United States Stove Company 1537Q User Manual

Model 1537Q

SOLID FUEL WARM AIR FURNACE

Owners Manual

*FOR PARALLEL INSTALLATION WITH AN

EXISTING FORCED AIR, GAS OR OIL

FIRED FURNACE (U.S. ONLY)

*FOR INSTALLATION AS A CENTRAL FURNACE

CAUTION: Read All Instructions Carefully Before Starting the Installation or Operating the Furnace.

Improper Installation May

Void Your Warranty

Save This Manual For

Future Reference

DO NOT USE THIS FURNACE IN A MOBILE HOME OR TRAILER

UNITED STATES STOVE COMPANY

227 Industrial Park Road

P.O.Box 151

South Pittsburg, TN 37380

(423) 837-2100

WARNOCK HERSEY

851239B 10/98

CONGRATULATIONS!

You've purchased one of America's Finest Wood and Coal Burning Furnaces. By heating with wood and coal you're helping to CONSERVE AMERICA'S ENERGY! Wood is our Renewable Energy Resource. Please do your part to preserve our wood supply. Plant at least one tree each year. Future generations will thank you.

NOTE:

IMPROPER INSTALLATION COULD VOID YOUR WARRANTY!

YOUR UNIT MUST BE INSTALLED BY A QUALIFIED FURNACE INSTALLER.

NOTE: (See Page 5, First Paragraph)

tools and materials needed

Pencil 6 Foot Folding Rule or Tape Tin Snips Drill, Hand or Electric Drill Bit (For Sheet Metal Screws) 1/8" Dia. Screw Driver (Blade-Type) Gloves Sabre Saw 5/16" Nut Driver or 5/16" Socket with Rachet

MATERIALSTOOLS

6" Pipe, 6" Elbow, Collar and Thimble; as required (24 gauge min.) 1/2" Sheet Metal Screws 6" Inside Diameter Listed Residential Type or Building Heating Appliance Chimney or Existing Masonry Chimney (SEE Page 8). Electrical Wiring 6" Draft Regulator 1/2" Conduit (Conduit Connectors) Furnace Cement (Manufacturer Recommends: Rutland Black - Code 78 or Equivalent Plenum and Duct Work as Required

Caution Labels

Your Furnace has the following labels. Read and obey all labels.

DANGER: RISK OF FIRE OR EXPLOSION. DO NOT burn garbage, gasoline, drain oil, or other flammable liquids.

WARNING: FIRE HAZARD. DO NOT operate with fire draft exceeding .06 inches W.C. DO NOT operate with fuel loading or ash removal doors open. DO NOT store fuel or other combustible material within the marked installation clearances. DO NOT store fuels, paints, thinners, flammable liquids, or other highly volatile substances in the

furnace room.

CAUTION: HOT SURFACES Keep children away. Do not touch during operation.

CAUTION! 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.

SAFETY NOTICE:

If this heater is not properly installed, a house fire may result. For your safety, follow the installation directions. Contact local building or fire officials about restrictions and installation inspection requirements in your area.

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 ACCUMULATED ASH.

rules for safe installation and operation

Read these rules and the instructions carefully. Failure to follow them will cause a hazard that could result in death, serious bodily injury, and/or property damage.

Check your local codes. This installation must comply with their rulings.

Do not install this furnace in a mobile home or trailer. Always connect this furnace to a chimney and vent to the outside. Never vent to another room or

inside a building. Do not connect this furnace to an aluminum Type B gas vent. This is not safe and is prohibited by the

National Fire Protection Association Code. This furnace requires a masonry or listed factory built chimney for residential type or building heating appliance chimney. Use a 6" diameter chimney or larger, that is high enough to give a good draft. (See Page 8)

Be sure that if a masonry chimney is used, it is safely constructed and in good repair. Have the chimney inspected by the Fire Department or an inspector.

Inspect chimney connector and chimney before and frequently during the heating season for any deposit of creosote or soot which must be removed (see Chimney Maintenance, page 21.)

Provide air for combustion into the room where the furnace is located. If the intake is not in the same room, air must have free access to the room.

CAST IRON PARTS MUST BE "SEASONED" TO AVOID CRACKING. BUILD ONLY SMALL FIRES ON FIRST USE.

To prevent injury, do not allow anyone to use this furnace who is unfamiliar with the correct operation of the furnace.

10.

11.

12.

13.

14.

15. Your Furnace is designed to be installed in a parallel air flow arrangement with a gas or oil-fired

forced air upflow-type central furnace, or it may be installed as a central furnace.

For further information on using your furnace safely, obtain a copy of the National Fire Protection Association (NFPA) publication "Chimney's, Fireplaces and Solid Fuel Burning Appliances" NFPA

211. The address of the NFPA is Batterymarch Park, Quincy, MA 02269. Keep the ashpit section free of excess ashes. Do not allow ashes to stack higher than the sides of the

ash pan. DISPOSAL OF ASHES - Place ashes in a metal container with a tight fitting lid. Keep the closed

container on a noncombustible floor or on the ground, well away from all combustible materials. Keep the ashes in the closed container until all cinders have thoroughly cooled. The ashes may be buried in the ground or picked up be a refuse collector.

CAUTION - The special paints used on your furnace may give off some smoke while they are curing during first few fires. Build small fires at first. The metal used in construction of the furnace and duct work has a light coating of oil. This could give off smoke and/or odors from registers when furnace is used for the first time. This should disappear after a short period of time. Once this burn-off has occurred, it should not reoccur.

CARING FOR PAINTED PARTS - This furnace has a painted outside jacket, which is durable but it will not stand rough handling or abuse. When installing you furnace, use care in handling. Clean with soap and warm water when furnace is not hot. DO NOT use any acids or scouring soap, as these wear and dull the finish. DISCOLORATION WILL OCCUR IF THE FURNACE IS OVERFIRED. FOLLOW OPERATING INSTRUCTIONS CAREFULLY.

Keep the feed and ash doors closed at all times except while tending the furnace.

HOW THE FURNACE FUNCTIONS

Your Supplemental Furnace is designed to be a supplemental or central heating source for your home. This solid fuel furnace may be installed in conjunction with a properly operating central furnace that is listed or certified in accordance with nationally recognized safety standards and equipped with the required controls and other safety features and which has been installed with appropriate standards of National Fire Protection Association with installation clearances specified in the furnace nameplate marking. The installation must be accomplished by a qualified agency (one who is engaged in, and is responsible for, or is thoroughly familiar with the installation and operation of the gas, oil, and solid fuel burning heating appliances, who is experienced in such work, familiar with all precautions required, and has complied with all the requirements of the authority having jurisdiction.) The installation shall be in strict accordance with the manufacturer's installation instructions furnished with the solid fuel furnace. The chimney connector of the furnace is to be installed to provide clearances to combustible material not less than specified in the individual classifications and marked on the furnace. The chimney connector must be connected to a chimney suitable for use with residential type or building heating appliances which burn solid fuel. The furnace is designed to operate in either parallel or series air flow arrangement with the central furnace or as a central furnace. PARALLEL INSTALLATION: The design is such that when the blower comes on,

the blower on the central system also comes on. The blower will only come on when the temperature in the plenum has reached the setting on the blower control. This is to insure that there is sufficient warm air in the system to make it efficient for the unit to operate. When the central system thermostat calls for heat, the central system will operate by the burner igniting and the blower coming on. It is possible that both systems will operate simultaneously. It is recommended that for the most efficient use of your Supplemental Furnace, that it be fired as much as possible in order to reduce the demand on your existing central heating system. This unit has an optional motorized natural draft kit that operates from a wall thermostat. When the temperature falls below the setting on the wall thermostat, the motorized natural draft will open to increase heat. The warm air supply outlet of the supplementary furnace shall not be connected to the cold air return inlet of the central furnace because the possibility exists of components of the central furnace overheating and causing the central furnace to operate other than is intended. SERIES INSTALLATION: This type of installation uses only the blowers of the existing central furnace. The solid fuel fan/limit control must also control the functions of the existing furnace. All electrical power must come from a single branch circuit (see Fig. 15). CENTRAL FURNACE INSTALLATION: As a central furnace, the unit functions independently of any other system. The blower will come on when the plenum temperature reaches the setting on the blower control.

Model 1537Q Dimensions

43-7/8

40-11/16

24-1/16

FIG. 1

32-1/4

3-1/2

33-7/8

18"

6" CHIMNEY

12" 9"

FIG. 2

Locating the Furnace

The furnace should be located in the

1. same room as the central system and as close as possible, but no closer than 9". There should be no wall between the furnace and the warm air outlet duct that is connected directly to the warm air outlet plenum of the central furnace. See Fig. 2.

The unit will require installation with

2. the following clearances:

Unit to sidewall . . . . . .12" (305 mm)

Unit to backwall . . . . . 30" (760 mm)

Chimney connector pipe to sidewall

. . . . . . . . . . . . . . . . . . 21" (530 mm)

Chimney connector pipe to backwall

. . . . . . . . . . . . . . . . . . 18" (460 mm)

Hot air ducts to combustibles

. . . . . . . . . . . . . . . . . . . 6" (150 mm)

CENTRAL FURNACE

48"

18"

6" SOLID DAMPER

6" BAROMETRIC DRAFT REGULATOR (OPTIONAL)

18"

NOTE: Install only on a noncombustible floor.

(REFER TO FIG. 2 & 3) Place the furnace on a noncombus-

3. tible floor.

Check figures 2 and 3. Be sure you

4. have the clearances shown from the furnace and the connector pipe to combustible surfaces. If you have a solid brick or stone wall behind your heater, you can place the furnace as close as you wish to the wall. If the wall is only faced with brick or stone, treat it as a combustible wall.

NON-COMBUSTIBLE FLOOR

FIG. 3

THIMBLE

chimney connection

6" SOLID DAMPER

6" BAROMETRIC DRAFT REGULATOR (OPTIONAL)

6" ELBOW

6" CHIMNEY CONNECTOR

NON-COMBUSTIBLE WALL

FIG. 4

6" ELBOW

MASONRY CHIMNEY

Before using an existing masonry chimney, clean the chimney and inspect the flue liner to be sure it is safe to use. Make repairs before attaching the furnace. See Page 4, item 5. Look at Fig. 4. The connector pipe and fittings you will need to connect directly to a masonry chimney are shown. The chimney connection should be as short as possible. If the connector pipe must go through a combustible wall before entering the masonry chimney, consult a qualified mason or chimney dealer. The installation must conform to local fire codes, and N.F.P.A. 211.

DO NOT CONNECT THIS FURNACE TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE.

The chimney used for a furnace must not be used to ventilate the cellar or basement. If there is a cleanout opening at the base of the chimney, close it tightly.

REFER TO CHIMNEY MANUFACTURER'S INSTRUCTIONS AND PARTS.

6" CHIMNEY CONNECTOR

6" ELBOW

FIG. 5

6" SOLID DAMPER

6" BAROMETRIC DRAFT REGULATOR (OPTIONAL)

10'

2' MIN.

3' MIN.

LISTED FACTORY BUILT CHIMNEY

Carefully follow chimney manufacturer's instructions. Use only a Listed Residential Type or Building Heating Appliance Chimney. If your chimney starts at the ceiling (Fig. 5), you will need enough 6" pipe to reach the ceiling. The top of the chimney must be at least 3 feet above the roof and be at least 2 feet higher than any point of the roof within 10 feet (Fig. 5).

Rules for Connector Pipe Installation

The crimped end of the chimney con-

1. nector fits inside the furnace flue collar. Install additional chimney connector and elbow with the CRIMPED END TOWARD THE FURNACE. This will allow any condensation in the flue to run back into the furnace. Use 6" dia. (minimum 24 gauge) black chimney connector. Slope any horizontal pipe upward toward

2. the chimney at least 1/4 inch for each foot of horizontal run. You must have at least 18 inches of

3. clearance between any horizontal piping and the ceiling. (See Fig. 3) The chimney connector must not extend

4. into the chimney flue (See Fig. 6). Seal each chimney connector pipe joint

5. with furnace cement. Also seal the pipe at the chimney. Use 3 sheet metal screws at each chim-

6. ney pipe joint to make the piping rigid. The chimney connector may include a

7. section for a barometric draft regulator between the furnace and the chimney (Fig. 4, 5, 6, & 7). The barometric draft regulator must be installed in the same room (same pressure zone) as the furnace. Install the barometric draft regulator

8. strictly in accordance with the instructions that are provided with the barometric draft regulator. A solid damper can be placed between

9. the barometric draft regulator and the chimney. (Fig. 4, 5, 6, & 7)

RIGHT WRONG WRONG

FIG. 6

NON-COMBUSTIBLE INSTALLATION PER NFPA 211

Adjusting the Barometric Draft Regulator

Drill a hole in the chimney connector

1. within 18" of the flue collar below the barometric draft regulator just large enough for the tube of the manometer. Build a fire after all chimney connec-

2. tions have been made. Use a manometer to measure the draft

3. in the flue. (U.S. Stove Model DG-26) Adjust the barometric draft regulator to

4. obtain a draft of 0.05" - 0.06" W.C. under stable conditions.

6" SOLID DAMPER

6" BAROMETRIC DRAFT REGULATOR (OPTIONAL)

MEASURE FLUE DRAFT HERE

FIG. 7

Assembly of Furnace

Your furnace requires the following items to be assembled or installed by the service person:

Feed Door Handle Feed Door Latch Smoke Curtain Blowers and Blower Controls Electrical Connections

Remove all parts from inside the

1. furnace and inspect for damage, including the firebrick as some breakage could occur during shipment. Assemble the feed door handle

2. as shown in Figure 8. Install the latch as illustrated in Figure 9. Attach the smoke curtain to the

3. firebox as shown in Figure 10. Install Honeywell thermostat on rear of furnace cabinet as shown

4. in Figure 11. Remove blowers from cartons. Remove junction box cover. At-

5. tach clip nuts as per Figure 11. Install blowers and gaskets with 1/4"-20 x 3/4" bolts as shown. Wire right side blower first per wiring diagram (Figure 12) and

6. replace cover on junction box on blower. Wire left blower same as above and replace cover.

7. Complete all wiring in junction box by referral to the wiring diagram

8. and Figure 11 - Blower and Component Assembly. Replace cover on junction box. Check operation of shaker grates with grate handle before operat-

9. ing furnace.

WASHER FEED DOOR HANDLE

LOCKNUT

FIG. 8

FIG. 9

SMOKE DOOR CLIP

NUT

CARRIAGE BOLT

FIG. 10

SMOKE CURTAIN

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