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Owner’s Installation and Operation Manual
Model CL1660E
Report No: 0215WH080S
This unit is certied UL 391(R2014)
U.S. ENVIRONMENTAL PROTECTION AGENCY
Certied to comply with the 2017 particulate
emission standards. Not approved for sale after
May 15, 2020
Installation is to be preformed by a
qualied installer.
SAVE THESE INSTRUCTIONS
NOT FOR USE IN A MOBILE HOME
United States Stove Company
227 Industrial Park Rd.
South Pittsburg, TN 37380
852858B-3002G
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37.79”
26.54”
48”
48.81”
CAUTION:
• Power source not controlled by furnace main disconnect.
• Respect all local and national codes when installing this unit.
• This unit is not to be connected to a chimney ue serving another appliance.
• This unit is designed to burn solid hardwood only.
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Specications
CONGRATULATIONS!
You’ve purchased a heater from North America’s oldest manufacturer of wood burning products.
By heating with wood you’re helping to CONSERVE ENERGY!
Wood is our only Renewable Energy Resource. Please do your part to preserve our wood supply. Plant at least
one tree each year. Future generations will thank you.
Combustible: Wood
Flue Pipe Diameter: 6” (153cm)
Flue Pipe Type: (Standard Single Wall or Double Wall): Black or Blued Steel 2100°F (650°C) Class “A”
Minimum Chimney Height: 12’
Maximum Log Length: 28”
Electrical: 120V, 60Hz, 3.4A per blower
Dimensions
Combustion Chamber:
Width x Depth:
Volume:
Cubic Feet:
Door Opening: Width x Height: 12.625” X 12.5”
Weight (lbs): 509lbs
17.4” X 28.3”
6.27 cubic ceet
This manual describes the installation and operation of the Clayton, CL1660E
wood heater. This heater meets the 2016 U.S. Environmental Protection Agency’s
emission limits for wood heaters sold after May 15, 2016. Under specic EPA
test conditions this heater has been shown to deliver heat at a rate of 33,438
to 77,456 BTU/hr. This heater achieved a particulate emissions rate of 0.305
0215WH080E
This 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.
The operation of this wood heater in a manner inconsistent with the owner’s manual will void your warranty and
is also against federal regulations.
This heater is designed to burn natural wood only. Higher efciencies and lower emissions generally result when
burning air dried seasoned hardwoods, as compared to softwoods or to green or freshly cut hardwoods.
This 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.
lbs/mmBTU when tested to method CSA B415.1-10 (*and an overall efciency
of 61.9%.) The maximum overall heat output of this heater was tested to be
104,720 BTU/hr.
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Safety
• Do not operate with fuel loading or ash removal doors open.
• Do not connect this unit to a chimney ue serving another appliance.
• Danger: Risk of re or explosion. Do not burn garbage, gasoline, naphtha, motor oil, or other inappropriate
materials. Do not use chemicals or uids to start the re.
• Warning: Risk of re. Do not operate with ue draft exceeding .060” water column/14.93 Pascals. Do not
operate with fuel loading and ash removal doors open. Do not store fuel or other combustible materials
within marked installation clearances. Inspect and clean ues and chimney regularly.
• Caution: Hot surfaces. Keep children away. Do not touch during operation.
• The heat exchanger, ue pipe, and chimney must be cleaned regularly to remove accumulated creosote
and ash. Ensure that the heat exchanger, ue pipe, and chimney are cleaned at the end of the heating
season to minimize corrosion during the summer months. The appliance, ue pipe, and chimney must be
kept in good condition. These instructions also apply to a draft inducer if used. To prevent ame or smoke
spillage, the slide bafe must be pulled out and the fuel loading door left cracked for 10 seconds prior to
opening door fully. Load fuel carefully or damage may result.
• Hot while in operation. Keep children, clothing and furniture away. Contact may cause skin burns.
• Do not use chemicals or uids to ignite the re.
• Do not leave the furnace unattended when the door is slightly opened.
• Do not burn garbage, ammable uid such as gasoline, naphtha or motor oil.
• Always close the door after the ignition.
• Consult your municipal building department or re ofcials about permits, restrictions and installations
requirements in your area.
• 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.
• CAUTION: CLEAN OUT 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.
• CAUTION: Do not operate furnace with power disconnected from the unit.
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Unpacking And Preassemble
UNPACKING
1. Remove all packaging from the furnace.
2. Remove the supplied tools and parts from the furnace.
BRICK ALIGNMENT
Inspect for any damage. Ensure that the bricks are positioned correctly and not broken (see illustration for
proper brick arrangement).
Proper Fire Brick Alignment
TOOLS AND MATERIALS NEEDED FOR INSTALLATION
The following is a list of tools and materials needed to install your furnace.
• 7/16” socket wrench.
• 5/16” socket (Best if using a power drill and a socket bit).
• Pair of pliers or channel-locks.
• Power drill with an 1/8” drill bit to install sheet metal screws into connector pipe..
• Sheet metal screws.
• Non-combustible oor protector as specied in this manual.
• All chimney and chimney connector components required for your particular venting installation..
• Electrical wiring tools and supplies.
• Ductwork for supply and return air.
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Furnace Installation
Ceiling
INSTALLATION OPTIONS
The installation of this furnace includes supplying electrical power, return (fresh air) ductwork, and supply air
ductwork. This furnace may be installed as a stand alone wood furnace.
See kit installation section in this manual to ensure proper assembly, installation and operation of your new
furnace.
If installing in an area with a fan it should not be allowed to create negative pressure in the room where the
furnace is installed.
LOCATING YOUR FURNACE (INSURE THAT THE REQUIRED MAINTENANCE CLEARANCES ARE MAINTAINED)
Your furnace must be installed as shown in this manual and in compliance with all local and national codes.
It is of the utmost importance that the clearances to combustible materials be strictly adhered to during
installation of the furnace. Refer to the table and diagrams below for minimum required clearances.
Dimension Inches
A Backwall to Appliance 17
B Sidewall to Appliance 12
C Backwall to Flue 23
D Sidewall to Flue 22.5
E Supply Duct (rst 6 feet) 6
F Supply Duct (after rst 6 feet) 1
G Minimum Duct height 6
H Ceiling Height to Floor 84
J Top of Door to Ceiling 48
* Closest Point of Zero Clearance 2’
Side wall
Back wall
A
B
D
CLEARANCE TO COMBUSTIBLES
C
Side wall
F
G
J
H
CLEARANCE TO COMBUSTIBLES
E
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MAINTENANCE CLEARANCES
Your furnace has recommended minimum
maintenance clearance requirements. These
clearances insure that there is adequate room
to preform maintenance and service your
furnace. DO NOT store fuel within the specied
clearances. The clearances will change
depending on what kits are installed with your
furnace. See the tables and diagram below to
determine the clearances for your furnace.
N
Standard unit (no additional kits)
Dimension Inch
K Maintenance Clearance (Front) 24
L Maintenance Clearance (Left) 10
M Maintenance Clearance (Right) 10
N Maintenance Clearance (Rear) 29
Unit with Blower Kit
Dimension Inch
K Maintenance Clearance (Front) 24
L Maintenance Clearance (Left) 24
M Maintenance Clearance (Right) 24
N Maintenance Clearance (Rear) 36
FLOOR PROTECTOR
The furnace must be placed on solid
concrete, solid masonry, or when installed on
a combustible oor, on a oor protector. The
oor protector is required to provide heat, live
ember, and ash protection and must be of a
non-combustible, continuous solid surface to
protect against inltration of live embers and
ash. If a oor pad is used, it should be listed to UL
1618 (type 1 ember protection) or equal. For UL
Listed oor protectors, refer to manufacturers
instructions for installation directions. The oor
protector or non combustible oor must extend
under the furnace and beyond each side as
shown below.
ML
K
MAINTENANCE CLEARANCE
P
RQ
Dimension Inch
O Front 16
P Rear 2
Q Left 8
R Right 8
O
FLOOR PROTECTOR REQUIREMENTS
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Duct Work Installation
We strongly recommend that the hot air ductwork 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.
This furnace can be installed in two ways, as a stand alone unit, or in series with an existing furnace.
SUPPLY AIR (HOT AIR) PLENUM
The warm-air supply duct shall be constructed of metal in accordance with NFPA 90B, 2-1.1. The plenums installed
to the furnace shall be constructed of metal in accordance with NFPA 90B, 2-1.3.
When installing this furnace the hot air plenum is to have a minimum height of 24” (610mm) if the top of the rst
vertical section is not ush with the top of the rst horizontal section of ductwork. If the top of the plenum is ush
with the top of the rst horizontal section of ductwork then the minium height is 15” (381mm).
RETURN AIR (FRESH AIR)
The return (fresh) air intake on the furnace is on the rear of the unit. The ductwork must be mechanically
attached to the unit or blower kit box with sheet metal screws to ensure a proper operation.
STAND ALONE INSTALLATION
If installing this furnace as a stand alone unit, ensure all local codes and all instructions in this manual are followed,
including clearance to combustibles, oor protector specications and safety warnings.
Supply Air (Hot Air) Duct Work Outlet Size
26.54”
Supply Air Plenum With
Minimum Height Of 15”
Supply Air Plenum Minimum
Height Of 24”
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INSTALLATION
CENTRAL INSTALLATION
ADD-ON INSTALLATION
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Accessory Installation
THERMODISC
THERMODISC
COVER
4” ELECTRICAL
JUNCTION BOX
BLOWERS
BLOWERS GASKET
CLIP NUTS
(Not used in the upper center hole)
ASSEMBLY OF FURNACE
Your furnace requires the following items to be
assembled or installed by the service person:
Blowers and Blower Controls
Electrical Connections
1. Remove all parts from inside the furnace and
inspect for damage, including the rebrick as
some breakage could occur during shipment.
2. Install the thermodisc on rear of furnace
cabinet with the two screws provided. Mount
the conduit assembly from the junction box to
the thermostat bracket. Crimp the two female
terminals to each of the wire leads. Plug the
wires to the thermodisc. NOTE: It does not matter
which of the two wires plugs to which terminal
on the thermodisc.
3. Remove blowers from cartons. Remove junction
box cover. Attach clip nuts as in gure shown.
Install blower(s) and gasket(s with 1/4"-20 x 3/4"
bolts as shown.
4. Wire right side blower rst (See wiring diagram)
and replace cover on junction box on blower.
5. Wire left blower same as above and replace
cover.
SMOKE CURTAIN
Using two 1/4-20 x 1-1/4”
Carriage bolts, two smoke curtain
clips, and two nuts, attach the
smoke curtain in place above
the fuel feed door as shown. After
installation, the smoke curtain
should swing freely back into the
furnace.
DOOR LATCH INSTALLATION
With two 1/4-20 x 3/4 hex bolts each, attach the door latch to the door latch mounting
brackets on the left side of the door frame 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.
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Electrical Installation
105°C
All electrical connections should be done by a qualied electrician
It is recommended to connect the furnace to its own 15 amp 120 Volt circuit from the house power supply
NOTE: Wire leads from the distribution blower are usually
BOTH BLACK. Makes no difference which leads from the
motor(s) connects to the corresponding leads coming out of
the conduit.
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Chimney Installation
CHIMNEY
Your wood furnace may be hooked up with a factory built or masonry chimney, matching the diameter of the
exhaust. If you are using a factory built chimney, it must comply with UL 103 or CSA-B365 standard; therefore it must
be a Type HT (2100°F). It is extremely important that it be installed according to the manufacturer’s specications.
If you are using a masonry chimney, it is important that it be built in compliance with the specications of the
National Building Code. It must be lined with re clay bricks, metal or clay tiles sealed together with re cement.
(Round ues are the most efcient).
The interior diameter of the chimney ue must be 6”. A ue which is too small may cause draft problems, while a
large ue favors rapid cooling of the gas, and hence the build-up of creosote and the risk of chimney res. Note
that it is the chimney and not the furnace which creates the draft effect; your furnace’s performance is directly
dependent on an adequate draft from your chimney.
Do not connect this unit to a chimney ue serving another appliance.
The following recommendations may be useful for the installation of your chimney:
• It must rise above the roof at least 3’ (0.9m) from the uppermost point of contact.
• The exterior portion should be double or triple wall pipe to ensure proper draft.
• The chimney must exceed any part of the building or other obstruction within a 10’ (3.04m) distance by a
height of 2’ (0.6m).
• Installation of an interior chimney is always preferable to an exterior chimney. The interior chimney will be
hotter than an exterior chimney that is being cooled by the ambient air outside the house. Therefore the gas
which circulates will cool slower, thus reducing the build-up of creosote and the risk of chimney res.
• The draft caused by the tendency for hot air to rise will be increased with an interior chimney.
• Using a re screen at the extremity of the chimney requires regular inspection in order to insure that it is not
obstructed thus blocking the draft, and it should be cleaned when used regularly.
IMPORTANCE OF PROPER DRAFT
Draft is the force which moves air from the appliance up through the chimney. The amount of draft in your
chimney depends on the length of the chimney, local geography, nearby obstructions and other factors. Too
much draft may cause excessive temperatures in the appliance. Inadequate draft may cause back pufng into
the room and ‘plugging’ of the chimney. Inadequate draft will cause the appliance to leak smoke into the room
through appliance and chimney connector joints.
An uncontrollable burn or excessive temperature indicates excessive draft.
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.
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MASONRY CHIMNEY
Ensure that a masonry chimney meets the minimum standards of the National Fire Protection Association (NFPA)
by having it inspected by a professional. Make sure there are no cracks, loose mortar or other signs of deterioration
and blockage. Have the chimney cleaned before the furnace is installed and operated. When connecting the
furnace through a combustible wall to a masonry chimney, special methods are needed as explained in the
“Combustible Wall Chimney Connector Pass-Throughs” Section.
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COMBUSTIBLE WALL CHIMNEY CONNECTOR PASS-THROUGHS
Method A. 12” (304.8 mm) Clearance to Combustible Wall
Member: Using a minimum thickness 3.5” (89 mm) brick
and a 5/8” (15.9 mm) minimum wall thickness clay liner,
construct a wall pass-through. The clay liner must conform
to ASTM C315 (Standard Specication for Clay Fire Linings)
or its equivalent. Keep a minimum of 12” (304.8 mm) of brick
masonry between the clay liner and wall combustibles. The
clay liner shall run from the brick masonry outer surface to
the inner surface of the chimney ue liner but not past the
inner surface. Firmly grout or cement the clay liner in place
to the chimney ue liner.
Method B. 9” (228.6 mm) Clearance to Combustible Wall
Member: Using a 6” (152.4 mm) inside diameter, listed,
factory-built Solid-Pak chimney section with insulation
of 1” (25.4 mm) or more, build a wall pass-through with a
minimum 9” (228.6 mm) air space between the outer wall of
the chimney length and wall combustibles. Use sheet metal
supports fastened securely to wall surfaces on all sides,
to maintain the 9” (228.6 mm) air space. When fastening
supports to chimney length, do not penetrate the chimney
liner (the inside wall of the Solid-Pak chimney). The inner end
of the Solid-Pak chimney section shall be ush with the inside
of the masonry chimney ue, and sealed with a non-water
soluble refractory cement. Use this cement to also seal to
the brick masonry penetration.
Method C. 6” (152.4 mm) Clearance to Combustible Wall
Member: Starting with a minimum 24 gauge (.024” [.61 mm])
6” (152.4 mm) metal chimney connector, and a minimum 24
gauge ventilated wall thimble which has two air channels of
1” (25.4 mm) each, construct a wall pass-through. There shall
be a minimum 6” (152.4) mm separation area containing
berglass insulation, from the outer surface of the wall thimble
to wall combustibles. Support the wall thimble, and cover
its opening with a 24-gauge minimum sheet metal support.
Maintain the 6” (152.4 mm) space. There should also be a
support sized to t and hold the metal chimney connector.
See that the supports are fastened securely to wall surfaces
on all sides. Make sure fasteners used to secure the metal
chimney connector do not penetrate chimney ue liner.
Method D. 2” (50.8 mm) Clearance to Combustible Wall
Member: Start with a solid-pak listed factory built chimney
section at least 12” (304 mm) long, with insulation of 1” (25.4
mm) or more, and an inside diameter of 8” (2 inches [51 mm]
larger than the 6” [152.4 mm] chimney connector). Use this
as a pass-through for a minimum 24-gauge single wall steel
chimney connector. Keep solid-pak section concentric with
and spaced 1” (25.4 mm) off the chimney connector by
way of sheet metal support plates at both ends of chimney
section. Cover opening with and support chimney section
on both sides with 24 gauge minimum sheet metal supports.
See that the supports are fastened securely to wall surfaces
on all sides. Make sure fasteners used to secure chimney ue
do not penetrate ue liner.
NOTES:
Connectors to a masonry chimney, excepting method B, shall extend in one continuous section through the
wall pass-through system and the chimney wall, to but not past the inner ue liner face. A chimney connector
shall not pass through an attic or roof space, closet or similar concealed space, or a oor, or ceiling.
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To
Appliance
CHIMNEY CONNECTOR
Your chimney connector and chimney must have a 6” diameter. If this is not the case, we recommend you
contact your dealer in order to insure there will be no problem with the draft.
The furnace pipe must be made of aluminized or cold roll steel with a minimum thickness of 0.021” or 0.53 mm. It
is strictly forbidden to use galvanized steel.
Your connector should be assembled in such a way that the male section (crimped end) of the pipe faces
down. Attach each of the sections to one another with three equidistant metal screws. Seal the joints with furnace
cement.
The pipe must be short and straight. All sections installed horizontally must slope at least 1/4 inch per foot, with
the upper end of the section toward the chimney. Any installation with a horizontal run of furnace pipe must
conform to NFPA 211. You may contact NFPA (National Fire Protection Association) and request the latest edition
of the NFPA Standard 211.
To insure a good draft, the total length of the furnace pipe should never exceed 8’ to 10’ (2.4m to 3.04 m).
(Except for cases of vertical installation, cathedral-roof style where the smoke exhaust system can be much
longer and connected without problem to the chimney at the ceiling of the room).
There should never be more than two 90 degrees elbows in the smoke exhaust system.
Installation of a “barometric draft stabilizer” (replace register) on a smoke exhaust system is prohibited.
Furthermore, installation of a draft damper is not recommended. With a controlled combustion wood furnaces
the draft is regulated upon intake of the combustion air in the furnace and not at the exhaust.
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FACTORY BUILT CHIMNEY
When a metal prefabricated chimney is used, the manufacturer’s installation instructions must be followed. You
must also purchase (from the same manufacturer) and install the ceiling support package or wall pass-through
and “T” section package, restops (where needed), insulation shield, roof ashing, chimney cap, etc. Maintain
proper clearance to the structure as recommended by the manufacturer. The chimney must be the required
height above the roof or other obstructions for safety and proper draft operation.
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Wood Heat Utilization
The top down method of re building is recommended for this appliance. After making sure that the stove air
intake controls are fully open (open all three air controls to there maximum setting). 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.
Then a fourth layer of loose, small kindling and twisted newspaper sheets tops off the pile.
Higher efciencies and lower emissions generally result when burning air dried seasoned hardwoods, as
compared to softwoods 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;
Burning these materials may result in release of toxic fumes or render the heater ineffective 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
Your furnace was designed to burn wood only; no other materials should be burned. Waste and other ammable
materials should not be burned in your furnace. DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE. DO NOT
BURN GARBAGE, GASOLINE, NAPTHA, ENGINE OIL, OR OTHER INAPPROPRIATE MATERIALS. Any type of wood may
be used in your furnace, but specic varieties have better energy yields than others. Please consult the following
table in order to make the best possible choice.
10. Salt water driftwood or other previously salt water
saturated materials;
11. Unseasoned wood; or
12. Paper products, cardboard, plywood, or
particleboard. The 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 affected wood heater.
TYPE
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
Red Spruce 29 1800 .1 Easy 16.1
WEIGHT
(LBS. CU. FT., DRY)
34 2900 .2
PER CORD
EFFICIENCY
RANKING
SPLITS
Very
Difcult
MILLIONS BTU’s/
CORD
20.1
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It is EXTREMELY IMPORTANT that you use DRY WOOD only. The 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. This point cannot be over
stressed; the vast majority of the problems related to the operation of a wood furnace is caused by the fact that
the wood used was too damp or has dried in poor conditions.
These problems can be:
• Ignition problems
• Creosote build-up causing chimney res
• Low energy yield
• Blackened windows
• Incomplete log combustion
AIR CONTROL’S
AIR CONTROL
Low Burn Rate High Burn Rate
Primary Air Damper Fully Closed Fully Open
Tertiary Air Damper Fully Closed Fully Open
18
FULLY CLOSED
Tertiary Air Damper
FULLY CLOSED
Primary Air Damper
LOW BURN RATE SETTING
FULLY OPENED
Tertiary Air Damper
MAXIMUM BURN RATE SETTING
FULLY OPENED
Primary Air Damper
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Operation
NOTICE: To minimize the risk of smoke spillage when opening the door with a re in your furnace, crack
the door open no more than 1” and wait for at least 10 seconds before opening it more to allow pressure
stabilization inside the furnace.
Smaller pieces of wood will dry faster. All logs exceeding 6” in diameter should be split. The wood should not be
stored directly on the ground. Air should circulate through the cord. A 24” to 48” air space should be left between
each row of logs, which should be placed in the sunniest location possible. The upper layer of wood should be
protected from the elements but not the sides.
TESTING YOUR WOOD
When the furnace is thoroughly warmed, place one piece of split wood (about ve inches in diameter) parallel
to the door on the bed of red embers.
Adjust all air controls to there maximum settings and close the door. If ignition of the piece is accomplished
within 90 seconds from the time if was placed in the furnace, 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 furnace. Large amounts of creosote could be deposited in your chimney, creating
potential conditions for a chimney re.
THE FIRST FIRES
The fresh paint on your furnace needs to be cured to preserve its quality. Once the fuel charge is properly
ignited, only burn small res in your furnace for the rst four hours of operation. Never open the air control’s more
than necessary to achieve a medium burn rate.
Make sure that there’s enough air circulation while curing the furnace. DO NOT connect your furnace to the
duct work during this curing process. The odors could be smelled during the 3 or 4 rst res. Never start your
furnace outside. You will not be able to see if you are over heating.
LIGHTING YOUR WOOD FURNACE
1. Make sure that your furnace has been installed as per the instructions outlined in this manual and the proper
power is supplied to it.
2. Open the fuel loading door.
3. Note: If there already is a bed of hot/glowing coals in the combustion chamber, proceed directly to the
Preheating step.
4. Place several pieces of small dry kindling in the front of the combustion chamber directly on the rebricks.
5. Lay a few twists of newspaper over the kindling.
6. Lay more dry kindling (crisscrossing) on top of the previous layers and possibly a few more twists of newspaper
if needed.
7. Light the lowest newspaper in the stack.
Note: In some draft situation you may be required to leave the door cracked no more than ½” only till a re is
established in the stack
No chemical product should be used to light the re.
PREHEATING YOUR WOOD FURNACE
1. Once the kindling is burning well or the glowing coal bed is stirred up, lay 2 or 3 pieces of well-seasoned
cordwood down so that the ame from the kindling re can circulate around the logs and close the door.
Note: You may need to add more kindling to help ignite the cordwood.
2. Before loading your furnace fully you will want a well-established re in the combustion chamber. This
typically takes 15-20 minutes.
HEATING WITH YOUR WOOD FURNACE
1. Spread the re and coals evenly towards the center of the combustion chamber before loading your
furnace fully or adding more wood.
2. Avoid overlling the combustion chamber. Air must be allowed to circulate freely through the upper portion
of the combustion chamber for the stove to perform best. Typically this would mean not to load your furnace
more than ¾ of the way up the door opening.
CAUTION: Never alter the “damper slide” or the adjustment range to increase ring for any reason. Doing so
could result in heater damage and will void your warranty.
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OPERATION
Controlled combustion is the most efcient technique for wood heating because it enables you to select the
type of combustion you want for each given situation. The wood will burn slowly if the wood furnace air intake
control’s are adjusted to reduce the oxygen supply in the combustion chamber to a minimum. On the other hand,
wood will burn quickly if the air control’s are adjusted to admit a larger quantity of oxygen in the combustion
chamber. Real operating conditions may give very different results than those obtained during testing according
to the species of wood used, its moisture content, the size and density of the pieces, the length of the chimney,
altitude and outside temperature.
WARNINGS:
• Never over re your furnace. If any part of the furnace starts to glow red, over ring is happening. Readjust
the air intake control at a lower setting.
• The installation of a log cradle or grates is not recommended in your wood furnace. Build re directly on
rebrick.
• Never put wood above the rebrick lining of the rebox.
RELOADING
Once you have obtained a good bed of embers, you should reload the unit. In order to do so, open the air
controls to maximum a few seconds prior to opening the furnace’s door. Then proceed by opening the door
very slowly. Then bring the red embers to the front of the furnace and reload the unit.
For optimal operation of your wood furnace, we recommend you to operate it with a wood load approximately
equivalent to the 3/4 of the height of re bricks.
It is important to note that wood combustion consumes ambient oxygen in the room. In the case of negative
pressure, it is a good idea to allow fresh air in the room, either by opening a window slightly or by installing a fresh
air intake system on an outside wall.
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 (3mm or more), it should be removed to reduce the risk of a chimney re.
We strongly recommend that you install a magnetic thermometer on your smoke exhaust pipe, approximately
18” above the furnace. This thermometer will indicate the temperature of your gas exhaust fumes within the
smoke exhaust system. The ideal temperature for these gases is somewhere between 275°F and 500°F. Below
these temperatures, the build-up of creosote is promoted. Above 500 degrees, heat is wasted since a too large
quantity is lost into the atmosphere.
TO PREVENT CREOSOTE BUILD UP
OPERATION AFTER LOSS OF ELECRICAL POWER - This unit is not intended to be operated during power outage
situations. If there is a power outage while the unit is being red, do not add more wood, close all air controls to
there minimum setting, and remove the air lter. Do not re the unit again until power has been restored.
Always burn dry wood. This allows clean burns and higher chimney temperatures, therefore less creosote deposit.
Leave the air control full open for about 5 min. every time you reload the furnace to bring it back to proper
operating temperatures. The secondary combustion can only take place if the rebox is hot enough.
Always check for creosote deposit once every two months and have your chimney cleaned at least once a
year. If a chimney or creosote re occurs, close all dampers immediately. Wait for the re to go out and the
heater to cool, then inspect the chimney for damage. If no damage results, perform a chimney cleaning to
ensure there is no more creosote deposits remaining in the chimney.
ASH 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. The closed container of ashes should be
placed on a noncombustible oor or on the ground, away from all combustible materials, pending nal disposal.
The ashes should be retained in the closed container until all cinders have thoroughly cooled.
If there is a soot or creosote re:
• Establish a routine for the storage of fuel, care for the appliance and ring techniques.
• Check daily for creosote buildup until experience shows how often cleaning is necessary.
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• Be aware that the hotter the re, the less creosote is deposited, and that weekly cleaning can be necessary
in mild weather, even though monthly cleaning can be enough in the coldest months.
• Have a clearly understood plan to handle a chimney re.
CAUTIONS:
• Ashes could contain hot embers even after two days without operating the furnace.
• The ash pan can become very hot. Wear gloves to prevent injury.
• Never burn the furnace with the ash trap open. This would result in over ring the furnace. Damage to the
furnace and even house re may result.
TAMPER WARNING
This 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.
VISIBLE SMOKE
The amount of visible smoke being produced can be an effective method of determining how efciently 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 specic 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. Use the included moisture meter to insure your wood has a 20% or less moisture
content.
EFFICIENCY
Efciencies can be based on either the lower heating value (LHV) or the higher heating value (HHV) of the fuel.
The lower heating value is when water leaves the combustion process as a vapor, in the case of wood stoves the
moisture in the wood being burned leaves the stove as a vapor. The higher heating value is when water leaves
the combustion process completely condensed. In the case of wood stoves 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. Therefore, efciency calculated using the lower heating value of
wood will be higher than efciency calculated using the higher heating value. In the United States all wood stove
efciencies should be calculated using the higher heating value. The best way to achieve optimum efciencies
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; after a good re is established a lower burn rate may be a better option for
efcient heating. A lower burn rate slows the ow of usable heat out of the home through the chimney, and it
also consumes less wood.
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 conned
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.
OVER FIRING
Attempts to achieve heat output rates that exceed heater design specications can result in permanent
damage to the heater
OPERATIONAL TIPS
• 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), for an optimal low burn rate, once there is a well established
re in the furnace, close the damper on the door, and the rear pilot air damper completely, and open the
secondary air damper to its maximum setting
• 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 efciency and leads to accelerated creosote buildup
in your chimney.
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Maintenance
Your wood furnace is a high efciency furnace and therefore requires little maintenance. It is important to
perform a visual inspection of the furnace every time it is emptied, in order to insure that no parts have been
damaged, in which case repairs must be performed immediately. Inspect and clean the chimney and connector
pipe periodically for creosote buildup or obstructions.
GASKET
It is recommended that you change the door gasket (which makes your furnace door air tight) once a year, in
order to insure good control over the combustion, maximum efciency 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 furnace again approximately 24
hours after having completed this operation. This unit’s feed door uses a 3/4” diameter rope gasket. This unit’s
ash door uses a 1/2” diameter rope gasket.
PAINT
Only clean your furnace with a dry soft cloth that will not harm the paint nish. If the paint becomes scratched or
damaged, it is possible to give your wood furnace a brand new look by repainting it with a 1200° F heat resistant
paint. For this purpose, simply scrub the surface to be repainted with ne sand paper, clean it properly, and apply
thin coats (2) of paint successively.
AIR TUBES
The air tubes assembled in this unit are designed to provide an accurate mix of secondary air to insure the
highest efciency. Any damage or deterioration of these tubes may reduce the efciency of combustion. The
air tubes are held in position by either screws or snap pins. Locate these to either side of the tube and remove to
allow the tube to be removed and replaced.
WARNING: Never operate the furnace without a gasket or with a broken one. Damage to the furnace or
even house re may result.
ATTENTION: This 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.
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Replacement Parts
Gasket, Flue Collar
88032 1
Left Shoulder
28053 1
Back Panel
28067 1
Weldment, Air Inlet
610582 1
Wooden Knob Assembly
892767 2
Ring, Flue Collar
22761 1
Moisture Meter
80697 1
Door Latch (C000022)
23786 1
Right Shoulder
28054 1
Damper Slide
610583 1
Flue Collar, 6” C.I.
40246 1
Wooden Handle
W3100-02 2
In order to maintain warranty, components must be replaced using original manufacturers parts purchased
through your dealer or directly from the appliance manufacturer.
Use of third party components will void the warranty.
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Replacement Parts
Half Firebrick
891414A 14
Cast Grate
40605 1
Left Brick Retainer
28060 1
Side Panel
28065 2
F140 Thermodisc
80714 1
Control Mounting Bracket
22140 1
Control Mounting Bracket
22140 1
Blower Gasket
88127 2
Right Brick Retainer
28061 1
Fan Cntrl Cord Assy
68231 3
24
Weldment, Cabinet Top
610581 1
Supply Cord
80232 1
4 X 4 Junction Box
80131 1
Blower Assembly
80600 2
Cover, Junction Box
80231 1
Page 25
Replacement Parts
Feed Door Handle
89636 1
Handle Assembly
891098 1
3/8” Rope Gasket Door
88033 4.25ft
Ashpan Weldment
610498 1
Curtain, Smoke
23800 1
Feed Door
40499 1
Left Brick Retainer
28060 6
Fiber Board
892760 1
5/8” ROPE GASKET
88066 3ft
Assembly, Ash Door
610496 1
Front Filler
28064 1
Firebrick (4-1/2 X 9) Pumice
89066A 26
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Service Record
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
Service Provider:
Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the
manufacturer’s instructions. Always use the manufacturer's specified spare part when replacement is necessary.
Service 01 Date:________________________
Engineer Name:_____________________________________
License No.:________________________________________ License No.:_______________________________________
Company:__________________________________________
Telephone No.:______________________________________
Stove Inspected: Chimney Swept:
Items Replaced:____________________________________
Service 03 Date:________________________
Engineer Name:_____________________________________
License No.:_______________________________________ License No.:_______________________________________
Company:__________________________________________
Telephone No.:______________________________________
Stove Inspected: Chimney Swept:
Items Replaced:____________________________________
Service 02 Date:________________________
Engineer Name:_____________________________________
Company:_________________________________________
Telephone No.:______________________________________
Stove Inspected: Chimney Swept:
Items Replaced:____________________________________
Service 04 Date:________________________
Engineer Name:_____________________________________
Company:________________________________________
Telephone No.:______________________________________
Stove Inspected: Chimney Swept:
Items Replaced:____________________________________
Service 05 Date:________________________
Engineer Name:_____________________________________
License No.:_______________________________________ License No.:_______________________________________
Company:__________________________________________
Telephone No.:______________________________________
Stove Inspected: Chimney Swept:
Items Replaced:____________________________________
Service 07 Date:________________________
Engineer Name:_____________________________________
License No.:_______________________________________ License No.:_______________________________________
Company:__________________________________________
Telephone No.:______________________________________
Stove Inspected: Chimney Swept:
Items Replaced:____________________________________
Service 06 Date:_______________________
Engineer Name:_____________________________________
Company:_________________________________________
Telephone No.:______________________________________
Stove Inspected: Chimney Swept:
Items Replaced:____________________________________
Service 08 Date:_______________________
Engineer Name:_____________________________________
Company:_________________________________________
Telephone No.:______________________________________
Stove Inspected: Chimney Swept:
Items Replaced:____________________________________
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How to order Replacement Parts
This manual will help you obtain efcient, dependable service from your stove, and enable you to order repair
parts correctly.
Keep this manual in a safe place for future reference.
When writing, always give the full model number which is on the nameplate attached to the stove.
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 _____________________________
4. The serial number _______________________________
United States Stove Company
227 Industrial Park Road
South Pittsburg, TN 37380
(800) 750-2723
www.usstove.com
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