United States Stove BCAC User Manual

OMNI-TEST LABORATORIES, INC.

LISTED BY

PORTLAND

OREGON, USA

website: www.usstove.com

COAL BURNING CIRCULATOR HEATER

MODELS CAC/BCAC

Installation, Operation and Maintenance Instructions

SAFETY NOTICE:

If this heater is not properly installed, a house ﬁ re may result.

For your safety, follow the installation directions.

Contact local building or ﬁ re ofﬁ cials about restrictions and

inspection requirements in your area.

Please Read this entire manual before you install and use your new room heater. Failure to

follow instructions may result in property damage, bodily injury, or even death.

United States Stove Company • 227 Industrial Park Road • P.O. Box 151 • South Pittsburg, TN 37380

CAC 1

Report #: 215-S-16-4

CAUTION:

Read all instructions carefully before starting the installation

or operation of this heater.

Improper installation may void your warranty.

DO NOT USE THIS HEATER IN A MOBILE HOME OR TRAILER

This unit was tested and listed to UL 1482-1996 by OMNI-Test Laboritories

851396 E

TABLE OF CONTENTS

IMPORTANT SAFETY INFORMATION ............................................................................................................................................................2

BUILDING CODES AND SAFETY STANDARDS .............................................................................................................................................3

HOW THIS HEATER OPERATES ....................................................................................................................................................................3

SELECTING A LOCATION FOR THE HEATER ...............................................................................................................................................3

FLOOR PROTECTION ......................................................................................................................................................................................5

CHIMNEY CONNECTOR AND CHIMNEYS .....................................................................................................................................................5

HEATER INSPECTION .....................................................................................................................................................................................9

TOOLS AND SUPPLIES NEEDED FOR INSTALLATION ................................................................................................................................9

HEATER INSTALLATION .................................................................................................................................................................................9

MINIMUM CLEARANCES TO COMBUSTIBLE WALLS AND CEILINGS ...................................................................................................9

TO SAFELY AND PROPERLY INSTALL THIS HEATER .........................................................................................................................10

HEATER OPERATION ....................................................................................................................................................................................11

TO BUILD A FIRE ......................................................................................................................................................................................11

FIRETENDING ..........................................................................................................................................................................................12

MINIMUM FIRE ADJUSTMENT ......................................................................................................................................................................13

COAL FACTS ............................................................................................................................................................................................13

HOW TO TAKE CARE OF THE HEATER AND VENTING SYSTEM (ROUTINE MAINTENANCE) ..............................................................13

HEATER MAINTENANCE .........................................................................................................................................................................13

DISPOSAL OF ASHES ..............................................................................................................................................................................13

VENTING SYSTEM ( CHIMNEY AND CHIMNEY CONNECTOR) ............................................................................................................14

CHIMNEY CONNECTOR PIPE-CORROSION INSPECTION ..................................................................................................................14

TROUBLESHOOTING ....................................................................................................................................................................................14

THE VENTING SYSTEM-KEY TO GOOD HEATER PERFORMANCE ....................................................................................................14

WHAT TO DO IF THE HEATER SMOKES, BURNS POORLY OR EXCESSIVE CREOSOTE ACCUMULATES IN THE CHIMNEY ..............

WHAT TO DO IF THE HEATER BURNS TO RAPIDLY OR OVERHEATS ..............................................................................................15

QUICK REFERENCE TO THE MOST COMMON SOLUTIONS FOR THE MOST COMMON HEATER OPERATIONAL PROBLEMS ...........16

FINAL CHECKLIST OF DO’S AND DON’TS .......................................................................................................................................................16-17

REPAIR PARTS DIAGRAM AND LIST ...............................................................................................................................................................18-19

WARRANTY CLAIM INFORMATION AND REPAIR PARTS ...................................................................................................................................20

IMPORTANT SAFETY INFORMATION

To assure that satisfactory and safe service is received from this heater:

1. Read these instructions entirely before beginning any part of the installation.

2. Use these instructions as a guide during the installation of the heater.

3. Be sure these instructions become the property of and are reviewed by all future users of this heater to encourage proper operation and

mainte-..........................................................................................................................................................................................................................

nance of this appliance.

THIS HEATER IS ONLY FOR BURNING COAL. USE OF ANY OTHER SOLID FUEL EXCEPT FOR COAL IGNITION PURPOSES IS A VIOLATION OF FEDERAL LAW.

Soot – Formation and Need for Removal When coal is burned, the products of combustion combine with moisture to form a soot residue which accumulates on the ﬂ ue lining. When ignited, this soot makes an extremely hot ﬁ re. The chimney connector and chimney should be inspected at least once every two months during the heating season to determine if a soot buildup has occurred. If soot has accumulated, it should be removed to reduce the risk of a chimney ﬁ re.

This heater is designed to burn stove size bituminous or anthracite coal and to provide heat to one or more rooms. Because of its radiating characteristics, this heater must be installed as an unenclosed, freestanding unit with clearances to combustibles as speciﬁ ed by these instructions. This heater must be connected to a Listed Factory-Built Residential Type and Building Heating Appliance Chimney or a properly constructed and maintained masonry chimney. DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE. This heater is not designed to burn lignite coal, liquid fuels, and gaseous fuels or household refuse. Any attempt to burn these type fuels, to enclose the heater or to attach the heater to an air circulation system or a stoking device can be very hazardous.

THIS HEATER IS NOT DESIGNED TO BE USED IN A MOBILE HOME. Do Not Overﬁ re - if Heater or Chimney Connector Glows, You are Overﬁ ring.

Improper installation or use of this heater can cause:

1. Damage to the heater from overheating.

2. Hazardous temperatures to develope on combustible materials adjacent to the heater, chimney connector or chimney.

3. Possible hazardous accumulation of coal gases within the heater.

4. Release of hazardous gas into the dwelling.

2 CAC

BUILDING CODES AND SAFETY STANDARDS

These instructions comply with the applicable

National Fire Protection Association and Underwriters’ Laboratories, Inc. Standards for the installation and operation of this type heater. Before beginning the installation, you should check with local building ofﬁ cials to assure compliance with local regulations and codes. This heater is safety listed by Omni Test Laboratories as speciﬁ ed by the listing label attached to the heater.

HOW THIS HEATER OPERATES

The chimney draft draws in combustion air through an adjustable air inlet thermostat located inside the cabinet. Air ﬂ ows through and across the bed of fuel, causing the ﬁ re to progress through the fuel bed. Heat is transferred to the air that ﬂ ows between the cabinet and the ﬁ rebox. Any attempt to alter this air by connecting this heater to a duct system or air movement fans other than the optional B36 listed blower, available from your heater dealer, can lead to improper and possibly hazardous operation of this heater.

SELECTING A LOCATION FOR THE HEATER

When selecting a location for the heater, be sure attention is given to the following considerations:

If the heater is to be vented into a Listed High Temperature Type HT Factory-Built Residential Type And Building Heating Appliance Chimney, review the installation instructions for the chimney to comply with requirements for proper chimney location, height, space requirements, etc.

If the heater is to be vented into a masonry chimney, the heater should be located as near the chimney as possible without failing to comply with the requirements for minimum spacing between the chimney connector, heater and combustibles. (Be sure chimney is constructed according to NFPA standards.)

The location of the heater must provide at least the minimum clearances between the heater, chimney connector and combustible materials as speciﬁ ed by ﬁ gures 1, 2, 3, 4.

If the heater is to be located on a combustible ﬂ oor, there must be suitable ﬂ oor space to install a ﬂ oor protector beneath and extending beyond the heater as shown by ﬁ gure 5 and as described by the Floor Protection section of this manual.

The heater should be located centrally within the area where heat is desired but out of trafﬁ c areas to minimize the likelihood of persons accidentally contacting the hot surface of the heater.

The heater should be located away from doorways and central heat outlets and inlets to reduce the chance of drafts blowing smoke, ashes or sparks out of the heater during refueling or ash removal.

The heater should be located where a small supply of fuel may be kept conveniently close but not within 36 inches of the heater.

Locate the heater so that drapes, curtains, furniture and other combustible materials will not be closer than the clearances shown by ﬁ gures 1, 2, 3, and 4 OR install a clearance reduction system. See MINIMUM CLEARANCES TO COMBUSTIBLE WALLS AND CEILINGS section of this manual for details.

FIGURE 1 - MINIMUM CLEARANCES TO COMBUSTIBLES

FIGURE 2 - MINIMUM CLEARANCES TO COMBUSTIBLES

CAC 3

FIGURE 3 - MINIMUM CLEARANCES TO COMBUSTIBLES

SIDE SECTION VIEW

FIGURE 4 - MINIMUM CLEARANCES TO COMBUSTIBLES

PLAN SECTION VIEW

4 CAC

FIGURE 5 - FLOOR PROTECTION

FLOOR PROTECTION

This heater has been designed to prevent excessive temperatures on the ﬂ oor beneath the heater. It is important, however, that a combustible ﬂ oor be protected by a 3/8 inch minimum thick noncombustible inorganic millboard having a thermal conductivity of k=0.43 BTU/ft.2/in./hr./°F or a listed ﬂ oor protector beneath the heater extending beyond the heater as shown by ﬁ gure 5. The ﬂ oor covering is required to prevent damage or possible ignition from sparks or glowing embers that might escape the heater during refueling or

ash removal or drop from the joints of the chimney connector.

CHIMNEY CONNECTOR AND CHIMNEYS

It is very important to assure safe and satisfactory performance from your heater that it be properly connected to a correctly constructed and maintained chimney. If a Listed High Temperature Type HT Factory-Built Residential and Building Heating Appliance Chimney is used, follow the chimney manufacturer’s installation instruc-

FIGURE 6 - RISE OF HORIZONTAL

CHIMNEY CONNECTOR PIPE

tions carefully. If a masonry chimney is to be used, be sure it is constructed to the National Fire Protection Association (N.F.P.A) and local code standards. A copy of the N.F.P.A 211 Chimney, Fireplaces, Vents and solid Fuel Burning Appliances may be obtained from N.F.P.A., Inc. Batterymarch Park, Quincy, MA 02269.

The Chimney connector (pipe from heater to chimney) must be 6 inches

in diameter and made from 24 gauge or heavier steel. The length of the chimney connector and number of elbows* used should be kept to a minimum. Moisture that might collect in the chimney should be directed to the heater by providing a slope of 1/4 inch per foot in a horizontal run of the chimney connector and installing all pipes with the crimped end toward the heater, (See ﬁ gure 6). The chimney connector should extend at least two inches into the ﬂ ue of a factory-built chimney. When mak- ing a horizontal connection to a masonry chimney, the connector should extend to the inside face of the vertical ﬂ ue liner, (see ﬁ gures 7 and 8). When connecting the heater to a masonry ﬁ replace, the chimney connector should extend into the chimney’s liner as shown by the side section view of ﬁ gure 4. All chimney connector joints should be sealed with furnace cement and secured with No. 8 sheet metal screws as described by the TO SAFELY AND PROPERLY INSTALL THIS HEATER section of this manual. *Use Corrugated Elbows.

DO NO USE MORE THAN TWO 90 DEGREE ELBOWS IN THE Chimney CONNECTOR. Installations which require two degree elbows must be vented into a ﬂ ue of at least 8” diameter or 8” square to prevent chimney draft restrictions, (see ﬁ gure 2). DO NOT PASS A CHIMNEY CONNECTOR THROUGH A FLOOR OR CEILING OF ANY KIND. Only Listed Factory-Built Residential Type and Building Heating Appliance Chimneys or masonry chimneys constructed to N.F.P.A. standards should pass through a ﬂ oor or ceiling.

RISE: 1/4” FOR EACH FOOT OF CONNECTOR LENGTH

PIPE ANGLE UP

HORIZONTAL

TO HEATER

TO CHIMNEY

CAC 5

There are ﬁ ve allowable ways that a chimney connector can be connected to a masonry chimney by passing through a combustible wall. NFPA Standard 211 allows the following wall pass-through systems.

Use a minimum 3-1/2” thick brick masonry wall framed into the combustible wall. A ﬁ reclay liner (ASTM C315 or equivlent) having a 5/8” minimum wall thickness must be used and it must be at least 12” away from any material that could catch ﬁ re. The inside diameter of the ﬁ reclay liner shall be sized for the proper snug ﬁ t of a 6” diameter chimney con nector pipe. The ﬁ reclay liner shall run from the outer surface of the brick wall to, but not beyond, the inner surface of the chimney ﬂ ue and shall be ﬁ rmly cemented in place. See Part A of Figure 7.

Use a solid insulated listed factory-built chimney (UL 103 HT) length having an inside diameter of 6” and having 1” or more of solid insulation. There must be at least a 9” air space between the outer wall of the chimney length and any combustible materials. The inner end of the chimney length shall be ﬂ ush with the inside of the masonry chimney ﬂ ue shall be sealed to the ﬂ ue and to the brick masonry penetration with nonwater-soluble refractory cement. Sheet steel supports which are at least 24 gauge(0.024”) in thickness shall be securely fastened to wall surfaces on all sides. Fasteners between supports and the chimney length shall not penetrate the chimney liner. See Part B of Figure 7.

Use a 10” diameter ventilated thimble made of at least 24 gauge(0.024”) steel having two 1” air channels. The ventilated thimble must be separated from combustible materials by a minimum of 6” glass ﬁ ber insulation. The opening in the combustible wall shall be covered and the thimble supported with sheet steel supports which are at least 24 gauge (0.024”) in thickness. The sheet steel supports shall be securely fastened to wall surfaces on all sides and shall be sized to ﬁ t and hold the chimney section. Fasteners used to secure chimney sections shall not penetrate chimney ﬂ ue liner. See Part C of Figure 7.

Use an 8” inside diameter solid insulated listed factory-built chimney length which has 1” or more of solid insulation. The minimum length of this chimney section shall be 12” and will serve as a pass-through for the 6” diameter chimney connector. There must be at least a 12” air space between the outer wall of the chimney section and any combustible materials. The chimney section shall be concentric with and spaced 1” away from the chimney connector by means of sheet steel support plates on both ends of the chimney section. The opening in the combustible wall shall be covered and the chimney section supported on both sides with sheet steel supports which are at least 24 gauge (0.024”) in thickness. The sheet steel supports shall be securely fastened to wall surfaces on all sides and shall be sized to ﬁ t and hold the chimney section. Fasteners used to secure chimney sections shall not penetrate chimney ﬂ ue liner. See Part C of Figure 7.

A listed factory-built wall pass-through system may be purchased and installed according to the instructions packaged with it to provide a safe method of passing the chimney connector through a combustible wall for connection to a masonry chimney.

Additional requirements pertaining to Figure 5 and the above wall pass-through systems:

Insulation material used as part of wall pass-through system shall be of noncombustible material and shall have a thermal

1. conductivity of 1.0 Btu • in./ft.² • °F (4.88 kg • cal/hr • m² • °C) or less All clearances and thicknesses are minimums: larger clearances and thickness are acceptable.

2. A chimney thimble, as shown for 3” and 4” above (Parts C and D respectively of Figure 7) shall be for types “3” and “4”

3. connections to facilitate removal of the chimney connector for cleaning. The chimney thimble shall be of ASTM C315 ﬁ reclay with 5/8” minimum wall thickness , or material or equivalent durability. The inside diameter of the thimble shall be sized for the proper snug ﬁ t of a 6” diameter chimney connector pipe. The thimble shall be installed without damage to the chimney ﬂ ue. The thimble shall extend through the chimney wall to, but not beyond, the inner surface of the chimney ﬂ ue and shall be permanently cemented in place with high temperature cement. A chimney connector to a masonry chimney, except for 2” above (Part B of Figure 7), shall extend through the wall pass-

4. through system to the inner face of the chimney ﬂ ue, but not beyond. It does not have to be fastened in place so long as it cannot accidently be pulled out of the chimney or shoved into the chimney ﬂ ue. If fasteners are used to secure the chimney connector to a masonry chimney, the fasteners shall not penetrate the chimney ﬂ ue liner. Any material used to close up any opening for the connector shall be noncombustible.

If the chimney connector does not have to pass through a combustible wall to get to a masonry chimney, connect the chimney connector to the masonry chimney as shown in ﬁ gure 8. The ﬁ reclay liner shown by ﬁ gure 8 should be sized for the proper snug ﬁ t of a 6” diameter chimney connector pipe. The ﬁ reclay liner should be ﬁ rmly cemented in place as shown. As previ- ously stated, any metal prefabricated chimney this heater is connected to must be a listed Hi-Temp Type HT Factory Built Residential Type and Building Heating Appliance Chimney. When a metal prefabricated chimney is used, the manufacturer’s installation instructions must be followed precisely. You must also purchase (from the same manufacturer) and install the ceiling support packageor wall pass through and “T” section package, ﬁ restops (when needed), insulation shield, roof ﬂ ashing, chimney cap, etc. Maintain the proper clearance to the structure as recommended by the manufacturer. This clearance is usually a minimum of 2 inches, although it may vary by manufacturer or for certain components. A listed chimney cap should be installed to prevent entrance of rain and help elimnate down drafts. An unapproved chimney cap, protector or spark arrester can become clogged when leaves or other matter. This blocks the chimney and causes smoke, and the dangerous carbon monoxide in smoke, to spill back into your home where it can kill you.

6 CAC

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