Clayton 1600EF Administrator Guide

851846F-0704G
Installation/Operator’s Manual
External Furnace Model: 1600EF
COAL ONLY
United States Stove Company • 227 Industrial Park Road • South Pittsburg, TN 37380 • www.usstove.com
SAFETY NOTICE:
If this furnace is not properly installed, a house re may result! For your safety, follow these installation instructions.
Contact local building or re ofcials about restrictions and installation requirements in your area. This furnace
must be installed by a qualied technician. Keep these instructions for future reference.
Safety Tested to UL 391
Tested & Listed
By:
Report #
215-S-13b-2
Portland
Oregon USA
U.S. Environmental Protection Agency
Certied to comply with 2015
particulate emissions standards.

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Unit Dimensions
LIMIT SWITCH
ACCESS
A
6.00
31-5/8"
12" COLD AIR
RETURN
14-1/4"
43-7/16"
29-3/16"
10" HOT AIR OUTLET
HOT WATER COIL ACCESS
(OPTIONAL)
BLOWER SPEED
SELECTOR SWITCH
B
D-RINGS FOR GUY WIRE
ATTACHMENT
17-5/16"
55-5/8"
5-3/16"
45-3/4"
65-1/2"
2-9/16"
29-1/2"
24-1/4"
6" FLUE GAS OUTLET
LO MED HI

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INTRODUCTION
Thank You for your purchase of a U.S. Stove Coal Burning External Furnace. Your decision to buy our Clayton
Furnace was undoubtedly reached after much careful thought and consideration. We are very proud you chose
this 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 with the purchase, but for recommendations
for professional installation for your home. The qualied professional installer 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. They are specialist in this eld.
IMPORTANT
Before installing and using your furnace, please read the following pages thoroughly and carefully. If you follow
the instructions, your furnace will give you safe and more dependable service for years to come.
• Check your local codes. This installation must comply with their rulings.
• This is an outdoor hot air furnace and must NOT be installed inside the home or a building.
• This furnace must be connected to a 110 volt Ground Fault Circuit Interrupter (GFCI) outlet suitable for
outdoor use.
• A back-up generator, 2,000 watts minimum, is recommended in case of a power failure.
• Always have a properly functioning smoke or ionization detector and a CO detector installed in your home.
• To prevent injury or damage, do not allow anyone who is unfamiliar with the furnace to operate it.
• Spend adequate time with your furnace to become well acquainted with the 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 NOTICE
The BTU ranges and heating capacity specications are provided as a guide and in no way guarantee the
output or capacity of this unit. The actual BTU output depends on the type of fuel being burned and its conditions,
the thermostat setting, the draft adjustment and the chimney to which the unit is attached. The actual area
that this 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, the location of the unit and more importantly the duct work and
return air facility.
Warning:
Do not alter this appliance in any way other than specied in these instructions. Doing so may void your warranty.
GENERAL INFORMATION
Your 1600EF furnace comes ready for installation. No assembly required. Unpack your furnace and insure that
there is no shipping damage. If damage exist, please contact your dealer immediately. Review the items included
with your furnace located inside the rebox.
1 - 10” Starter Collar
1 - 12” Starter Collar for Cold Air Return
8 - #10 x 3/4 Screws w/ Sealing Washer
1 - Literature Package
This furnace may be installed as a Stand-Alone Central Furnace or as a Supplementary Furnace in the US only.
For Canadian installations, it may be installed as a Stand-Alone Central Furnace Only.
If installed as a Central Furnace, this unit will have it’s own central ducting system and will essentially be your
primary heat source. If installed as a Supplementary Furnace, the 1600EF will assist an Electric, Gas or Oil Fired
Furnace in heating your home by utilizing the existing furnace’s duct work system. The 1600EF must not be wired
in conjunction with the existing furnace. The outdoor furnace may be operated with the supplied wall thermostat
or a 24 volt thermostat that you supply yourself.
The furnace should be placed outdoors on a level noncombustible base, preferably a 4’ x 8’ concrete pad, as
close to the home as clearances to combustibles will allow. If locating the furnace more than 10 feet away from
the home, a minimum of 6 feet of Class “A” HT 2100 All Fuel 6 inch chimney pipe is required - Do not place the
furnace more than 40 feet away from the home. Maintain all clearances stated in this manual.
Class “A” HT 2100 All Fuel 6” Chimney Pipe is recommended for optimum performance and can be purchased
from your local dealer. A Chimney Base Plate should be installed over the ue outlet and sealed to maintain
weather resistance. A 2” clearance to combustibles must be maintained from the pipe. We suggest using either
Simpson Dura-Vent or Metal Fab chimney products for your installation.
If you choose to use single wall stainless, the ue temperatures will be reduced which promotes the formation
of creosote, possibly creating a re hazard. If you use single wall stainless pipe, the minimum clearance to
combustibles is 20”.

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Attach the appropriate chimney pipe lengths to the chosen chimney base plate and nish with a rain cap.
Secure the chimney with guy wires to each of the four anchors point on the furnace. Your furnace requires it’s
own chimney system and can not share a ue with another appliance.
Once you have selected a location for the furnace and connected your furnace to a chimney and a 110 volt
GFCI outlet, you will need to commence an initial ring. DO NOT connect the furnace to your duct work at this
time. Your new furnace has a protective coating of oil and paint on the surface which could produce smoke or
odors during the initial ring and will burn off. Build a small re - DO NOT ll the rebox to it’s full capacity for the
initial burn. This initial ring allows the metals and castings to cure.
After completing the ring and allowing it to cool, you are ready to nish the installation. Refer to the remainder
of this manual for detailed instructions.
CLEARANCES
Sides of furnace, 12”; Rear of furnace, 15” (allow approximately 20”
for the return box); Front of furnace, 36”; Heat Duct, 2” for the rst 9
feet then 1” thereafter.
FLUE PIPE INSTALLATION
Clearances to combustible materials will vary with the type of ue
connection used. Be sure to maintain the specied clearances for
your type of installation.
TYPE OF FLUE REQUIRED
CONNECTION CLEARANCE
Class A 103HT All-Fuel or Equivalent 2”
Double Wall, Stainless Steel or ....6”
Double Wall, Black Pipe w/
Stainless Steel Inner wall
24 Gauge or Heavier .................20”
Single Wall Stainless Steel or Black Pipe
The above clearances to combustibles must be maintained.
CHIMNEY REQUIREMENTS
A Class “A” HT 2100 All Fuel 6” Chimney Pipe and Base Plate should be used for the installation. See Illustration.
Place the Base Plate over the ue outlet of the furnace and drill eight(8) pilot holes into the Cabinet Top. Apply
a generous amount of high temperature sealant to the
bottom of the base plate, and around the ue outlet.
Position the base plate over the ue and secure with
the eight(8) screws provided. Then attach the ue pipe
sections.
A minimum chimney height of 6 feet is required not
including the rain cap. In order to determine proper
chimney height above the roof, measure from the side of
the chimney horizontally. As you move up the chimney,
the length increases. Once this measurement reaches 10
feet, this is the base height of the chimney. The chimney
must be 2 feet taller than the base height. If the chimney is
closer than 10 feet from the peak of the roof, the chimney
must be 2 feet taller than the peak of the roof. The 2 feet
measurement does not include the rain cap.
Once correct chimney height is achieved, check the
chimney draft. It should not exceed 0.06 inches of water
column. Then secure with three screws at each joint and
attach guy wires down to the rings located around the
top of the furnace cabinet.
See illustration.
22”
12”
20” 15”
COMBUSTIBLE WALL
COMBUSTIBLE WALL
FLUE
(TOP VIEW)
MINIMUM CLEARANCES
TO A COMBUSTIBLE
WALL
CAUTION:
DO NOT store
combustible or
flammable materials or
liquids near the
furnace.

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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 backpufng 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.
CONNECTING HOT AIR DUCT TO FURNACE
We strongly recommend that the hot air duct work be installed by a home heating specialist. If doing the
installation yourself, before you decide which installation will best suit your needs, consult a qualied heating
technician and follow his recommendations as to the safest and most efcient method of installation.
The warm-air supply-duct system shall be constructed of metal in accordance with NFPA 90B, 2-1.1. The plenums
installed to the furnace be constructed of metal in accordance with NFPA 90B, 2-1.3.
Outside the house you must use 10 inch galvanized pipe, wrapped with weather proof, UV resistant insulation.
The 12 inch return may be galvanized pipe and attached to the home so as to not pressurize the home.
NEVER reduce the 10” hot air or the 12” return air as this will result in restricted air ow and cause the furnace to
not operate properly.
NEVER draw cold outside air into the blower housing. By doing so, the furnace’s heat chamber will not reach the
necessary temperature to heat the home.
The duct work should be designed so the external static pressure does not exceed 0.2 inches water column while
developing air velocities of 600 to 1,000 feet per minute in the main trunk duct and 400 to 600 feet per minute at
the registers. The heat outlet should never be less than ten inches (10”) round or 79 square inches.
This furnace must be installed with a cold air return system. The system must be a minimum of twelve inches
(12”) to readily transfer the cold air from the home back to the furnace. If desired, a cold air lter box may be
constructed with a minimum opening of 225 square inches.
The warm-air supply outlet of the outdoor furnace must not be connected to the cold-air-return inlet of an
existing central furnace because the possibility exist of components of the existing furnace overheating and may
cause the central furnace to operate other than intended.
ATTENTION:
This heater needs periodic inspection and repair for proper operation. It is against federal regulations to
operate this heater in a manner inconsistent with operating instructions in this manual.

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Types Of Installation
NO DUCT WORK INSTALLATION
Cold air return must be installed in all installations, even those without an air duct system. If you do not, the
furnace will not be able to heat the home. A lter should be installed in the cold air return. Furnace lters should
be checked and cleaned/replaced regularly.
When there is no duct system to connect the furnace to, keep the following in mind:
1. You must separate the hot air duct from the cold air return. Ideally, locate each at opposite ends of the
home. This method will work well in homes that are built on concrete slabs and should create a good air ow.
If you do not, air will not ow evenly through the home.
2. In homes with a basement, you may run the hot air duct to the basement and pull the cold air return from
the main oor. This will create the perfect air ow since hot air rises.
CENTRAL DUCT CONNECTION
When connecting to a central duct system, avoid 90 degree elbows as this will reduce air ow delivery. A duct
run in excess of 40 feet is NOT RECOMMENDED. The air ow and heat output will be greatly decreased.
Run 10” insulated hot air duct from the outdoor furnace through a wall or window of the structure. Then attach
a exible hot air duct to the existing duct work. Connect the duct with a 45 degree elbow or at an angle so the
hot air from the outdoor furnace is delivered downstream. This will insure proper air ow into the system.
Avoid delivering hot air through an air conditioning coil as this will cause an obstruction reducing heat output.
The following illustrations may be used as examples for your installation.

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Installation Examples
Installation #1
With this installation, a back draft damper (optional)
is inserted into the heat run before the plenum of
the existing furnace to prevent air from the existing
furnace to blow back into the furnace when it is not
in use. When a back damper is employed, it should
be located as close to the existing furnace plenum as
practical.
INSTALLATION #2
The bafe on this system should be made the full width
of the furnace plenum in order to properly direct the air
into the distribution ducts.
INSTALLATION #3
Extending the hot air duct from the furnace into the
existing plenum will help direct the ow of air from the
furnace as well as the ow in the existing furnace. Ducting
entering the existing plenum at an angle (approximately
45 degrees) will facilitate air ow from the furnace while
diverting air from the existing furnace.

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Read and follow these instructions in the event you
have to replace or re-assemble components of your
furnace.
DOOR HANDLES
Insert door handle into door. From rear side of door,
place a 1/2” washer over the threaded part of the
handle, then attach the lock nut. Tighten the nut, then
back off 1/4 turn to allow free operation of the handle.
Follow these same directions for the ash door handle
assembly.
(2) Door Handle
(2) 1/2” Washer
(2) 1/2” Lock Nut
ASH DOOR SPIN DRAFT
Screw the spin draft onto the 3/8” x 2-1/2” carriage
bolt. Then screw the spin draft and bolt into the ash
door allowing approximately 1/2” of the bolt to stick
through the back side of the ash door. Secure the bolt
in place with the 3/8”-16 lock nut.
(1) Spin Draft
(1) 3/8-16 Carriage Bolt
(1) 3/8-16 Lock Nut
FUEL & ASH DOOR LATCH
With two 1/4-20 x 3/4 hex bolts each, attach the door
latches to the door latch mounting brackets on the
left side of the door frames 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.
Feed Door
Illustration
Ash Door
Illustration
(1) Feed Door Latch
(1) Ash Door Latch
(4) 1/4-20 x 3/4 Hex Bolt
(4) 1/4-20 Kep Nut
BRACKET
SHAKER GRATE HANDLE
Insert the Shaker Rod into the hole on the ash door
frame as shown. Then attach the Shaker Bracket to the
front of the furnace using two 1/4-20 x 3/4” Hex Bolts
and two 1/4-20 Lock Nuts. Next, insert the shaker Rod
into the bracket and attach to the shaker grate bar
using the 1/4-20 x 1” Hex Bolt and a 1/4-20 Lock Nut. The
bolt and nut retaining the shaker bar and rod should be
left loose to allow free movement of the grates.
(1) Shaker Rod
(1) Shaker Bracket
(1) 1/4-20 x 1” Hex Bolt
(2) 1/4-20 x 3/4” Hex Bolt
(3) 1/4-20 Lock Nut
FRONT
SMOKE CURTAIN
SMOKE CURTAIN
CLIP
NUT
BOLT
1/4-20 NUT
SMOKE CURTAIN
CLIP
1/4-20 x 1-1/4
CARRIAGE BOLT
SMOKE CURTAIN
SMOKE CURTAIN
Using two 1/4-20 x 1-1/4” Carriage bolts, the smoke
curtain clips and two nuts, attach the smoke curtain
in place above the Fuel Feed Door as shown below.
After installation, the smoke curtain should swing
freely back into the furnace.
(1) Smoke Curtain
(2) Smoke Curtain Clips
(2) 1/4-20 x 1-1/4 Carriage Bolt
(2) 1/4-20 Kep Nut
Furnace Assembly Instructions

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1. To replace the Honeywell Limit Control (A): Unplug from
power supply
The control may be removable thru the access panel on
item “B”. However it may be easier to remove item “B”
entirely for better access. Remove item “B” by means of
the eight(8) screws. If siliconed, use a utility knife to score
the silicone along the edges of the part. Take off the cover
of the control (A), remove the three wires, and continue to
remove the control by means of the two screws retaining
it. Use the wiring diagram in the rear of this manual to re-
connect the new control. Reattach item “B” and re-silicone
all the seams with weather resistant silicone.
2. To remove the return air box (D): Unplug from power
supply.
If siliconed, use a utility knife to score the silicone along the
edges of the part. Remove item “B” as described above.
Then remove the four(4) screws down each side and the
four(4) across the top of the return air box. Pull the box
back away from the unit enough that you can reach in to
remove the snap-in plug (C) from the top of the box. The
power supply cord will need to be feed back thru the plug
in the bottom of the air box for complete removal. When re-
attaching, make sure that the three plugs in the top of the
Fan Center (G) are properly plugged in. Do not forget to put
the snap-in plug (C) back in place. Re-silicone all the seams
with weather resistant silicone.
3. To remove the Distribution Blower (E): Unplug from
power supply.
Remove items”B” and “D” as described above. Unplug
the blower from the top of the Fan Center (G). Remove the
four(4) screws retaining the blower.
4. To remove the Blower Motor: Unplug from power supply.
Perform number 3 above. Before removing the motor from
the housing, measure two things:
1. The distance from the edge of the motor to the edge
of the motor bracket. Record (d1) _________________
2. The distance of the shaft remaining outside the coupling
on the blower wheel. Record (d2) __________________
These two measurements dictate the position of the blower
inside the housing and is critical in determining motor
longevity. Repositioning of the blower motor, bracket, and
wheel in respect to one another should keep as close to the
factory position as possible.
Remove the three(3) screws (I) from the blower housing.
Then loosen the bolt (J) on the motor shaft. Next, loosen or
remove the bolt (K) in the motor bracket to remove the
motor.
5. To remove the Blower Capacitor (F): Unplug from
power supply.
This may be accomplished by working thru the 12 inch
diameter return duct hole in the Return Box. Otherwise, you
must remove items”B” and “D” as described above. Unplug
the blower from the top of the Fan Center (G). Using pliers
with rubber coated handles, unplug the two connections
on the capacitor. Remove the two screws and cap bracket.
Distribution Blower & ACC.
A
C
B
D
C
F
E
HG
J
I
d1
d2
K
All electrical connections should be done by a qualied
electrician.

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FIREBOX BRICK REPLACEMENT
This furnace comes from the factory with the rebrick
installed. However, if brick replacement is necessary,
follow these instructions. Before furnace operation,
remove the brick retaining strip. This piece is used
during shipping to reduce brick damage.
There are 6 full brick and 1 half brick per side. Install
the half brick rst by putting the bottom of the brick
in rst and let it rest against the rebox side and re
grates. Then slide it to the rear. After that, install the #2,
#3, #4, #5 & #6 brick, sliding the 6th brick forward to
allow for the 7th brick. Repeat for opposite side.
1. Make certain the unit has been unplugged from the power source. Remove the cover from the motor
and remove the two wire nuts and grounding screw. With a pair of pliers, remove the strain relief and cord
assembly from the motor. If motor comes with the cord, the above step is not required. However, you will
have to remove the panel on the inner cabinet side to rewire the motor. Do so by removing the rivets with a
3/16” drill bit. Screws may be used to replace the rivets.
2. Remove the draft assembly from the furnace by loosening the two bolts retaining draw band.
3. To remove the motor from the tubing assembly, simply loosen the set screw in the collar on the motor and
slide it off the tube.
4. If replacing the Flipper, remove the two #8 screws retaining the plate to the tube.
5. Reverse the above steps for re-assembly
BAFFLE/BRICK REPLACEMENT
If bafe replacement is necessary, slide the bafe
out until you can access the nuts thru the ue outlet.
Once the nuts have been removed, slide the bafe off
the rod and thru the opening in the rebrick. You may
have to remove one of the rebrick to make bafe
removal easier.
There are 4 full brick and 1 half brick in the top of the
furnace. Install the brick by inserting one end of the
brick angled upward and then allowing the opposite
end to rest on the rebox lip. Lay the brick between
the spacer and rebox back. Slide the bafe to the
rear and let it rest on that half brick. After installing
brick #2 in the front, install #3 and slide it under the
bafe. Finally install bricks #4 and #5.
Motorized Natural Draft Replacement
Firebrick And Bafe Replacement
(1) Draft Actuator
(1) Spin Draft
(1) 3/8-16 Carriage Bolt
(1) 3/8-16 Lock Nut
(1) Flipper Tube
(1) Flipper
(2) #8 Screw
NOTE: Prior to operation, be sure to remove the
brick retaining strips.

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GENERAL FURNACE OPERATION
After installation of the furnace is complete, it is ready for operation. The Honeywell Limit Control, in conjunction
with a wall thermostat, operates the distribution blowers and the motorized draft on the front of the furnace. The
limit control is located on the rear of the furnace in the upper left corner and is accessible by removing the two
screws in the cover plate. DO NOT operate your furnace with this plate removed! The control can be adjusted
to your desired blower On/Off times. The factory settings are 100/150/200. The wall thermostat setting operates
the ON time of the motorized draft. If the temperature is below the setting on the wall thermostat, the motorized
draft will come open. (Recommended setting at 5 to 10 degrees higher than other heating thermostats.) The rst
two set points on the limit control operates the distribution blower. When the furnace plenum reaches the second
set point on the limit control, the distribution blower will come on. If the temperature falls to the rst set point, the
distribution blower will shut-off. The distribution blower is a three speed blower and can be manually adjusted by
means of the three position switch located behind the sliding access panel on the cold air return box. When the
furnace reaches the third set point on the limit control, the draft blower will shut-off. The draft blower will come
back on if the temperature falls below the setting on the wall thermostat.
TESTING
1. Check the motorized draft by turning the room thermostat up high enough so that the motorized draft
opens. Then lower the thermostat setting to ensure it closes off.
2. Use a sheet of newspaper to test your draft by placing it inside the furnace and lighting it.
STARTING A COAL FIRE
• Shut off FAD when fuel door is open
• Open all draft controls on your furnace. Pull the slide bafe forward.
• Place about 10-15 lb. of coal in on the shaker grates. It should come up to about half of the rst rebrick
level.
• Place crumpled paper over the coal and crisscross a couple handfuls of dry kindling wood 3/4” in thickness
on top of paper.
• Ignite the paper and close loading door. Wait about 30 minutes until coal re is established before adding
more coal. NOTE: NEVER load coal over the level of rebrick.
• Close by-pass damper and set all draft controls to your own needs. It may take 3 to 4 coal res to determine
how your local coal and the Clayton Furnace reacts together. Adjusts drafts accordingly.
• When loading with a good bed of coals in the morning - Open by-pass damper.
1. In normal shaking, only rock the grates a small amount to sift ash through. Do not agitate the re bed too
often. This practice will waste coal. If glowing coal is visible in the ash pan, you have shaken to much.
2. Remove all ashes every day from ash pit.
CAUTION: Ashes should be placed in a metal container with a tight tting lid. The closed container of ashes
should be placed on a non-combustible oor or on the ground well away from all combustible materials pending
nal disposal. If the ashes are disposed of by burial in soil or otherwise locally dispersed, they should be retained
in the closed container until all coals have thoroughly cooled.
3. With your poker, push hot burning embers to the rear of the unit and add green coal in front. NEVER load
over height of rebrick. This can result in damage to your furnace and home.
4. Close by-pass damper.
• Too much draft air will cause clinkering of coal and will waste heat up the chimney. Shut draft down to as
low a point as you can and still heat your home.
1. NOTE: Never stand in front of loading door when opening it. Stand to the side.
2. NEVER completely cover the live re with fresh coal. Always leave a generous area of glowing coal at the
top of the re and at the rear.
3. Always keep the ash pit clean.
• If the re goes out or does not hold overnight, look for:
1. Poor draft.
2. Incorrect damper settings.
3. Improper ring methods for coal being used.
4. More combustion air needed.
5. Coal not sized to the furnace. We recommend 1” to 3” diameter pieces of coal.
6. Ashes, if allowed to accumulate in the ash pit, will not allow the passage of required air for combustion. Keep
ash pit clean.
7. This furnace is not to be used with an automatic stoker unless so certied.
Testing And Operating Procedures

-12-
• There are ONLY two types of coal allowed for use in this furnace: Bituminous Coal (soft coal) and Anthracite
Coal (hard coal). NEVER USE Cannel (or Channel) coal or Brown (Lignite) Coal.
• See our Bulletin RC454 at the rear of this manual for the best information available on burning coal.
• DANGER: Risk of Fire or Explosion - Do not burn garbage, plastics, gasoline, drain oil or other ammable
liquids. Plastics, when burned, form hydrouoric and hydrochloric acids which will damage and destroy your
furnace pipe and chimney. The burning of trash or oil can result in an extremely hot re and is sometimes a
cause of chimney res. NEVER BURN GREEN WOOD OR TIRES.
• WARNING: Risk of Fire - Do not operate with ue draft exceeding .06 inches of water column and must be set
with a draft gauge to maintain a steady draft. (Barometric Damper recommended.)
OPERATING NOTES
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. Manure or animal remains;
9. Salt water saturated materials;
10. 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 heater.
Burning these materials may result in release of toxic fumes or render the heater ineffective and cause smoke.
CAUTION: Never use gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter uid, or similar liquids to start
or “freshen up” a re in the furnace. Keep all such liquids well away from the furnace while it is in use. This 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 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 efciently 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 specic unit to produce the smallest amount of visible
smoke.
EFFICIENCY
Efciencies 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. The higher heating value is
when water leaves the combustion process completely condensed. 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 efcient heating.
A lower burn rate slows the ow of usable heat out of the home through the chimney, and it also consumes less
coal.
• Do not operate with the fuel loading or ash removal doors open.
• Do not store fuel or other combustible material within marked installation clearances.
• Inspect and clean your ues and chimney regularly.
• CAUTION: Hot Surfaces - Keep children away. Do not touch during operation. Maximum draft marked on
nameplate.
• Equip your home with re extinguishers and smoke detectors appropriately located.
• Coal should be placed directly onto the cast iron shaker grate of the Clayton furnace. Do not use additional
grates and/or irons.
• Do not allow ashes to build up higher than 2” above grates.
• Never allow the ashes in the ash pan to touch the grate section. REMOVE ASHES FREQUENTLY!
• Be extremely careful when removing furnace ash pan; it can get very hot.
• With new steel, there is a small amount of oil or dirt on the metal. You may smell an odor. This is normal during
the rst operation. You may want to build a small re in the furnace to “burn off” this dirt and oil before
installing the duct work.
• The furnace is designed to burn air dried coal at a predetermined ring rate. Over ring could result in
damage to the heat exchanger and cause dangerous operation. Over ring occurs when the ash door is
left open during operation or a highly volatile fuel, i.e. large amounts of small kindling, is used. If any portion
of the connector pipe glows orange or red, you are in an over-ring situation. Close all dampers.
• When tending the rebox always pull the bafe slide rod out prior to opening load door. Open load door
slowly to avoid a “ash back”. After closing load door, push the bafe slide rod to the rear.

-13-
• In event of chimney re, shut all draft controls and call your re department immediately. Alert everyone in
the house. If the re is still burning vigorously, throw baking soda into rebox or discharge a re extinguisher
into the rebox. After chimney re is over, completely inspect system for damage before further use.
• NEVER throw water on the re or at the furnace, as rapidly expanding steam could result in a severe
scalding.
• Slow res: It is not recommended burning the Clayton furnace any more than necessary early in the fall and
late spring, as you cannot keep the rebox hot enough (without overheating your home) to burn gases. Slow
res can cause excessive creosote build-up in smoke pipe, chimney and rebox.
• Inspect air lters regularly. The air lter should be changed at least every 30 days.
• Oil motors every 90 days with a few drops of 30 wt. oil.
• Check the t on the load door. It must t tightly. If it does not, check for deterioration or wear of the ceramic
rope seal. Replace defective seals.
• In the event of a power failure, the furnace will not distribute heat to the home. We recommend the use of a
back-up generator, 2,000 watts minimum, for continued use until regular power is restored
• Inspect ue pipes, ue pipe joints and ue pipe seals regularly to ensure that smoke and ue gases are not
drawn into, and circulated by, the air-circulation system.
• CAUTION: clean out of the heat exchanger, ue 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.
NOTE: For further information on using your furnace safely, obtain a copy of the National Fire Protection
Association publication “Using Coal and Wood Stoves Safely.” NFPA NO. NW-8-1974. The address of the NFPA is
470 Atlantic Ave., Boston, Massachusetts 02210.
THIS IS A COAL only FURNACE AND SHOULD NOT BE ALTERED IN ANY WAY! DOING SO WILL VOID YOUR
WARRANTY!
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 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 re.
OVER FIRING
Attempts to achieve heat output rates that exceed heater design specications can result in permanent
damage to the heater. 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.
ASH REMOVAL AND DISPOSAL
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.
SMOKE AND CO MONITORS
Burning coal 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 conned
areas can be dangerous. Make sure your 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.
GASKETS
It is recommended that you change the door gasket (which makes your stove door air tight) once a year, in
order to insure good control over the combustion, maximum efciency 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 stove again approximately 24 hours after
having completed this operation. This unit’s doors use a 3/8” diameter rope gasket.
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)
• Use smaller pieces of wood during start-up and a high burn rate to increase the stove temperature
• Burn small, intense res instead of large, slow burning res when possible
• Learn your appliance’s operating characteristics to obtain optimum performance.

-14-
Trouble Shooting And Problem Solving
Problem Solution
1. Smoke puffs from furnace
• Check chimney draft. Check for blocked chimney or ue pipe. Use mirror to
check chimney clearance.
• Check ash pit — if it is too full, empty.
• Make sure all of chimney mortar connections are airtight.
• Check ash drawer. Make sure it’s airtight.
• Check chimney for possible down-draft caused by taller surrounding trees or
objects. Correct with proper chimney vent cap.
• Check the possibility of a cold chimney forcing cool gases backward.
Remedied by properly insulating chimney with non-combustible liner — non-
combustible insulation.
• Fuel may be too green.
• Make sure no other fuel burning devices are connected to the chimney
impairing the draft.
• Check chimney draft, it should be .06 inches of water column. This service is
provided by a certied chimney sweep.
2. Inadequate heat being
delivered to your home
• Check home insulation — is it adequate?
• Check hook-up to furnace — is it installed correctly?
• Cool air inlet may be inadequate.
• Make sure your hot air duct (and other duct work) is airtight.
• Is air to the blower available?
3. Excess smoke or ames coming
out door when refueling
• Wait 15 seconds and open door SLOWLY — then refuel.
• Check length of ue pipe to chimney.
• Make sure chimney cap is not too close to the top of the chimney.
• Check chimney draft — make sure chimney ue pipe is clean and chimney is of
adequate height.
• Make sure you’re not suffocating the re with excessive amounts of unburned
coal.
• Slide bafe should be pulled out prior to load door opening.
4. Distribution blower vibrating • Tighten blower wheel to motor shaft.
• Check for bad fan bearings.
5. Distribution blower continues to
run or will not run
• Check fan limit or heat sensor and cable.
• Check to see that blower is properly wired. (See Wiring and Assembly
Instructions).
• Check fuse box or power source.
• Check power supply.
6. Motorized draft stays open or
will not close
• Check wiring.
• Check thermostat or thermostat wire for short.
• Make sure temperature is calling for heat.
7. Odor from rst re
• The odor from new steel should disappear in a few hours.
• If the odor remains, call you dealer immediately. A bad weld can cause a fume
leak.
8. Excessive Creosote
• Make sure your unit is serviced by its own proper chimney.
• Check length of ue pipe and its connections.
• Make sure you are burning the smallest, hottest re to adequately heat your
home.
• Also see Solutions to Problem number 1.
9. If the re goes out or does not
hold over night
• Poor Draft.
• Incorrect damper settings.
• Improper ring methods if burning coal.
• More combustion air needed.
• Coal not sized to the furnace. We recommend 1” to 3” diameter pieces of coal.
• Ashes, if allowed to accumulate in the ash pit, will not allow passage of the
required air for combustion. Keep ash pit clean.
• This furnace is not to be used with an automatic stoker unless so certied.

-15-
Wiring Diagram
SERVO MOTOR

-16-
Parts Diagram

-17-
Parts List
Key Description Part # Qty
1 Grate Retainer 40312 2
2 Shaker Bar 891341 1
3 Shaker Grate Section 40314 5
4 Front Liner 40344 1
5 Back Liner 40313 1
6 Full Firebrick (4-1/2 x 9 x 1-1/4) 89066 16
7 Half Firebrick (2-1/4 x 9 x 1-1/4) 891414 3
8 Slide Bafe 24231 1
9 Bafe Rod 86662 1
10 Inside Cover Plate 24220 1
11 Gasket, Water Coil Cover C97999 1
12 #12 x 3/4: Tek Screw C23799 3
13 Carriage Bolt, 1/4-20 x 1-1/4 Long 83445 2
14 Smoke Door Clip 23787 2
15 Kep Nut, 1/4-20 83250 2
16 Smoke Curtain 23800 1
17a Door Handle 69655 1
17b Door Handle (Ash Door) 24179 1
N/S Lock Nut, 1/2-13 83444 2
N/S Washer 83835 2
18 Feed Door Latch 23786 1
19 Feed Door Assy. (w/Rope Gasket) 69653 1
20 Shaker Handle 69005 1
21 Bracket, Shaker Handle 24204 1
22 Ash Door Latch 23823 1
23 Ash Pan 68882 1
24 Carry Handle 24233 1
25 Ash Door Assy. (w/Rope Gasket) 68880 1
26 Draft Cap 23859 2
27 Outer Side Wall, Left (25715) 891889 1
28 Panel-L, Inner Cabinet, Painted 25746B 1
29 Clip, Outer Wall (25718) 891912 2
30 Bracket, Alignment (25719) 891913 2
31 Cabinet Door Stop (25720) 891891 1
32 Insulation, Cabinet Side 88149 4
33 Outer Side Wall, Right (25716) 891890 1
34 Panel-R, Inner Cabinet, Painted 25717B 1
35 Harness, 2 Circuit Plug 80587 1
36 Filler, Top (25721) 891892 1
37 Hood, Front (25744) 891907 1
38 Assembly, Cabinet Back 69647 1
39 Insulation, Back 88153 1
40 Insulation Holder 83884 16
Key Description Part # Qty
41 Inner Top, Painted 25726B 1
42 Insulation, Top-Front 88150 1
43 Insulation, Top-Middle 88151 1
44 Insulation, Top-Rear 88152 1
45 Mount, Flue Outlet (25727) 891916 1
46 Weldment, Cabinet Top (69648) 891910 1
47 D-Ring Clip 83912 4
48 Bottom Intake, Painted 25722B 1
49 Assembly, Cabinet Door 69649 1
50 Latch, Cabinet Door 891865 1
51 1800 CFM Blower Assembly 80590 1
N/S 1/4-20 x 3/4 Self Tapping Screw 83236 4
N/S Washer 83045 4
52 Blower Motor 80588 1
53 Fan Center Assembly 69651 1
54 Honeywell Limit Control 80145 1
55 Harness, 3 Circuit Plug 80586 1
56 7/8” Snap Bushing-Heyco (BLK) 83909 3
57 Cable Chase (25732) 891897 1
58 Gasket, Access Panel 88155 1
59 Probe Access Panel (25733) 891898 1
60 Cover, Water Coil (25725) 891894 1
61 Bottom, Blower Box (25734) 891899 1
62 1-1/4” Bushing, Heyco 83910 1
63 Right Side, Blower Box (25737) 891902 1
64 Left Side Assy., Blower Box 69650 1
65 Back, Blower Box (25736) 891901 1
66 Top, Blower Box (25735) 891900 1
67 MTG. Bracket, Blower Box (25741) 891906 2
68 Motorized Natural Draft (MND) Asy 69654 1
N/S MND Motor 80592 1
69 3” Draw Band 23888 1
70 1/4-20 x 1” Hex Bolt 83379 2
71 1/4-20 Lock Nut 83261 2
72 Plate, Electrical Connection, Painted 25745B 1
73 Strain Relief Bushing 80154 1
74 Hook, Handle (25748) 891919 1
75 Handle, Separable 891884 1
N/S Spring Handle 891135 1
76 12” Stub Collar 89799 1
77 10” Stub Collar 891868 1
N/S #10 x 3/4 Tek Screw w/ Washer 83572 96
N/S = Not Shown
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.

-18-
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.
Key Description Part # Qty
1 Weldment, Draft Tube 68872 1
2 Spin Draft 40379 1
3 3/8-16 x 2-1/2 Carriage Bolt 83503 1
4 Lock Nut, 3/8-16 83274 1
5 Actuator, Motorized Draft 80592 1
6 Tube, Flipper 23899 1
7 Flipper 23898 1
8 #8 x 1/2 Tek Screw, Hex Head 83455 2
9 Strain Relief 80154 1
10 Power Supply Cord 80593 17 in.
11 Male, Tyco Terminal 80382 2
Parts Diagrams And Lists - Motorized Draft Kit
4

-19-
Key Description Part # Qty
1 Electrical Box Cover 25742 1
2 Electrical Box Body 25743 1
3 Switch, 3-Position 80692 1
4 Harness, 6 Circuit Receptacle 80583 1
5 Harness, 3 Circuit Receptacle 80584 1
6 Harness, 2 Circuit Receptacle 80585 1
7 Transformer, Fan Center 80130 1
8 Strain Relief 80154 1
9 Power Supply Cord 80232 1
10 #10 x 1/2 Sheet Metal Screw 83172Z 13
11 Washer, Internal tooth, #10 83240 1
Parts Diagrams And Lists - Fan Center Control

-20-
Domestic Hot Water Coil Kit - Optional
DOMESTIC HOT WATER
COIL
REAR WALL OF
FIREBOX
TURN INSIDE NUTS UP
TO END OF THREADS
1. NUT
2. WASHER
3. GASKET
2
3
4
5
6
ACCESS
PANEL
1
This Furnace will accept the installation of a
Domestic Hot Water Coil Kit. The U.S. Stove kit is a
1124 Water Coil and it may be purchased from your
local dealer.
1. Remove the access panel on the rear of the
furnace enclosure.
2. With a utility knife, cut away a section of the
insulation directly behind the access panel.
3. Remove the cover plate from the rear of the
furnace rebox.
4. Place one nut on each end of the water coil
and thread each nut up to the end of the
threads on the coil.
5. Insert the coil through the holes from the inside
of the rebox. Install a gasket, washer and nut
onto each end of the water coil. Tighten the
nuts down securely to insure an air tight seal.
The installation is now ready to be plumbed to your
existing hot water system. Choose one of the three
methods described in the Hot Water Coil instructions.
6. Remove knockouts from the access panel and
re-attach to the furnace enclosure.
Have a qualied plumber connect your domestic
hot water pipe to the coil with the appropriate
ttings.