United States Stove Company 1800GC User Manual
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UNITED STATES
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STOVE COMPANY
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Keeping America Warm
Since 1869
Y
CANADACANADA
CANADA
MODEL: 1600GC / 1800GCMODEL: 1600GC / 1800GC
MODEL: 1600GC / 1800GC
MODEL: 1600GC / 1800GCMODEL: 1600GC / 1800GC
THE WOOD AND COAL FURNACE
SAFETY NOTICE: IF THIS FURNACE IS NOT PROPERLY INSTALLED, A HOUSE FIRESAFETY NOTICE: IF THIS FURNACE IS NOT PROPERLY INSTALLED, A HOUSE FIRE
SAFETY NOTICE: IF THIS FURNACE IS NOT PROPERLY INSTALLED, A HOUSE FIRE
SAFETY NOTICE: IF THIS FURNACE IS NOT PROPERLY INSTALLED, A HOUSE FIRESAFETY NOTICE: IF THIS FURNACE IS NOT PROPERLY INSTALLED, A HOUSE FIRE
MAY RESULT. FOR YOUR SAFETY, FOLLOW THE INSTALLATION DIRECTIONS.MAY RESULT. FOR YOUR SAFETY, FOLLOW THE INSTALLATION DIRECTIONS.
MAY RESULT. FOR YOUR SAFETY, FOLLOW THE INSTALLATION DIRECTIONS.
MAY RESULT. FOR YOUR SAFETY, FOLLOW THE INSTALLATION DIRECTIONS.MAY RESULT. FOR YOUR SAFETY, FOLLOW THE INSTALLATION DIRECTIONS.
CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS ANDCONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND
CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND
CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS ANDCONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND
INSTALLATION REQUIREMENTS IN YOUR AREA.INSTALLATION REQUIREMENTS IN YOUR AREA.
INSTALLATION REQUIREMENTS IN YOUR AREA.
INSTALLATION REQUIREMENTS IN YOUR AREA.INSTALLATION REQUIREMENTS IN YOUR AREA.
Installation/Operator's Manual # 851502Installation/Operator's Manual # 851502
Installation/Operator's Manual # 851502
Installation/Operator's Manual # 851502Installation/Operator's Manual # 851502
CANADACANADA
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TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTSTABLE OF CONTENTS
Introduction .......................................................................................................3
Locating Your Furnace......................................................................................3
Clearances ........................................................................................................3
Chimney Requirements.....................................................................................3-4
Smoke Pipe Installation.....................................................................................4-5
Add-on Series Installation .................................................................................5-7
Assembly Instructions .......................................................................................7-10
Wiring Diagram for Series Installation with Existing Electric Furnace ...............11
Wiring Diagram for Series Installation with Existing Gas or Oil Furnace...........12
Testing and Operating Procedures ...................................................................13-14
Trouble Shooting and Problem Solving.............................................................15
Parts Lists
Model 1600/1800 ..............................................................................................16-17
Motorized Natural Draft .....................................................................................18
Installation of Optional Equiptment ...................................................................19
2
INTRODUCTIONINTRODUCTION
INTRODUCTION
INTRODUCTIONINTRODUCTION
CLEARANCESCLEARANCES
CLEARANCES
CLEARANCESCLEARANCES
Thank you for your purchase of a U.S. Stove Woodburning
furnace. Your decision to buy a Hotblast Furnace was undoubtedly reached after much careful thought and consideration. We
are very proud you chose the U.S. Stove 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 in your purchase, but in his recommendations for professional installation in your home. The qualified professional
installer (as recommended by your dealer) 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 his field.
IMPORTANTIMPORTANT
IMPORTANT
IMPORTANTIMPORTANT
Before installing and using your Hotblast Furnace, please
read the following pages thoroughly and carefully. If you
follow the instructions, your Hotblast furnace will give you safe
and more dependable service in the years to come.
! First step; check your local codes. This installation must
comply with their rulings.
! Do not install this furnace in a mobile home or trailer.
! Always have a smoke or ionization detector installed in
your home.
! To prevent injury or damage, do not allow anyone who is
unfamiliar with the furnace to operate it.
! Spend some time with your furnace to become well
acquainted with different settings and how each will
affect its burning patterns. It is impossible to state just
how each setting will affect your furnace because of
the variations in each installation.
DISCLAIMER NOTICEDISCLAIMER NOTICE
DISCLAIMER NOTICE
DISCLAIMER NOTICEDISCLAIMER NOTICE
The BTU ranges and heating capacity specifications are
provided as a guide only and in no way guarantee the output
or capacity of the units. The actual BTU output depends on the
type of fuel being burned and its conditions, the thermostat
setting, the draft adjustment and the chimney that the unit is
hooked up to. The actual area that the 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, and the location of the unit.
FLAMMABLE WALL
MODEL 1600 - 20"(50.8cm)
MODEL 1800 - 25"(63.5cm)
MODEL
1600 - 22"(55.88cm)
1800 - 19"(48.26cm)
MODEL
1600 - 12"(30.48cm)
1800 - 8"(20.32cm)
REDUCED CLEARANCESREDUCED CLEARANCES
REDUCED CLEARANCES
REDUCED CLEARANCESREDUCED 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 asbestos board placed directly against a wall
protects it. Materials installed in this manner give very little
protection. These materials are good heat conductors, so they
will be almost as hot on their back side as they are on the
exposed side. Therefore, the combustible wall behind is still a
fire hazard.
A wall can be kept cool using these items but only if they're
mounted and spaced out from the wall by an inch or two to
allow free circulation of room air behind the protective panel.
The protective panel should start within a few inches of floor
level.
The three rules to follow when constructing wall protectors:
1. Non-combustibility of all materials including mounting
or supporting.
2.A well ventilated air space between protector or wall.
3.Sufficient strength and rigidity so that the protector and
air space will be durable.
2" FROM CEILING
CONSTRUCTINGCONSTRUCTING
CONSTRUCTING
CONSTRUCTINGCONSTRUCTING
NON-FLAMMABLENON-FLAMMABLE
NON-FLAMMABLE
NON-FLAMMABLENON-FLAMMABLE
WALLSWALLS
WALLS
WALLSWALLS
FLUE
MODEL 1600 - 15"(38.1cm)
MODEL 1800 - 18"(45.72cm)
(TOP VIEW)
MINIMUMMINIMUM
MINIMUM
MINIMUMMINIMUM
CLEARANCE TOCLEARANCE TO
CLEARANCE TO
CLEARANCE TOCLEARANCE TO
FLAMMABLE WALLSFLAMMABLE WALLS
FLAMMABLE WALLS
FLAMMABLE WALLSFLAMMABLE WALLS
CAUTION: Do not
store combustible or
flammable material
near furnace.
PROTECTIVE COVERING
AND ALL SUPPORTS MUST
BE NON-COMBUSTIBLE.
LOCATING YOUR FURNACELOCATING YOUR FURNACE
LOCATING YOUR FURNACE
LOCATING YOUR FURNACELOCATING YOUR FURNACE
The furnace is to be installed maintaining clearances as shown
in illustration.
Do not place the furnace directly on a combustible floor. If you're
placing it on a combustible floor, an approved fire retardant
material equivalent to 3/8" asbestos millboard should be placed
under the furnace. The material must extend at least 16" (40.64cm)
in front of and 8" (20.32cm) on either side of the fuel-loading and
ash-removal doors, and underneath the chimney connector and
extending at least 2" (5.05cm) on either side of the chimney
connector.
1" AIR SPACE
2" FROM FLOOR
CHIMNEY REQUIREMENTSCHIMNEY REQUIREMENTS
CHIMNEY REQUIREMENTS
CHIMNEY REQUIREMENTSCHIMNEY REQUIREMENTS
A masonry or Class A All-Fuel Metal Insulated Chimney must be
used in all airtight wood furnace installations. The minimum
recommended flue size for the U.S. Stove Hotblast Furnace is 6"
(15.24cm) (inside diameter) for round flues, and 7" x 7" (17.78cm)
for square flues. When making new chimney installations,
always follow the chimney manufacturers instructions.
3
NOTE: Type of chimney: Class A All-Fuel also referred to as
Low-Heat appliance type chimney per Uniform Mechanical
Code:
Chimney, low-heat appliance type is a factory built, masonry
or metal chimney suitable for removing the products of
combustion from fuel-burning low-heat appliances producing combustion gases not in excess of 1000°F (538°C) under
normal operating conditions but capable of producing com
bustion gases of 1400°F (760°C) during intermittent forced
firing for periods up to one hour. All temperatures are
measured at the appliance flue outlet.
TOP OF CHIMNEY MUST BE
2 FT. (60.96cm) ABOVE
HIGHEST POINT OF ROOF
2 FT. (60.96cm) MINIMUM
MINIMAL 3 FT.
(91.44cm) FROM TOP
OF CHIMNEY TO
POINT AT WHICH IT
PASSES THROUGH
THE ROOF.
CHIMNEY FLUE
SHOULD BE
CONSTANT DIAMETER
THROUGHOUT ITS
ENTIRE HEIGHT.
APPROVED
CHIMNEY
CLEANOUT DOOR
SHOULD HAVE
AIRTIGHT FIT. DO
NOT LEAVE OPEN
WHEN FURANCE IS
IN OPERATION.
CAP SHOULD HELP
PREVENT DOWNDRAFT
WHILE STILL PROVIDING
ADEQUATE EXHAUST.
3 FT. (91.44cm)
MINIMUM
RECOMMENDED
MINIMAL 20 FT.
(6.10m) HEIGHT
CHIMNEY FLUE
MUST BE AS
LARGE OR
LARGER THAN
FURNACE FLUE
PIPE
8.The portion of an all-fuel metal chimney that extends
above the roof should be well secured.
9.A masonry chimney should be built on footings and not
attached to the house.
10. A rain cap, complete with an animal or bird screen,
should be installed on top of the chimney.
CREOSOTE — FORMATION AND NEEDCREOSOTE — FORMATION AND NEED
CREOSOTE — FORMATION AND NEED
CREOSOTE — FORMATION AND NEEDCREOSOTE — FORMATION AND NEED
FOR REMOVALFOR REMOVAL
FOR REMOVAL
FOR REMOVALFOR 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 flue of a slow-burning fire. As a result, creosote
residue accumulates on the flue lining. When ignited, this
creosote makes an extremely hot fire.
The chimney connector and chimney should be inspected at
least twice monthly during the heating season to determine if a
creosote build-up has occurred. If creosote has accumulated, it
should be removed to reduce the risk of a chimney fire.
SMOKE PIPE INSTALLATIONSMOKE PIPE INSTALLATION
SMOKE PIPE INSTALLATION
SMOKE PIPE INSTALLATIONSMOKE 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 flue connection used. Be sure to
maintain the specified clearances for your type of installation.
TYPE OF FLUE REQUIRED
CONNECTION CLEARANCE
24 Gauge or Heavier 18" (45.72cm)
Single Wall Stainless Steel
or Black Pipe
Double Wall Stainless Steel 6" (15.24cm) Model 1600
8" (20.32cm) Model 1800
Class A All-Fuel or Equivalent 2" (5.08cm)
COMBUSTIBLES
SMOKE PIPE
CHIMNEY THIMBLE SHOULD BE
CONSTRUCTED OF FIRE CLAY, AND
SHOULD FIT TIGHTLY TO FLUE PIPE.
1.The wood furnace should be the only heating appliance
using a chimney flue. One furnace per flue.
2.A masonry chimney should have a tile or stainless steel
liner.
3.The masonry chimney should not have any missing
mortar or loose bricks.
4.There should be no mortar or parts of the chimney
blocking the chimney flue.
5.There should be a two inch clearance between any
chimney (masonry or metal) and combustibles (such
as the house).
6.The chimney should extend at least 2' above the
highest point of the house, or 2' above the point at
which the chimney is 10' from the roof.
7.The chimney should be relatively straight and vertical.
According to NFPA standards, single wall stove pipes can be
within 9" (22.86cm) of combustibles provided an approved fire
retardant material covered with 28 gauge sheet metal, spaced
out 1" (2.54cm) on non-combustible spacers, is utilized. See
illustration.
18" (45.72cm)
CEILING OR WALL
When using a Class A or double wall flue pipe connection,When using a Class A or double wall flue pipe connection,
When using a Class A or double wall flue pipe connection,
When using a Class A or double wall flue pipe connection,When using a Class A or double wall flue pipe connection,
follow the manufacturer's instructions.follow the manufacturer's instructions.
follow the manufacturer's instructions.
follow the manufacturer's instructions.follow the manufacturer's instructions.
9" (22.86cm)
18" (45.72cm)
4
When constructing a single wall smoke pipe, the followingWhen constructing a single wall smoke pipe, the following
When constructing a single wall smoke pipe, the following
When constructing a single wall smoke pipe, the followingWhen constructing a single wall smoke pipe, the following
guidelines must be observed.guidelines must be observed.
guidelines must be observed.
guidelines must be observed.guidelines must be observed.
1.The smoke pipe should be 24 gauge or heavier stain less
steel or black pipe.
2.Secure all joints with three #8 screws.
3.If the smoke 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"
(15.24cm) diameter smoke pipe needs an 18" (45.72cm)
thimble).
4.The smoke pipe should not be used as a chimney.
IMPORTANT INFORMATION FORIMPORTANT INFORMATION FOR
IMPORTANT INFORMATION FOR
IMPORTANT INFORMATION FORIMPORTANT INFORMATION FOR
ALL SMOKE PIPESALL SMOKE PIPES
ALL SMOKE PIPES
ALL SMOKE PIPESALL SMOKE PIPES
The smoke pipe must be constructed and installed so that it
maintains clearances, keeps condensation and creosote
within the pipe, and is capable of withstanding a 2000°F to
3000°F (1093°C to 1649°C) chimney fire.
1.The smoke pipe should slant down toward the furnace a
minimum of 1/4" to the foot. At no time should the pipe
turn downward toward the chimney or run horizontal.
2.There should be no more than two 90 degree elbows.
3.The smoke pipe should never be longer than 6 feet.(1.83m)
If it is absolutely necessary to make a run of more than
six feet (not recommended) use extra support brackets
every 3 feet (.91m).
4.The smoke pipe should never be reduced to a smaller
size than flue opening on the furnace.
5.The smoke pipe should not block the flue of the
chimney or extend into it in any way.
6.A good airtight thimble should be used to hold the
smoke pipe in the chimney. It should be constructed so
the smoke pipe can be removed for cleaning.
7.The smoke pipe should not leave the heated portion of
the building to reach the chimney.
8.The smoke 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.Heat reclaimers should not be installed or used in the
smoke pipe.
10. The smoke pipe should not be located near or in a walk
way or well traveled area.
11. All male ends of smoke pipe should run or point towards
the furnace.
When you have installed the smoke pipe connecting your furnace
to the chimney, tap the pipe hard with your fingernail. Remember
the sound it makes - it will be a "ting" echoing inside the stove pipe.
If later you tap and hear a muffled thud, you are building up soot
in the pipe and should clean it. This pipe should be cleaned at
least once or twice during the heating season.
DO NOT CONNECT TWO HEATERS TO THE SAME CHIMNEY
FLUE. The National Fire Prevention Association recommends
that woodburning appliances vent into a separate chimney from
gas or oil furnaces. If such an installation is contemplated, first
check with a local building inspector to find out if a separate flue
for a woodburner is required.
If codes allow, use extreme care in making such installations. Be
sure that one pipe is higher than the other so that the two openings
will not be opposite each other. Also, when connecting two
heaters into the same chimney flue, the flue size should be large
enough to handle both heaters. Very few codes and
standards allow same flue connection. Such installations can
cause severe problems. Gas hoods and barometric dampers
allow excess air into the chimney causing cooling of the flue
gases and a greater creosote build-up potential. If the same flue
connections are used, chimneys must be inspected more frequently and the chimney should be cleaned any time the
creosote deposits exceed 1/4" thickness. A creosote fire in such
a chimney can burn out of control because of the air leak through
the barometric damper or gas hood. Keeping the chimney clean
and burning well-seasoned wood is absolutely necessary. This
type of installation does require more frequent inspection and
maintenance.
ADD-ON SERIESADD-ON SERIES
ADD-ON SERIES
ADD-ON SERIESADD-ON SERIES
INSTINST
INST
INSTINST
The downstream series techniqueis the onlyapproved method
for using the 1600 and 1800 furnaces in combination with an
existing gas, oil or electric forced air furnace. While it requires
reworking the main duct system, it typically results in a simpler,
less restrictive installation.
Certification testing establishes the minimum cross-sectional
area for the transfer duct permitted for a specific add-on. A large
transfer duct will allow freer flow of air through the additional
elbows involved in the add-on installation.
Additional space will be required in the furnace room for an addon. There must be a room beside the existing furnace for the addon and the transfer duct which runs from the hot air plenum of the
existing furnace down to the cold air inlet of the add-on.
While oil, gas and electric furnaces may be connected to
combustible return air ducts in the form of joist panning, wood
furnaces normally require noncombustible return air duct work.
Combustible return ducts connected to an existing oil, gas or
electric furnace need not to be replaced with noncombustible
ducts when an add-on is installed; the add-on connections make
reverse flow during a power failure very unlikely.
Major changes to the main distributionduct system are normally
required in order to route the existing duct over the new hot
plenum of the add-on. Any indivdual ducts connected directly to
registers from the existing plenum also have to be routed over to
the add-on plenum because all of the air must pass through the
add-on before reaching any distribution ductwork.
There are two options for managing the duct alternations. In
some cases, it is more practical to move the existing furnace and
place the add-on in the location it previously occupied. By
locating the add-on where the original furnace was, fewer supply
duct alterations will be needed. On the other hand, alterations to
the return ducts will be needed to re-route them to the new
location of the cold air plenum.
The other option is to leave the existing furnace in its original
location and re-route the supply ducts to the new add-on plenum.
In your design of add-on installations, always choose the approach
that involves using the least elbows. By keeping the number of
elbows to a minimum, duct restrictions and blower noise will be
reduced.
5
ALLAALLA
ALLA
ALLAALLA
TIONTION
TION
TIONTION
The connection of the add-on to an existing furnace imposes a
greater work-load on the air-circulating blower. Unless
compensating adjustments are made, the additional restriction
will reduse air flow, and overheating of the existing furnace can
result. To provide a reference point for later adjustments,you
must test air flow before any installation work begins.
There are two methods of evaluating existing air flow: the static
pressure drop method and the temperature rise method.
HOTBLAST FURNACE MODIFICATIONSHOTBLAST FURNACE MODIFICATIONS
HOTBLAST FURNACE MODIFICATIONS
HOTBLAST FURNACE MODIFICATIONSHOTBLAST FURNACE MODIFICATIONS
1. Cut and insert a piece of sheet metal of sufficient thickness to
provide a tight fit over the opening on the back of the Hotblast
furnace.
2. Cut an opening in the side of the Hotblast furnace that will face
your existing furnace. (see illustration)
6"
(15.24 cm)
FINISHED
OPENING
10" x 16"
BEND BACK
FLANGE
CUTOUT
8" H x 14" W
(20.32 x 35.56 cm)
1" (2.54 cm)
10" (25.4 cm)
CONNECTING HOT AIR DUCT TO FURNACECONNECTING HOT AIR DUCT TO FURNACE
CONNECTING HOT AIR DUCT TO FURNACE
CONNECTING HOT AIR DUCT TO FURNACECONNECTING HOT AIR DUCT TO FURNACE
We strongly recommend that the hot airduct work be installed by a home
heating specialist. If doing the installation yourself, before you decide
which installation will best suit your needs, we recommend that you consult
a qualified heating technician and follow his recommendations as to the
most safe and efficient method of installation.
2" MIN.
1" MIN.
(2.54 cm)
6' (182.88cm)
EXISTING
FURNACE
(if used)
HOT AIR
PLENUM
(5.08 cm)
HOTBLAST
FURNACE
16" (40.64 cm)
6' (182.88cm)
DUCTWORKDUCTWORK
DUCTWORK
DUCTWORKDUCTWORK
INSTALLATIONINSTALLATION
INSTALLATION
INSTALLATIONINSTALLATION
HOT AIR DUCT
And MinimumAnd Minimum
And Minimum
MINIMUM CLEARANCES
TO COMBUSTIBLES
And MinimumAnd Minimum
ClearancesClearances
Clearances
ClearancesClearances
1" MIN.
(2.54 cm)
6
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