United States Stove Company DR6 User Manual
COAL BURNING
CIRCULATOR HEATER
MODEL CAC
website: www.usstove.com
Installation, Operation and Maintenance Instructions
TABLE OF CONTENTS
IMPORTANT SAFETY INFORMATION ............................................................................................................................................................. 1
BUILDING CODES AND SAFETY STANDARDS ............................................................................................................................................. 2
HOW THIS HEATER OPERATES ..................................................................................................................................................................... 2
SELECTING A LOCATION FOR THE HEATER ................................................................................................................................................ 2
FLOOR PROTECTION ..................................................................................................................................................................................... 4
CHIMNEY CONNECTOR AND CHIMNEYS ..................................................................................................................................................... 4
HEATER INSPECTION ..................................................................................................................................................................................... 8
TOOLS AND SUPPLIES NEEDED FOR INSTALLATION ................................................................................................................................ 8
HEATER INSTALLATION .................................................................................................................................................................................. 8
MINIMUM CLEARANCES TO COMBUSTIBLE WALLS AND CEILINGS ................................................................................................... 8
TO SAFELY AND PROPERLY INSTALL THIS HEATER ............................................................................................................................. 9
HEATER OPERATION .................................................................................................................................................................................... 10
TO BUILD A FIRE ..................................................................................................................................................................................... 10
FIRETENDING .......................................................................................................................................................................................... 11
MINIMUM FIRE ADJUSTMENT ..................................................................................................................................................................... 12
COAL FACTS ............................................................................................................................................................................................ 12
HOW TO TAKE CARE OF THE HEATER AND VENTING SYSTEM (ROUTINE MAINTENANCE) ................................................................ 12
HEATER MAINTENANCE ......................................................................................................................................................................... 12
DISPOSAL OF ASHES ............................................................................................................................................................................. 12
VENTING SYSTEM ( CHIMNEY AND CHIMNEY CONNECTOR) ........................................................................................................... 13
CHIMNEY CONNECTOR PIPE-CORROSION INSPECTION .................................................................................................................. 13
TROUBLESHOOTING .................................................................................................................................................................................... 13
THE VENTING SYSTEM-KEY TO GOOD HEATER PERFORMANCE .................................................................................................... 13
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 ................................................................................................. 14
QUICK REFERENCE TO THE MOST COMMON SOLUTIONS FOR THE MOST COMMON HEATER OPERATIONAL PROBLEMS .............. 15
FINAL CHECKLIST OF DO’S AND DON’TS ............................................................................................................................................................ 15
WARRANTY CLAIM INFORMATION AND REPAIR PARTS ...................................................................................................................................... 16
14
IMPORTANT SAFETY INFORMATION
SAFETY NOTICE: IF THIS HEATER IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT. FOR YOUR SAFETY, FOLLOW THE
INSTALLATION INSTRUCTIONS. CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA.
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.
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 specified 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.
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.
CAC 1
851396 B
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 officials to assure compliance with local regulations and codes.
This heater is safety listed by Warnock Hersey International, Inc. as specified 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
flows through and across the bed of fuel, causing the fire to progress through the fuel bed. Heat is transferred to the air
that flows between the cabinet and the firebox. Any attempt to alter this air by connecting this heater to a duct system
or air movement fans other than the optional KB902 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:
1. 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.
2. If the heater is to be vented into a masonry chimney, the heater should be located as near the chimney as pos sible 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.)
3. The location of the heater must provide at least the minimum clearances between the heater, chimney connector
and combustible materials as specified by figures 1, 2, 3, 4.
4. If the heater is to be located on a combustible floor, there must be suitable floor space to install a floor protector
beneath and extending beyond the heater as shown by figure 5 and as described by the Floor Protection
section of this manual.
5. The heater should be located centrally within the area where heat is desired but out of traffic areas to minimize
the likelihood of persons accidentally contacting the hot surface of the heater.
6. 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.
7. The heater should be located where a small supply of wood may be kept conveniently close but not within 36
inches of the heater.
8. Locate the heater so that drapes, curtains, furniture and other combustible materials will not be closer than the
clearances shown by figures 1, 2, 3, and 4 OR install a clearance reduction system. See MINIMUM CLEAR
ANCES TO COMBUSTIBLE WALLS AND CEILINGS section of this manual for details.
FIGURE 1 - MINIMUM CLEARANCES
TO COMBUSTIBLES
FIGURE 2 - MINIMUM CLEARANCES TO
COMBUSTIBLES
2 CAC
FIGURE 3 - MINIMUM CLEARANCES TO COMBUSTIBLES
SIDE SECTION VIEW
FIGURE 4 - MINIMUM CLEARANCES TO COMBUSTIBLES
PLAN SECTION VIEW
CAC 3
FIGURE 5 - FLOOR PROTECTION
FLOOR PROTECTION
This heater has been designed to prevent excessive temperatures on the floor beneath the heater. It is important, however, that
a combustible floor 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 floor protector beneath the heater extending beyond the heater as
shown by figure 5. The floor 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
instructions 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
figure 6). The chimney connector should extend at least two
inches into the flue of a factory-built chimney. When making a
horizontal connection to a masonry chimney, the connector should
extend to the inside face of the vertical flue liner, (see figures 7 and 8). When connecting the heater to a masonry fireplace, the
chimney connector should extend into the chimney’s liner as shown by the side section view of figure 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.
DO NO USE MORE THAN TWO 90 DEGREE ELBOWS IN THE Chimney CONNECTOR. Installations which require two degree
elbows must be vented into a flue of at least 8” diameter or 8” square to prevent chimney draft restrictions, (see figure 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 floor or ceiling.
4 CAC
FIGURE 6 - RISE OF HORIZONTAL
CHIMNEY CONNECTOR PIPE
RISE:
1/4" FOR EACH FOOT
OF CONNECTOR
LENGTH
PIPE ANGLE UP
HORIZONTAL
TO HEATER
TO CHIMNEY
There are five 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.
1.
Use a minimum 3-1/2" thick brick masonry wall framed into the combustible wall. A fireclay 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 fire. The inside diameter of the fireclay liner shall be sized for the proper snug fit of a 6" diameter chimney
con nector pipe. The fireclay liner shall run from the outer surface of the brick wall to, but not beyond, the inner surface
of the chimney flue and shall be firmly cemented in place. See Part A of Figure 7.
2.
Use a solid insulated listed factory-built chimney 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 flush with the inside of the masonry chimney flue shall be
sealed to the flue 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.
3.
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 fiber 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 fit and hold the chimney section. Fasteners used to secure chimney sections shall not penetrate
chimney flue liner. See Part C of Figure 7.
4.
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 fit and
hold the chimney section. Fasteners used to secure chimney sections shall not penetrate chimney flue liner. See Part
C of Figure 7.
5.
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
1.
thermal 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
fireclay with 5/8" minimum wall thickness , or material or equivalent durability. The inside diameter of the thimble shall
be sized for the proper snug fit of a 6" diameter chimney connector pipe. The thimble shall be installed without damage
to the chimney flue. The thimble shall extend through the chimney wall to, but not beyond, the inner surface of the
chimney flue 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
4.
pass-through system to the inner face of the chimney flue, 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 flue. If fasteners are used to
secure the chimney connector to a masonry chimney, the fasteners shall not penetrate the chimney flue liner.
Any material used to close up any opening for the connector shall be noncombustible.
5.
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 figure 8. The fireclay liner shown by figure 8 should be sized for
the proper snug fit of a 6” diameter chimney connector pipe. The fireclay liner should be firmly cemented in place as
shown. As previously 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, firestops (when needed), insulation shield, roof flashing, 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.
CAC 5
There are basically two methods of metal prefabricated chimney installation. One method is to install the chimney inside
the residence through the ceiling and the roof. The other method is to install an exterior chimney that runs up the outside
of the residence.
REMEMBER: Follow the chimney manufacturer's installation instructions and maintain the manufacturer's specified clearance distance.
Additional chimney informationis presented throughout this manual. READ IT THOROUGHLY TO BE MORE THOROUGHLY INFORMED.
CONNECTION OF CHIMNEY CONNECTOR TO A MASONRY CHIMNEY THROUGH A COMBUSTIBLE WALL
PART A, FIGURE 7
(FIGURE 7 CONTINUED ON NEXT PAGE)
MINIMUM 12 IN.
TO COMBUSTIBLES
PART B
FIGURE 5 (FIGURE 5 CONTINUED)
FACTORY-BUILT
CHIMNEY LENGTH
MASONRY CHIMNEY
CONSTRUCTED TO
NFPA 211
MINIMUM CHIMNEY CLEARANCES FROM MASONRY TO
SHEET STEEL SUPPORTS AND COMBUSTIBLES 2 IN.
NONSOLUBLE
REFACTORY
CEMENT
MINIMUM CHIMNEY CLEARANCE TO
BRICK AND COMBUSTIBLES IS 2 IN.
CHIMNEY FLUE
AIR SPACE
CHIMNEY FLUE
MINIMUM CLEARANCES 12
IN. OF BRICK ALL AROUND
CHIMNEY CONNECTOR TO
HEATER
FIRE CLAY LINER
(5/8" MIN. WALL THICKNESS)
MIN. 3-1/2" THICK BRICK
MASONRY WALL
MINIMUM CLEARANCE
9 IN. ALL AROUND
CHIMNEY CONNECTOR
TO HEATER
CHIMNEY LENGTH
AIR SPACE
9 IN. MINIMUM
FLUSH WITH INSIDE
OF FLUE
MASONRY CHIMNEY CONSTRUCTED
TO NFPA 211
USE CHIMNEY MFRS. PARTS TO
ATTACH CONNECTOR SECURELY
SOLID INSULATED, LISTED
FACTORY-BUILT CHIMNEY LENGTH
SHEET STEEL SUPPORTS
(24 GAUGE MIN. THICKNESS)
6 CAC
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