Clayton 1602M User Manual
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Installation/Operator’s Manual
Model: 1602M
Wood or Coal Gravity Style (Up-Flow) Supplemental Furnace
SAFETY NOTICE:
If this furnace is not properly installed, a house re may result! For your safety, follow these installation
instructions. Contact local building or re ofcials about restrictions and installation requirements in your
area. This furnace must be installed by a qualied technician. Keep these instructions for future reference.
Safety Tested to UL 391
United States Stove Company • 227 Industrial Park Road, P.O. Box 151 • South Pittsburg, TN 37380 • www.usstove.com
1USSC 851767 rev 0
INTRODUCTION
Thank You for your purchase of a U.S. Stove Wood/Coal
Burning Gravity Style (Up-Flow) Furnace. Your decision to
buy our Clayton Furnace was undoubtedly reached after much careful thought and consideration. We are very
proud you chose this furnace and trust you will receive
the comfort and economy that others realize when heating with a U.S. Stove product.
Your dealer is important in your experience with the furnace not only with the purchase, but for recommendations for professional installation in your home. The
qualied professional installer has been expertly trained
in solid-fuel furnace installation to assure the safety and
comfort for your family while saving you money. Trust your
experienced installer. He is a specialist in this eld.
IMPORTANT
Before installing and using your Clayton furnace, please
read the following pages thoroughly and carefully. If you
follow the instructions, your Clayton furnace will give you
safe and more dependable service for years to come.
• First step: Check your local codes. This installation must
comply with their rulings.
• Do Not install this furnace in a mobile home or trailer
• Always have a smoke or ionization detector and a CO
detector installed in your home.
• To prevent injury or damage, do not allow anyone
who is unfamiliar with the furnace to operate it.
• This furnace must be installed ONLY in the prescribed
manner shown in illustrations 1, 2, or 3 under the In-
stallation Examples in this manual. It is NEVER to be
installed as a counter-ow or down-draft furnace, or
in any manner wherein the heated air is directed in a
downward ow into the home or toward to an existing
central furnace.
• NEVER INSTALL outside the home.
• Spend adequate time with your furnace to become
well acquainted with the different settings and how
each will affect its burning patterns. It is impossible to
state just how each setting will affect your furnace because of the variations in each installation.
DISCLAIMER NOTICE
The BTU ranges and heating capacity specications are
provided as a guide and in no way guarantee the output
or capacity of this unit. The actual BTU output depends
on the type of fuel being burned and its conditions, the
thermostat setting, the draft adjustment and the chimney
to which the unit is attached. The actual area that this
unit will heat depends on factors such as the conditions
of the building, 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 specied in these instructions. Doing so may void your warranty.
Do not place the furnace directly on a combustible oor.
If you are placing it on a combustible oor, an approved
re retardant material, equivalent to 3/8” UL Listed millboard, should be placed under the unit. The material must
extend at least 16 inches beyond the front of the unit and
8 inches on either side of the fuel loading door opening.
It must also extend underneath the chimney connector
and to each side of the connector by at least 2 inches.
CLEARANCES
COMBUSTIBLE WALL
20”
22”
FLUE
COMBUSTIBLE WALL
12”
REDUCED CLEARANCES
NFPA guidelines and most codes permit reduced clearances to combustible walls and ceilings if adequate
protection is added. A common mistake is to assume
that sheet metal, masonry, or millboard placed directly
against a wall protects it. Materials installed in this manner actually provides very little protection. These materials
are good heat conductors, so they will be almost as hot
on their back side as they are on the exposed side. Therefore, the combustible wall behind is still a re hazard.
A wall can be kept cool using these items but only if they
are mounted and spaced out from the wall by an inch
or two to allow free air circulation behind the protective
panel. The protective panel should also have a gap between the oor and ceiling.
Three rules to follow when constructing wall protectors:
1. Non-combustibility of all materials including mounting and supporting.
2. A well ventilated air space between protector and wall.
3. Sufcient strength and rigidity so that the protector
and air space will be durable.
2” FROM CEILING
CONSTRUCTING
NON-COMBUSTIBLE
WALLS
15”
(TOP VIEW)
MINIMUM CLEARANCES
TO A COMBUSTIBLE
WALL
CAUTION:
DO NOT store
combustible or
flammable materials or
liquids near the
furnace.
PROTECTIVE COVERING
AND ALL SUPPORTS MUST
BE NON-COMBUSTIBLE
LOCATING YOUR FURNACE
1” AIR SPACE
The furnace is to be installed maintaining the clearances
specied in the following illustrations.
2” FROM FLOOR
2 USSC
CHIMNEY REQUIREMENTS
A reclay lined masonry or Class A 103HT All-Fuel Metal
Insulated Chimney must be used in all airtight wood furnace installations. The minimum recommended ue size
for the model 1602 is 6 inches, inside diameter. When making new chimney installations, always follow the chimney
manufacturer’s instructions.
If at all possible, use the factory built, class A 103HT chimney mentioned above. They are safer and perform better
than traditional masonry chimneys. If a masonry chimney
is a must, be certain it has a re clay liner and that it is
intact, clean and recently inspected. And remember,
masonry chimneys are far more prone to the formation of
hazardous creosote.
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 ue of a slow-burning re. As a result,
creosote residue accumulates on the ue lining. When
ignited, this creosote makes an extremely hot re.
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 re.
SMOKE PIPE INSTALLATION
Clearances to combustible materials (i.e. paneling, ceiling tile, sheet rock, plaster, draperies, casements or wood
trim, etc.) will vary with the type of ue connection used.
Be sure to maintain the specied clearances for your type
of installation.
TYPE OF FLUE REQUIRED
CONNECTION CLEARANCE
24 Gauge or Heavier ..................................18”
Single Wall Stainless Steel
or Black Pipe
Double Wall, Stainless Steel or
Double Wall, Black Pipe w/
Stainless Steel Inner wall
Class A 103HT All-Fuel or Equivalent
.................... 6”
..........2”
1. The furnace should be the only heating using the
chimney ue . One furnace per ue outlet.
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.
4. There should be no mortar or parts of the chimney
blocking the chimney ue.
5. There should be a two inch clearance between any
chimney (masonry or metal) and combustibles. (such
as the house)
6. The chimney should extend at least 2 foot above the
highest point of the house, or 2 foot above the point at
which the chimney is 10 foot from the roof.
7. The chimney should be relatively straight and vertical.
8. The portion of an all-fuel metal chimney that extends
above the roof should be well secured.
9. A masonry chimney should be built on footings and
not attached to the house.
10. A rain cap, complete with an animal or bird screen,
should be installed on top of the chimney.
According to NFPA standards, single wall stove pipes
can be within 9” of combustibles provided an approved
re retardant material covered with 28 gauge sheet
metal, spaced out 1” on non-combustible spacers, is
utilized. See illustration.
When using a Class A or double wall ue pipe connection,
follow the manufacturer’s instructions.
When constructing a single wall smoke pipe, the following
guidelines must be observed.
1. The connector pipe should be 24 gauge or heavier
stainless steel or black pipe.
2. Secure all joints with three #8 screws.
3. If the connector 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” diameter smoke pipe needs an 18” thimble).
4. The connector pipe should never be used as a chimney.
3USSC
IMPORTANT INFORMATION FOR ALL
CONNECTOR PIPES
The connector pipe must be constructed and installed
so that it maintains clearances, keeps condensation and
creosote within the pipe, and is capable of withstanding
a 2100°F degree chimney re.
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.
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 ue opening on the furnace.
5. The connector pipe should not block the ue 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.
7. The connector pipe should not leave the heated portion of the building to reach the chimney.
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.
9. The connector pipe and any elbows must be of 24
gauge 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.
12. Install a cast iron adjustable damper in the rst joint of
the connector pipe, nearest to the ue collar.
DAMPERS ON STOVE PIPES
When burning coal, we recommend a Barometric Draft
Damper be installed at a safe convenient place between
chimney and your furnace preferably less than 3’ from the
ue collar.
When you have installed the connector pipe between
your furnace and the chimney, tap the pipe hard with
your ngernail. Remember the sound it makes - it will be a
“ting” echoing inside the stove pipe. If later you tap and
hear a mufed 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 wood burning appliances vent into a separate ue from
gas or oil furnaces. If such an installation is contemplated,
rst check with a local building inspector to nd out if a
separate ue for a wood burner is required.
Use of a Barometric Draft Control (when burning wood) is
recommended ONLY in the event your chimney creates
excessive draft leading to an over-ring condition.
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 guidelines
only and are intended to enable the furnace user to obtain
reasonable efciency 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:
1. The use of a cold air return and/or lter box is mandatory.
This will not only increase your blower life and provide
ltered air, it will also help prevent the blower or blowers
from “capturing” heated air exiting from the top of the
furnace heat outlets.
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.
3. All larger furnaces (or those with multi-speed blowers)
absolutely require BACK PRESSURE to prevent premature
motor winding failure. If allowed to operate at high RPM
(As in “FREE AIR” mode - no duct work or ow restrictions)
the windings overheat, insulation melts and the motor
simply burns up - not covered under warranty.
CONNECTING HOT AIR DUCT
TO FURNACE
We strongly recommend that the hot 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 qualied heating technician
and follow his recommendations as to the safest and most
efcient method of installation.
The following illustrations are the ONLY acceptable congurations when installed with existing oil or gas furnaces.
INSTALLATION EXAMPLES
INSTALLATION #1
With this installation, a back draft damper (optional) 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
damper is employed, it should be located as close to the
existing furnace plenum as practical.
HEATED AIR DISCHARGE
The Clayton furnace is designed for use as a supplemental
heating source. When used as a supplementary furnace,
it 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.
4 USSC
INSTALLATION #2
Extending the hot air duct from the furnace into the existing
plenum will help direct the ow of air from the furnace as
well as the ow in the existing furnace. Ducting entering
the existing plenum at an angle (approximately 45 degrees)
will facilitate air ow from the furnace while diverting air
from the existing furnace.
INSTALLATION #3
The bafe on this system should be made the full width of
the furnace plenum in order to properly direct the air into
the distribution ducts.
RETURN AIR IS VERY IMPORTANT
When installing a Clayton Furnace, return air MUST BE in-
corporated 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 lter box, model
UFB908 or an equivalent fabricated from sheet metal.
When installing a cold air return, the minimum size shall
be a 16” x 20” or equivalent (320 sq. in.) in order to insure
proper furnace performance. Failure to provide return air
ducts of the specied size will void your warranty.
A lter should be installed in the cold air return. Furnace lters should be checked and cleaned/replaced regularly.
If return air is not provided, the warm air distributed into
your home will be restricted and the efciency of the
furnace is 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 airtight, the blowers on
the furnace could depressurize the room and pull toxic
ue gases from the furnace, a gas water heater, or gas
furnace. The fumes could then be distributed throughout
the house.
THE PLENUM OPENINGS DIFFER
BETWEEN THE 1602 AND 1802
PLENUM OPENING
MODEL 1602 - 13” x 18” Rectangular
MODEL 1802 - 18” x 18” Rectangular
NEGATIVE
PRESSURE IN
BASEMENT
COMBUSTION AIR
All res need air (specically oxygen) to burn. Furnaces,
replaces, 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
the home will prevent “air starvation” of the furnace. A
simple positive air supply can be constructed using dryer
vent and a modied termination.
5USSC
FURNACE ASSEMBLY INSTRUCTIONS
Unpack your Furnace and insure that there is no shipping
damage. If damage exist, please contact your dealer immediately.
Your Clayton Furnace will require some assembly before
operation. All needed hardware and components for the
following assemblies are included within the parts boxes
inside the furnace and in the ash pan. Read and follow
these instructions for proper furnace assembly.
DOOR HANDLES
Insert door handle into door. From rear side of door, place
a 1/2” washer over the threaded part of the handle, then
attach the lock nut. Tighten the nut, then back off 1/4
turn to allow free operation of the handle.
Follow these same directions for the ash door handle assembly.
(2) Door Handle
(2) 1/2” Washer
(2) 1/2” Lock Nut
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 1/420 Lock Nuts. Next, insert the shaker Rod into the bracket
and attach to the shaker grate bar using the 1/4-20 x 1”
Hex Bolt and a 1/4-20 Lock Nut. The bolt and nut retaining
the shaker bar and rod should be left loose to allow free
movement of the grates.
(1) Shaker Rod
(1) Shaker Bracket
(1) 1/4-20 x 1” Hex Bolt
(2) 1/4-20 x 3/4” Hex Bolt
(3) 1/4-20 Lock Nut
BRACKET
ASH DOOR SPIN DRAFT
Screw the spin draft onto the 3/8” x 2-1/2” carriage bolt.
Then screw the spin draft and bolt into the ash door allowing approximately 1/2” of the bolt to stick through the
back side of the ash door. Secure the bolt in place with
the 3/8”-16 lock nut.
(1) Spin Draft
(1) 3/8-16 Carriage Bolt
(1) 3/8-16 Lock Nut
FUEL & ASH DOOR LATCH
With two 1/4-20 x 3/4 hex bolts each, attach the door
latches to the door latch mounting brackets on the left
side of the door frames as illustrated. The slots in the brackets and latches are for door seal adjustment. Make the
proper adjustments, then tighten the nuts. The door’s gasket should be snug against the door frame on the furnace.
(1) Feed Door Latch
(1) Ash Door Latch
(4) 1/4-20 x 3/4 Hex Bolt
(4) 1/4-20 Kep Nut
Feed Door
Illustration
Ash Door
Illustration
SMOKE CURTAIN
Using two 1/4-20 x 1-1/4” Carriage bolts, the smoke curtain clips and two nuts, attach the smoke curtain in place
above the Fuel Feed Door as shown below. After installation, the smoke curtain should swing freely back into the
furnace.
(1) Smoke Curtain (2) Smoke Curtain Clips
(2) 1/4-20 x 1-1/4 Carriage Bolt (2) 1/4-20 Kep Nut
1/4-20 NUT
SMOKE CURTAIN
CLIP
1/4-20 x 1-1/4
CARRIAGE BOLT
SMOKE CURTAIN
SMOKE CURTAIN
CLIP
SMOKE CURTAIN
NUT
BOLT
FRONT
6 USSC
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