United States Stove Company WONDERCOAL 2847 User manual

Owners Manual
Model 2847
WONDERCOAL
AUTOMATIC COAL BURNING CIRCULATOR HEATER
*ASSEMBLY
*INSTALLATION
*OPERATION
*REPAIR PARTS
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WARNOCK HERSEY
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851171A 3/96
HOW TO ORDER REPAIR PARTS
Thismanualwillhelpyoutoobtainefficient,dependableservice
from the heater, and enable you to order repair parts correctly.
Keep this manual in a safe place for future reference.
Whenwriting,alwaysgivethefullmodelnumberwhichisonthe
nameplate attached to the inside of the cabinet door of the
heater.
When ordering repair parts or options, always
givethefollowinginformationasshowninthelist:
1. The PART NUMBER
2. The PART DESCRIPTION
3. The MODEL NUMBER: 2847
4. The SERIAL NUMBER:________________
Before installing your heater, fill in the serial number of your
heater in the space provided above.
United States Stove Company
227 Industrial Park Rd.
P.O.Box 151
South Pittsburg, TN 37380
[phone]
United States Stove Company
227 Industrial Park Rd.
P.O.Box 151
South Pittsburg, TN 37380
[phone]
SAFETY NOTICE:
If this heater is not properly installed, a house fire may result.
For your safety, follow the installation directions.
Contact local building or fire officials about restrictions and
inspection requirements in your area.
CAUTION:
Read all instructions carefully before starting the installation
or operation of this heater.
Improper installation may void your warranty.
DO NOT USE THIS HEATER IN A MOBILE HOME OR TRAILER
WONDERCOAL

TOOLS AND MATERIAL NEEDED
TOOLS
Pencil
6 Foot Folding rule or tape
Tin Snips
Drill, hand or electric
Drill bit, 1/8" dia.
(for sheet metal screws)
Gloves
Screwdriver (blade-type)
5/16" Nut Driver or
5/16" Socket w/Ratchet
MATERIALS
Chimney Connection- 6" Dia. Black
Steel (24 Ga. minimum): Straight or
Corrugated Elbow (as required)*
1/2" Sheet Metal Screws
6" Inside Diameter Underwriters
Laboratories (UL) listed Residential
Type and Building Heating Appliance
Chimney or lined, 6" existing
Masonry Chimney.
Floor Protector Material: 3' x 4'-6" as
specified on page 4.
Furnace Cement (Manufacturer
recommends: Rutland Code 78 or
Equivalent)
* Avoid adjustable elbows, they leak!
223
CIRCULATOR DIMENSIONS
Fig. 1
WONDERCOAL
32 1/4
16 1/8
33 1/2
4 1/8
8 5/16
19 1/4
Notes

1.
2.
3.
4.
5.
6.
7.
8.
22
RULESFORSAFEINSTALLATIONANDOPERATION
Read these rules and the instructions carefully.
SAFETYNOTICE:Ifthisheateris notproperlyinstalled,ahousefiremayresult. For
your safety, follow the installation directions. Contact local building or fire officials
about restrictions and installation inspection requirements in your area.
Check local codes. The installation must
complywith theirrulings. Donot install this
heater in a mobile home or trailer.
Alwaysconnectthisheatertoachimneyor
vent to the outside. Never vent to another
room or inside a building.
Do not connect a COAL burning heater to
an aluminum Type B gas vent. This is not
safe and is prohibited by all codes. This
heater requires connection to approved
chimneys:Eitherafactorybuilt6"UL103HT
or a lined and approved and recently in-
spected and cleaned masonry chimney
with a 6" flue, preferably round. A larger
masonry flue may be used, so long as the
flue-sectiondiameterisnotgreaterthan50
sq. in.
Thechimneyportion(whetherfactory-built
ormasonry)mustbetallenoughtoprovide
sufficient draft and safe exit of smoke and
combustionproducts.PleaserefertoPage
5.
Be sure that your Chimney is safely con-
structedandingoodrepair.Havethechim-
ney inspected by the Fire Department or a
qualified inspector (such as a Chimney
sweep). Your insurance company may be
able to recommend a qualified inspector.
Inspect chimney connector and chimney
twice monthly during the heating season
for any deposit of creosote or soot which
must be removed.
Provideairforcombustionfromoutsidethe
house into the room where the heater is
located. If the intake is not in the same
room, air must have free access to the
room.
CAST IRON PARTS MUST BE "SEA-
SONED" TO AVOID CRACKING. BUILD
ONLY SMALL FIRES ON FIRST USE.
To prevent injury, do not allow anyone to
use this heater who is unfamiliar with the
correct operation of the heater. Do not
allowchildren to use or inany way operate
this heater.
Forfurtherinformationonusingyourheater
safely, obtain a copy of the National Fire
Protection Association (NFPA) publica-
tion"UsingCoalandWoodStovesSafely"
NFPA No. HS-10-1978. The address of
the NFPA is Battery March Park, Quincy,
MA. 02269.
Keep the ash pit section free of excess
ashes. Do not allow ashes to stack higher
than the sides of the ash pan.*
DISPOSALOF ASHES- Ashes should be
placed in a metal container with a tight
fitting lid. Keep the closed container on a
non-combustible floor or on the ground,
well away from all combustible materials.
Keep the ashes in the closed container
until all cinders have thoroughly cooled.
Theashes may be buried inthe ground or
used as fertilizer.
CAUTION: The special paints used on
your heater may give off some smoke
while they are curing during first few fires.
Build small fires at first. The metal used in
constructionofthe heaterhas alight coat-
ingof oil. This could giveoff smokeand/or
odors when heater is used for the first
couple of times. This should disappear
afterashortperiod.Oncethisburn-offhas
occurred, it should not reoccur.
CARING FOR PAINTED PARTS- This
heaterhasapaintedoutsidejacket,which
isdurablebutwillnotstandroughhandling
orabuse.Wheninstallingyourheater,use
care in handling. Clean with soap and
warm water when heater is not hot. DO
NOT use any harsh chemicals (acids or
caustics) or scouring powder, as these
wear and dull the finish.
KEEP THE FEED DOOR, ASH DOOR
AND CABINET DOOR CLOSED AT ALL
TIMES EXCEPT WHILE TENDING THE
HEATER. DO NOT OVERFIRE THE
HEATER. THIS WILL HAPPEN IF THE
FEED DOOR, OR PARTICULARLY THE
ASH DOOR, IS LEFT OPEN DURING
OPERATION. UNDER EXTREME CON-
DITIONS THIS CAN PRODUCE DAN-
GEROUS RESULTS. AS A MINIMUM, IT
WILLALLOWTHEPAINTTODISCOLOR.
Use coal only. DO NOT USE the coal
bricks that are manufactured from coal
dust and a wax-type binder.
CAUTION: DO NOT TOUCH THE
HEATER UNTIL IT HAS COOLED.
ALWAYS WEAR GLOVES WHEN
REFUELING THIS UNIT OR WORKING
WITH METAL CABINET PARTS.
9.
10.
11.
12.
13.
14.
15.
*Never allow ashes to contact the grate(s).
3
F36 BLOWER KIT
AnOptionalBlower Kit isavailablefor the 2847 Wondercoalautomatic coal
burningcirculatorheater. Ifthiskitisnotavailablewhereyouhavepurchased
thisWondercoalheater,youcanpurchasetheF36BlowerKitdirectlyfromthe
factory. To order contact the United States Stove Company at the address
andtelephone numbergiven onthe backpage.

LOCATING THE HEATER
AS A LOCATION IS SELECTED,
KEEP THE FOLLOWING IN MIND:
1. The chimney connection should be as
possible.Theheatermusthaveitsownchimney
flue.Donotconnectthis unit to a chimney flue,
serving another appliance. If there is no chim-
ney near where you wish to place the heater,
youcan use aUL103HTResidentialType and
BuildingHeatingApplianceChimney(Fig.5,6,
6A & 6B).
2. Place the heater on solid masonry or solid
concrete. When the heater is used on a com-
bustible floor protector of one layer of 3/8"
millboard having a thermal conductivity of
K=0.84 BTU in./ft. 2 hr. Deg. F with 28-gauge
sheetmetaloraULListedfloorprotector.Have
the floor protector extend 16" beyond the door
sideoftheheaterandundertheconnectorpipe
in the back.
3. CheckFigures2,3,and4.Besureyouhave
the clearances shown from the heater and the
connector pipe to combustible surfaces. If you
have a solid brick or stone wall behind your
heater, you can place the heater as close as
youwishtothewall.Ifthewallisonlyfacedwith
brick or stone, treat it as a combustible wall.
CAUTION:
Keep furnishings and other
combustible materials away
from the heater.
421
Fig. 3
Fig. 2
Fig. 4
20"
21"
16"
8"
52 1/4"
20"
19 1/4"
44"
4 3/4"
NOTE: DASHED LINES SHOW
STRAIGHT UP AND THROUGH
THE WALL INSTALLATION
8" 32 1/4" 16"
FLOOR PROTECTOR
(TOP VIEW)
SIDEWALL
NON-COMBUSTIBLE
CONSTRUCTION IN
ACCORDANCE WITH
NFPA 211
WONDERCOAL
NOTE: BEFORE FIRING
HEATER
Slide firebricks toward the
rear so no gaps remain
between them.
LIST OF PROBLEMS POSSIBLE CAUSE SOLUTION
1. Smoking when feed A) Insufficient Draft. A) Set Thermostat high
door is open. B) Clogged chimney or B) Clean Chimney
chimney connector. C) Add raincap to chimney
2. Flame spillage when A) Insufficient Draft. A) Set Thermostat high
feed door is open. B) Smothering fire when B) Add fuel so as not to
adding fresh fuel. smother fire.
3. Creosote build-up A) Thermostat setting too A) Set thermostat higher to
low type fuel. attain higher fuel temp-
eratures. This will aid in
preventing build-up of
creosote.
4. Heater does not heat. A) Blower control set too A) Set blower control to a
low. higher temperature.
B) Insufficient flue draft. B) Set flue draft
TROUBLE SHOOTING TIPS FOR MODEL 2847

CHIMNEY CONNECTION
Two basic types of chimneys are ap-
proved for use with solid fuel: Factory-
built and masonry. Factory-built chim-
ney must comply with UL103HT stan-
dard.
Do not expect your stove or furnace to
create draft. Draft is not a function of the
appliance.Draftispurelyafunctionofthe
chimney. Modern stoves and furnaces
are much more airtight and efficient than
those of the past; and, therefore require
greater draft. A minimum of .05, mea-
sured in water column (gauges to mea-
sure chimney draft are readily available
at stove shops and are economical to
purchase or rent) is required for proper
drafting to prevent back-puffing, smoke
spillage, and to maximize performance.
Chimneysperform two functions -oneof
which is apparent: The chimney pro-
videsameansforexhaustingsmokeand
flue
Fig. 6
520
THIMBLE
COLLAR
PIPE
ELBOW
PIPE
NON-COMBUSTIBLE
WALL
FLOOR PROTECTOR
FLUE CONNECTION - NON-COMBUSTIBLE WALL
PIPE
FLOOR PROTECTOR
REFER TO CHIMNEY
MANUFACTURERS PARTS
AND INSTRUCTIONS
2 FT MIN.
10 FT. 3 FT.
MIN.
Fig. 5
Thru-the-Wall Installation
gases resulting from combustion of the
fuel. Secondarily, though, the chimney
provides "Draft" which allows oxygen to
be continuously introduced into the
appliance, so that proper combustion is
possible. As of April 1, 1987, all heaters
and furnaces manufactured by United
States Stove Company should be
installed using a factory built chimney
that meets the "Type HT" requirement of
UL 103 (when a factory - built chimney is
used).
*Sizethechimneytotheflueoutletonthe
stove. (6" outlet = 6" I.D. chimney)
*Avoidusingelbowsexceptasnecessary
(they reduce draft).
*Make sure all horizontal runs of
connector pipe go up hill (1/4" elevation
for each horizontal foot).
IMPORTANT
1
4
5
37
8
11
2
9
6
10
13
18
21
17
16
REPAIR PARTS AUTOMATIC COAL BURNING CIRCULATOR HEATER MODEL 2847 - INTERIOR
19
20
23
22
24
27
25
31
26
28
29
32
33
34
30
35
36
14
15 12
28
29

619
REPAIR PARTS LIST - MODEL 2847 (SEE PAGE 20)
AUTOMATIC COAL BURNING CIRCULATOR
Key No. Description Qty. Part No.
1 Shaker Handle 1 40045
2 Second Heat Shield 1 22030
3 Heat Shield 1 22110
4 Draft Damper Hinge Pin 1 17200
5 Draft Damper Frame 1 40075
6 Base 1 67859
7 Draft Control Damper 1 67132
8 Clip 1 83818
9 Coal Grate 1 40101
10 Grate Support 2 22536
11 Firebrick 10 89066
12 Firebox 1 68979
13 Front & Rear Liner 3 40100
14 Flue Collar 1 23234
15 Flue Collar Gasket 1 88032
16 Firebrick Retainer 2 40132
17 Hinge Pin 1 83872
18 Smoke Curtain 1 22090
* Smoke Curtain Bracket 2 22171
19 Coal Grate Frame 1 40102
Feed Door Assembly 68605
20 Feed Door 1 40199
21 1/4-20 Kep Nut 2 83250
22 Draft Wheel 1 40056
23 1/4-20x1" Machine Screw 1 83227
24 Door Handle 2 40091
25 Feed Door Rope Gasket 3.75FT 88033
26 Two-step Latch 1 22434
27 Wood Handle 1 89523
28 Flat Washer 2 83045
29 1/4-20 Kep Nut 3 83250
30 Latch Spacer 1 21467
Ash Door Assembly 67781
31 Ash Door 1 40187
32 Ash Door Gasket 2.5FT 88033
33 Latch 1 22108
34 Ash Pan 1 67444
35 Hinge Pin (Long) 1 23441
36 Flue Baffle 1 23249
* NOT SHOWN
FLOOR PROTECTOR
2 FT MIN.
10 FT.
MINIMUM 3 FT.
MIN.
APPROVED COWL
20"
MIN.
6" MIN. APPROVED
THIMBLE
60" MIN.
PIPE
FLOOR PROTECTOR
REFER TO CHIMNEY
MANUFACTURERS PARTS
AND INSTRUCTIONS
2 FT MIN.
10 FT. 3 FT.
MIN. 11 FT. MIN.
CHIMNEY CAP MANDATORY
Cathedral Ceiling Installation - Fig. 6A
Typical Masonry Chimney Installation - Fig. 6B

718
17
15
1
2
16
6
3
5
10
13
9
7
4
8
11
REPAIR PARTS AUTOMATIC COAL BURNING CIRCULATOR HEATER MODEL 2847 - EXTERIOR
14
WONDERCOAL
12
CAUTION:
NOT ALL FIREPLACES
ARE SUITABLE FOR
INSTALLATION OF A COAL
HEATER.
Many people may wish to convert an
existingfireplacetoheateruse.Usually,
safe connection of stovepipe to a ma-
sonrychimneyrequiresmoreeffortthan
connection to a prefabricated chimney.
Thefireplacemustbeclosedandsealed
atthedamperintheflue.Goodsealants
arehigh temperature caulking,ceramic
wool, and furnace cement. Always re-
member to inspect the masonry chim-
ney and fireplace. If necessary, clean
the flue and smoke shelf before begin-
ning your installation. Install the heater
intothechimneyso that the system can
be dismantled for cleaning and inspec-
tion.
Before deciding to convert your fire-
placeor existing chimney, keepinmind
thatolderfireplaces and their chimneys
are unsafe. They must be structurally
sound,andthefluelinermustbeingood
condition.Donotuse achimney if itis
unlined (should have a tile clay liner
to protect brickwork), have it relined
professionally.Clearancestocombus-
tiblesare explainedintheprevious sec-
tion on masonry chimneys. If you have
any questions regarding the condition
ofthe chimney,consultaqualified engi-
neer,competentmason,certifiedChim-
ney Sweep, or knowledgeable inspec-
tor.
Many prefabricated fireplaces fall into
the"zero-clearancefireplace"category.
This is a factory metal fireplace with
multilayeredconstruction.Itisdesigned
to provide enough insulation and/or air
coolingsothatthebase,backandsides
can be safely placed in close contact
with combustible floors and walls. Al-
though many prefabricated fireplaces
have been tested by nationally recog-
nized organizations for use as fire-
places, they have not been tested to
acceptheaters.Infact,theiruseassuch
may void the manufacturer's warranty.
Steel-lined fireplaces, on the other
hand, can be used with heaters. These
units use a 1/4-inch firebox liner and an
airchamberinconnectionwith8inches
of masonry to meet code. They contain
all the essential parts of a fireplace,
firebox, damper, throat, smoke shelf,
andsmokechamber.Manyofthemlook
exactly like a masonry fireplace and
must be checked closely for above re-
quirements before installing a coal
heater into them.
Another method frequently used by
some people is to vent the heater di-
rectly into the fireplace. This does not
meet code since the heater is being
vented into another appliance - the
fireplace. This method should not be
attempted because combustion prod-
ucts will deposit and build up in the
firebox or fireplace. Be certain not to
install a hazard in you house. You will
void your warranty with this installa-
tion.
VENTING INTO A FIREPLACE

178
FIREPLACE INSTALLATION
Connectionofthestovepipedirectlyinto
the existing masonry chimney over the
fireplace opening is the only approved
method. This installation performs bet-
ter, yielding easy to clean and inspect
forcreosote.Before beginning this type
of installation plan carefully; a high de-
gree of skill is required to insure safety.
An entry port for the stovepipe must be
cut through the chimney with minimum
damage to the fire clay liner. Some
involvedmeasurementsmayberequired
to locate the flue liner exactly. Before
cutting, take time to mark the size and
position of the entry port. Position the
entryport so that at least 8 inches ofthe
flue liner remains below the port.
Keep in mind that mantels and
combustible trim around the fireplace
must have adequate clearances from
the heater and stovepipe or must be
protectedinanapprovedmanner.Also,
be sure to leave at least 24" clearance
between the top of the stovepipe and
the combustible ceiling or other com-
bustibles.Placingthecenteroftheentry
port 2 feet below the ceiling will insure
proper clearance for 6 inch, 8 inch, and
10 inch stovepipes. Next, install a fire
clay (at least 5/8 in. thick) or metal
thimble, being sure that the thimble is
flush with the inner flue lining. Secure
thethimbleinplacewithrefractorymor-
tar. The thimble should be surrounded
on all sides with 8 inches of brickwork
(solid masonry units) or 24 inches of
stone.
Install the stovepipe as far as possible
into the thimble, but not past the inside
of the flue lining. There should be a
smallairspace(approximately1/2inch)
between the stovepipe and thimble,
allowing for expansion of the stove-
pipe. Seal this airspace with high-tem-
perature caulking or ceramic wool. Fi-
nally,besuretowire thedamperclosed
andapplythesamesealant youusedat
the stovepipe and thimble junction.
Do not use the Type B installation (not
illustrated in this manual), that is, vent-
ing up through the fireplace opening,
regardless of whether the fireplace
opening is closed.
MASONRY CHIMNEY have several
positiveattributes: If properly built, they
are quite durable, and most
homeowners consider them more at-
tractive perhaps than a non-enclosed
factory built chimney.
And,if the chimneyislocated within the
confines of the house (that is, not at-
tached to an exterior wall), its mass
alone will store heat longer and con-
tinue to release the heat long after the
fire has died. Masonry chimneys have
many disadvantages though.
Masonry chimneys constructed on an
exterior wall are exposed to cold out-
door temperatures, promoting greater
heater loss, higher accumulations of
creosote,andreduceddraftwhichleads
to poorer heater or furnace perfor-
mance.
Concrete block chimneys (when not
protected by a brick veneer) are inher-
entlyunsafe,resultinpoordraft,andare
subject to rapid deterioration. They do
not meet code and are not recom-
mended.
REPAIR PARTS
AUTOMATIC COAL BURNING CIRCULATOR HEATER
MODEL NUMBER 2847
(SEE PAGE 18)
KEY NO. PART NO. DESCRIPTION QTY.
1 89062 Door Knob 1
2 83005 10-24x1/2" Machine Screw 2
3 83033 8-32x1/4" PH Screw 1
4 83093 Spring Latch 1
5 83244 10-24 Kep Nut 1
6 67968 Cabinet Door Frame 1
7 86191 Thermostat Linkage Adjuster 1
8 85381C Control Panel Plate 1
9 89142 Thermostat Knob 1
10 67725 Cabinet Front 1
11 67967 Cabinet Left Side 1
12 24240 Flue Collar Ring 1
13 68350 Cabinet Top 1
14 67743 Thermostat Assembly 1
15 68505 Cabinet Back 1
16 89065 Door Hinge 2
17 67969 Cabinet Door 1
REPAIR PARTS LIST

916
INSTRUCTIONS FOR TWO-STEP LATCH OPERATION
1. Followtheseinstructionstooperate youunitsafely whenoperatingthefeeddoor.
2. Turn handle clockwise to the 12 o'clock position, pull the door open until you
engage the second step (Fig. 11).
3. Hold the door in that position for approximately 10 seconds.
4. Thentoopendoor,turn thehandlecounter clockwisetothe9o'clockpositionand
then continue to pull the door open. (Fig. 11A)
5. To close and latch the door, reverse steps 2 thru 4.
NOTE:
THIS NEW LATCHING MECHANISM MEETS CODES AND
PROVIDES MORE SAFETY FOR THE USER OF THIS STOVE.
NOTE:
DURING OPENING AND CLOSING OF THE FEED AND ASH DOORS
OF THIS HEATER, IT MAY SEEM THAT THE FIT OF THE DOOR IS
"TOO TIGHT". AS THE HEATER IS FIRED, THE GASKETING
"SETTLES" OR "SEATS" ITSELF IN THE DOOR. THE TIGHT FIT AT
THE FACTORY AND BEFORE THE HEATER'S INITIAL FIRING IS TO
INSURE A GOOD SEAL AFTER THE GASKETING "SETTLES".
Fig. 11 Fig. 11A
TYPE "A"
FIREPLACE
CONVERSION
Fig. 7
5/8" FIRECLAY
FLUE LINER
STOVEPIPE CONNECTOR
SEALED AT THIMBLE
HORIZONTAL 6" STOVEPIPE
(24 GAUGE) WITH 1/4"
RISE PER FOOT
6" STOVEPIPE ELBOW
CLEARANCE REDUCER
(FOR MANTEL)
6" STOVEPIPE - HAVING
THREE SHEET METAL SCREWS
PER JOINT OF STOVEPIPE
U.L. LISTED
FLOOR PROTECTOR
DAMPER THROAT
CLOSED AND SEALED
Most masonry chimneys have a
cleanout. If yours does, make sure it is
gasketed or otherwise sealed. A loose
fitting door will contribute greatly to the
draft problems.
If you have any question regarding
venting your appliance, feel free to
contact the factory at the address and
phonenumberonthisOwner'sManual.
You may also contact NFPA (National
FireProtectionAssociation)andrequest
NFPA Standard 211 (1984 Edition).
Their address is Battery March Park,
Quincy,Massachusetts02269.Another
helpful publication is NFPA Standard
908, available at the same address.
Specify 1984 Edition on either of the
above publications.

10 15
SERVICE HINTS
Do not expect a heater to draw. It is the
chimney that creates the draft. Smoke
spillage into the house or excessive
build-up of water or creosote in the
chimneyare warnings that the chimney
is not functioning properly. Possible
causes are:
1. Theconnection pipe maybepushed
into the chimney too far, stopping the
draft (Fig. 8).
2. Two heaters connected into the
same chimney flue.
3. Thesamefluebeingusedtoventilate
the cellar or basement. If there is a
cleanout opening at the base of the
chimney, it must be closed tightly and
sealed.
4. If the flue is too cool, water will
condense in the chimney and run back
into the stove. Creosote formation will
be rapid and may block the chimney.
Operatetheheateratahighenoughfire
to keep the chimney warm preventing
this condensation.
5. The chimney top may be lower than
another part of the house or a nearby
tree. The wind blowing over a house or
a tree falls on top of the chimney like
water over a dam, beating down the
smoke. The top of the chimney should
be at least 3 feet higher than any point
of the roof within 10 feet (Fig. 6).
6. Other chimney/flue inadequacies
covered elsewhere in this manual.
When coal is burned, the products of
combustion combine with moisture to
form a soot residue which accumulates
onthefluelining.Whenignited,thissoot
makes an extremely hot fire.
The chimney connector should be in-
spected at least twice monthly during
the heating season to determine if a
creosote buildup has occurred.
If creosote has accumulated, it should
be removed. Failure to remove creo-
sote or soot may cause a house fire.
Creosote may be removed by using a
chimneybrushorothercommonlyavail-
able materials.
Chimney fires burn very hot -- up to
2100 degrees F. If you experience a
chimney fire, immediately call the fire
department.Theyhavetheprofessional
meansfor extinguishing a chimney fire.
Onceachimneyfirehasoccurred,itcan
only be extinguished by removing its
sources of oxygen. This can be accom-
plishedbyshuttinganymechanicaldraft
device such as dampers, discharging a
CO2 (carbon dioxide) or halon fire ex-
tinguisherdirectlyintothestovethrough
an appropriately placed cleanout. If us-
ing a Halon extinguisher, please re-
memberthat is totally displacesoxygen
and could become a hazard in itself if
enough were discharged into a living
space.
CAUTION
A chimney fire may cause ignition of wall studs or rafters which you thought
were safe distance from the chimney. If you have a chimney fire, have your
chimney inspected by a qualified person before using again.
NOTE:
A draft reading of .05 to .06 w.c. is suggested for proper burning of this unit
when using bituminous coal as fuel. When using anthracite coal, this draft
readings is a minimum reading.
CHIMNEY MAINTENANCE
CREOSOTE-FORMATION AND NEED FOR REMOVAL
RULES FOR CONNECTOR PIPE INSTALLATION
1. Thecrimpedendofthestovepipefits
inside the heater flue collar. Install ad-
ditional pipe and elbow with the
CRIMPED END TOWARD THE
HEATER. This will allow any
condensationintheflueto runbackinto
theheater. Smokewillnotescapewhen
installed in this manner.
2. Slope any horizontal pipe upward
toward the chimney at least 1/4 inch for
each foot of horizontal run.
3. You must have at least 18 inches of
clearance between any horizontal pip-
ing and the ceiling.
4. The pipe cannot extend into the
chimney flue. (Fig. 8)
The door knob is mounted inside of the
cabinet door to facilitate shipping and
must be reversed for proper usage.
To get cabinet door open, place hand
under cabinet frame (right hand side
cabinet door side) and push door out.
INSTALLING CABINET DOOR KNOB:
1. Removethemachinescrewanddoor
knob (Fig. A).
2. Placedoorknobonoutsideofcabinet
door. Then place machine screw
through hole and into door knob and
tighten (Fig. B).
RIGHT WRONG WRONG
Fig. 8
5. Seal each connector pipe joint with
furnace cement. Also seal the pipe at
the chimney.
6. Use 3 Sheet Metal screws at each
joint to make the piping rigid.
7. Itis recommended thatnomorethan
two 90 degree bends be used in the
stovepipe installation as more than two
may decrease the amount of draw and
possible, use only corrugated (nonad-
justable) elbows. They are much more
airtight.
8. The chimney connector must not
pass through an attic or roof space,
closet,oranyconcealedspace,orfloor,
ceiling, wall or combustive construc-
tion.
CABINET DOOR CATCH ASSEMBLY
Fig. B
Fig. A

OPERATING INSTRUC-
TIONS
FUEL
Eggsize Bituminous coal forresidential
furnaces, or any of the specially pack-
aged fireplaces coals can be used.
Coal with a low ash content (2% to 6%)
is recommended. (See Page 12 & 13)
NOTE:Storecoalinadry,well-venti-
lated area.
LIGHTING
1. Set the thermostat on "High" for
maximum draft.
2. Open the feed door and place paper
andkindling on the grate for startingthe
fire.
3. Light fire and close feed door.
4. Add about 15 pounds of coal de-
pending on model after fire is burning
briskly. Use care not to smother the
kindling fire.
5. Set thermostat higher or lower for
desired temperature.
ADDING FUEL
Whenstartingafire,addsmallamounts
of fuel periodically as required (enough
toburnfor3to5hours).Asyou become
more familiar with the operation of your
heater, it is possible to add coal to burn
for longer durations of between 8 to 12
hours, but doing so carelessly will pro-
mote incomplete combustion and con-
siderable sitting, along with a very dirty
inefficient fire.
1. SetthermostattoHIGHbeforeopen-
ing feed door.
2. Coal Fire- Never smother the fire
whenaddingcoal(seeCAUTION).Gas
accumulation and a mild smoky explo-
sion will occur:
a. Add fresh kindling if the bed of
coals has cooled.
b. Add up to 20 lbs. of coal. Never
add coal above top of the firebrick.
c. Stir the coal and watch the fire.
Be sure the new coal is burning
before you close the doors and turn
the thermostat down. 11
14
3. Shake Grates vigorously back and
forth to dump ashes into ash pan. Do
this at least once every 12 hours of
operation.
4. Empty ash pan regularly. Do not
allowashestobuilduptograte,asgrate
will warp and burn out, and you might
spill the ashes when removing the pan.
Dispose of hot ashes properly. (See
note 11 on page 3)
CAUTION: BUILD A FIRE ON INTE-
GRAL GRATE THAT IS PROVIDED
WITH THE HEATER.
MINIMUM FIRE
The burning rate at the low setting can
be further adjusted by opening or clos-
ing the minimum fire air shutter (Fig.
10,Pg. 14) on the draft control door.
1. Partiallyclosetheshuttertomakethe
fuel burn longer.
2. Open the shutter, exposing a large
opening, to reduce the formation of
creosote on soot (see notes on Chim-
ney Maintenance).
3. Do not operate the heater with the
minimum fire air shutter completely
closed.
CAUTION: DO NOT OVERFIRE THE
HEATER,ASSTATEDEARLIER,THIS
CAN PRODUCE A DANGEROUS
CONDITION AND EVEN CAUSE A
HOUSE FIRE. IF ANY PORTION OF
THE HEATER OR ANY CHIMNEY
CONNECTOR GLOWS RED OR DIS-
COLORS, THE HEATER IS BEING
OVERFIRED.
CAUTION: DO NOT OPERATE THIS
HEATER WITH FEED OR ASH DOOR
OPEN. THIS HEATER IS DESIGNED
FOR THERMOSTATIC OPERATION.
OPERATION WITH EITHER DOOR
OPEN WILL OVERHEAT AND DAM-
AGE THE HEATER.
CAUTION: NEVER STORE FLAM-
MABLE LIQUIDS, ESPECIALLY
GASOLINE,IN THEVICINITY OFTHE
HEATER.
Fig. 10
NOTE: More than one recalibration
may be necessary. At room temp.
(72*F) and "Low" setting, the draft
damper door should be closed.
CAUTION: NEVER USE THE MANU-
FACTURED COAL BRICKS THAT
ARE MADE FROM COAL DUST AND
A WAX-TYPE BINDER.
WARNING: THE USE OF WOOD IN
THIS STOVE EXCEPT FOR COAL IG-
NITIONPURPOSES,ISA VIOLATION
OF FEDERAL LAW.
CAUTION: GASES THAT ARE
DRIVEN FROM FRESH COAL MUST
BE BURNED OR THEY WILL ACCU-
MULATE AND EXPLODE. NEVER
SMOTHER A FIRE WHEN ADDING
FRESH COAL.
CAUTION: NEVER USE GASOLINE,
GASOLINE-TYPE LANTERN FUEL,
KEROSENE, CHARCOAL LIGHTER
FLUID, OR SIMILAR LIQUIDS TO
STARTOR"FRESHENUP"AFIRE IN
THE HEATER.
ADJUSTING THE THERMOSTAT
The thermostat control was calibrated
atthefactory.Theoperationoftheheater
may require a change in calibration.
Calibrationadjustmentsshouldbemade
at room temperature.
If the room temperature is not satisfac-
tory, the thermostat operating range
may be changed as follows:
A. To increase the amount of heat at a
"HIGH" setting, adjust the wire link-
age to increase the draft damper
opening (Fig. 10).
1. Unhook linkage wire at point C
2. Take point A in left hand and B
right hand then turn B clockwise
about 3 turns.
3. Then hook linkage wire back to
draft control damper door at
point C.
B. To decrease the amount of heat at
"LOW" setting:
1. Check feed and ash doors to be
sure that they are closed tightly.
2. Check the connector pipe to see
that it is sealed in the flue collar
and at all joints.
3. If no air leaks are found, adjust
linkage the same as above,
except turn B counterclockwise
about 3 turns.
C. Adjusting the minimum Air Shutter:
The minimum air shutter has an
infinite number of settings. Several
adjustments may be necessary for
the unit to work most effectively for
your particular installation.
1. The minimum air shutter may be
adjusted to the closed position in
installations where the draft is
"above normal". Generally, .06
w.c. or above would be consid-
ered "above normal".
2. In installation where the draft is
"below normal", the minimum air
shutter would be adjusted toward
the open position.
MINIMUM FIRE
AIR SHUTTER
(C)
(B)
(A)

12 13
Your Wondercoal is capable of burning both
bituminous and Anthracite coal. Anthracite is
the best coal fuel because its long even burn
time, high heat output, and cleanliness make
ita good choice for thehome. However, keep
in mind it is a much more difficult fuel to use
and requires more care and patience.
SIZE OF COAL: Most sizes of bituminous
coal will work in your Wondercoal Heater; for
best results we recommend large nut coal to
smalleggcoal(1-3/4"diameterto4"diameter).
When burning anthracite, use egg or broken
with sizes between 2-5/16" and 4-3/8". Note
thatitisimportanttothelifeofyourstovetobuy
coal which has been sized and cleaned.
Cleaning insures removal of rocks and other
materials.
STOVEOPERATION: Allcoalfiresshouldbe
startedwithwoodwhichwillallowthefiretoget
hot enough to ignited the coal. The Best
ignition fires utilize dry pine or other resinous
soft woods as kindling, with hard wood (oak,
hickory, ash) added to increase the heat prior
to adding the coal.
BITUMINOUS: Once your kindling and wood
fire has produced a bed of well established
coalsstart adding coal in layersallowing each
to ignite before adding more. Bituminous has
a high volatile content and, as a result, should
be fired with the "conical method" - with the
highest portion of your firebed in the center of
the firebox. The first flames will be long and
generally orange or yellow and produce quite
a bit of smoke. As the gases burn off the
flames become shorter, change color and
produce less smoke.
Once the fire is WELL ESTABLISHED add
coal to the center of the firebox forming the
cone. Burning in this fashion allows heat to
drive off the volatile gases, and turbulence
createdincreasestheburnefficiency. Youwill
have to experiment with your particular setup
as no two chimney's and installations are
goingto bethe same. Justremember toallow
enough secondary air to enter and keep your
stove pipe damper open so that volatiles are
properly burned. Before refueling, take the
time to break up the cone a little with a poker,
especially if it has caked over or formed a
crust. But,becarefulnottomixthecoalasthis
increases the chances of forming clinkers.
Whenshakingthegratebe gentle. Justafew
short movements - front to rear - are better
than a lot of agitation. The objective is to
remove a small amount of the ashes without
disturbing the fire. Stop when you see a glow
in the ashes or the first red coals fall into the
ash pan. Excessive shaking wastes fuel and
can expose the grate to very high tempera-
tures which can cause warpage or burnout.
For overnight operation (long duration burn
time) shake the fire and add coal, retaining
your center cone. Once the volatiles are
burnedoffclose thefeed doorandadjust your
stovepipe damper. Then adjustyour thermo-
stat to the desired heat level.
You will have more MAINTENANCE with
bituminous than with anthracite coal as more
soot will collect on heating surfaces and in
pipes, requiring more frequent cleaning.
ANTHRACITE: Before starting the fire open
the stove pipe damper, turn the automatic
thermostat to high, open the ash pit door and
feed door, place newspaper and finely split
kindlingonthegrate,lightthepaper,addlarger
hardwoodafterthekindlingisburningbrightly.
CAUTION: Never use gasoline, lantern
fuel, kerosene, charcoal lighter fluid, or
other flammable liquids to start or freshen
up a fire in this heater. Place the larger
pieces of wood on the fire so that are slightly
separated and form a level for the addition of
coal. It will take 10 to 20 minutes before this
wood is thoroughly ignited. Adding coal too
soon will cut the air supply and smother the
fire.
Add a thin layer of coal (preferably smaller
chunks) to the wood fire, being careful not to
disturb it too much or cut off the draft. Then,
add a second heavier layer after the coal is
ignited and burning well. If necessary, add a
third layer to bring the coal up to the top of the
BANKING THE FIRE: For extended
operation,suchasovernight,youwillneedto
bankthefire. Todosoheapcoalupalongthe
sides and back of the firebox so that the fire
gradually burns it over a longer period of
time. Youwillalsoreducetheintensity of the
fire without letting it go out. Follow the same
procedureas for refueling. If possible, avoid
shaking, as a heavier layer of ash will help
reduce the intensity of the fire during this
time. After loading let the fire establish itself
forabout30minutes. Thencloseyourdamper
and automatic control to the point where the
house does not become too cold. It is
importantthatyoubeginbankingearlyenough
before retiring or leaving that you can make
necessary adjustments after the fire is well
established.
To revive a coal fire that is almost out, you
should (1) open the ash door and stove pipe
damperandclosethespindamper(Fig.9)on
the door to get a good enough draft through
the grate. (2) Place a thin layer of dry coals
overtheentiretopofthefire. DONOTPOKE
OR SHAKE THE FIRE AT THIS TIME! (3)
After the fresh coal has become well ignited
shake the grate (just a little) and you will be
ready to refuel.
DO NOT burn coke, charcoal, high volatile
bituminous coal, sub bituminous, lignite or
cannel coal (sometimes called channel or
candlecoal). NEVERburnwaxorchemically
impregnated sawdust logs - their intended
use is for fireplaces only.
front liner (not above!). Be sure you have
closed your ash door.
Before adding further fuel, be sure you leave
ared spot of glowing coalsin the center of the
firebox to insure that you have not smothered
thefireandtohelpignitethegasesgivenoffby
the new charge. A deep charge will give a
moreheatandalongerfirebutitmaytakeone
to two hours before the whole bed is fully
ignited.
Whenthefireiswell establishedandtheroom
isbecomingwarm,partiallyclosethedampers.
Youwillhavetoexperimentwithyourparticular
setting of all dampers and controls as your
chimney provides the draft necessary to not
onlyexhaustthesmoke,buttopullcombustion
airintotheheateraswell-andnotwochimney's
performthesame. Underidealdraftconditions
you should be able to turn the secondary air
supply on the feed door to a near closed
position- but leave the ashpit damperat least
partially open to prevent the fire from going
out. Adjust the stove pipe damper to reduce
the draft on the fire. With anthracite you will
see short blue flames above the coal, except
when the fire is started or a new charge is
added. If,however, there is no flame then the
fire needs more air from the bottom (unless it
is near the end of its burn cycle and needs to
be recharged).
Only when the coal is burned down to half its
originaldepthitistimetoaddfreshcoal. When
doing so, open your stove pipe damper and
turn your thermostat damper to high, which
will allow the fire to burn off any accumulated
gases. Open the feed door, and with a small
rake, hoe or hooked poker pull the glowing
coals to the front of the firebox. Try not to
disturb the fire too much. Next, add a fresh
chargetotheback beingcarefulnottosealoff
thetop. Closethefeeddoorbutleavethespin
damper (Fig. 9) open for a few minutes until
the until the volatile gases have burned off. It
is not necessary to shake down the ashes
each time you refuel your Wondercoal.
Experience will be your best teacher.
A draft reading of -.05 to -.06 in w.c. is
required for anthracite to burn.
C
L
O
S
E
D
O
P
E
N
Fig. 9
BURNING COAL IN YOUR WONDERCOAL CIRCULATOR