Clayton 1602R Administrator Guide

851775B-1908E
Model: 1602R
Wood or Coal Gravity Style (Up-Flow) Central or Supplemental Furnace (USA)
Stand-Alone Central Furnace for Canadian installations
United States Stove Company • 227 Industrial Park Road, P.O. Box 151 • 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 ocials about restrictions and installation requirements in your area. is furnace must be installed by a
qualied technician. Keep these instructions for future reference.
Installation/Operator’s Manual
SAVE THESE INSTRUCTIONS
Certified for installations in the USA and Canada.
Safety Tested to UL 391-2010 and CAN/CSA B366.1-M91
U.S. Environmental Protection Agency
Certified to comply with 2015 particulate emissions standards.

2
INTRODUCTION
ank You for your purchase of a U.S. Stove Wood/Coal Burning
Gravity Style (Up-Flow) Furnace. Your decision to buy our fur-
nace was undoubtedly reached aer much careful thought and
consideration. We are very proud you chose this furnace and
trust you will receive the comfort and economy that others real-
ize 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 profes-
sional installation in your home. e qualied professional in-
staller 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 this
eld.
DISCLAIMER NOTICE
e BTU ranges and heating capacity specications are provided
as a guide and in no way guarantee the output or capacity of
this unit. e actual BTU output depends on the type of fuel be-
ing burned and its conditions, the thermostat setting, the dra
adjustment and the chimney to which the unit is attached. e
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 NOTES
• Equip your home with re extinguishers and smoke detec-
tors appropriately located.
• e furnace is designed to burn air dried wood and coal at a
predetermined ring rate.
• Do not burn garbage, gasoline, naphtha, engine oil or other
inappropriate materials. Plastics, when burned, form hydro-
uoric and hydrochloric acids which will damage and de-
stroy your furnace pipe and chimney. e 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.
• Solid-fuel burning appliances need to be cleaned frequently
because soot, creosote, and ash may accumulate. Establish
a routine for storage of fuel, ring techniques, and care for
the appliance.
• Keep Ash and Fuel loading doors closed during operation.
Check the t on the load door as it must t tightly. If it does
not, check for deterioration or wear of the ceramic rope seal.
Maintain all seals in good condition.
• Do not store fuel or other combustible material within
marked installation clearances or within the space required
for re-fueling and routine maintenance.
• Wood should be placed directly onto the cast iron shaker
grate of the furnace. Do not use additional grates and/or
irons.
• Slow res: It is not recommended burning the 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. It is
better to keep a small, intense re as oppose to a large smol-
dering re. Be aware that the hotter the re, the less creosote
is deposited. Weekly cleanings may be necessary in mild
weather, even though monthly cleaning may be enough dur-
ing the coldest months.
• Inspect and clean your chimney and stove pipe regularly.
Check daily for creosote build-up until experience shows
how oen cleaning is necessary.
• Do not over dra the furnace! It is designed to operate at .06
inches of water column and must be set with a dra gauge to
maintain a steady dra. (Barometric Damper recommend-
ed.) If allowed to operate at a higher rate, it could cause a
solid fuel re to burn out of control.
• Never over re your furnace. Over ring could result in
damage to the heat exchanger and cause dangerous opera-
tion. Over ring occurs when the ash door is le open dur-
ing 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.
Have a clearly understood plan for such a situation.
• In event of a chimney re, completely shut all dra controls
and call your re department immediately. Alert everyone
in the house. If the re is still burning vigorously, throw bak-
ing soda into rebox or discharge a re extinguisher into
the rebox. Aer 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.
• Do not allow ashes to build up higher than 2” above grates.
Never allow the ashes in the ash pan touch the grate section.
REMOVE ASHES FREQUENTLY!
• Be extremely careful when removing the furnace ash pan; it
can get very hot.
• CAUTION: Ashes should be placed in a steel/metal con-
tainer with a tight tting lid. e closed container of ash-
es 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. Do
not place other waste inside this container.
• With new steel, there is a small amount of oil or dirt on the
metal. You may smell an odor. is is normal during the
rst operation. You may want to assemble the furnace out of
doors and build a small re in it to “burn o” this dirt and
oil before installing the unit.
• When tending the rebox always pull the bae slide rod out
prior to opening load door. Open load door slowly to avoid
a “ash back”. Aer closing load door, push the bae slide
rod to the rear.
• Inspect air lters regularly. e air lter in the lter box
should be changed at least every 30 days.
• Oil motor on forced air dra every 90 days with a few drops
of 30 wt. oil.

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• e distribution blower motors may be one of two types. If
the motor has sealed bearings, no oiling is required.
• If the motor is equipped with ll holes, the motor should be
oiled every 90 days with several drops of 30 wt. oil.
• If exhaust or attic fans (or similar) are used, they MUST
NOT create a negative pressure inside the area or room
where the furnace is installed. is will starve the furnace of
combustion air and will not function properly.
CAUTION: CLEANOUT OF THE HEAT EXCHANGER, FLUE
PIPE, CHIMNEY, AND DRAFT INDUCER IF USED, IS ESPE-
CIALLY IMPORTANT AT THE END OF THE HEATING SEA-
SON TO MINIMIZE CORROSION DURING THE SUMMER
MONTHS, CAUSED BY ACCUMULATIVE ASH.
NOTE: For further information on using your furnace safely,
obtain a copy of the National Fire Protection Association pub-
lication “Using Coal and Wood Stoves Safely.” NFPA NO. NW-
8-1974. e address of the NFPA is 470 Atlantic Ave., Boston,
Massachusetts 02210.
IMPORTANT
Before installing and using your furnace, please read the follow-
ing pages thoroughly and carefully. If you follow the instructions,
your furnace will give you safe and more dependable service for
years to come.
• First step: Check your local codes. is installation must
comply with their rulings.
• Determine if the installation will be as a Central or Supple-
mental Furnace.
• Do Not install this furnace in a mobile home or trailer
• Always have a smoke or ionization detector and a CO detec-
tor installed in your home.
• To prevent injury or damage, do not allow anyone who is
unfamiliar with the furnace to operate it.
• is furnace must be installed ONLY in the prescribed
manner shown in illustrations 1, 2, or 3 under the Instal-
lation Examples in this manual. It is NEVER to be installed
as a counter-ow or down-dra furnace, or in any manner
wherein the heated air is directed in a downward ow into
the home or toward to an existing central furnace.
• NEVER INSTALL outside the home.
• Spend adequate time with your furnace to become well ac-
quainted with the dierent settings and how each will aect
its burning patterns. It is impossible to state just how each
setting will aect your furnace because of the variations in
each installation.
LOCATING YOUR FURNACE
e furnace is to be installed maintaining the clearances speci-
ed in the following illustrations.
Do not place the furnace directly on a combustible oor. If you
are placing it on a combustible oor, an approved re retar-
dant material, equivalent to 3/8” UL Listed millboard, should
be placed under the unit. e material must extend at least 16
inches beyond the front of the unit and 8 inches on either side of
the fuel loading door opening. It must also extend underneath
the chimney connector and to each side of the connector by at
least 2 inches.
CLEARANCES
REDUCED 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
millboard placed directly against a wall protects it. Materials
installed in this manner actually provides very little protection.
ese materials are good heat conductors, so they will be almost
as hot on their back side as they are on the exposed side. ere-
fore, the combustible wall behind is still a re hazard.
A wall can be kept cool using these items but only if they are
mounted and spaced out from the wall by an inch or two to allow
free air circulation behind the protective panel. e protective
panel should also have a gap between the oor and ceiling.
ree rules to follow when constructing wall protectors:
1. Non-combustibility of all materials including mounting and
supporting.
2. A well ventilated air space between protector and wall.
3. Sucient strength and rigidity so that the protector and air
space will be durable.
CHIMNEY REQUIREMENTS
A reclay lined masonry or Class A 103HT All-Fuel Metal Insu-
lated Chimney must be used in all airtight wood furnace instal-
lations. e minimum recommended ue size for this furnace
is 6 inches, inside diameter. When making new chimney instal-
lations, always follow the chimney manufacturer’s instructions.
Keep chimney clean and in good condition.
If at all possible, use the factory built, class A 103HT chimney
PROTECTIVE COVERING
AND ALL SUPPORTS MUST
BE NON-COMBUSTIBLE
CONSTRUCTING
NON-COMBUSTIBLE
WALLS
2 in [5cm]
FROM FLOOR
2 in. [5cm]
FROM CEILING
1 in [2.5cm]
AIR SPACE
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.
[50.8cm]
[38.1cm]
[55.9cm]
[30.5cm]

4
18” [46cm] 18” [46cm]
9” [23cm]
mentioned above. ey are safer and perform better than tra-
ditional masonry chimneys. If a masonry chimney is a must,
be certain it has a re clay liner and that it is intact, clean and
recently inspected. And remember, masonry chimneys are far
more prone to the formation of hazardous creosote.
1. e furnace should be the only heating using the chimney
ue . One furnace per ue outlet.
2. A masonry chimney should have a tile or stainless steel
liner.
3. e masonry chimney should not have any missing mortar
or loose bricks.
4. ere should be no mortar or parts of the chimney block-
ing the chimney ue.
5. ere should be a two inch clearance between any chimney
(masonry or metal) and combustibles. (such as the house)
6. e chimney should extend at least 2 foot above the high-
est point of the house, or 2 foot above the point at which
the chimney is 10 foot from the roof.
7. e chimney should be relatively straight and vertical.
8. e 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 NEED
FOR REMOVAL
When wood is burned slowly, it produces tar and other organic
vapors, which combine with expelled moisture to form creo-
sote. e creosote vapors condense in the relatively cool chim-
ney ue of a slow-burning re. As a result, creosote residue ac-
cumulates on the ue lining. When ignited, this creosote makes
an extremely hot re.
e 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 re.
SMOKE 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 ue connection used. Be sure to maintain
the specied clearances for your type of installation.
TYPE OF FLUE REQUIRED
CONNECTION CLEARANCE
24 Gauge or Heavier........................................... 18” [45.7cm]
Single Wall Stainless Steel
or Black Pipe
Double Wall, Stainless Steel or.......................... 6” [15.2cm]
Double Wall, Black Pipe w/
Stainless Steel Inner wall
Class A 103HT All-Fuel or Equivalent............ 2” [5.1cm]
According to NFPA standards, single wall stove pipes can be
within 9” of combustibles provided an approved re retardant
material covered with 28 gauge sheet metal, spaced out 1” on
non-combustible spacers, is utilized. See illustration.
When using a Class A or double wall ue pipe connection, fol-
low the manufacturer’s instructions.
When constructing a single wall smoke pipe, the following
guidelines must be observed.
1. e connector pipe should be 24 gauge or heavier
stainless steel or black pipe.
2. Secure all joints with three #8 screws.
3. If the connector pipe must pass through a wall, an ap-
proved insulated or ventilated thimble, at least three times
the diameter of the smoke pipe must be used. (i.e. a 6” di-
ameter smoke pipe needs an 18” thimble).
4. e connector pipe should never be used as a chimney.
TOP OF CHIMNEY MUST BE
2 FEET [61cm] ABOVE
HIGHEST POINT OF THE
ROOF WITHIN 10 FEET
[305cm].
2 FT [61cm]
MINIMUM 3 FT [91cm]
MINIMUM
RECOMMENDED
MINIMUM HEIGHT
20 FT [610cm]
MINIMUM 3 FT[91cm] FROM
TOP OF CHIMNEY TO
POINT AT WHICH IT
PASSES THROUGH THE
ROOF.

5
IMPORTANT INFORMATION FOR ALL
CONNECTOR PIPES
e connector pipe must be constructed and installed so that
it maintains clearances, keeps condensation and creosote within
the pipe, and is capable of withstanding a 2100°F degree chim-
ney re.
1. At no time should the connector pipe turn downward to-
ward the chimney or run perfectly horizontal. e connec-
tor pipe should slope down toward the furnace a minimum
of 1/4”[0.6cm] per 12”[30.5cm].
2. ere should be no more than two 90 degree elbows.
3. e connector pipe should never be longer than six feet. If
it is absolutely necessary to make a run of more than six
feet (not recommended) use extra support brackets every 3
feet[91cm].
4. e connector pipe should never be reduced to a smaller
size than ue opening on the furnace.
5. e connector pipe should not block the ue of the chimney
or extend into it in any way.
6. A good airtight thimble should be used to hold the connec-
tor pipe in the chimney. It should be constructed so the con-
nector pipe can be removed for cleaning.
7. e connector pipe should not leave the heated portion of
the building to reach the chimney.
8. e connector 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. e connector pipe and any elbows must be of 24 gauge or
greater.
10. e connector pipe should not be located near or in a walk
way or well traveled area.
11. All male ends of connector pipe should run or point to-
wards the furnace.
12. Install a cast iron adjustable damper in the rst joint of the
connector pipe, nearest to the ue collar.
DAMPERS ON STOVE PIPES
When burning coal, we recommend a Barometric Dra Damper
be installed at a safe convenient place between chimney and your
furnace preferably less than 3 feet [91cm] from the ue collar.
When you have installed the connector pipe between your fur-
nace and the chimney, tap the pipe hard with your ngernail.
Remember the sound it makes - it will be a “ting” echoing inside
the stove pipe. If later you tap and hear a mued thud, you are
building up soot in the pipe and should clean it. is pipe should
be cleaned at least once or twice during the heating season.
DO NOT CONNECT TWO HEATERS TO THE SAME CHIM-
NEY FLUE. e National Fire Prevention Association recom-
mends that wood burning appliances vent into a separate ue
from gas or oil furnaces. If such an installation is contemplated,
rst check with a local building inspector to nd out if a separate
ue for a wood burner is required.
Use of a Barometric Dra Control (when burning wood) is rec-
ommended ONLY in the event your chimney creates excessive
dra leading to an over-ring condition.
HEATED AIR DISCHARGE
is furnace is designed for use as a supplemental heating
source. When used as a supplementary furnace, it is connected
in conjunction with an oil, gas, or electric furnace to the existing
duct work which distributes the heated air into several rooms
and/or areas.
ough United States Stove Company expressly Does Not rec-
ommend the use of its furnaces to be installed and/or used as
a free-standing heater, it is possible to achieve a reasonably safe
and functional installation IF certain standard procedures are
followed. e following are guidelines only and are intended to
enable the furnace user to obtain reasonable eciency from his
furnace, and with due respect to safety when installing as a “free-
standing heater”. If installed correctly, and in accordance with
the instructions found in this manual, your warm air furnace
may be installed as a “space heater” within living quarters, cab-
ins, garage, or workshop. Please adhere to the following:
1. e use of a cold air return and/or lter box is mandatory.
is will not only increase your blower life and provide l-
tered air, it will also help prevent the blower or blowers from
“capturing” heated air exiting from the top of the furnace
heat outlets.
2. If installed as purchased , without directing the heat away
from the furnace itself, it will simply sit and cycle, turning
the blowers o and on. e thermostat may not function
properly.
3. All larger furnaces (or those with multi-speed blowers) ab-
solutely require BACK PRESSURE to prevent premature
motor winding failure. If allowed to operate at high RPM
(As in “FREE AIR” mode - no duct work or ow restric-
tions) the windings overheat, insulation melts and the mo-
tor simply burns up - not covered under warranty.
IMPORTANCE OF PROPER DRAFT
Dra is the force which moves air from the appliance up through
the chimney. e amount of dra in your chimney depends on
the length of the chimney, local geography, nearby obstructions
and other factors. Too much dra may cause excessive tempera-
tures in the appliance. Inadequate dra may cause backpung
into the room and ‘plugging’ of the chimney.
“Inadequate dra will cause the appliance to leak smoke into the
room through appliance and chimney connector joints.”
“An uncontrollable burn or excessive temperature indicates ex-
cessive dra.”
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 recommen-
dations as to the safest and most ecient method of installation.
e following illustrations are the ONLY acceptable congura-
tions when installed with existing oil or gas furnaces.