing the installation yourself,  
before you decide which installation will best suit your needs,  
consult a qualified heating technician and follow his recommen-  
dations as to the safest and most efficient method of installation.  
The warm air duct must be constructed of metal with a minimum  
temperature rating of 250°F  
DAMPERS ON STOVE PIPES  
When you have installed the connector pipe between your  
furnace and 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.  
The following illustrations are the only acceptable configurations  
when installed with existing oil or gas furnaces.  
DO NOT CONNECT TWO HEATERS TO THE SAME CHIMNEY  
FLUE. The National Fire Prevention Association recommends  
that woodburning 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  
woodburner is required.  
INSTALLATION EXAMPLES  
INSTALLATION NO.1  
With this installation, a back draft damper is inserted into the heat  
run before the plenum of the existing furnace to prevent air from  
the existing furnace to blow back into the furnace when it is not  
in use. When a back draft damper is employed, it should be  
located as close to the existing furnace plenum as practical.  
If codes allow, use extreme care in making such installations. Be  
surethatonepipeishigherthantheothersothatthetwoopenings  
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 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 frequently 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 instal-  
lation does require more frequent inspection and maintenance.  
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INSTALLATION NO. 2  
INSTALLATION NO. 3  
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.  
Extending the hot air duct from the furnace into the existing  
plenum will help direct the flow of air from the 1600M as well as  
the flow in the existing furnace. Ducting entering the existing  
plenum at an angle (approximately 45 degrees) will facilitate air  
flow from the furnace while diverting air from the existing furnace.  
EXISTING  
FURNACE  
FURNACE  
2" MIN.  
1" MIN.  
1" MIN.  
9 FEET  
9 FEET  
HOT AIR  
PLENUM  
EXISTING  
FURNACE  
(if used)  
FURNACE  
HOT AIR DUCT  
MINIMUM CLEARANCES  
TO COMBUSTIBLES  
CAUTION: The warm air supply outlet of the supplementary  
furnace should not be connected to the cold-air return inlet of the  
central furnace because a possibility exists of components of the  
central furnace overheating causing it not to operate properly.  
RETURN AIR IS VERY IMPORTANT  
When installing a Clayton Furnace, return air must be incorpo-  
rated into the system. Return air can be provided by installing a  
separate duct system or by tying into the cold air return of an  
existing gas or oil furnace. The cold air return duct can be  
connected to the furnace with either a factory manufactured U.S.  
Stove filter box or an equivalent fabricated from sheet metal (See  
pages 22-23).  
INCORRECT  
INSTALLATION  
NO RETURN  
When installing a cold air return, the following minimum  
size should be maintained to insure proper furnace  
performance.  
AIR PROVIDED  
Model 1600M — 16" x 20" or equivalent (320 sq. in.)  
FURNACE  
EXISTING  
FURNACE  
Failure to provide return air ducts of the specified size  
voids the furnace warranty.  
A filter should be installed in the cold air return. Furnace filters  
should be checked and cleaned or replaced regularly.  
COMBUSTION AIR  
All fires need air (specifically oxygen) to burn. Furnaces, fire-  
places, and wood-burning furnaces need enough oxygen for  
complete combustion of their fuels. The incomplete combustion  
that takes place when a furnace is "air starved" causes carbon  
monoxide (CO) to be formed in quantities that can be dangerous  
inside a well-sealed house. Having a source of combustion air  
from outside prevents this "air starvation" of the furnace. A simple  
positive air supply can be constructed using dryer vent and a  
Ifreturnairisnotprovided, thewarmairdistributedintoyourhome  
will be restricted and the efficiency of the furnace decreased.  
Without a return air system, warm air will be drawn into your  
basement, unnecessarily heating unused areas of the home. In  
extreme cases, if your basement or utility room is fairly air tight,  
the large blower on the 1600M could depressurize the room and  
pull toxic flue gases from the furnace, a gas water heater, or gas  
furnace. The fumes could then be distributed throughout the  
house.  
modified termination.  
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ASSEMBLY INSTRUCTIONS  
Your furnace is shipped from the factory in four (2) packages. 1)  
BRICK INSTALLATION  
(PRE-INSTALLED AT FACTORY)  
the furnace, 2) the blower. The draft kit and parts box containing  
all parts necessary, and the fan thermodisc kit is boxed and  
packed in the firebox or ash pan. Before assembling the furnace,  
check to make sure there is no shipping damage, and that all  
necessary parts are located in the firebox. See parts list below.  
NOTE: Prior to operation, be sure to remove brick  
retaining strips.  
If you find shipping damage or any of the parts missing, contact  
the dealer immediately. He will take the necessary steps to  
correct the problem.  
MODEL 1600M - (6) BRICKS ON EACH SIDE  
FIREBOX LEFT SIDE  
Parts List  
All models include the following:  
(2) Door Handles  
(1) 1/4" x 1" Hex Bolt  
(1) 3/8" Lock Nut  
(1) 3/8" Jam Nut  
(2) 3/8" x 2 1/2" Carriage Bolt  
(6) 1/4" x 3/4" Hex Bolts  
(1) Smoke Door  
(1) Fuel Door Latch  
(1) Ash Door Latch  
(2) 1/2" Washers  
(9) 1/4" Kep Nuts  
(2) Spin Draft  
BRICK RETAINING STRIP  
SLIDE 4th BRICK BACK  
BEFORE INSTALLING 5th  
AND 6th BRICK  
(4) Brass Coil Knobs  
(1) Shaker Handle  
(1) Hinge Bracket  
(2) 1/4" x 1-1/4" Carriage Bolts  
(2) Smoke Door Clips  
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.  
DOOR HANDLE INSTALLATION  
Insert door handle into door. From rear side of door place  
1/2" washer over threaded part of door handle. Then attach  
1/2" lock nut, being careful not to over tighten. Handle should turn  
freely.  
FUEL & ASH DOOR LATCH INSTALLATION  
Withtwo1/4"x3/4"hexbolts,attachthedoorlatchtothedoorlatch  
mounting bracket on the left side of door frame as illustrated.  
Adjust latch until door closes securely.  
FUEL DOOR  
ILLUSTRATION  
ASH DOOR  
ILLUSTRATION  
LOCK  
WASHER  
HEX  
NUTS  
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SMOKE CHAMBER (If re-assembly is necessary):  
1. Place #1 firebrick in the back of smoke chamber.  
2. Slide baffle plate into smoke chamber, flat side down.  
3. Place remaining firebrick in smoke chamber as numbered  
below.(Inplacingthefirebrickinthesmokechamber,liftthe  
left side of firebrick first and drop into place.) See Illustra  
tions below.  
2
(41/2) BRICKS  
1
1/2 BRICK  
3
5
4
6
TOP  
THE MODEL 1600M PLENUM OPENING  
13"x18" Rectangle Plenum Opening  
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SMOKE DOOR INSTALLATION  
DISTRIBUTION BLOWER INSTALLATION  
Distribution blower slides onto rear of furnace.  
Engage blower flange with channels and press down.  
SMOKE DOOR CLIPS  
1/4" LOCK  
NUTS  
1/4" X 1-1/4"  
CARRIAGE BOLTS  
FRONT  
OF  
FURNACE  
SHAKER GRATE HANDLE INSTALLATION  
1. Attach angle with two 1/4" x 3/4" hex bolts and two 1/4"  
lock nuts.  
SMOKE DOOR  
FUEL  
LOADING  
DOOR  
2. Attach handle with 1/4" x 1" hex bolt and 1/4" lock nut.  
3. Put brass knob onto end of handle.  
FRAME  
1
INSTALLING ASH DOOR SPIN DRAFT  
1. Screw spin draft onto 3/8" x 2-1/2" carriage bolt.  
2. Screw spin draft and bolt assembly into ash door  
allowing approximately 1/2" of the bolt to extend  
beyond the inside of the door.  
3. Secure bolt in place with 3/8-16" locking nut.  
2
SPIN DRAFT CAP  
3/8-16 x 2-1/2"  
CARRIAGE  
BOLT  
3
3/8-16" LOCK NUT  
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ELECTRICAL INSTALLATION  
ALL WIRING MUST  
BE DONE BY A  
QUALIFIED  
Predrilled holes are provided on the back of  
the furnace for mounting the electrical box.  
ELECTRICIAN  
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ALL WIRING MUST BE DONE  
BYAQUALIFIEDELECTRICIAN  
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TESTING AND OPERATING PROCEDURES  
5. Close the spin draft cap on ash door.  
TESTING:  
1. Check the draft blower (optional) by turning the room  
6. The motorized natural draft cycles on demand from the  
U.S. Stove wall thermostat. Setting the thermostat four  
degrees higher that your existing thermostat is recom-  
mended.  
thermostat up high enough so that the draft blower turns  
on. Then ower the thermostat setting until you hear it shut  
off.  
2. Use a sheet of newspaper to test your draft by placing it  
inside the furnace and lighting it.  
During operation, the motorized natural draft remains  
open until the thermostat temperature setting is reached.  
With completion of the tests above, you are ready to light the  
furnace. Follow the operating steps.  
CAUTION: Hot Surfaces. Keep children away. Do not  
touch while in operation.  
STARTING A WOOD FIRE  
Using Forced Air Draft (optional)  
CAUTION: Cleaning of the heat exchanger, flue pipe,  
chimney and draft inducer, if used, is especially important  
at the end of the heating season to minimize corrosion  
during the summer months caused by accumulated ash.  
Shut off FAD when fuel door is open.  
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.  
1. Open spin draft cap on ash door.  
CAUTION: Do not use chemicals or fluids to start the fire.  
2. Pull the slide baffle rod to the front position.  
3. Open the fuel load door and light fire using kindling and  
several sheets of newspaper, then close the furnace door.  
The furnace door should remain closed for 5 to 10 minutes  
in order to establish the fire. If the fire has established, you  
are ready to load the furnace.  
CAUTION: To avoid excessive temperatures, do not op-  
erate with fuel door or ash pan open.  
STARTING A COAL FIRE  
If you burn coal a Forced Air Draft may be required.  
CAUTION: To prevent flame and smoke spillage, the slide baffle  
must be pulled out and the fuel door must be cracked for ten  
seconds before being fully opened.  
Shut off FAD when fuel door is open.  
Open smoke pipe damper all the way. Open all draft controls  
on your furnace. Pull the slide baffle forward.  
Do not over fire your furnace! After you have become familiar with  
its operating, you should know how much wood to use.  
Place about 10-15 lbs. of coal in on the shaker grates. It should  
come up to about half of the first firebrick level.  
4. Load the furnace, close the load door and push the  
slide Baffle rod to rear.  
Place crumpled paper over the coal and criss-cross a couple  
handfuls of dry kindling wood 3/4" in thickness on top of paper.  
5. Close the spin draft cap on ash door.  
6. The forced air draft cycles on demand from the wall  
thermostat. Setting the U.S. Stove thermostat four degrees  
higher than your existing thermostat is recommended. In  
operation, the power draft blower will run until the U.S.  
Stove thermostat temperature setting is reached. The draft  
regulator on the forced air draft is preset at the factory and  
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 Hotblast Furnace reacts together-adjusts drafts  
accordingly.  
should require no adjustment.  
STARTING A WOOD FIRE  
UsingManaulNaturalDraft  
Loading with a good bed of coals in the morning-open by-pass  
damper.  
Shut off FAD when fuel door is open.  
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.  
1. In normal shaking, only rock the grates a small amount to  
sift ash through.  
2. Remove all ashes every day from ash pit.  
3. With your poker, push hot burning embers to the rear of the  
unit and add green coal in front. NEVER load over height  
of firebrick. This can result in damage to your furnace and  
home.  
1. Turn up thermostat to open manual damper.  
2. Open spin draft cap on ash door.  
3. Pull the slide baffle rod to the front position.  
4. Close by-pass damper.  
4. Open the fuel load door and light fire using kindling and  
several sheets of newspaper, then close the furnace door.  
The furnace door should remain closed for 5 to 10 minutes  
in order to establish the fire. If the fire has established, you  
are ready to load the furnace.  
Too much draft air will cause clinkering of coal and will waste  
heat up the chimney. Shut draft down to as low a point as you  
can and still heat your home.  
1. NOTE: Never stand in front of loading door when opening  
it. Stand to the side.  
CAUTION: To prevent flame and smoke spillage, the slide baffle  
must be pulled out and the fuel door must be cracked for ten  
seconds before being fully opened.  
2. NEVER completely cover the live fire with fresh coal.  
Always leave a generous area of glowing coal at the top  
of the fire and at the rear.  
Do not over fire your furnace! After you have become familiar with  
its operation, you should know how much wood to use.  
3. Always keep the ash pit clean.  
4. Load the furnace, close the load door and push the slide  
baffle rod to rear.  
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Do not store fuel or other combustible material within marked  
installation clearances.  
OPERATING NOTES  
Do not over draft the furnace! It is designed to operate at .06  
inches of water column and must be set with a draft gauge to  
maintain a steady draft. (Barometric Damper recommended.)  
Disposal of Ashes - Ashes should 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,  
well away from all combustible materials, pending final disposal.  
If the ashes are disposed of by burial in soil or otherwise locally  
dispersed, they should be retained in the closed container until  
all cinders have thoroughly cooled outside.  
Do not allow ashes to build up higher than 2" above grates.  
Be extremely careful when removing furnace ash pan; it can  
get very hot.  
With new steel, there is a small amount of oil or dirt on the  
metal. You may smell an odor. This is normal during the first  
operation. You may want to assemble the furnace out of doors  
and build a small fire in it to "burn off" this dirt and oil  
before installing the unit.  
NOTE: For further information on using your furnace safely,  
obtain a copy of the National Fire Protection Association publi-  
cation "Using Coal and Wood Stoves Safely." NFPA NO. NW-8-  
1974. The address of the NFPA is 470 Atlantic Ave., Boston,  
Massachusetts 02210.  
The furnace is designed to burn air dried wood at a predeter-  
mined firing rate. Over firing could result in damage to the heat  
exchanger and cause dangerous operation. Over firing occurs  
when the ash door is left open during operation or a highly  
volatile fuel, i.e. large amounts of small kindling, is used.  
THIS IS A WOOD AND COAL  
BURNING FURNACE AND  
SHOULD NOT BE ALTERED  
When tending the firebox always pull the baffle slide rod out  
prior to opening load door. Open load door slowly to avoid a  
"flash back". After closing load door, push the baffle slide rod  
to the rear.  
IN ANY WAY!  
Equip your home with fire extinguishers and smoke detectors  
Canadian Requirments for Supplementary  
(add-on) furnaces.  
appropriately located.  
Inspect air filters regularly. The air filter in the filter box should  
be changed at least every 30 days.  
Oil motor on forced air draft every 90 days with a few drops  
of 30 wt. oil.  
Do not use duct elbows having an inside radius of less than  
6 in. (150mm) on the (oil, electric, gas) furnaces.  
On electric furnaces, Do not connect to a down flow furnace.  
The distribution blower motor may be one of two types.  
If the motor has sealed bearings, no oiling is required.  
Do not connect ductwork so that a reverse flow is possible.  
If the motor is equipped with fill holes, the motor should be oiled  
every 90 days with several drops of 30 wt. oil.  
Operate the (oil, electric, gas) furnace periodically to ensure  
that it will operate satisfactorly when needed.  
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.  
Do not relocate or bypass any of the safety controls in the  
original (oil, electri, gas) furnace installation.  
Do not connect to any gas furnacethat has not been certified  
Inspect and clean your chimney and stove pipe regularly.  
initiallyas complying with CAN/CGA-2.3  
In event of chimney fire, shut all draft controls and call your fire  
department immediately. Alert everyone in the house. If the fire  
is still burning vigorously, throw baking soda into firebox or  
discharge a fire extinguisher into the firebox. After chimney fire  
is over, completely inspect system for damage before further  
use.  
The operation of the gas furnace must be verified for accept  
able operation before and after installation of the add-on  
appliance by a gas fitter who is reconized by the regulatory  
authority.  
Do not connect to any gas furnace that is not equipped with  
an air-circulation blower, or to a chimney or vent serving a gas  
furnace or gas appliance.  
Slow fires: It is not recommended burning the Clayton furnace  
any more than necessary early in the fall and late spring, as you  
cannot keep the firebox hot enough (without overheating your  
home) to burn gases. Slow fires can cause excessive creosote  
build-up in smoke pipe, chimney and firebox.  
This Add-On Supplymentary Furnace should only be installed on  
a furnace duct system and chimney that are in good operating  
condition.  
Wood should be placed directly onto the cast iron grate of the  
Clayton furnace. Do not use additional grates and/or irons.  
In the event of a power failure, you may operate the 1600M  
furnace provided the following instructions are followed:  
Outside Combustion air may be necessary if:  
1. Any air filter should be removed.  
1. The solid-fueled fired appliance does not draw steadily,  
smell, experiences smoke roll-out, burn poorly, or back  
drafts whether or not there is combustion present.  
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 the built-in draft regulator will automatically  
open to the preset factory spacing.  
2. Any of the above syptoms are all eviated by opening a  
window slightly on a calm day.  
3. The house is equipped with a well-sealed vapor barrier and  
tight fitting windows and/or has powered devices which  
exhaust house air.  
Do not burn garbage, plastics, gasoline, drain oil or other  
flammable liquids. Plastics, when burned, form hydrofluoric  
and hydrochloric acids which will damage and destroy your  
furnace pipe and chimney. The burning of trash or oil can result  
in an extremely hot fire and is sometimes a cause of chimney  
fires. NEVER BURN GREEN WOOD OR TIRES.  
4. There is excessive condensation on the windows in the  
winter.  
5. A ventilation system is installed in the house.  
12  
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TROUBLE SHOOTING AND PROBLEM SOLVING  
1. Problem:  
4.Problem:  
Smoke puffs from furnace  
Distributionblowervibrating  
Solution:  
Solution:  
A. Check chimney draft. Check for blocked chimney or  
flue pipe. Use mirror to check chimney clearance.  
A. Tighten blower wheel to motor shaft.  
B. Check for bad fan bearings.  
B. Check ash pit — if it is too full, empty.  
C. Make sure furnace room is not too airtight.  
5. Problem:  
Distribution blower continues to run or will not run  
Solution:  
D. Make sure all of chimney mortar connections are  
airtight.  
A. Check fan thermodisc or heat sensor and cable.  
E. Check ash drawer. Make sure it's airtight.  
B. Check to see that blower is properly wired.  
(See Wiring and Assembly Instructions).  
F. Check chimney for possible down-draft caused by  
tallersurroundingtreesorobjects.Correctwithproper  
chimney vent cap.  
C. Check fuse box or power source.  
D. Check power supply.  
G. Check the possibility of a cold chimney forcing cool  
gases backward. Remedied by properly insulating  
chimneywithnon-combustibleliner-non-combustible  
insulation.  
6. Problem:  
Draft blower continues to run or will not run  
Solution:  
H. Fuel may be too green.  
A. Checkwiring.  
I. Makesurenootherfuelburningdevicesareconnected  
to the chimney impairing the draft.  
B. Check thermostat or thermostat wire for short.  
C. Make sure temperature is calling for heat.  
J. Check chimney draft, it should be .06 inches of water  
column. This service is provided by a certified  
chimneysweep.  
7. Problem:  
Odor from first fire  
Solution:  
2. Problem:  
Inadequate heat being delivered to your home  
Solution:  
A. The odor from new steel should disappear in a few  
hours.  
A. Check home insulation — is it adequate?  
B. Check hook-up to furnace — is it installed correctly?  
B. Iftheodorremains,callyoudealerimmediately.Abad  
weld can cause a fume leak.  
C. Cool air inlet may be inadequate or furnace room too  
airtight.  
8. Problem:  
Excessive Creosote  
Solution:  
D. Yourwoodfuelmaybetoolowgrade. Hardwoodsare  
recommended.  
A. Check the grade of wood you are burning.  
E. Make sure your hot air duct (and other duct work) is  
airtight.  
B. Make sure your unit is serviced by its own proper  
chimney.  
F. If furnace room is warm but your home isn't, check  
back draft dampers.  
C. Check length of flue pipe and its connections.  
D. Makesureyouareburningthesmallest,hottestfireto  
adequately heat your home.  
G. Is air to the blower available?  
3. Problem:  
E. Also see Solutions to Problem one.  
Excess smoke or flames coming out door when refueling  
Solution:  
9. Problem:  
If the fire goes out or does not hold overnight  
Solution:  
A. Wait15secondsandopendoorSLOWLY-thenrefuel.  
B. Checklengthoffluepipetochimney.Yourunitshould  
be within six (6) feet of your chimney.  
A. Poor draft.  
B. Incorrect damper settings.  
C. Make sure chimney cap is not too close to the top of  
the chimney.  
C. Improper firing methods for coal being used.  
D. Morecombustionairneeded.  
D. Check chimney draft — make sure chimney flue pipe  
is clean and chimney is of adequate height.  
E. Coalnot sizedtothefurnace. Werecommend1"to3"  
diameter pieces of coal.  
E. Make sure you're not suffocating the fire with  
excessive amounts of unburned wood.  
F. Ashes, if allowed to accumulate in the ash pit, will not  
allowthepassageofrequiredairforcombustion.Keep  
ash pit clean.  
F. Slide baffle should be pulled out prior to load door  
opening.  
G. Thisfurnaceisnottobeusedwithanautomaticstoker  
unless so certified.  
13  
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PARTS LIS
MODEL 1600M  
TE:  
FULL BRICK  
ALF BRICK  
!! IMPORTA
When ordering rep
a "G" must be add
end of the part nu
any part painted G
thefurnace
ITEM  
1
2
3
4
5
6
7
8
9
10  
*
11  
12  
13  
14  
DECRIPTION  
PART #  
69452G  
69453G  
69088  
69454G  
C98771  
C98971  
68882  
24233  
23852  
C000047  
80351  
89066  
ITEM  
15  
16  
17  
18  
19  
20  
21  
22  
DECRIPTION  
Baffle Rod  
Top Insulation  
Front Filler  
PART #  
86603  
C98871  
23817  
23818  
22761  
23859  
83835  
40313  
40344  
Left Side Weldment, Painted  
Right Side Weldment, Painted  
Top Wrapper  
Back Weldment, Painted  
Side Insulation (2 ea.)  
Back Insulation  
Ash Pan Weldment  
Carrying Handle  
Shaker Grate Section  
Shaker Bar  
Snap in Recepticle  
Full Brick (16 ea.)  
Half Brick (3 ea.)  
Slide Baffle Plate  
Grate Retainer  
Draft Cover  
Top Flue Ring  
Draft Cap (2)  
3/8" x 2-1/2" Bolt (2)  
Back Liner  
23  
Front Liner  
23887  
24231  
40312 (2)  
* = NOT SHOWN  
14  
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PARTS LIST  
38  
40  
33  
37  
27  
34  
26  
32  
39  
31  
33  
29  
43  
45  
46  
28  
38  
30  
35  
36  
44  
38  
47  
ITEM  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
*
DESCRIPTION  
PART#  
23786  
ITEM  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
DESCRIPTION  
PART#  
Top Safety Latch  
Feed Door  
1/4" x 1-1/4" Carriage Bolt  
1/4-20 Kep Nut  
83445(2)  
83250(6)  
23800  
69091  
Ash Door  
68880  
Smoke Door Curtain  
Smoke Door Clip  
1/2" Hex Nut  
Door Latch Handle  
Ash Door Latch  
1/2" Flat Washer  
1/2" Lock Nut  
24179(2)  
23823  
23787(2)  
83276(2)  
C21899  
89574(4)  
83339(6)  
69005  
83835(2)  
83444(3)  
C21399(4)  
1/2" Coupling  
Brass Coil Knob  
1/4" x 3/4" Hex Bolt  
Shaker Grate Handle  
Hinge Bracket  
5/16" x 1" Hinge Pin  
1/2" Rope for Fire Door 52" 88057  
1/2" Rope for Ash Door 32" 88057  
24204  
Aqua-Siphon Cover  
1/-20 Kep Nuts  
23819  
1/4" x 1" Hex Bolt  
83379  
83250(4)  
15  
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PARTS LIST  
MODELS 1600M  
Fan Thermodisc Kit #69455  
1
3
ITEM  
DESCRIPTION  
PART#  
2
1
2
3
3-Speed Switch  
Plastic Knob  
80361  
C9267M  
80388  
Low Speed Thermodisc  
MODEL 1600M  
- Blower Motor Kit #69160 (1400CFM)  
- Blower Housing Kit #69281  
5
4
6
ITEM  
DESCRIPTION  
PART#  
80416  
4
5
6
3-Speed Motor 1/3 hp  
Blower Housing (1600)  
Capacitor  
C46799  
C45699  
16  
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FORCED AIR DRAFT PARTS LIST (Kit #: 69189)  
PRE-ASSEMBLED AT FACTORY  
(OPTIONALKIT)  
ITEM  
DESCRIPTION  
PART#  
80422  
C40899  
69192  
83244  
83379  
83261  
1
2
3
4
5
6
Draft Blower  
Power Supply Cord  
FAD Bracket  
10-24 Kep Nut (3ea.)  
1/4-20 x 1" Bolt (2ea)  
1/4-20 Lock Nut  
17  
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INSTALLATION OF OPTIONAL EQUIPMENT  
INSTALLING DOMESTIC HOT WATER COIL  
1. Remove access panel at rear of enclosure.  
2. With a utility knife cut out the section of fiberglass insulation  
directly behind the access panel.  
2
ACCESS  
PANEL  
3. Remove cover plate from rear of firebox.  
1
4. Place one nut on each end of the coil and thread each as  
far as they will go.  
5. Place the coil through 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 outside  
of the firebox. Tighten the nuts down securely to insure an  
airtight installation. The installation is now ready to be plumbed  
to your existing domestic hot water system. Choose one of the  
three methods described in the Hot Water Kit Installation  
Instructions.  
6. Remove knockouts from access panel and attach to furnace  
enclosure.  
7. Have a qualified plumber connect your domestic hot water  
pipe to the coil with appropriate fittings.  
3
4
5
REAR WALL OF FIREBOX  
DOMESTIC HOT  
WATER COIL  
TURN INSIDE NUTS UP  
TO END OF THREADS  
1. NUT  
2. WASHER  
3. GASKET  
6
18  
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INSTALLING OPTIONAL BACK DRAFT DAMPER  
The back draft damper may be installed in either a vertical or horizontal section of the hot air duct. It should be positioned as close to  
the plenum opening of the furnace as practical. Press female end of the back draft damper over Clayton Furnace collar or male end  
of the duct pipe. When properly placed the arrows on the air flow decal should point away from the furnace.  
DUCT  
OSITION SO  
FLOW WILL  
MPER  
OTTOM.  
SO  
WILL  
N  
AL  
LATION  
19  
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HOW TO ORDER REPAIR PARTS  
THIS MANUAL WILL HELP YOU OBTAIN EFFICIENT, DEPENDABLE SERVICE FROM THE  
HEATER, AND ENABLE YOU TO ORDER REPAIR PARTS CORRECTLY.  
KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.  
WHEN WRITING, ALWAYS GIVE THE FULL MODEL NUMBER WHICH IS ON THE NAMEPLATE  
ATTACHED TO THE BACK OF THE HEATER.  
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE  
FOLLOWING INFORMATION AS SHOWN IN THIS LIST:  
1. The PART NUMBER  
2. The PART DESCRIPTION  
3. The MODEL NUMBER: 1600M  
4. The SERIAL NUMBER: ____________________  
UNITED STATES STOVE COMPANY  
227 Industrial Park Road  
P.O. Box 151  
South Pittsburg, TN 37380  
(423) 837-2100  
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