Fire Chief FCOS1600 User manual

MADE
IN
USA
Fire Chief
Outdoor Woodburning Furnace
Model FCOS1600
Owner's Manual
VOLUME I
June 2010
Manutactured By:
Fire Chief Industries
@ ~
7280 Old State Route 21
I nte rlek
Barnhart, Mo. 63012
Tnt.d I<> 311
I- HOO-87s..4788 or 63 6-942-4747 SIO"""""
$9.95

"Save These Instructions "
Con9r'lul'lion, 1
You have selected the finest quality outdoor wood burning furnace, manufactured
WIth pride in the USA. Please lake a few moments to carefully read the owner's manual
By taking the lime to fami li arize yourself WIth your new Fire Chief OutdOO( Furnace, you
WIll be able 10 look forward 10 years of trouble-free, dependable service
Installation
fllst. Check Local Codes The lnsl ll llation must comply with ailloca! luling, and reQuirement s.
Thi. f urnllc.;s iJn outdoor hot .Ir fum"" "nd must bill in' tlilled
e cco ro/ng 10 Ihe mllnuf"ctu,er •• peclflculon •.
Til
ls furn.ce must be eonneeled to. grounded electr icel circulI .
Till , f urnace requ i res a baell·up electric g,ne,,,'o, , 2000 Willis minImum
in cas, of power f" lIure.
AIW.ys lIave a prop"'y in".ned and functioning smolle de/ector Ins/lllled
In your hom •.
•
To prev.nr aeeiden/"llnJury , do not allow anyone 10111 0 is unfamma, wi/II
til e fu ,nllC. to operate it .
Sp.nd limefllmiliiJrizi ng yourself wi/II you, Fire Chief Fum.ee , .. p.cla"y
tile different setlfngs lind III , effec t Ill ey lI ave on burn p/lllerns . III.
Impossible 10 stllte how each iJelling willaffecl your furnllce due to
va,iations in settings , fuels lind temper.tUfU.
Transportation Damages
Every e lt on has been made 10 In'ure Ihal youl File Chi ef Will afflve in perfect condition
Any
vilible damage should be Iloled all the freight bill al the time of delivery If upon ul"lpaclrl1"l9
your Fife Chief you filld damage had occuned du.ll"lg Iransl! Ilolify your euppl'e' immediately.
Your supplier will advise you as 10 whal acllol"l' mu81 be laken to cOffecllhe problem
Disclaimer Not ice
The ~eled BTU rabng of your I"\fIW Fife Chle! was oblaitled under ideal laboralOIY lestillll
(;olldllIOIl' The ,ctual BTU outpul you experiellC6 may valY somewh,,1 depending on the Iype ,
cOlld~101l alld mol5b.lfe of Ihe fuel used. damper adluslmenl : chimney Iype 'l"Id other vatlable
faclora Therefore, the manufacturer disctaims any guaral"lleo as 10 the BTU oulpul or capacity
of
your furnace Fire Chle! Il"Idustrles will void alld disctalm allY responsibility 101 Ihe follOWing:
InSla!llllion
01 a !umace Itlal has been altered or modified ill any way: Installatloll of lh a lumace
olher than as Instructed III this manual 11"I51 aliaiion and or use of any compol"lenl or part IlO t
approved by Fire Chia! Il"Idustries for use 01"1 Ihie lumace Be sure 10 complele and retum your
warranty card wilhil"l Ihirty (30) days
of purchase ill order 10 receive warrallly coverage on your
fumace
Manufacturer's Notice
Please be advised thai we periodically make changes 10 Improve our producte Therefore
the Il"IlormaliOI"l in Ihls
"'lInual may nOI be completely compatible With·your Fore Chief
THIS IS AN OUTDOOR
WOOD BURNING FURNACE
AND SHOULD NOT BE ALTERED IN ANY WAY!
,

Table of Contents
General Furnace Overview and Components ..... 4
Furnace Clearances and Operation .. .... 5
By-Pass Damper Operation ......... ........ 6
Chimney Clearances .......................................................... 7
Wood Storage and Care .......................................................... 7
Furnace Facts and Information _ .............................................................. 7
Electrical Kit Inslallalion.................... . ............"..... . .. _,_ 9
Hot Air Duct and Cold Air Return Installation .................................. 10
Installation: Central Duct........... 11
InstallatIOn Downdraft Furnace or With No Duct Work ...................... 12
First Fi ring RecommendatIOns . ..........................,......... 13
Fuel Recommendations ..................................... 13
Ash Removal .. . ,..........................................................13
Heat Dump System and Heat Fuse link .......... .. ..... .. .............................. 14
Ma in tenance ............."......,",.................................
Wiring Diagram .........................,..........................,......
Parts Diagram ......................................,....................... ' ..
Parts List ....................................................... ' .. ' .•
.. .. . ...... 15
..
. 16
17
16
Troubleshooting Guide ... ... .. ...................................................... 19
Warranty Information ............... ....................................... .. 24
Model and Serial Number Registration ................... .. ...... •. .. 25
ALWAYS KEEP YOUR WOOD COVERED YEAR ROUND .
DRY WOOO WILL PROOUCE MORE BTU OUTPUT
AND LONGER BURN TIMES .
,

GENERAL INFORMATION
The FIrE! Chief 051600 IS an airtight central solid fuel outdoor furnace engineered
to provide the most viable solution to the ongoing problem of homeowner utility depen-
dence The 051600 is designed to accommodate the heating requirements of the
average sized home, even dunng Winter's coldest months Constructed of high grade,
heavy gauge steel and IS continually welded to assure the utmosl in structural strength
The insulated 6 cubic foot fireooK
Will accommodate a log up to 28" length
The design of the secondary combusllon chamber increases fuel efficiency
by cre--
ating a "secondary bum" of smoke and wood gases before they are vented up the chim-
ney By sending the gases back through the secondary combustion chamber less fuel is
wasted, the furnace
bums at a higher eff iciency and for longer burn times
The cast iron door is custom fitted
to provide an a lf tight seal, greatly extending
the burn time and insuring ma)(imum effiCiency
In fuel consumption The insulated
wrap around sides are designed for maKlmum heat transfer. The weather-resistant ser-
vice door offers protection for the fuel and ash door from the elements
For total comfort and conyenlence,
we added a thermostatically controlled 1800
cfm. CIrculation blower system The blower draws the cold ollr from the home, across the
heat chamber before going through the hot air duct and returning the warmed air to your
home Th
is fully automatic blower furnishes rapid heal disbursement to your home,
minimizing recovery time. Average bum time per load of fuel is sIx to twelve hours
depending
on wood type and condition, desired temperature within the home and amoont
of fuel. We have Incorporated all of Ihese features as standard equipment, offenng you
the most efficient. durable and affordable appliance possible Abnormally cold weather
could reduce
fhe bum lime
The FCOS1600 is a wood burning furnace -it can not be turned · off and on" to
control the furnace temperaturE! like gas
or electnc furnaces Once the fire is established,
it has to burn, until I! burns Itself out
INC LUDED WITH YOUR 051600 FI RE CHI EF FURNACE ;
1 1 0"X 25' Insulated Flexible Heat DUct
2 10 ~ Staner Collars
2 Clamps
1 12~ S tarter Collar for Cold Air Return
1 Owner's Ma nual with Warranty Card
1 Elec trical Con trol Kit ( shipped on top of the furnace)
1 Tube of Silicone
4 11 4 ~ Nuts
17 tHO" Green Sc rews
4 tHO X 3 / 4 ~ Screws
2 #8 X 112" Screws ( Atta c hed to Fan Limit Control Cover )
1 Fan
Lim it Contro l ( with Wire Conduit)
1 Blower Motor
1 Blower Housi ng Cover with Control Center
•

GENERAL INFORMATION , cont.
Before beginning your installation. consult with local authorities regarding the codes
governing all such installations.
00 NOT connect your Fire Chief OSI600 Wood Furnace to any
flue that services ANY other appliance.
Your Fire Chief 051600 may be placed outdoors or indoors. If outdoors, ~ must be placed on a
level. non-combustible base. preferably a 4' X S' concrete pad. as close to the home as
clearances to combustibles permit -do not place the furnace more than 40' from the house. The
furnace must be connected to a grounded electrical circuit
with access to a backup generator
(2000 watt minrnum) . lf locating the furnace more than 10' (ten feet) from the home, a minimum
of 6' (six feet) of Class "A" HT 2100 All Fuel
S" Chimney Pipe is required. If installing indoors.
your furnace must be placed on a non-combustible floor. Air f
or combustion must be provided
into room where furnace is located. Allow air free access to furnace for combustion and
"u''';;' .Sides of furnace. 12"; Rear 01 furnace. 31"; Front of
, , I 16" from the rear of the furnace and 3" thereafter.
~
~ . ~'~~
Maintain the "1012 Rule " for the flue· the flue must be 2' (two feet) higher than any part of
the building
or peak of the roofwithin a horizontal distance of 10' (ten feet). The 2 fl. height does
not include the
cap . REFER TO PAGE &: FOR COMPLETE INSTRUCTIONS.
Class "A" HT 2100 All FuelS" Chrnn-ey Pipe is recommended for optimum performance and must
maintain a
2" clearance from combustibles. The OSI600 will ship with an adaptor plate and 4· #10
3/ 4" galvanized screws wrth washer and gaskets to match the chimney your dealer supplies. If
the adaptor plate provided WIth your fumace does not fit the chimney your dealer has in stoc!l.
please call ourtoll free number, 800-875-4788 for assistance.
Important: Please keep in mind that drffer&nl chimney manufaclurers pipe will not interchange
WIth other brands. A lube of h!glHemp silioone caulk is included wirh your furnace. Before
silicomng the adaptor plale 10 the top of your OSI600 , insure the chimney you purchase will fit the
adaptorpia/e.
Guy wire brackets are attached to the sides of the OSI600. A heavy guage of stainless
steel wire can be purChased al your dealer or local hardware store to use as guy wire to help
support your chimney. Attach t
he appropnate chimney pipe lengths to the adaptor plate finishing
wrth a chimney cap. Important: Your furna ce requires Its o wn chimney system and can
not share a nue with any o ther product.
If you choose to use single wall stainless, the ftue temperature will be reduced which
promotes the formation
of creosole. possibly creating a fire hazard. If you use smgle wall
stainless pipe (minimum 24" gauge). minimum
cl earance is 18" Irom combustibles.
DO NOT U$Q Gal vanited or Bla ck Pipe to vent your furnace.
Once you have mel local requirements governing the inslallation a nd positioning of lhe f urn ace.
insta ll the Electrical Control Kit. Open the Electrical Control Kit and confirm that all items were
shipped wi
lh your OSI 600. Install the Electri ca l Control Kit. REFER TO PAGE 9 FOR COMPLETE
INSTRUCTIONS.
After i IIi the "' i ~~: •• ,. and the Electrical C ~~"~"~01~~~~'~"~~~~~~~~~~
OSI600.
to your ... t,
a $ mall iiC~i,; ".flrebox to full capa city during Ihe Inllial fIri ng . Your n ew
,

"BURN WOOD ONLY"
-Keep children away-
-Do Not T ouch during o perati on-
GENERAL INFORMATION, cont.
furnace has a protective coating ofoil or paint on the surface which coukl produce smoke
or odors during the initial firing and will bum off. Allow adequate ventilation during this initial
break-In firing 10 let any odors escape. Th is initial firing allows the metals to cure. After
successfully completing the initi al firing. you are ready to att;;tch the flexible hot air duct and
cold air return to complete your ins ta ll ation REFER TO PAGE 10 FOR COMPLETE
INSTRUCTIONS.
The fan limit control is factory pre-sel at 170· as the "ON" temperature setting
and 110 · as the ·OFF" temperature setting. Th is means when the heat chamber
reaches 170 ·, Ihe blower will turn "ON", when the chamber cools to 110 ·, the blower
Will turn ·OFF", This process is called a heating cycle
By.Pa .. p am p .r:
The By-pass damper has several purposes; starting the fire, improving the effi-
ciency and cleaning the chimney. When starting a fire in your 051600 , you musl pull
the rod out, lor a stronger draft during ignition. Once the fire has started, close the by-
pass damper, which allows the secondary combustion chamber to engage increasing the
furnace's operation to peak efficiency If the bypass rod is not closed during operation,
the lurnace's efficiency will be greatly reduced allOWing the heat to escape up the chim-
ney Finally, when cleamng the chimney, the rod must be pulled out 10 allow any build-up
in the chimney to fail into the firebox.
-This Unit is not to
be c onne cted to a chi mn ey I lue se rvi ng a no th er ap plla nce,-
Furnace Chi mn l1 Y lo c Oitlon : R. q ul rts Class "A " HT 2100 A ll F y. 1 6"
Chimney
The lurnace requires a minimum of 6' (six feet) of chimney. When positioning the
furnace, maintain the " 10 f2 Rule" for the chimney. In order to determine proper
chimney height above the rool, measure from the side of the chimney horizontally. As
you move up the chimney, the length of the measurement increases Once thiS mea-
surement reaches 10 feet. this height on the chimney is your base height. The chimney
must be 2 feetlaller than the base height If the chimney Is closer than 10 feet from the
peak of the roof. the chimney must be 2 feet higher than the peak of the roof, The 2 feet
above
the base height does not Include the cap. The furnace must be placed on a level.
non-combustible surface or 4' X 8' concrete pad. See Dia gr am on p age 7.
•

GENERAL INFORMATION , co nt .
Keep wood covered at all time s.
over emphasize the importance of keeping your wood supp ly cov-
~
~~~~::'.:~Wood stored/stacked, uncovered, exposed to ra in and snow has a
content, causing the formation
of creosote. it smokes, takes longer to
I I poorer fires with lower sustained BTU output. Unseasoned wood
ends up costing more
in time trying to achieve and maintain proper temperatures in the
firebox while using more wood with less heat
output Covering the woodpile will keep it
dry and offer
you the hottest fires with the greatest BTU output. If you store the wood
near your furnace, be sure
to maintain proper clearance from the furnace to prevent a
fire hazard.
Remember , keeping your wood dry will produce h otte r fi res and
I ncreased BTU output.
tn order to create the most efficient draft, the chimney size should be 6" with a
maximum of 08 inches water column draft. With the use of a draft gauge or
manometer, the flue draft can be measured,
if mOfe than .08 inches of water column
draft can be adjusted
with the installation of a nue damper.
IMPORTANT FACTS ABOUT INSTALLING AND OPERATING
YOUR FIRE CHIEF 051600
-Installation is to be performed by a qualified In s taller .
, ALWAYS consult local building inspectol'B for codes concerning the installation of your
furnace.
• ALWAYS have access to a backup generator, 2000 walt minimum.
• USE Class 'A" HT 2100 All Fuel 6' Chimney for your Fire Chief 081600 .
• NEVER use galvanized pipe in your flue connection.
• INSPECT the flue periodically lor structural integrity.
• CLEAN the flue regularly to prevent creosote accumulation
10'
,
NOTE; When positioning the
furn<!ce -the roof Is not level.
The
roof of the furnace
slopes to the rear, approxi-
mately 1/2', to allow for ra i n/
snow run-off.

GENERAL INFORMATION , cant.
• NEVER use chemicals or gasoline to start or maintain your fire.
« NEVER burn garbage, oil, trash or gasoline in your furnace.
• NEVER leave the ash pan or fuel door open during operation.
• REMOVE ashes on a daily basis -before they reach the grates _to insure proper air
How .
•
NEVER use wet, unseasoned wood or wood exposed 10 a recenl ralnfall -doing so
causes a rapid accumulation of hazardous creosote, 8 proven cause of nue fires.
• NEVER burn plasti cs , wood products containing glue , paraffin or those trealed with
chemical preservatives in your Fire Chief Furnace The combustion
of these
subs/anres may release hannful, toxic gases.
• NEVER UNPL UG THE FURNA CE FROM THE POWER SOURCE. THIS WI LL
CAUSE THE FURNACE TO OVERHEAT. If It IS too warm in the house do the follow
ing: Reduce the spin drafts to allow less flow of air to the fire box, use less fuel
(
wood ).
• NEVER leave the ash or fuel do or open to attempt to reg u late the fi re· this will
overheat the furnace and void the warranty.
·00 not co nne ct this unit to a chimney nue serving anothe r appliance.
· Refe r to nameplate on furna ce for add i ti onal Info rmat io n.
Warn i ng - Risk of Fir e
• DO N OT operate with fuel draft exceeding . OS " (19.9 Pal In. of water column.
• DO NOT operate with fuel loading or ash removal doors open.
• DO NOT store fuel or other combustible materials within marked installation
clearances.
Danger-
Ri sk of Fi re or Exp lo sio n
• Do not burn garbage, gasollne, drain oil or other flammable liquids.
•

INSTAllA Tl ON OF elECTRICAL CO MP O NENT S
1- Install the blower on to brackets located on part A blower housing using 4- 11 4" bolts
and 4- 11 4" nuts provided.
2- Attach blower housing part A to back of furnace using 6- 1/4" bolts.
3- Align the fan timit control ball: with the gasket to the 4 holes on the back of the
furnace with 4 - #10 X 3/4" screws lor a watertight seal.
4- Pass the wire condu~ th ru the hole on Part A blower housing. Re-install the locking
nut on weather tight frtting.
5- Insert the plug from the fan limit control into the control center marlled Ian limit.
6- lnsert the plug from the blower molor into Ihe conlrol center marKed blower.
7- Mounl cover on fan limit control box with 2 - #8 screws.
8- Mount blower service cover part Busing 19 -#10 9reen screws pr ov ided.
Nole: You may ron the power cord thro the return cold air duct or you mey
access
the hole from the bottom of the blower housing cover. The hole must be
sealed efterward regardless of routing choice.
Connect the 10" starter collar to the heat supply vent of the furnace. Connect the 12"
starter coliar to the cold air return on the back of the blower housing cover.
Note: Where part A and part 8
of Ihe blower housing come together as well as
where it is attached to the back
of furnace. insure there Is no crac!c.s . The blower will
pull outside cold air into housing and reduce the temperature
of the heat chamber.
Q
UT Hot Supply AN
17' Cckl
Re1Y,nAiI
~
<Cl
Control Center
See CIos. updi3g'''''
• •
.. ,
~
,
,
an limit Control
Control Center Close-up
Blower /kIlor
1
'"
TOPV1EW
•
l'
Fan limit
•

HOT AIR DU CT INSTALLATION
Hot Ai r Duc t : Included with your 051600 _ 25' of ten Inch I.D. flexible Insu-
lat ed h ot air duct wi th 2 clamps, two 10" Sfer f er col/ars end one twelve inch
st ar t er collar.
The 10" insulated fleK hot air duct is for indoor use only. When using the
insulated fleK duct always insure the duct is pulled tight to prevent air drag
inside duct. Outside the house. you must use 10 " galvanized pipe. wrapped With
weatherproof UV-jacketed Insulation for protection from the sun's UV rays. The 12"
return air may be galvanized pipe.
The 12" return air must be attached to the home so
as not to pressurize the home.
The warm air supply air duct should be constructed of
materials with a minimum temperature rating of 250 degrees Fahrenheit
NEVER reduce the 10" hot air or 12" return air as this will effect the air flow and the
furnace will 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 \0 heat the home.
The duct work should be designed so the
edemal static pressure does not exceed
.02 water column inches While developing air velocities of 600 feet to 1, 000 feet per
minute
in the main trunk duct and 400 feet to 600 feet per minule althe registers The
heat outlet should never be less than ten Inches (10") round or 79 square inches.
The Fire Chief 05 1600 m us t be Ins t alle d wi th a co ld air re tu rn sys tem.
The system must be a minimum of twelve inches (12'·) to readily transfer the cold air
back to the furnace If desired, a cold air liller bo)( may be constructed with a minimum
opening
of 225 square inches
A basement window is an e)(ceiient locatIOn for running the hot
air duct vent as
well as the vent for the cold air return The cold air Is an Integral part of the system and
must be used when installing Ihe furnace -failure to use the cold air return
witt pressu ri ze
the home causing the furnace not to work properly. II a basement Is not available. you
may access the home through a window, wall
or crawl space for both the plenum and air
return.
Bur ylnll Duct Work: 00 NOT BURY FLEXIBLE DUCT SUPPLIED WITH FURNAC E.
To bury the duct work below ground. use schedule 40 or 80 PVC or black plastic
culven pipe with smooth Inner walls Dig a treflch to accommodate both the heat duct
and the return air duct. The trench must be a minimum
of 24" deep. To funher insure
efficiency, minimize heat loss and
prevent moisture formation, line the trench with ' "
(one inch) pink styrofoam insulation sheetlflg on the Sides and bottom of the trench The
duct run should not e~ceed 40 feet If the run e)(ceeds 40 feet, you run the risk of
reduc in g the furnace·s eHlciency and air flow REMEMB ER TO AVOID 90° elBOWS tN
DUCT LINE.
00 NOT USE FLEXIBLE H OT AIR DUCT INSIDE pvc OR CULVERT PIPE.
ALWA YS KEEP Y OUR WOOD C OVERED YEAR ROUND .
DRY WOOD WILL PRODUCE MORE BTU OUTPUT
AND A LONGER BURN TIME .
"

TYPES OF INSTALLATION
Your Fire Chief Furnace is designed to be a supplemental or centre! heating source for your
~me This wood burnr.g furnace may be installed paratlel WIth a properly operating electric, gas or
Oil-fired central furnace thai Is listed or certified
in accordance with a n8lion lil ily recognized safety
Itlilooard
wit" in installation clearances as specifl8d on t he Fire Chief nameplate When In a paralle!
In slall8lion the static pressure of the central furnace plenum may not exceed 0.15 inch 01 water
COlumn IiInd maximum setting on central furnace limit switch is 182 'F. W~h the Fire Chief
woodburnlng lurnace in an "Interconnection Arrangemenf yoor wood burning furnace should
be
upstream of the central furnace. The Fire Chief furnace warm air suppty should never be connected
to return air of the cent...1f Um&ee Instanation should be perfonned by I qUlllfled Instalier.
Inst81la l ion should be dooo by 8 qU81ifie(/ proIeuiooBl . Ma:.: HnI.ffl run
40 ' wiI greatly reslricf the 8/f /low and fHJa/ output • therefore, is no/
recommended. l.-\'httn conn&C1lf1fJ file 051600 fo acentral duct system, avoid 90 degr&e elbows -as
WJlh any fUffl8ce, Ihe more turns and branches in /he ducting lhe less air flow delivery. DO NOT
USE FLEX OUCT OUTSIOE.
Run 10" In sulated hot air duct from the outside rurnace through a window or wall of the house.
Attach the I nsulat ed ne~lbte hot Il r duct, furrushed with the furnace, to 1M central duct
system of the home Connect the duct with a
.5 ' elbow or OIl an angle 10 the hot ai" from the
05 1600 Is delivered down stream. This will insure propel" air flow into the duel system AV Oid
dallverlng the hot air through the air conditioning coli as this will cause an oOstnJClion reducing the
amoon! of heat output. 00 n ot reduce the sin of the hot Il r duct. As with any furnace, the
greater run. turns and branches in the dud.ing the less air flow and he81 output delivered. Use of
go' elbows is not recommended. 'MIen usng the nsulated t o"" flex dud inside the house. insure the
fIe~ dud ~ pulled tight to avoid air drag in dud .
The 12" cold air return duct mull run to the house to prevent pn:!6IIuriU1tion of the home. fa ihJre to
connect the cold air retum will cause the furnace not to operate. Nev er reduce the .ae of the
return . Reducing the size of the cold air retu rn will restrict the hot air flow and put e~cess pressure
on the blower motor. You may lemWlate the coIcI a.. return where )'OU enter the house - ttMs will
provide adequate Circutation within the home. See diagram b$IOw.
Connect Hot Air at an .:~ ;";;;;"''''''''''''''''.
going downiheam to d ~
COLO RETuRN AIR
THE 10 " FLEX DUCT MUST NOT BE EXPOSED TO
THE OUTDOORS. IT IS FOR INDOOR USE ONLY.

TY PES OF INSTALLATIONS , Continued
I run in excess of 40' will greatly
~
~:~~~~~~~~:~:~ Installation should be done by a
air flow I heat output and is not recommended. Both Ihe hal air ducl and
return duct may be accessed through the floor
in a mobile or modular home.
In a mobile home, with a
down-draft furnace, do not attach
the hot air duct from the
OS16OO
to the hot air plenum, doing so will
cause the heat to rise through the
central furnace instead of going
through the duct work. Split the
hot air supply
of the OS16OO by
using a ''Y' and install one branch
into each
of the hot air ducts, be
sure both are pointing dO'Mlstre a m.
(See diagram -maximum reduc-
tion for each
~ y ~ duel run , 8").
Fire Chief
051600
Hot Air
Cold Air
l'
8" /; ~
/ ,
. ::t Downdraft
..... ~ Furn ace
,
8"
rt'
..
No Duct work Ins tallat ion Conn ec tions: Ins t alla t Ion sh ould be done by II
q uali fi ed pro fes si on lil . Cold a ir ret urn mus t be ins t all ed in a/l inst alla t ions,
even t hosa withou t duc t work.
When there is no duct system to connect to the hot air flex duct, 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, if you do not the air will not flow evenly through
out the home. This method will work well
on homes built on concrete sl a bs
00'
create a good air flow.
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 floor, this will create a perfect air flow,
since hot air rises. The cold air return must be connected, even if the home does
not have ducl work -if
you do not connect the cold air return, the furnace will not be
able to heat the home. See a diagram below for homes with no duct and a
basement.
HOi Air
Cold Air
r=:> r=:>
Hot Air
"

" Bum Wood Only"
Caul i on - Hot Surf aces:
-Keep children away.
-Do
not touch dur ing operation.
-T he fu e l lo ading do o r has a remo va ble hand le ( #17 ), whi ch c an be ato red In
ve nt ed b o tt o m pan el (#11 ).-Refer to part s di agr am on pag e 17 .
OPERATION
Sta rti ng yo ur lim t "r eal fi re: Ch~k fa be oortllin the spin drafts are wide opl/n /0 allow oxygen into
the firebox.
Pl ace several crumpied newspapers on Iha grate w;th some dry IOndling layered on lop of the
p.apers. ignite the newspaper.
When Iha kindling is buming. add several small pieces of wood -allow the
wood to lully engage In names. After about 20 minutes the fire should be establ~hed . allowing you to
add more wood -do nol overload and smother the fire. Add more wood slowty so the flames have time to
angutf the fresh wood . Once the fire is burning and there is a glowing ember bed. adjust the drafts to
achieve the desired bum pattern. Leaming how to adjust the drafts to maintain Iha desired temperature
for your home may take a few days. Aner a short time you will know which settings and adjustments work
best for your home. Over-firing by overloading/over-fueling the furnace causes the metal
to superheat
and expand. then
0001 rapid ly which causes cracking. therefore voiding the warranty. Over- fi ring or abuse
can easily be determined
upOn inapection.
C,Iu
ti on: NEVER use chemicals or gasoline to start or maintain your fi re. 00 not burn oil.
garbage. trash. plastic or
an y fuel other than wood In your furnace. doing so will void the warranty.
Fuel R ecom me nda ti ons : MAX IMUM Log Si ze 28"; He lll nns; sl lln l glo ves liN! rec ommended .
We 9dvise using only dry. seasoned hardwoods
in your Fire Chief OSI600 rather than highly
rosined wooda such as pijne . Firewood should be cut at least one full season prior to the time of ~s
intended used for optimum heat output. Firewood should be stacked to provide a free now of air
between !he logs, tl1us allowing more rapid seasoning of the wood. If wood is storad outdoors, it should
be completely covered yaar round to protect II from moisture and exposure to the elements.
Use extreme CBUtion when opening the doors during Opefation. temperatures can exceed 300· -
wait at ~ast 10 (ten) seconds sfte< releasing the first latch, then proceed to the fully open pOsition. The
dusllatch system has been IncorpOrated as a safety feature -designed to eliminate the pOssibility of
gaseous ignition. Heat re si stant gl ov es are rec om men de d when opening Iha fuel doof1l. reguleting the
spijn draft or emptying the ash pan.
A, h
Rem ov. l: Remove the ashes from your Fire Chief OS16OO at least once a day - or as often as
necessary to e<l5ure the ashes do not accumulate to the height of the grates. If ash build-up occurs at
grate level, it will cause premature t.lilure of !he firebox, voiding the warranty. The air lIow was ~Igned
to keep the grate area coolin addition to prollidlng the firebox with warmed air fo r beUer combustion. II
tl1e ash level Is Improperly maintained, the firebox will be starved f or a ir . greatly redu~ing the efficiency
and heat outptJt 01 your lurnace. Place hOI ashes in a covered. a ir tig ht melal container -place the
contaifler on a non-rombustible su rface. Discard the hot ashes in a safe manner. Remove the Ash Pan
from the furnace and dump tl1e ashes in to a metal container wfth a tight filling lid. The closed container
01 ashes should be placed on a non-combustible noer or on the ground _lIewsy from a ll combustible
materials, pending final diSpOsal.
If the ashes are dispOsed of by burial in soil or otherwise locally
dispersed. they should
be retained in Iha closed metal container until all cind ef1! have thoroughly cooled.
A l
waya k eep y ou r w oo d co ver ed yea r ro u nd .
output and a lo ng er b u rn tlm a.
Dry wo o d w i ll produ ce mor e Blu

FCOS1600 HEAT DUMP SYSTEM - HEAT FUSE LINK
Your OS1600 has an automatic sa fety feature -Heat Dump Release System. In
case of power failure. the Heat Dump Release will open the spring loaded lid when the
internal furnace temperature reaches 370·. The heat sensitive fuse
li nk, located within
the top of the heat chamber, causes the lid to open, allowing excess heal 10 escape.
This safety feature is designed to activate before any extreme heal can damage the
furnace
Connect to Generator immediately . If the Heat Dump
not continue to burn the furnace. DO NOT UNPLUG
draft dampers. DO NOT add any fuel ( wood) - allow
the fire to die. After the electricity is restored, replace the fuse fink before
resuming normal operation.
Replacing the Heat Fuse Link: Remove the aoorn nut on top of Ihe release lid and pull
the bolt down thru the lid. Removed the separated fuse links and connect the new fuse
link to tile shaft inside of tile furnace heat chamber. Connect the opposite end of the fuse
link to the bolt that goes thru the lid. Feed the bolt through the lid and replace the aco rn
nut onto the bolt on lop of the lid. As a precaution, keep a replacement on hand.
II
;
II
Heat Dump Lid ~CLOSED" - indicating
NORMAL OPERATION.
NOTE: Do not allow snow or ice to
build up on lid.
Heat Dump Lid 'OPEN" - indicating
POWER LOSS.
THIS IS VERY IMPORTANT; NEVER disengage this safety feature or fail to connect
the fusa link
as th is will vo id ai/ warranties. NEVER lay anything on lop of the release lid.
The area must be kept free of any objects or obstructions. A visual inspection by factory
personnel can easily de/emll'ne If the furnace over-heated and proper steps were fol-
lo wed. If the furnace is found to be deliberately or improperly used , all warran·
ties will be void .
To order a replacement Heat Fuse link: Call 800.875.4788. One replacement fuse
link will be included in the hardware pack of your furnace. Cost for each additional
haat fuse link, $4.95 -Part Number: FCFUSELINK -Heat Fuse Link.

CREOSOTE FORMATION AND THE NEED FOR REM OV AL:
When wood Is burned slowly,
It produces an org!lniC vapor which combines with expelled
molstum to lorm creosolEl The creosote vapors condense in Ihe relalively cooled chimney flue of
a $Iow burning /ira As a result, creosote residue accumul!ltes on th e flue lining, When ignited
th is creosote makes an extremaly hot /ire The chimney connector !lnd the chimney should tle
In spacted at least twice monthly during the heating Sf!!lson to determln" If a creosote tlulld-up has
occurred II creosotEl has accumulated it should tle removed to reduce risk of a chimney lire,
Ma i ntenance of the FCOS1600
At the tlaginmng of e!lch heating season, take time to thoroughly check your lurna ce a nd chimney
system Make sure thera 8re no le!lks where the metal panels are
Join ed or at the caulk lines Should
you lind a leak, hi-temp silicone
Will correct the problem, Check the doors for signs 01 rust. Should rust
devaiop, l
ighUy sand ex steel wool the &urftlCe !lnd follow-up With tllack, high tem~rature paint to keep the
doors looking
new_ Check Ihe gaskets II they are frayed and burnt, repla ce the gasket. Check the
chimney pipe for Signs of cr=te formallon, ~ you find creosote, thoroughly clean the chimney system
rep~ciflg the chimney cap se<::ure ly so rain or snow does not run down the chimney Into Ihe lireoox _If the
cap is removed for any length of time when the furnace is not In use, cover the pipe so no moisture gets
into the fireoox, Check the chimney pipe for holes or loosened connections - replace and secure as
necassary, Check the heat duct and cold alf return to tle sure they have not come loose or been
damaged If so, tighten or replace !IS needed. Check th e duct work lor any air leaks that Will affect the
furnace's perform!lnce -airtight duct work
Increas.es efficiency and furnace performance while delivering
higher STUs, Remove
any accumulated ashes al the end 01 the season By lollowing these procedures
your furneca
Will prOVide many years of 1I"0uble-free service.
ALWAYS:
C locatethe OSI6oo
on a leve l, solid, non-comllustitlle surf3ce.
C
F~low Ioc!II codes concerning in staHa~on reQUifements .
C Connect power
cord to a grounded t 10 outlet
C Connect cold!lir return to the house.
C Use
C~~ " A" HT2too All Fue l6" Chimney.
C Follow guidel
in es within thIS manu~ 1 regard in g tlum procedures.
C Operate furnace
With fuel door and ash drawer closed.
C Inspect the furnace several hmes a year to Insure furnace caulking Is adequate
C Inspect chimney
Pipe for creosote formanon.
C Use dry , 5easOfled hardwood· maximum length, 28 "- always keep your wood covered.
C Have access
to a backup generator In case 01 powerl ailure, minimum 01 2000 watts.
jIi[ VER ;
• Never allow anyone
to operate the furnace who Is not lam lTi ar with the unit
Operate furnace With spin draft Wide open unattended.
•
•
•
•
•
•
•
•
•
Operate With !hI! fu el door and ash drawer o~n .
Use gasoline, 011 or any other flammable IlQukllO start or maintain the fire.
Sum garbage,
plastIC . wood containing glue, paraffin or treated with chemical pres.ervauves.
Operate your furnace without a tlackup power supply (generator)
Fuel your furnace
With wei, unseasoned wood
Use SO ' angles when running duct work.
Operate the furnace without the ch imn ey attached.
Aiter the furnael!
in any way.
WARNING -RISK OF FIRE
•
DO NOT op<lr;;ote with fuel drsft exceeding OS " (19 9 Pa l In . of water column
•
DO NOT operate With fuel loading Of ash removal doors open.
• DO NOT store luel or other comtlus!itlle materiels with in marked inSl allation claarancea
• Inspect
and clean flues and chimney regularfy.
Ol n
gll r- Risk of FI «o or Explosion
• Do not tlum garllage, gasoline, drain oil or other flammatlle liquids
"

120VAC
"""".
SU PPL Y
FCOSI600
WIRING DIAGRAM
OUTDOOR FURNACE
"
SLOWER
M010R

FCOS1600 Parts Diagram
D
i
, ..
"
07

FCOS1600 PARTS LIST
RepaIr Part Number Off' shawn in «Bold~ type
1. Chimney Anchor Pl a te (Included with installation kit)
2. Hea t Dump ~ Cap with Hilrdware
l a. Hea t Fuselink - FCFUSE U NI<
3. Heat Dump Sp ring Brack et s for t op of Furnace (2)
4. E~ t ension Springs for Heal Dump
S. He at Dump Spring Bratkets for tid (2 )
6. Roof Panel
7. Inner Hat Channel
8. InnerTop Panel
9. Door Handle · FCO STHANOLE
9a. latch Cam (Not Shown)
1 0. Left Side Inner Panel
n. Left Side Outer Panel
12 . Staner Collar for 10" Insulated Heat Duct - FCOSIOCO L LAR (2 Included)
13. Starter Collar for 12" Cold Air Return -SNGCLR12 (lln(luded )
14. Hi tch Pin Clip (2)
15.
By ·Pass Damper Rod
16. By - PilSS Damper Plate
17 . Spring Handle
18 . Fuel Doo r Handl e· FCFOH
19. Fuel Door Latch
20. Fuel Door with Spin Drafts (2)
21. Fuel Door Ga5ke l, 5/8" -FC GSKTS8
22 . Door Pins- FCOP
23. Ouler Door Hinge
24. Weather
Resis t ~nl Front Door
25. Spin Dr ~ ft for Ash Pan · F CSO
26. Ash Drawer
27 . Right Side Inner Panel
28. Righ t Side Outer Panel
29. Fan Limit Center· F CF L CS "
3D. f~n limit Box & COver. FC OSFlCBOX
31.
Bottom Blower Housing Cover
32 . Rear Panel
33 . Blower Motor w/Capacilor' FCOSMOTOR
34. Blower Housing· FCB H
lS. Bl ower Housing Cover
36.
EleClri t ~1 C ontrol Center - F C16ECC
18

PROBLEM
1. Bugs found in wood.
2. Circulation blower win
not turn on.
3. Circulation blower I"\.Ins
continuously.
4. Circvl"tion blower vibrates
during o~ratlon.
S. Odor det ected In home
during Initial firing.
TROUBLESHOOTING
PROBABLE CAUSE
• Wood has rotted or h"s been
laying ar ound for an extended
per iod of time.
• Defective fan limit controi.
• · OW setting Is too Iowan
the fan limi t control.
• Defective fan
limit.
• Improper wiring.
• Sack draft damper in duct
line Is closed.
• Screw on squirrel cage Is not
tight.
• Balance we ights on squirrel
cage have become diSlocated.
• Defective main bearings.
• There Is an oily film
thil t re-
mained on the steel lIfter the
manufacturing process. Fi r ing
the unit hilS raised the t e m~ r ,, ·
t ur e of the fi rebox to a level that
Is sufficient to vaporize the resi-
due.
19
SUGGESTED REMEDY
Insp e ct the wood for obViOUS
signs of Insect infestation suth
lIS burrows or holes lInd avoid
using if possible. Do not store
Indoors.
Check by rola ting the knob to
"
ON" pOSitIon, the blower
should turn on. If the blower
doesn·t run, replace the
f<ln limit
control.
Pointers shOUld be set at 110
and 170 degrees.
Replace fan
lim it.
Review wiring diagram.
If wired
corr e ctl y, seek professional tiS-
slst"nce.
Open Oamper.
Check squirrel
tilge alignme nt
"nd position SO th"t it does not
drag on the ho us ing during ro-
t il tion; then tighten the screw
sufficiently
to f" sten the squir-
rel cage securely
to the sha ft .
You m"y attempt 10 "djust the
weights yourself to obtain an ac-
c
epl"ble bal"nce. If you are un-
SUCCessful, con tact your sup-
plier.
Return the blower to your
supplier for replacement.
This odor should disappear
li fter" few hours of usage.

PROBLEM
6. Smoke fr om the fire
chamber is puffing bad;;
through spi n drafts .
7. Down
drnll on ch imney
(iJused by one or
more of
the following:
TROUBLESHOOTING
PROBABLE CAUSE
• Chimney not high enough.
• Chimney blocked or dirty.
• Ch i mney has a cold spot
wh i ch inhibits exhaust dis-
charge from rising properly.
This symptom may occur in fac-
t
ory built chimneys bealuse the
Insulation haS settled or iJ 5eiJm
has ruptured. In masonry
chimneys, mortar loss may bE:
cauSi"9 the aspiration of cooler
outside
!lir Into the stack.
• There is an obstruction ou t-
side the chimney, such as a
tree.
• Chimney Is located too close
to
the peak of t he roof or does
not rise above It
to provide the
proper draft.
• Chimney Is located too dose
to another building.
• Obstruction In chimney.
• Excessive ash accumulation.
• Creosote build-up.
8. Excessive smoke dls-• InSUfficient draft.
charge from fuel door during
reloading.
9. FliJmes dischargirl9 from
fuel
door durlrlg reloading.
• Obstructed chimney or
clogged chimney cap.
• Cre<:>sote build-up.
• insufficient nMural draft or
an obstruction In the chi mney
system.
"
SUGGESTEp REMEPY
Chimney should be a min i mum
of 6' high.
Clean chimney.
Check entire chimney system for
structural integrity ilIOd leakage.
Correct
or repair as needed.
Remove obstr
uction .
Relocate chimney termination
Or increase height as required.
Relocate chimney termination.
Check enUre chimney system
Including stove pipe run. Cl e an
chimney to remove a ny fo reign
met ter.
Remove If necessary.
Clean chimney.
SEE #6
SEE #7
SEE #7
Open spin drafts.
SEE #6 AND #7