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Installation/Operator’s Manual
SAVE THESE INSTRUCTIONS
Certifi ed for installations in the USA and Canada.
Certified to comply with 2015 particulate emissions standards.
Model: 1602R
Wood or Coal Gravity Style (Up-Flow) Central or Supplemental Furnace (USA)
Stand-Alone Central Furnace for Canadian installations
If this furnace is not properly installed, a house re may result! For your safety, follow these installation instructions. Contact
local building or re o cials about restrictions and installation requirements in your area. is furnace must be installed by a
quali ed technician. Keep these instructions for future reference.
United States Stove Company • 227 Industrial Park Road, P.O. Box 151 • South Pittsburg, TN 37380 • www.usstove.com
Safety Tested to UL 391-2010 and CAN/CSA B366.1-M91
U.S. Environmental Protection Agency
SAFETY NOTICE:
851775B-1908E
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INTRODUCTION
ank You for your purchase of a U.S. Stove Wood/Coal Burning
Gravity Style (Up-Flow) Furnace. Your decision to buy our furnace was undoubtedly reached a er 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. e quali ed 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.
DISCLAIMER NOTICE
e BTU ranges and heating capacity speci cations are provided
as a guide and in no way guarantee the output or capacity of
this unit. e actual BTU output depends on the type of fuel being burned and its conditions, the thermostat setting, the dra
adjustment and the chimney to which the unit is attached. e
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 speci-
ed in these instructions. Doing so may void your warranty.
GENERAL NOTES
• Equip your home with re extinguishers and smoke detectors appropriately located.
• e furnace is designed to burn air dried wood and coal at a
predetermined ring rate.
• Do not burn garbage, gasoline, naphtha, engine oil or other
inappropriate materials. Plastics, when burned, form hydro uoric and hydrochloric acids which will damage and destroy your furnace pipe and chimney. e burning of trash
or oil can result in an extremely hot re and is sometimes
a cause of chimney res. NEVER BURN GREEN WOOD
OR TIRES.
• Solid-fuel burning appliances need to be cleaned frequently
because soot, creosote, and ash may accumulate. Establish
a routine for storage of fuel, ring techniques, and care for
the appliance.
• Keep Ash and Fuel loading doors closed during operation.
Check the t on the load door as it must t tightly. If it does
not, check for deterioration or wear of the ceramic rope seal.
Maintain all seals in good condition.
• Do not store fuel or other combustible material within
marked installation clearances or within the space required
for re-fueling and routine maintenance.
• Wood should be placed directly onto the cast iron shaker
grate of the furnace. Do not use additional grates and/or
irons.
• Slow res: It is not recommended burning the furnace any
more than necessary early in the fall and late spring, as you
cannot keep the rebox hot enough (without overheating
your home) to burn gases. Slow res can cause excessive
creosote build-up in smoke pipe, chimney and rebox. It is
better to keep a small, intense re as oppose to a large smoldering re. Be aware that the hotter the re, the less creosote
is deposited. Weekly cleanings may be necessary in mild
weather, even though monthly cleaning may be enough during the coldest months.
• Inspect and clean your chimney and stove pipe regularly.
Check daily for creosote build-up until experience shows
how o en cleaning is necessary.
• Do not over dra the furnace! It is designed to operate at .06
inches of water column and must be set with a dra gauge to
maintain a steady dra . (Barometric Damper recommended.) If allowed to operate at a higher rate, it could cause a
solid fuel re to burn out of control.
• Never over re your furnace. Over ring could result in
damage to the heat exchanger and cause dangerous operation. Over ring occurs when the ash door is le open during operation or a highly volatile fuel, i.e. large amounts
of small kindling, is used. If any portion of the connector
pipe glows orange or red, you are in an over- ring situation.
Have a clearly understood plan for such a situation.
• In event of a chimney re, completely shut all dra controls
and call your re department immediately. Alert everyone
in the house. If the re is still burning vigorously, throw baking soda into rebox or discharge a re extinguisher into
the rebox. A er chimney re is over, completely inspect
system for damage before further use.
• NEVER throw water on the re or at the furnace, as rapidly
expanding steam could result in a severe scalding.
• Do not allow ashes to build up higher than 2” above grates.
Never allow the ashes in the ash pan touch the grate section.
REMOVE ASHES FREQUENTLY!
• Be extremely careful when removing the furnace ash pan; it
can get very hot.
• CAUTION: Ashes should be placed in a steel/metal container with a tight tting lid. e closed container of ashes should be placed on a non-combustible oor or on the
ground well away from all combustible materials pending
nal 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 coals have thoroughly cooled. Do
not place other waste inside this container.
• With new steel, there is a small amount of oil or dirt on the
metal. You may smell an odor. is is normal during the
rst operation. You may want to assemble the furnace out of
doors and build a small re in it to “burn o ” this dirt and
oil before installing the unit.
• When tending the rebox always pull the ba e slide rod out
prior to opening load door. Open load door slowly to avoid
a “ ash back”. A er closing load door, push the ba e slide
rod to the rear.
• Inspect air lters regularly. e air lter in the lter box
should be changed at least every 30 days.
• Oil motor on forced air dra every 90 days with a few drops
of 30 wt. oil.
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• e distribution blower motors may be one of two types. If
the motor has sealed bearings, no oiling is required.
• If the motor is equipped with ll holes, the motor should be
oiled every 90 days with several drops of 30 wt. oil.
• If exhaust or attic fans (or similar) are used, they MUST
NOT create a negative pressure inside the area or room
where the furnace is installed. is will starve the furnace of
combustion air and will not function properly.
CAUTION: CLEANOUT 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 ACCUMULATIVE ASH.
NOTE: For further information on using your furnace safely,
obtain a copy of the National Fire Protection Association publication “Using Coal and Wood Stoves Safely.” NFPA NO. NW8-1974. e address of the NFPA is 470 Atlantic Ave., Boston,
Massachusetts 02210.
IMPORTANT
Before installing and using your furnace, please read the following pages thoroughly and carefully. If you follow the instructions,
your furnace will give you safe and more dependable service for
years to come.
• First step: Check your local codes. is installation must
comply with their rulings.
• Determine if the installation will be as a Central or Supplemental Furnace.
• 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.
• is furnace must be installed ONLY in the prescribed
manner shown in illustrations 1, 2, or 3 under the Installation Examples in this manual. It is NEVER to be installed
as a counter- ow or down-dra 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 di erent settings and how each will a ect
its burning patterns. It is impossible to state just how each
setting will a ect your furnace because of the variations in
each installation.
LOCATING YOUR FURNACE
e furnace is to be installed maintaining the clearances speci ed in the following illustrations.
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. e 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
[55.9cm]
22”
COMBUSTIBLE WALL
[30.5cm]
12”
[50.8cm]
20”
FLUE
15”
[38.1cm]
(TOP VIEW)
MINIMUM CLEARANCES
TO A COMBUSTIBLE
WALL
CAUTION:
DO NOT store
combustible or
flammable materials or
liquids near the
furnace.
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.
ese materials are good heat conductors, so they will be almost
as hot on their back side as they are on the exposed side. erefore, 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. e protective
panel should also have a gap between the oor and ceiling.
ree 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. Su cient strength and rigidity so that the protector and air
space will be durable.
2 in. [5cm]
FROM CEILING
PROTECTIVE COVERING
CONSTRUCTING
NON-COMBUSTIBLE
WALLS
1 in [2.5cm]
AIR SPACE
2 in [5cm]
FROM FLOOR
CHIMNEY REQUIREMENTS
A reclay lined masonry or Class A 103HT All-Fuel Metal Insulated Chimney must be used in all airtight wood furnace installations. e minimum recommended ue size for this furnace
is 6 inches, inside diameter. When making new chimney installations, always follow the chimney manufacturer’s instructions.
Keep chimney clean and in good condition.
If at all possible, use the factory built, class A 103HT chimney
AND ALL SUPPORTS MUST
BE NON-COMBUSTIBLE
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mentioned above. ey 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.
TOP OF CHIMNEY MUST BE
2 FEET [61cm] ABOVE
HIGHEST POINT OF THE
ROOF WITHIN 10 FEET
[305cm].
2 FT [61cm]
MINIMUM
MINIMUM 3 FT[91cm] FROM
TOP OF CHIM NEY TO
POINT AT WHICH IT
PASSES THROUGH THE
ROOF.
3 FT [91cm]
MINIMUM
RECOMMENDED
MINIMUM HEIGHT
20 FT [610cm]
cumulates on the ue lining. When ignited, this creosote makes
an extremely hot re.
e 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 speci ed clearances for your type of installation.
TYPE OF FLUE REQUIRED
CONNECTION CLEARANCE
24 Gauge or Heavier ........................................... 18” [45.7cm]
Single Wall Stainless Steel
or Black Pipe
Double Wall, Stainless Steel or .......................... 6” [15.2cm]
Double Wall, Black Pipe w/
Stainless Steel Inner wall
Class A 103HT All-Fuel or Equivalent ............ 2” [5.1cm]
1. e 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. e masonry chimney should not have any missing mortar
or loose bricks.
4. ere should be no mortar or parts of the chimney blocking the chimney ue.
5. ere should be a two inch clearance between any chimney
(masonry or metal) and combustibles. (such as the house)
6. e 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. e chimney should be relatively straight and vertical.
8. e 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.
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. e creosote vapors condense in the relatively cool chimney ue of a slow-burning re. As a result, creosote residue ac-
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.
18” [46cm] 18” [46cm]
9” [23cm]
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. e 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. e connector pipe should never be used as a chimney.
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IMPORTANT INFORMATION FOR ALL
CONNECTOR PIPES
e 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. At no time should the connector pipe turn downward toward the chimney or run perfectly horizontal. e connector pipe should slope down toward the furnace a minimum
of 1/4”[0.6cm] per 12”[30.5cm].
2. ere should be no more than two 90 degree elbows.
3. e 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[91cm].
4. e connector pipe should never be reduced to a smaller
size than ue opening on the furnace.
5. e 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. e connector pipe should not leave the heated portion of
the building to reach the chimney.
8. e 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. e connector pipe and any elbows must be of 24 gauge or
greater.
10. e 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 Dra Damper
be installed at a safe convenient place between chimney and your
furnace preferably less than 3 feet [91cm] 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 mu ed thud, you are
building up soot in the pipe and should clean it. is pipe should
be cleaned at least once or twice during the heating season.
DO NOT CONNECT TWO HEATERS TO THE SAME CHIMNEY FLUE. e 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 Dra Control (when burning wood) is recommended ONLY in the event your chimney creates excessive
dra leading to an over- ring condition.
HEATED AIR DISCHARGE
is 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.
ough 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. e following are guidelines only and are intended to
enable the furnace user to obtain reasonable e ciency from his
furnace, and with due respect to safety when installing as a “freestanding 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. e use of a cold air return and/or lter box is mandatory.
is 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 o and on. e 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.
IMPORTANCE OF PROPER DRAFT
Dra is the force which moves air from the appliance up through
the chimney. e amount of dra in your chimney depends on
the length of the chimney, local geography, nearby obstructions
and other factors. Too much dra may cause excessive temperatures in the appliance. Inadequate dra may cause backpu ng
into the room and ‘plugging’ of the chimney.
“Inadequate dra will cause the appliance to leak smoke into the
room through appliance and chimney connector joints.”
“An uncontrollable burn or excessive temperature indicates excessive dra .”
Take into account the chimney’s location to insure it is not too
close to neighbors or in a valley which may cause unhealthy or
nuisance conditions.
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 quali ed heating technician and follow his recommendations as to the safest and most e cient method of installation.
e following illustrations are the ONLY acceptable con gurations when installed with existing oil or gas furnaces.
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INSTALLATION EXAMPLES
Installation #1
With this installation, a back dra 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-dra damper is employed, it should be located as close to the existing furnace plenum as practical.
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
e ba e on this system should be made the full width of the furnace plenum
in order to properly direct the air into the distribution ducts.
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INSPECT FLUE PIPES, FLUE PIPE JOINTS AND FLUE
PIPE SEALS REGULARLY TO ENSURE THAT SMOKE
AND FLUE GASES ARE NOT DRAWN INTO, AND CIRCULATED BY, THE AIR CIRCULATION SYSTEM.
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2” [5cm]
9 ft [274cm]
1” [2.5cm]
RETURN AIR IS VERY IMPORTANT
When installing this furnace, return air MUST BE incorporated
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. e 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
speci ed 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 e ciency 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. e fumes could then be distributed throughout the
house.
9 ft [274cm]
1” [2.5cm]
PLENUM OPENING SIZE
Rectangular
13”[33cm] x 18”[46cm]
NEGATIVE
PRESSURE IN
BASEMENT
COMBUSTION AIR
All res need air (speci cally oxygen) to burn. Furnaces, replaces, and wood burning furnaces need enough oxygen for
complete combustion of their fuels. e 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 into the room where the furnace is
installed will prevent “air starvation” of the furnace. A simple
positive air supply can be constructed using dryer vent and a
modi ed termination.
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FURNACE ASSEMBLY INSTRUCTIONS
Unpack your Furnace and insure that there is no shipping damage. If damage exist, please contact your dealer immediately.
Your 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 o 1/4 turn to allow
free operation of the handle.
Follow these same directions for the ash door handle assembly.
SHAKER GRATE HANDLE
Insert the Shaker Rod into the hole on the ash door frame as
shown. en attach the Shaker Bracket to the front of the furnace using two 1/4-20 x 3/4” Hex Bolts and two 1/4-20 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. e bolt and nut retaining the shaker bar and
rod should be le 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
(2) Door Handle
(2) 1/2” Washer
(2) 1/2” Lock Nut
ASH DOOR SPIN DRAFT
Screw the spin dra onto the 3/8” x 2-1/2” carriage bolt.
en screw the spin dra 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.
For Canadian Installations, this spin dra is replaced by a
block-o plate and must not be tampered with or removed to
increase the ring rate of the furnace.
(1) Spin Dra
(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 le side of the door
frames as illustrated. e slots in the brackets and latches are
for door seal adjustment. Make the proper adjustments, then
tighten the nuts. e door’s gasket should be snug against the
door frame on the furnace.
BRACKET
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. A er 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
(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
8
Ash Door
Illustration
SMOKE CURTAIN
SMOKE CURTAIN
CLIP
SMOKE CURTAIN
NUT
BOLT
FRONT
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SPRING HANDLES WIRING DIAGRAM
Attach the four(4) spring handles to the Feed/Ash Doors, Ba e
Rod, and Shaker Rod by twisting the springs counter-clockwise
while applying pressure until you have screwed them approximately 3/4”-1” onto the rods.
(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 control to the cabinet back.
e conduit assembly should already be attached to the
limit control, otherwise, do so then make the correct wiring connections to the limit control. See wiring diagram.
4. Next, mount the junction box and insulation using two of
the #10 x 1/2 screws provided. Make a small slice in the
5 x 5 insulation to allow the wires from the dra blower
to protrude, then Install it between the cabinet back and
junction box, with the foil side to the cabinet back. Attach
the conduit assembly from the limit control to the junction
box as shown.
5. If not already installed, snap the rocker switch into the top
of the junction box. Provide a 110 volt power supply and
connect to the junction box with the cable clamp to the
right side.
6. Attach the two longer conduit assemblies to the junction
box and to each blower.
7. Before mounting the Fan Center, make all the wire connections per the wiring diagram, then attach the fan center
to the junction box.
All electrical connections should be done by a quali ed electrician. NOTE: e extra brown wire on the fan center has no
use. It should be capped o or removed. e conduit may be cut
shorter to provide a cleaner installation.
F
I
G
H
E
B
C
J
K
A
D
Item Description Qty.
A 800 CFM Blower (2)
B Gasket, Blower (2)
C Tinnerman Clip, 1/4-20 (8)
D 1/4-20 x 3/4 Bolt (8)
E Conduit Assembly (5 ) (2)
F Honeywell Limit Control (1)
G Conduit Assembly (1 ) (1)
H Junction Box (1)
I Rocker Switch (1)
J Romex Cable Clamp (1)
K Fan Center Control (1)
- 73B Wire Nut (3)
- 74B Wire Nut (1)
- Female Term. (blue) (1)
- Female Term. (red) (1)
- #10 x 1/2 Screw (8)
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FORCED DRAFT BLOWER - 69189
Using two 1/4-20 x 1” bolts and nuts, attach the dra blower adapter
to the dra tube on the front of the furnace. en mount and secure
the dra blower to the adapter with the three 10-24 Kep nuts. Plug the
blower into the outlet on the front of the furnace.
For Canadian installations, you must install the Dra Regulator. Do so
by drilling out the rivet and removing the air shutter from the blower.
en mount the regulator over the screened plate using the same three
screws.
Screened
Plate
(1) Dra Blower (2) 1/4-20 x 1 Hex Bolt
(1) Dra Blower Adapter (2) 1/4-20 Lock Nut
(1) Dra Regulator (Canada Only) (3) 10-24 Kep Nut
For Canadian installations, you must install the cover plate once you
have completed the dra blower installation.
Using the two self drilling screws provided, attach the cover plate to the
dra cover located just below the Feed Door.
Dra
Air Shutter
Regulator
FIREBRICK AND BAFFLE REPLACEMENT
FIREBOX BRICK REPLACEMENT
is furnace comes from the factory with the rebrick installed. However, if brick replacement is necessary, follow these instructions. Before furnace operation, remove the brick retaining strip. is piece is
used during shipping to reduce brick damage.
ere are 6 full brick and 1 half brick per side. Install the half brick
rst by putting the bottom of the brick in rst and let it rest against the
rebox side and re grates. en slide it to the rear. A er that, install
the #2, #3, #4, #5 & #6 brick, sliding the 6th brick forward to allow for
the 7th brick. Repeat for opposite side.
NOTE: Prior to operation, be sure to remove the brick retaining
strips.
BAFFLE/BRICK REPLACEMENT
If ba e replacement is necessary, slide the ba e out until you can access the nuts thru the ue outlet. Once the nuts have been removed,
slide the ba e o the rod and thru the opening in the rebrick. You
may have to remove one of the rebrick to make ba e removal easier.
ere are 4 full brick and 1 half brick in the top of the furnace. Install
the brick by inserting one end of the brick angled upward and then
allowing the opposite end to rest on the rebox lip. Lay the brick between the spacer and rebox back. Slide the ba e to the rear and let it
rest on that half brick. A er installing brick #2 in the front, install #3
and slide it under the ba e. Finally install bricks #4 and #5.
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Page 11
FUEL RECOMMENDATIONS
e top down method of re building is recommended for this appliance. A er making sure that the stove air intake controls are fully open
(completely pull-out towards you), Place the largest pieces of wood on
the bottom, laid in parallel and close together. Smaller pieces are placed
in a second layer, crossways to the rst. A third layer of still smaller
pieces is laid crossways to the second, this time with some spaces between. en a fourth layer of loose, small kindling and twisted newspaper sheets tops o the pile. Higher e ciencies and lower emissions generally result when burning air dried seasoned hardwoods, as compared
to so woods or to green or freshly cut hardwoods
DO NOT BURN:
1. Garbage;
2. Lawn clippings or yard waste;
3. Materials containing rubber, including tires;
4. Materials containing plastic;
5. Waste petroleum products, paints or paint thinners, or asphalt
products;
6. Materials containing asbestos;
7. Construction or demolition debris;
8. Railroad ties or pressure-treated wood;
9. Manure or animal remains;
10. Salt water dri wood or other previously salt water saturated materials;
11. Unseasoned wood; or
TYPE WEIGHT
Hickory 63 4500 1.0 Well 31.5
White Oak 48 4100 .9 Fair 28.6
Red Oak 46 3900 .8 Fair 27.4
Beech 45 3800 .7 Hard 26.8
Sugar Maple 44 3700 .6 Fair 26.2
Black Oak 43 3700 .6 Fair 25.6
Ash 42 3600 .5 Well 25.0
Yellow Birch 40 3400 .4 Hard 23.8
Red Maple 38 3200 .3 Fair 22.6
Paper Birch 37 3100 .3 Easy 22.1
Elm/Sycamore 34 2900 .2 Very Di cult 20.1
Red Spruce 29 1800 .1 Easy 16.1
(LBS. CU. FT., DRY)
PER CORD EFFICIENCY
12. Paper products, cardboard, plywood, or particleboard. e prohibition against burning these materials does not prohibit the use of
re starters made from paper, cardboard, saw dust, wax and similar
substances for the purpose of starting a re in an a ected wood
heater.
Burning these materials may result in release of toxic fumes or render
the heater ine ective and cause smoke.
Dead wood lying on the forest oor should be considered wet, and requires full seasoning time. Standing dead wood can usually be considered to be about 2/3 seasoned. Splitting and stacking wood before it
is stored accelerates drying time. Storing wood on an elevated surface
from the ground and under a cover or covered area from rain or snow
also accelerates drying time. A good indicator if wood is ready to burn
is to check the piece ends. If there are cracks radiating in all directions
from the center then the wood should be dry enough to burn. If your
wood sizzles in the re, even though the surface is dry, it may not be
fully cured, and should be seasoned longer
ere are ONLY two types of coal allowed for use in this furnace: Bituminous Coal (so coal) and Anthracite Coal (hard coal). NEVER USE
Cannel (or Channel) coal or Brown (Lignite) Coal.
See our Bulletin RC454 on the following pages for the best information
available on burning coal.
Any type of wood may be used in your stove, but speci c varieties have
better energy yields than others. Please consult the following table in
order to make the best possible choice.
RANKING
SPLITS MILLIONS
BTU’s/CORD
WOOD FUEL UTILIZATION
It is EXTREMELY IMPORTANT that you use DRY WOOD only in
your wood stove. e wood should have dried for 9 to 15 months,
such that the humidity content (in weight) is reduced below 20% of the
weight of the log. It is very important to keep in mind that even if the
wood has been cut for one, two or even more years, it is not necessarily
dry, if it has been stored in poor conditions. Under extreme conditions
it may rot instead of drying. is point cannot be over stressed; the
vast majority of the problems related to the operation of a wood stove
is caused by the fact that the wood used was too damp or had dried in
poor conditions. ese problems can be:
- ignition problems
- creosote build-up causing chimney res
- low energy yield
- blackened windows
- incomplete log combustion
Smaller pieces of wood will dry faster. All logs exceeding 6” in diameter
should be split. e wood should not be stored directly on the ground.
Air should circulate through the cord. A 24” to 48” air space should be
le between each row of logs, which should be placed in the sunniest
location possible. e upper layer of wood should be protected from the
elements but not the sides.
When the stove is thoroughly warmed, place one piece of split wood
(about ve inches in diameter) parallel to the door on the bed of red
embers.
TESTING YOUR WOOD
Keep the air control full open and close the door. If ignition of the piece
is accomplished within 90 seconds from the time if was placed in the
stove, your wood is correctly dried. If ignition takes longer, your wood
is damp.
If your wood hisses and water or vapor escapes at the ends of the piece,
your wood is soaked or freshly cut. Do not use this wood in your stove.
Large amounts of creosote could be deposited in your chimney, creating
potential conditions for a chimney re.
11
Page 12
BULLETIN RC454
A GUIDE TO BURNING COAL IN YOUR FURNACE
Furnaces that are capable of burning coal usually will burn both
Bituminous and Anthracite coal. Anthracite is perhaps the best
coal fuel because of its long even burn time, high heat output,
and cleanliness which make it a good choice for the home. However, keep in mind it is a much more di cult fuel to use, requires
more care and patience, is not so widely available, and is usually
much more expensive than Bituminous.
SIZE OF COAL
Most sizes of Bituminous Coal will work in a coal furnace; for
best results we recommend large “nut” coal to small “egg” coal
(1-3/4” diameter to 4” diameter). When burning Anthracite, use
“egg” or “broken” with sizes between 2-5/16” thru 4-3/8”. Note
that it is important to the long life of your stove to buy coal which
has been sized and cleaned. Cleaning insures removal of rocks
and other minerals. Never use coal smaller than 1” or larger than
5” in diameter. Small sized coal will smother the re. Too large a
size of coal will not burn well.
STOVE OPERATION
All coal res should be started with wood which will allow the
re to get hot enough to ignite the coal. e best ignition res
utilize dry pine or other resinous so woods as kindling, with
hard wood (oak, hickory, ash) added to increase the heat prior to
addition of the coal.
Before starting the re, open the stove pipe damper (if equipped),
turn the thermostat to high, open the ash pit door and feed door,
place newspaper and nely split kindling on the grate, light the
paper, add larger hard wood a er the kindling is burning brightly. Caution: Never use gasoline, lantern fuel, kerosene, charcoal
lighter uid, or other ammable liquids to start or freshen up a
re in any heater. Place the larger pieces of wood on the re so
that they are slightly separated and form a level for the addition
of coal. It will take 10 to 20 minutes before this wood is thoroughly ignited. Adding coal too soon will cut the air supply and
smother the re.
BURNING BITUMINOUS
Once your kindling and wood re has produced a bed of well
established coals, start adding coal in layers allowing each to ignite before adding more. Bituminous has a high volatile content
and, as a result, should be red with the “conical method” - with
the highest portion of your re bed in the center of the rebox.
e rst ames will be long and generally orange or yellow and
produce quite a bit of smoke. As the gases burn o the ames
become shorter, change color and produce less smoke.
Once the re is WELL ESTABLISHED add coal to the center of
the rebox forming the cone. Burning in this fashion allows heat
to drive o the volatile gases, and turbulence created increases
the burn e ciency. ere will have to be some experimenting
with the individual setup as no two chimney’s or installations are
going to be the same. Just remember to allow enough air to enter
the rebox and keep the stove pipe damper open so that volatiles
are properly burned. Before refueling, take the time to break up
the cone a little with a poker, especially if it has caked over or
formed a crust. But, be careful not to mix the coal as this increases 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. e objective is to remove a small
amount of the ashes without disturbing the re. Stop when you
see a glow in the ashes or the rst red coals fall into the ash pan.
Excessive shaking wastes fuel and can expose the grate(s) to very
high temperatures which can cause warpage or burnout.
For overnight operation (long duration burn time) shake the re
and add coal, retaining the center cone. Once the volatiles are
burned o , close the feed door and adjust the stove pipe damper,
if equipped. en adjust the thermostat to the desired heat level.
More MAINTENANCE will be needed with bituminous coal
than with anthracite coal as more soot will collect on heating
surfaces and in pipes, requiring more frequent cleaning.
ANTHRACITE
Add a thin layer of coal (preferably smaller chunks) to the wood
re, being careful not to disturb it too much or cut o the dra .
en, add a second heavier layer a er the coal is ignited and
burning well. If necessary, add a third layer to bring the coal up
to the top of the front liner (not above!). Be sure to close the ash
door.
Before adding further fuel, be sure to leave a red spot of glowing
coals in the center of the rebox to insure that the re has not
been smothered and to help ignite the gases given o by the new
charge. A deep charge will give a more even heat and a longer
re, but it may take one to two hours before the whole bed is
fully ignited.
When the re is well established and the room is becoming
warm, partially close the dampers. Some experimenting will
have to take place with each particular setting of all dampers and
controls as the chimney provides the dra necessary to not only
exhaust the smoke, but to pull combustion air into the heater as
well - and no two chimney’s perform the same. Under ideal dra
conditions, one should be able to turn the secondary air supply
below the feed door (some models) to a near closed position but leave the ash pit damper at least partially open to prevent the
re from going out. Adjust the stove pipe damper to reduce the
dra on the re. With anthracite there will be short blue ames
above the coal, except when the re is started or a new charge is
added. If, however, there is no ame then the re needs more air
from the bottom (unless it is near the end of its burn cycle and
needs to be recharged).
Only when the coal is burned down to half its original depth it
is time to add fresh coal. When doing so, open the stove pipe
damper and turn the thermostat damper to high, which will allow the re to burn o any accumulated gases. Open the feed
door, and with a small rake, hoe, or hooked poker pull the glowing coals to the front of the rebox. Try not to disturb the re too
much. Next, add a fresh charge to the back being careful not to
seal o the top. Close the feed door, but leave the spin damper
(or thermostat) open for a few minutes until the volatile gases
have burned o . It is not necessary to shake down the ashes each
time you refuel the furnace. Experience will be your best teacher.
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Page 13
BANKING THE FIRE
For extended operation, such as overnight, the re will need to
be banked. To do so heap coal up along the sides and back of the
rebox so that the re gradually burns it over a longer period of
time. e intensity of the re will also be reduced without letting
it go out. Follow the same procedure as for refueling. If possible,
avoid shaking, as a heavier layer of ash will help reduce the intensity of the re during this time. A er loading, let the re establish
itself for about 30 minutes. en close your damper and automatic control to the point where the house does not become too
cold. It is important that you begin banking early enough before
retiring or leaving that you can make necessary adjustments a er
TESTING AND OPERATING PROCEDURES
the re is well established. To revive a coal re 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 dra through the grate. (2)
place a thin layer of dry coal over the entire top of the re. DO
NOT POKE OR SHAKE THE FIRE AT THIS TIME! (3) a er the
fresh coal has become well ignited shake the grate (just a little),
refuel. DO NOT burn coke, charcoal, high volatile bituminous
coal, sub bituminous, lignite or cannel coal (sometimes called
channel coal or candle coal). NEVER burn wax or chemically
impregnated sawdust logs - their intended use is for replaces
only.NEVER ll the stove or furnace above the rebrick or cast
iron liner.
GENERAL FURNACE OPERATION
A er installation of the furnace is complete, it is ready for operation. e Honeywell Limit Control, in conjunction with a wall
thermostat, operates the distribution blowers and the dra blower on the front of the furnace. e limit control can be adjusted
to your desired blower On/O times. e factory settings are
100/150/200 (USA) and 100/150/175 for Canadian Installations.
e wall thermostat setting operates the ON time of the dra
blower. If the temperature is below the setting on the wall thermostat, the dra blower will come on. (Recommended setting at
5 to 10 degrees higher than other heating thermostats.)
e rst two set points on the limit control operates the distribution blower(s). When the furnace plenum reaches the second set
point on the limit control, the distribution blower(s) will come
on. If the temperature falls to the rst set point, the distribution blower(s) will shut-o . e rocker switch on the top of the
junction box gives you the option to run one blower or two. If
the switch is ON, both blowers will come on when the plenum
reaches the set temperature.
When the furnace reaches the third set point on the limit control,
the dra blower will shut-o . e dra blower will come back on
if the temperature falls below the setting on the wall thermostat.
TESTING
Check the dra blower by turning the room thermostat up high
enough so that the dra blower turns on. en lower the thermostat setting until you hear it shut o .
Use a sheet of newspaper to test your dra by placing it inside the
furnace and lighting it.
STARTING A WOOD FIRE
Using Forced Air Draft
With completion of the tests above, you are ready to light the
furnace. Follow the operating steps.
CAUTION: DO NOT USE CHEMICALS OR FLUIDS TO
START THE FIRE. Never use gasoline, gasoline-type lantern
fuel, kerosene, charcoal lighter uid, or similar liquids to start or
“freshen up” a re in the furnace. Keep all such liquids well away
from the furnace while it is in use.
Do not over re your furnace! You should burn small loads of
wood in your furnace until you have become familiar with its
operation while burning the type and quality of wood that you’ve
chosen.
Open spin dra cap on ash door.
Pull the slide ba e rod to the front position.
Open the fuel load door and light re using kindling and several
sheets of newspaper, then close the furnace door. e furnace
door should remain closed for 5 to 10 minutes in order to establish the re. If the re has established, you are ready to load the
furnace.
CAUTION: To prevent ame and smoke spillage, the slide ba e
must be pulled out and the fuel door must be cracked for ten
seconds before being fully opened.
Load the furnace, close the load door and push the slide Ba e
rod to rear.
Close the spin dra cap on ash door, leaving it cracked about the
diameter of a dime.
e forced air dra 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
dra blower will run until the U.S. Stove thermostat temperature
setting is reached. e dra regulator on the forced air dra is
preset at the factory and should require no adjustment.
TAMPER WARNING
is wood heater has a manufacturer-set minimum low burn
rate that must not be altered. It is against federal regulations to
alter this setting or otherwise operate this wood heater in a manner inconsistent with operating instructions in this manual.
STARTING A COAL FIRE
If you burn coal, a forced air draft is required
Shut o FAD when fuel door is open
Open smoke pipe damper all the way. Open all dra controls on
your 1602. Pull the slide ba e forward.
Place about 10-15 lb. of coal in on the shaker grates. It should
come up to about half of the rst rebrick level.
Place crumpled paper over the coal and crisscross a couple handfuls of dry kindling wood 3/4” in thickness on top of paper.
Ignite the paper and close loading door. Wait about 30 minutes
until coal re is established before adding more coal. NOTE:
NEVER load coal over the level of rebrick.
Close by-pass damper and set all dra controls to your own
needs. It may take 3 to 4 coal res to determine how your local
13
Page 14
coal and the furnace reacts together. Adjusts dra s accordingly.
Loading with a good bed of coals in the morning - Open by-pass
damper.
In normal shaking, only rock the grates a small amount to si
ash through. Do not agitate the re bed too o en. is practice
will waste coal. If glowing coal is visible in the ash pan, you have
shaken to much.
Remove all ashes every day from ash pit.
CAUTION: Ashes should be placed in a steel/metal container
with a tight tting lid. e closed container of ashes should be
placed on a non-combustible oor or on the ground well away
from all combustible materials pending nal 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
coals have thoroughly cooled. Do not place other waste inside
this container.
With your poker, push hot burning embers to the rear of the unit
and add green coal in front. NEVER load over height of rebrick.
is can result in damage to your furnace and home.
Close by-pass damper.
Too much dra air will cause clinkering of coal and will waste
heat up the chimney. Shut dra down to as low a point as you can
and still heat your home.
NOTE: Never stand in front of loading door when opening it.
Stand to the side.
NEVER completely cover the live re with fresh coal. Always
leave a generous area of glowing coal at the top of the re and
at the rear.
Always keep the ash pit clean.
If the re goes out or does not hold overnight, look for:
Poor dra .
Incorrect damper settings.
Improper ring methods for coal being used.
More combustion air needed.
Coal not sized to the furnace. We recommend 1” to 3” diameter
pieces of coal.
Ashes, if allowed to accumulate in the ash pit, will not allow the
passage of required air for combustion. Keep ash pit clean.
is furnace is not to be used with an automatic stoker unless
so certi ed.
POWER OUTAGE OPERATION
U. S. Stove strongly suggest using a back-up generator to operate your furnace during a power outage situation. However, your
furnace may be operated without power for a short period of
time assuming your installation allows such operation. Please
review and follow these instructions.
Remove any and all air lters throughout the air ducting system
to increase the movement of air.
Reduce the combustion air intake to a minimum in order to slow
the burn rate of the appliance.
If the Dra Blower is installed, close it’s damper so that no more
than 1/4 of the total inlet area is open.
If you installation incorporates a bypass damper in the duct
work, the damper must be opened to allow heat to escape the
rebox so as not to damage any electrical components.
If the bypass damper is one that is designed to fall closed when
the blowers are not running and there is no way to open the passage, you will need to shut-o all combustion air to the appliance.
Observe the furnace operation closely and o en until power is
restored.
CAUTION: To avoid excessive temperatures, do not operate
with fuel door or ash pan open.
VISIBLE SMOKE
e amount of visible smoke being produced can be an e ective
method of determining how e ciently the combustion process
is taking place at the given settings. Visible smoke consist of unburned fuel and moisture leaving your stove. Learn to adjust the
air settings of your speci c unit to produce the smallest amount
of visible smoke. Wood that has not been seasoned properly and
has a high wood moisture content will produce excess visible
smoke and burn poorly.
EFFICIENCY
E ciencies can be based on either the lower heating value (LHV)
or the higher heating value (HHV) of the fuel. e lower heating
value is when water leaves the combustion process as a vapor, in
the case of woodstoves the moisture in the wood being burned
leaves the stove as a vapor. e higher heating value is when water leaves the combustion process completely condensed. In the
case of woodstoves this would assume the exhaust gases are room
temperature when leaving the system, and therefore calculations
using this heating value consider the heat going up the chimney
as lost energy. erefore, e ciency calculated using the lower
heating value of wood will be higher than e ciency calculated
using the higher heating value. In the United States all woodstove e ciencies should be calculated using the higher heating
value. e best way to achieve optimum e ciencies is to learn
the burn characteristic of you appliance and burn well-seasoned
wood. Higher burn rates are not always the best heating burn
rates; a er a good re is established a lower burn rate may be a
better option for e cient heating. A lower burn rate slows the
ow of usable heat out of the home through the chimney, and it
also consumes less wood.
OPERATIONAL TIPS
Operational Tips for Good, E cient, and Clean Combustion
Get the appliance hot and establish a good coal bed before adjusting to a low burn rate (this may take 30 minutes or more
depending on your wood)
Use smaller pieces of wood during start-up and a high burn rate
to increase the stove temperature
Be considerate of the environment and only burn dry wood
Burn small, intense res instead of large, slow burning res when
possible
Learn your appliance’s operating characteristics to obtain optimum performance
Burning unseasoned wet wood only hurts your stoves e ciency
and leads to accelerated creosote buildup in your chimney
14
Page 15
OVER FIRING
Attempts to achieve heat output rates that exceed heater design speci cations can result in permanent damage to the heater.
ASH REMOVAL AND DISPOSAL
Whenever ashes get 3 to 4 inches deep in your rebox or ash pan,
and when the re has burned down and cooled, remove excess
ashes. Leave an ash bed approximately 1 inch deep on the rebox bottom to help maintain a hot charcoal bed.Ashes should
be placed in a metal container with a tight- tting lid. e closed
container of ashes should be placed on a noncombustible oor or
on the ground, away from all combustible materials, pending nal disposal. e ashes should be retained in the closed container
until all cinders have thoroughly cooled.
SMOKE AND CO MONITORS
Burning wood naturally produces smoke and carbon
monoxide(CO) emissions. CO is a poisonous gas when exposed
to elevated concentrations for extended periods of time. While
the modern combustion systems in heaters drastically reduce the
amount of CO emitted out the chimney, exposure to the gases in
closed or con ned areas can be dangerous. Make sure you stove
gaskets and chimney joints are in good working order and sealing properly to ensure unintended exposure. It is recommended
that you use both smoke and CO monitors in areas having the
potential to generate CO.
GASKETS
It is recommended that you change the door gasket (which
makes your stove door air tight) once a year, in order to insure
good control over the combustion, maximum e ciency and
security. To change the door gasket, simply remove the damaged one. Carefully clean the available gasket groove, apply a
high temperature silicone sold for this purpose, and install the
new gasket. You may light up your stove again approximately
24 hours a er having completed this operation. is unit’s feed
door uses a 1/2” diameter rope gasket. is unit’s ash door uses a
3/8” diameter rope gasket.
THIS IS A WOOD AND COAL BURNING FURNACE AND SHOULD NOT BE ALTERED IN
ANY WAY! DOING SO WILL VOID YOUR WARRANTY!
ATTENTION:
is wood heater needs periodic inspection and repair for proper operation. It is against federal regulations to operate this
wood heater in a manner inconsistent with operating instructions in this manual.
15
Page 16
TROUBLE SHOOTING AND PROBLEM SOLVING
1. Problem:
Smoke pu s from furnace
Solution:
A. Check chimney dra . Check for blocked chimney or ue pipe.
Use mirror to check chimney clearance.
B. Check ash pit — if it is too full, empty.
C. Make sure furnace room is not too airtight.
D. Make sure all of chimney mortar connections are airtight.
E. Check ash drawer. Make sure it’s airtight.
F. Check chimney for possible down-dra caused by taller sur-
rounding trees or objects. Correct with proper chimney vent cap.
G. Check the possibility of a cold chimney forcing cool gases
backward. Remedied by properly insulating chimney with noncombustible liner — non-combustible insulation.
H. Fuel may be too green.
I. Make sure no other fuel burning devices are connected to the
chimney impairing the dra .
J. Check chimney dra , it should be .06 inches of water column.
is service is provided by a certi ed chimney sweep.
2. Problem:
Inadequate heat being delivered to your home
Solution:
A. Check home insulation — is it adequate?
B. Check hook-up to furnace — is it installed correctly?
C. Cool air inlet may be inadequate or furnace room too airtight.
D. Your wood fuel may be too low grade. Hardwoods are recom-
mended.
E. Make sure your hot air duct (and other duct work) is airtight.
F. If furnace room is warm but your home isn’t, check back dra
dampers.
G. Is air to the blower available?
3. Problem:
Excess smoke or ames coming out door when refueling
Solution:
A. Wait 15 seconds and open door SLOWLY — then refuel.
B. Check length of ue pipe to chimney. Your unit should be within
six (6) feet of your chimney.
C. Make sure chimney cap is not too close to the top of the chimney.
D. Check chimney dra — make sure chimney ue pipe is clean
and chimney is of adequate height.
E. Make sure you’re not su ocating the re with excessive amounts
of unburned wood.
F. Slide ba e should be pulled out prior to load door opening.
4. Problem:
Distribution blower vibrating
Solution:
A. Tighten blower wheel to motor sha .
B. Check for bad fan bearings.
5. Problem:
Distribution blower continues to run or will not run
Solution:
A. Check fan limit or heat sensor and cable.
B. Check to see that blower is properly wired.
(See Wiring and Assembly Instructions).
C. Check fuse box or power source.
D. Check power supply.
6. Problem:
Dra blower continues to run or will not run
Solution:
A. Check wiring.
B. Check thermostat or thermostat wire for short.
C. Make sure temperature is calling for heat.
7. Problem:
Odor from rst re
Solution:
A. e odor from new steel should disappear in a few hours.
B. If the odor remains, call you dealer immediately. A bad weld can
cause a fume leak.
8. Problem:
Excessive Creosote
Solution:
A. Check the grade of wood you are burning.
B. Make sure your unit is serviced by its own proper chimney.
C. Check length of ue pipe and its connections.
D. Make sure you are burning the smallest, hottest re to adequately
heat your home.
E. Also see Solutions to Problem one.
9. Problem:
If the re goes out or does not hold over night
Solution:
A. Poor Dra .
B. Incorrect damper settings.
C. Improper ring methods if burning coal.
D. More combustion air needed.
E. Coal not sized to the furnace. We recommend 1” to 3” diameter
pieces of coal.
F. Ashes, if allowed to accumulate in the ash pit, will not allow
passage of the required air for combustion. Keep ash pit clean.
G. is furnace is not to be used with an automatic stoker unless so
certi ed.
16
Page 17
PARTS DIAGRAM
23
35
34
319
16
17
27
25
26
24
20
18
28 29
4
3
2
1
37
3
8
9
7
10
30
36
22
21
34
33
6
15
13
12
16
17
14
11
2
3
5
32
31
17
Page 18
PARTS DIAGRAM AND LIST
Key Description Part # Qty
1 Feed Door Assy. (w/Rope Gasket) 69542 1
2 Door Handle 24179 2
N/S Lock Nut, 1/2-13 83444 2
N/S Washer 83835 2
3 Spring Handle 89574 4
4 Feed Door Latch 23786 1
5 Ash Door Assy. (w/Rope Gasket) 68880 1
6 Dra Cap 23859 1
7 Ash Door Latch 23823 1
N/S Hinge Pin, 5/16” x 1” C21399 4
8 Shaker Handle 69005 1
9 Bracket, Shaker Handle 24204 1
10 Ash Pan 68882 1
11 Grate Retainer 40312 2
12 Shaker Bar 891341 1
13 Shaker Grate Section 40314 5
14 Back Liner 40313 1
15 Front Liner 40344 1
16 Full Firebrick (4-1/2 wide x 9 tall x 1-1/4 thick) 89066 16
17 Half Firebrick (2-1/4 wide x 9 tall x 1-1/4 thick) 891414 3
18 Slide Ba e 24231 1
19 Ba e Rod 86603 1
20 Lock Nut, 1/2-13 83444 2
21 Gasket, Flue Collar 88032 1
22 Flue Collar 40246 1
23 Flue Collar Ring 22761 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 Cabinet Side, Le 68821 1
29 Insulation, Side C98771 2
30 Insulation Retainer 83884 41
31 Cabinet Side, Right 68822 1
N/S Cabinet Side, Back - 1800 69002 2
32 Receptacle, Snap-In 80351 1
33 Cabinet Back 69573 1
34 Insulation, Panel C98871 2
35 Cabinet Top 69088 1
36 Front Filler 23817 1
37 Dra Cover 23818 1
38 Room Blower - 800 CFM 80530 2
39 Blower Gasket 88127 2
40 Tinnerman Clip, 1/4-20 83340 8
41 Bolt, 1/4-20 x 3/4 83339 8
42 Conduit Assembly (5 ) 69578 2
Key Description Part # Qty
43 Honeywell Limit Control 80145 1
44 Conduit Assembly (1 ) 68859 1
45 Junction Box 25625 1
46 Fan Center Control 80130 1
47 Rocker Switch C42373 1
48 Romex Cable Clamp 80362 1
49 Water Coil Access Cover 23819 1
N/S Cover plate (Canadian Furnace Only) 25755 1
N/S = Not Shown
IMPORTANT NOTE:
When ordering repair parts, a color code (R) should be placed a er the part
number of any part that is painted.
43
47
49
44
48
46
45
38
42
39
40
41
IN ORDER TO MAINTAIN WARRANTY, COMPONENTS MUST BE REPLACED USING ORIGINAL
MANUFACTURERS PARTS PURCHASED THROUGH YOUR DEALER OR DIRECTLY FROM THE
USE OF THIRD PARTY COMPONENTS WILL VOID THE WARRANTY.
18
APPLIANCE MANUFACTURER.
Page 19
PARTS DIAGRAMS AND LISTS - 69189
1
2
Key Description Part # Qty
1Drq Blower Assembly 69190 1
2 FAD Bracket 69192 1
3 Bolt, 1/4-20 x 1” 83379 2
4 Lock Nut, 1/4-20 83261 2
5 Kep Nut, 10-24 83244 3
4
35
UFB908 COLD AIR RETURN / FILTER BOX - OPTIONAL KIT
As mentioned earlier in this manual, a cold air return and/or
lter box should be incorporated into your furnace installation.
A cold air return or lter box will increase the life of your blowers and o er ltered distribution air for your home. U.S. Stove
o ers the model UFB908 as an option and can be purchased
from your local dealer.
e UFB908 utilizes a standard 16” x 20” lter that can be
purchased from your local dealer or any hardware/duct work
supply store. When installing a UFB908, follow the installation
instructions supplied with the kit.
19
Page 20
DOMESTIC HOT WATER COIL KIT - OPTIONAL
is Furnace will accept the installation of a Domestic Hot Water Coil Kit. e U.S. Stove kit is a 1124 Water Coil and it may
2
1
ACCESS
PAN EL
3
REAR WALL OF
FIREBOX
5
4
be purchased from your local dealer.
1. Remove the access panel on the rear of the furnace enclosure.
2. With a utility knife, cut away a section of the insulation (if
equipped) directly behind the access panel.
3. Remove the cover plate from the rear of the furnace rebox.
4. Place one nut on each end of the water coil and thread each
nut up to the end of the threads on the coil.
5. Insert the coil through the holes from the inside of the rebox. Install a gasket, washer and nut onto each end of the
water coil. Tighten the nuts down securely to insure an air
tight seal.
e 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 quali ed plumber connect your domestic hot water
pipe to the coil with the appropriate ttings.
DOMESTIC HOT WATER
COIL
6
1. NUT
2. WASHER
3. GASKET
In the unlikely event that your furnace “over res” (a condition
evidenced by elbows, stove pipes, and connectors glowing red
in appearance or otherwise discoloring), then your installation is subject to excessive dra created by either a chimney
too tall or too great in diameter in conjunction with its height,
or some other factor of an indeterminate cause. In this event,
you should install a barometric dra regulator. Such installation will preclude any over- ring and/or any hazardous consequences of potential over ring.
Barometric dra regulators are generally available where you
purchased your stove or may be ordered directly from United
States Stove Company at a nominal charge.
TURN INSIDE NUTS UP
TO END OF THREADS
DR6 -
6” DRAFT REGULATOR KIT - OPTIONAL KIT
20
Page 21
HOW TO ORDER REPAIR PARTS
is manual will help you obtain e cient, dependable service from the furnace, and enable
you to order repair parts correctly.
Keep this manual in a safe place for future reference.
When placing an order or for warranty claims, please provide the following information
found on the Certi cation Plate located below the ash door.
PART NUMBER
PART DESCRIPTION
MODEL NUMBER - 1602R
SERIAL NUMBER______________
United States Stove Company
227 Industrial Park Road
P.O. Box 151
South Pittsburg, TN 37380
80-750-2723
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