United States Stove Furnace 1537G User Manual

TM  
Model 1537G  
OWNERS MANUAL  
SOLID FUEL  
WARM AIR FURNACE  
*FOR PARALLEL INSTALLATION WITH EXISTING  
FORCED AIR-GAS OR OIL FIRED FURNACE.  
*FOR INSTALLATION AS A CENTRAL FURNACE  
*THE 1537G CLAYTON FURNACE HAS BEEN  
APPROVED FOR U.S. INSTALLATIONS ONLY.  
IMPROPER INSTALLATION MAY VOID  
YOUR WARRANTY  
CAUTION:  
READALLINSTRUCTIONSCARE-  
FULLY BEFORE STARTING THE  
INSTALLATION OR OPERATING  
THE FURNACE  
DO NOT USE THIS FURNACE  
IN A MOBILE HOME OR TRAILER  
UNITED STATES STOVE COMPANY  
A
E
S
T
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S
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O
227 Industrial Park Road  
P.O.Box 151  
South Pittsburg, TN 37380  
(423) 837-2100  
T
VE  
I
WARNOCK HERSEY  
N
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S
C
U
S
R
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M
P
A
851340 5/98  
 
CAUTION LABELS  
Your Furnace has the following labels. Read and Obey all labels.  
DANGER: RISK OF FIRE OR EXPLOSION.  
DO NOT burn garbage, gasoline, drain oil, or other flammable liquids.  
WARNING: FIRE HAZARD.  
DO NOT operate with fire draft exceeding .06 inches w.c.  
DO NOT operate with fuel loading or ash removal doors open.  
DO NOT store fuels, paints, thinners, flammable liquids, or other highly  
volatile substances in the furnace room.  
CAUTION: HOT SURFACES  
Keep children away.  
Do not touch during operation.  
CAUTION!  
INSPECTFLUEPIPES, FLUEPIPEJOINTSANDFLUEPIPESEALSREGULARLY  
TO ENSURE THAT SMOKE AND FLUE GASES ARE NOT DRAWN INTO, AND  
CIRCULATED BY, THE AIR CIRCULATION SYSTEM.  
CAUTION!  
CLEANOUT OF THE HEAT EXCHANGER, FLUE PIPE, CHIMNEY, AND DRAFT  
INDUCER (IF USED), IS ESPECIALLY IMPORTANT AT THE END OF THE  
HEATINGSEASONTOMINIMIZECORROSIONDURINGTHESUMMERMONTHS,  
CAUSED BY ACCUMULATED ASH.  
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 installation inspection  
requirements in your area.  
3
 
RULES FOR SAFE INSTALLATION AND OPERATION  
Read these rules and the instructions carefully. Failure to follow them will cause a  
hazard that could result in death, serious bodily injury, and/or property damage.  
1. Check your local codes. The installation must comply with their rulings.  
2. Do not install this furnace in a mobile home or trailer.  
3. Always connect this furnace to a chimney and vent to the outside. Never vent to another  
room or inside a building.  
4. Do not connect this furnace to an aluminum Type B gas vent. This is not safe and is  
prohibited by the National Fire Protection Association Code. This furnace requires a  
masonry or Listed Factory Built Chimney for residential type or Building Heating Appliance  
Chimney. Usea6"diameter chimneyorlarger,thatishighenoughtogiveagooddraft.(See  
page 7)  
5. Besurethatifamasonrychimneyisused,itissafelyconstructedandin goodrepair. Have  
the chimney inspected by the Fire Department or an inspector.  
6. Inspectchimneyconnectorandchimneybeforeandfrequentlyduringthe heatingseason  
for any deposit of creosote or soot which must be removed (See Chimney Maintenance,  
page 15).  
7. Provide air for combustion into the room where the furnace is located. If the intake is not  
in the same room, air must have free access to the room.  
8. CAST IRON PARTS MUST BE "SEASONED" TO AVOID CRACKING, BUILD ONLY  
SMALL FIRES ON FIRST USE.  
9. To prevent injury, do not allow anyone to use this furnace who is unfamiliar with the  
correct operation of the furnace.  
10. For further information on using your furnace safely, obtain a copy of the National Fire  
Protection Association (NFPA) publication "Chimney's, Fireplaces and Solid Fuel Burning  
Appliances"NFPA211. TheaddressoftheNFPAisBatterymarchPark,Quincy,MA02269.  
11. Keep the ashpit section free of excess ashes. Do not allow ashes to stack higher than  
the sides of the ash pan.  
12. DISPOSAL OF ASHES- Place ashes in a metal container with a tight fitting lid. Keep  
the closed container on a noncombustible floor or on the ground, well away from all  
combustible materials. Keep the ashes in the closed container until all cinders have  
thoroughlycooled. Theashesmaybeburiedinthegroundorpickedupbyarefusecollector.  
13.CAUTION-Thespecialpaintsusedonyourfurnacemaygiveoffsome smokewhilethey  
are curing during first few fires., Build small fires at first. The metal used in construction of  
the furnace and duct work has a light coating of oil. This could give off smoke and/or odor  
from registers when furnace is used for the first time. This should disappear after a short  
period of time. Once this burn-off has occurred, it should not reoccur.  
14. CARING FOR PAINTED PARTS- This furnace has a painted outside jacket, which is  
durable, butitwillnotstandroughhandlingorabuse. Wheninstallingyourfurnace, usecare  
in handling. Clean with soap and warm water when furnace in not hot. DO NOT use any  
acids or scouring soap, as these wear and dull the finish. DISCOLORATION WILL OCCUR  
IF THE FURNACE IS OVERHEATED. FOLLOW OPERATING INSTRUCTIONS  
CAREFULLY.  
Your Furnace is designed to be installed in a parallel air flow arrangement with a gas  
or oil-fired forced air upflow-type central furnace, or it may be installed as a central  
furnace.  
4
 
HOW THE FURNACE FUNCTIONS  
PARALLEL INSTALLATION: (U.S. ONLY)  
Your CLAYTON Furnace is designed  
tobeasupplementalorcentralheatingsource  
for your home. This Solid Fuel Furnace may  
be installed in conjunction with a properly  
operating central furnace that is listed or cer-  
(See Optional Wiring Diagram, Page 13, Fig.  
14) The design is such that when the blower  
comes on, the blower on the central system  
also comes on. The blower will only come on  
when the temperature in the plenum has  
reached the setting on the blower control.  
Thisistoinsurethatthereissufficientwarmair  
in the system to make it efficient for the unit to  
operate. When the central system thermostat  
calls for heat, the central system will operate  
by the burner igniting and the blower coming  
on. It is possible that both systems will op-  
erate simultaneously. It is recommended that  
for the most efficient use of your CLAYTON  
Furnace, thatitbefiredasmuchaspossiblein  
order to reduce the demand on your existing  
central heating system. This unit has an op-  
tional forced draft kit that operates from a wall  
thermostat. Whenthetemperaturefallsbelow  
the setting on the wall thermostat, the forced  
draftwillcomeon(U.S.StoveOption11/DKU)  
The warm air supply outlet of the CLAYTON  
Furnace shall not be connected to the cold air  
returnofthecentralfurnace,becausethepos-  
sibility exists of components of the central  
furnace overheating and causing the central  
furnace to operate other than is intended.  
tified in accordance with nationally  
recog-  
nized safety standards and equipped with the  
required controls and other safety features  
and which has been installed in accordance  
with appropriate standards of the National  
Fire Protection Association with installation  
clearances specified in the  
furnace name-  
plate marking. The installation must be ac-  
complished by a qualified agency (one who is  
engaged in, and is responsible for, or is thor-  
oughly familiar with the  
installation and  
operationofthegas, oil, andsolidfuelburning  
heating appliances, who is experienced in  
suchwork,familiarwithalltherequirementsof  
the authority having  
installation shall be in strict accordance with  
themanufacturer's installationinstructions  
jurisdiction.) The  
furnished with the solid fuel furnace.  
The chimney connector of the furnace is  
to be installed to provide clearances to com-  
bustible material not less than specified in the  
individual classifications and marked on the  
furnace. The chimney connector must be  
connected to a chimney suitable for use with  
residentialtypeorbuildingheatingappliances  
which burn solid fuel.  
The Furnace is designed to operate in  
either parallel or series air flow arrangement  
with the central furnace or as a central fur-  
nace.  
CENTRAL FURNACE INSTALLATION: As  
a central furnace, the unit functions  
inde-  
pendently of any other system. The blower  
willcomeonwhentheplenum temperature  
reaches the setting on the blower control.  
5
 
DIMENSIONS OF FURNACE  
49-1/8"  
FIGURE 1  
1537G  
32-1/8"  
24-1/16"  
1-3/4"  
33-7/8"  
40-11/16"  
9"  
6
 
LOCATING THE FURNACE  
18"  
6" CHIMNEY  
1.The furnace should be located in the  
same room as the central system  
and as close as possible, but not  
closer than 9". There should be no  
wall between the furnace and the  
warmairoutletductthatisconnected  
directly to the warm air outlet plenum  
of the central furnace. (See Fig. 2)  
CENTRAL  
FURNACE  
12"  
9"  
48"  
2.  
The unit will require installation with  
the following clearances:  
Figure 2  
Unittosidewall...............12"(305mm)  
Unit to backwall............30"(760mm)  
Chimney connector pipe to sidewall  
.....................................21"(530mm)  
Chimney connector pipe to backwall  
.....................................18"(460mm)  
Hot air ducts to combustibles  
.......................................6"(150mm)  
(Refer to Fig. 2 & 3)  
18"  
6" SOLID DAMPER  
6" BAROMETRIC  
DRAFT REGULATOR  
(OPTIONAL)  
18"  
Place the furnace on a noncombus-  
tible floor.  
3.  
4.  
Check figures 2 and 3. Be sure you  
have the clearances shown from the  
furnace and the connector pipe to  
combustible surfaces. If you have a  
solid brick or stone wall behind your  
furnace, you can place the furnace  
ascloseasyouwishtothewall. Ifthe  
wall is only faced with brick or stone,  
treat it as a combustible wall.  
NON-COMBUSTIBLE FLOOR  
Figure 3  
7
 
THIMBLE  
6" ELBOW  
6" SOLID DAMPER  
6" BAROMETRIC  
DRAFT REGULATOR  
(OPTIONAL)  
6" CHIMNEY  
CONNECTOR  
NON-COMBUSTIBLE  
WALL  
6" ELBOW  
CHIMNEY CONNECTION  
Fig. 4  
MASONRY CHIMNEY  
Before using an existing masonry chimney, clean the chimney and inspect the flue liner to be sure  
it is safe to use. Make repairs before attaching the furnace. See page 4, item 5. Look at Fig. 4.  
The connector pipe and fittings you will need to connect directly to a masonry chimney are shown.  
The chimney connection should be as short as possible.  
If the connector pipe must go through a combustible wall before entering the masonry chimney,  
consult a qualified mason or chimney dealer. The installation must conform to local fire codes, and  
N.F.P.A. 211.  
DO NOT CONNECT THIS FURNACE TO A CHIMNEY FLUE SERVING ANOTHER  
APPLIANCE.  
The chimney used for a furnace must not be used to ventilate the cellar or basement. If there is  
a cleanout opening at the base of the chimney, close it tightly.  
REFER TO CHIMNEY  
2' MIN.  
MANUFACTURER'S  
INSTRUCTIONS AND  
PARTS.  
10'  
3' MIN.  
Fig. 5  
6" SOLID DAMPER  
6" BAROMETRIC  
DRAFT REGULATOR  
(OPTIONAL)  
6" CHIMNEY CONNECTOR  
6" ELBOW  
LISTED FACTORY BUILT CHIMNEY  
Carefully follow chimney manufacturer's instructions. Use only a Listed Residential Type or  
Building Heating Appliance Chimney. If your chimney starts at the ceiling (Fig. 5), you will need  
enough 6" pipe to reach the ceiling.  
The top of the chimney must be at least 3 feet above the roof and be at least 2 feet higher than any  
point of the roof within 10 feet (Fig. 5).  
8
 
RULES FOR CONNECTOR  
PIPE INSTALLATION  
1. The crimped end of the chimney connector fits  
insidethefurnacefluecollar. Installadditional chim-  
ney connectors and elbow with the CRIMPED END  
TOWARD THE FURNACE. This will allow any  
condensation in the flue to run back into the furnace.  
Use 6" dia. steel pipe and elbows for connection to  
chimney. Never use less than 24 gauge and  
al-  
though blued steel is satisfactory, high temp painted  
black is much more desirable.  
2. Slope any horizontal pipe upward toward the  
chimney at least 1/4 inch for each foot of horizontal  
run.  
RIGHT  
WRONG  
WRONG  
3. You must have at least 18 inches of clearance  
between any horizontal piping and the ceiling.  
(See Fig. 3)  
Fig. 6  
4. The chimney connector must not extend into the  
chimney flue. (See Fig. 6)  
5. Seal each chimney connector pipe joint with fur-  
nace cement. Also seal the pipe at the chimney.  
6. Use 3 sheet metal screws at each chimney pipe  
joint to make the piping rigid.  
7. The chimney connector may include a section for  
abarometricdraftregulatorbetweenthefurnaceand  
the chimney (Fig. 4,5, &7). The barometric draft  
regulator must be installed in the same room (same  
pressure zone) as the furnace.  
8. Install the barometric draft regulator strictly in  
accordance with the instructions that are provided  
with the barometric draft regulator.  
9. A solid damper must be used in the chimney  
connecting pipes between the flue collar and the  
chimney. When used in conjunction with a baromet-  
ric draft regulator, the solid damper must be placed  
between the barometric and the chimney. (See Fig.  
4,5,7)  
NON-COMBUSTIBLE  
INSTALLATION PER  
NFPA 211  
6" SOLID DAMPER  
6" BAROMETRIC  
DRAFT REGULATOR  
(OPTIONAL)  
MEASURE FLUE  
DRAFT HERE  
Adjusting the Barometric Draft Regula-  
tor  
1. Drill a hole in the chimney connector within 18" of  
the flue collar below the barometric draft regulator  
just large enough for the tube of the manometer.  
2. Build a fire after all chimney connections have  
been made.  
Fig. 7  
3. Use a manometer to measure the draft in the flue.  
4. Adjust the Barometric Draft Regulator to obtain a  
draftof0.05-0.06"W.C. understablefireconditions.  
9
 
ASSEMBLY OF FURNACE  
Your furnace requires the following items  
to be assembled or installed by the service  
person:  
Feed Door Pull Handle  
Feed Door Locking Handle  
Blower(s) and Blower Controls  
Electrical Connections  
Remove all parts from inside the furnace  
and inspect for damage, including the  
firebrick as some breakage could occur  
during shipment.  
Assemble the feed door pull handle as  
shown in Figure 8. Install thermostat  
assembly and cover (complete with  
handle) as illustrated in Figure 8.  
Align thermostat control knob with flat on  
thermostat control shaft and press onto  
shaft. (See Fig. 8)  
Attach feed door locking handle as in  
Figure 9 with screws and nuts provided.  
Note: Slotted holes are for adjustment of  
handle. Adjust handle until some  
pressure is required to lock feed door  
during firing sequence.  
1.  
2.  
Fig. 8  
3.  
4.  
Fig. 9  
Honeywell  
FAN/LIMIT  
CONTROL  
Install Honeywell Fan/Limit Control on  
rear of furnace cabinet as shown in  
Figure 10.  
Remove blower(s) from carton(s).  
Remove junction box cover. Attach clip  
nutsasinFigure10. Installblower(s)and  
gasket(s) with 1/4"-20x3/4" bolts as  
shown.  
Wire right side blower first (See wiring  
diagram, Fig. 11) and replace cover on  
junction box on blower.  
Wire left blower same as above and  
replace cover.  
5.  
6.  
4" ELECTRICAL  
JUNCTION BOX  
BLOWER  
ASSEMBLY  
7.  
8.  
Check operation of shaker grates with  
grate handle before operating furnace.  
CLIP NUTS  
(DO NOT USE CLIP NUT  
ON UPPER CENTER HOLE)  
GASKET  
(MODEL 1537G- 2 BLOWERS)  
Fig. 10  
10  
 
LOAD  
FAN  
LINE  
LOAD  
LIMIT  
LINE  
FAN "OFF"  
INDICATOR  
LIMIT  
INDICATOR  
BREAK OFF  
JUMPER FOR  
LOW VOLTAGE  
FAN "ON"  
INDICATOR  
Honeywell  
LIMIT SWITCH  
WIRE COLOR CODE  
G- GREEN- GROUND  
B- BLACK- POWER SUPPLY  
W- WHITE- POWER SUPPLY  
R1- WHITE- FAN CONTROL  
R2- BLACK- FAN CONTROL  
M1- BLACK- BLOWER MOTOR  
M2- WHITE- BLOWER MOTOR  
R2  
R1  
GROUND  
G
B
G
B
110  
VAC,  
60  
W
HZ.  
W
ELECTRICAL JUNCTION BOX  
M2  
M1  
M1  
M2  
BLOWER  
MOTOR  
BLOWER  
MOTOR  
WIRE NUT  
(7 PLACES)  
FIGURE 11  
IMPORTANT: POWER SUPPLY WIRING MUST NOT BE LESS THAN 90 CENTIGRADE.  
11  
 
INSTALLATION  
Please see all methods of Installation in  
Appendix at the rear of this booklet.  
Pipe to combustible:  
Sides: 21"  
Back: 18"  
The installation must be made only on a  
noncombustible floor.  
This is a furnace, not a free standing stove.  
Youmustdirectheatedairfrom8"outletsawayfrom  
the furnace, or it will not function properly.  
d) Install the smoke pipe connector to the  
chimney with 26-gauge pipe and elbows (to be  
purchased separately), maintaining the proper  
clearances for the specific model. Seal the smoke  
pipe in the chimney with furnace cement. (The  
chimney connector shall be securely supported,  
and joints fastened with sheet metal screws or  
rivets.)  
e) Install 8" diameter heat pipe to plenum of the  
central hot air furnace. Use 26-gauge pipe and  
connectors (to be purchased separately). (See  
Fig. 15) If central air conditioning is installed in the  
plenum, install heat pipe above the air conditioning  
unit. Secure heat pipe connection with supports  
and sheet metal screws.  
1. This installation must be done by a qualified  
heating equipment installer.  
2. The installation is to be done in compliance with  
National Fire Protection Association installation  
standards: No. 89M, 90B, 211, 70 (National Elec-  
tricalCode)andUniformMechanicalCode913,6-4,  
in the states where applicable. (Their code offers  
connecting smoke pipe connectors into chimney  
with other fuel burning appliances.)  
3. Rooms large in comparison with size of the  
appliance:  
a) Wood or Coal Burning Furnace needs air for  
combustion and circulation to house.  
f) Connect electrical supply in the electrical  
junction box that is mounted on the back of the  
Furnace. See Wiring Diagram (Fig. 11). Remove  
the cover from electrical junction box and connect  
power supply wires to wires designated, using wire  
nuts. The power cord supplied may be used for  
installation, if permitted by local codes and  
regulations. If the power cord supplied cannot be  
used, the power supply wiring must be 90 degrees  
centigrade in a metal cable and should be  
completed by a qualified installer complying with  
NFPA Standard No. 70 and local codes.  
g) Optional Plenum Fan Control Switch (Part  
No. 11PCS) is available for installation on the  
plenum of central hot air heating furnace. The  
purpose of this switch is to activate the circulating  
fan of the central hot air heating furnace when the  
temperature in the plenum exceeds 120 degrees  
F., and shut off the fan when the temperature in the  
plenum is reduced to 100 degrees F. This avoids  
overheating the plenum.  
b) Provision must be made to make up this air  
and not starve gas or oil furnace of combustion air.  
c) Have "Authority Having Jurisdiction"  
termine that air is of adequate makeup.  
de-  
(Refer-  
ence N.F.P.A. Nos. 30&54, Code for  
of Gas & Oil Equipment).  
Installation  
4. Have"AuthorityHavingJurisdiction"istoinspect  
all chimneys and installations for adequate venting  
and for compliance with standard and local codes  
andregulationsregardinginstallationofwood burn-  
ing appliances.  
5. Installation for Supplemental Heat Application to  
Existing Central System. (See Fig. 2 for typical  
installation.)  
a) Place Wood or Coal Burning Furnace so that  
the chimney connector will be as short as practical  
and avoiding unnecessary sharp turns in the smoke  
pipe connector and the installation of devices that  
would create excessive resistance to the flow of flue  
gases.  
b) Locate the Wood or Coal Burning Furnace as  
close as practical to the existing central hot air  
heating system, maintaining clearances as stated  
on the label on the fuel door.  
The electrical supply for operation of this fan  
control switch is to be obtained from the same  
electrical supply as the central hot air heating  
system. Follow the instructions of the wiring  
diagram (Fig. 11). Do not make connections across  
Limit Control in the furnace.  
c) Clearance from combustible materials must  
comply with those stated on the label on the fire  
door:  
Make electrical wire connections in accordance  
with NFPA Standard No. 70 and local codes in the  
power supply junction box (See Fig. 13). The wiring  
to complete the connections should be 18 AWG  
minimum copper and 90 degrees centigrade in a  
cable.  
Unit to combustible:  
Front: 48"  
Back: 30"  
Sides: 12"  
Plenum to Ceiling: 6"  
12  
 
Figure 12  
6
"
MIN.  
2" MIN. AIR SPACE  
REQUIRED BY CODE  
PLENUM  
CENTRAL  
FURNACE  
TO GAS/OIL/ELECTRIC  
TRANSFORMER AND  
COMBUSTION FAN OF  
SOLID FUEL UNIT  
Figure 13  
COMBINATION CONTROL  
LIMIT  
H
POWER  
SUPPLY  
JUMPER IN  
N
FAN  
GAS/OIL/ELECTRIC  
POWER SUPPLY  
JUNCTION BOX  
CAUTION!  
DO NOT CONNECT  
PLENUM FAN CONTROL  
SWITCH ACROSS FURNACE  
LIMIT CONTROL.  
FURNACE  
BLOWER  
MOTOR  
POWER FAILURE INSTRUCTIONS:  
Operation after loss of power--  
1. Remove filter if provided  
2. Do not expect to keep home at normal temperatures.  
3. Do not load fuel above bottom of feed door.  
13  
 
CAUTION  
OPERATING INSTRUCTIONS  
GASES THAT ARE DRIVEN FROM FRESH  
COAL MUST BE BURNED OR THEY WILL  
ACCUMULATE AND EXPLODE. NEVER  
SMOTHER A FIRE WHEN ADDING FRESH  
COAL.  
FUEL, Model 1537G  
A) Egg size (1-3/16" or larger) bituminous coal  
for residential furnaces, or any of the specially  
packed fireplace coals can be used. Coal with a  
low ash content (2% to 6%) is recommended.  
CAUTION  
B) Hardwood, 18" to 26" should be split and air  
dried (seasoned) for 6 months.  
LIGHTING  
DO NOT OPERATE WITH THE FEED AND/OR  
ASH DOOR OPEN. THIS FURNACE IS DE-  
SIGNED FOR THERMOSTATIC OPERATION.  
OPERATION WITH ANY OF THESE DOORS  
OPEN WILL OVERHEAT AND DAMAGE THE  
FURNACE.  
1.  
Set the thermostat on "HIGH" for maximum  
draft.  
2.  
Open the feed door and place paper and  
kindling on the grate for starting the fire.  
Light the fire and close the feed door.  
Add wood or about 15 lbs. of coal (depending  
on which model) after fire is burning briskly.  
Set thermostat for desired temperature.  
"MEDIUM" setting is normally satisfactory.  
Set higher or lower for your comfort.  
3.  
4.  
CAUTION  
NEVER USE GASOLINE, GASOLINE-TYPE  
LANTERN FUEL, KEROSENE, CHARCOAL  
LIGHTER FLUID, OR FLAMMABLE LIQUIDS  
TO START OR "FRESHEN UP" A FIRE IN THE  
FURNACE.  
5.  
ADDING FUEL  
WARNING  
When starting a fire, add small amounts of fuel  
instead of adding large quantities of fuel. This will  
give more complete combustion and less build-up  
of tars or soot in the chimney.  
NEVER STORE FLAMMABLE LIQUIDS, ES-  
PECIALLY GASOLINE, IN THE VICINITY OF  
THE FURNACE.  
ADJUSTING BLOWER LIMIT CONTROL SET-  
TINGS.  
1. Set thermostat to HIGH before opening feed  
door.  
The temperature in the plenum of the warm air  
furnace at which the blower turns on or turns off,  
is controlled by the setting of the pointers in the  
blower limit control (See Fig. 12). These pointers  
may be adjusted through their entire range of  
settings to achieve the desired warm air output  
from furnace. (See Fig. 15 below)  
2. Wood fire -  
Add wood to a convenient level.  
3. Coal Fire -  
a. Never smother the fire when adding coal (See  
Caution). Gasaccumulationandamildsmoky  
explosion will occur. Add fresh kindling if the  
bed of coals has cooled.  
b. Add up to 20 lbs. of coal per loading. Never  
add coal above the bottom of feed door  
opening.  
Move both pointers towards the right (counter  
clockwise) - this increases the temperature  
setting at which the blower will turn on and off.  
Move both pointers towards the left  
(clockwise) - this decreases the temperature  
setting at which the blower will turn on and off.  
Move pointers away or apart from each other-  
this increases the time that the blower will run  
on each warm air cycle.  
c. Stir the coal and watch the fire. Be sure the  
new coal is burning briskly before you close  
the doors and turn the thermostat down.  
d. Shakegratesvigorously1/2"lefttorighttospill  
ashes into the ash pan. Do this at least once  
every 12 hours of operation. Empty ash pan  
regularly. Do not allow ashes to build-up to  
grate as grate will warp and burnout, and you  
might spill the ashes when removing the pan.  
Dispose of hot ashes properly (See note 12 on  
page 4).  
Fig. 14  
BLOWER FAN  
"OFF" POINTER  
e. Rotation of the handle (5 o'clock to 7 o'clock)  
position will agitate coals and spill ashes into  
ash pan.  
BLOWER FAN  
"ON" POINTER  
f. It is advisable for you to get familiar with the  
shaker grate operation before firing.  
BLOWER LIMIT  
POINTER & STOP  
14  
 
SERVICE HINTS  
If the chimney is operating too cool, water  
will condense in the chimney and run back  
into the furnace. Creosote formation will be  
rapid and may block the chimney. Operate  
the furnace at a high enough fire to keep the  
chimney warm, preventing this condensa-  
tion.  
Do not expect a furnace 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 chimney are warnings that the  
chimneyisnotfunctioningproperly. Correctthe  
problembeforeusingfurnace. Possiblecauses  
are:  
4.  
5.  
If the fire burns well, but sometimes smokes  
or burns slowly, it may be caused by the  
chimney top being 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 above the  
roof and be at least 2 feet higher than any  
point of the roof within 10 feet (Fig. 5).  
1. The connector pipe may be pushed into the  
chimney too far, stopping the draft (Fig. 6)  
2. Do not connect two furnaces or a stove and  
furnace into the same chimney flue.  
3. The chimney used for a furnace must not be  
used to ventilate the cellar or basement. If  
there is a cleanout opening at the base of  
the chimney, it must be closed tightly.  
6.  
See page 28 for list of trouble shooting tips.  
A draft reading of .05 to .06 w.c. is suggested for proper burning of this unit when using  
wood or bituminous coal as fuel. When using anthracite coal, this draft reading is a  
minimum reading.  
CHIMNEY MAINTENANCE  
Creosote and Soot - Formation and Need for Removal  
When wood is burned slowly, it produces tar  
and other organic vapors, which combine with  
expelled moisture to form creosote. The  
creosote vapors condense in the relatively cool  
chimney flue of a slow-burning fire. As a result,  
creosote residue accumulates on the flue  
lining. When ignited, this creosote makes an  
extremely hot fire.  
If creosote or soot has accumulated, it should  
be removed to reduce the risk of a chimney fire.  
Chimney fires burn very hot. If the chimney  
catches fire, immediately call the fire  
de-  
partment, then reduce the fire by closing the  
inlet air control. Pour a large quantity of coarse  
salt, baking soda or cool ashes on top of the fire  
in the firebox.  
When coal is burned, the products of  
combustion combine with moisture to form a  
soot residue which accumulates on the flue  
lining. When ignited, this soot makes an  
extremely hot fire.  
CAUTION  
A chimney fire may cause ignition of  
wall studs or rafters which you thought  
were a safe distance from the chimney.  
If you have a chimney fire, have your  
chimney inspected by a qualified per-  
son before using again.  
The chimney should be inspected at least twice  
monthly during the heating season to  
determine if a creosote or soot build up has  
occurred.  
15  
 
16  
 
PARTS LIST  
MODEL 1537G  
(SEE DIAGRAM, PAGE 16)  
PART#  
68215  
40246  
88032  
23458  
40258  
40256  
40257  
89066  
40269  
68218  
68218  
22662  
22824  
23461  
23457  
23459  
22761  
22762  
68229  
24757  
80145  
80231  
89520  
23425  
68234  
22140  
23787  
68733  
68732  
68722  
86318  
24556  
83461  
83178  
23445  
40260  
89319  
23800  
68228  
68231  
83445  
83414  
83250  
89574  
DESCRIPTION  
QTY.  
1
KEY  
1
FIREBOX WELDMENT  
FLUE COLLAR  
1
2
FLUE COLLAR GASKET  
CABINET BOTTOM  
1
3
1
4
BACK LINER  
1
5
SHAKER FRAME  
2
6
SHAKER GRATE  
2
7
FIREBRICK  
12  
1
8
FRONT LINER  
9
ASH DOOR ASSEMBLY (INCLUDES DOOR & GASKET)  
FEED DOOR ASSEMBLY (INCLUDES DOOR & GASKET)  
FEED DOOR HINGE BRACKET  
DRAFT KNOB  
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
N/S  
19  
20  
21  
22  
23  
24  
25  
26  
27  
27a  
27b  
27c  
28  
29  
30  
31  
32  
N/S  
33  
34  
N/S  
35  
N/S  
36  
37  
1
1
1
CABINET SIDE (LEFT & RIGHT)  
CABINET TOP  
2
1
CABINET BACK  
1
FLUE COLLAR RING  
FORCED DRAFT RING  
BLOWER ASSEMBLY  
FEED DOOR HANDLE ASSEMBLY  
LIMIT CONTROL  
1
1
2
1
1
JUNCTION BOX  
1
ROUND WOODEN HANDLE  
HANDLE BRACKET  
1
2
BLOWER THERMOSTAT BRACKET  
RELAY BOX BRACKET  
SMOKE DOOR CLIP  
1
1
2
THERMOSTAT PANEL ASSEMBLY (INCLUDES A,B,C BELOW)  
COVER WELDMENT  
THERMOSTAT PANEL  
16GA. WIRE LINK  
-
1
1
.543FT  
1
ASH DOOR HANDLE  
HANDLE WASHER  
1
3/8-16 JAMB NUT  
2
DOOR LATCH  
1
SHAKER HANDLE  
1
BLOWER GASKET  
2
SMOKE CURTAIN  
1
ASH PAN WELDMENT  
FAN CONTROL CORD ASSEMBLY  
1/4-20 X 1-1/4 BOLT  
1
2
2
1/4 ID LOCK WASHER  
1/4-20 KEP NUT  
2
2
SPRING HANDLE  
2
17  
 
Central Installation  
(U.S. ONLY)  
COLD AIR DUCT  
6" PIPE  
90 ELBOW  
DAMPER  
OPTIONAL  
11 RPT  
PIPE  
CONNECTOR  
FURNACE  
FIGURE 15-1  
Add-On Installation  
(U.S. ONLY)  
COLD AIR DUCT  
8" PIPE  
6" PIPE  
90 ELBOW  
DAMPER  
PIPE  
CONNECTOR  
FURNACE  
EXISTING GAS/OIL/ELECTRIC FURNACE  
FIGURE 15-1  
18  
 
APPENDIX  
INSTALLATION A  
(U.S. ONLY)  
TO EXISTING  
DUCT WORK  
COLD AIR  
RETURN  
WARM AIR  
EXISTING  
FURNACE  
FILTER BOX  
SOLID FUEL  
FURNACE  
19  
 
INSTALLATION B  
(U.S. ONLY)  
PLENUM  
COLLECTOR BOX  
TO EXISTING  
DUCT WORK  
COLD AIR  
RETURN  
WARM AIR  
EXISTING  
FURNACE  
FILTER BOX  
SOLID FUEL  
FURNACE  
INSTALLATION C  
(U.S. ONLY)  
PLENUM ELBOW  
TO EXISTING  
DUCT WORK  
COLD AIR  
RETURN  
WARM AIR  
PLENUM TOP  
(OPTIONAL)  
EXISTING  
FURNACE  
FILTER BOX  
SOLID FUEL  
FURNACE  
20  
 
INSTALLATION D  
(U.S. ONLY)  
DUCT  
WORK  
2" MINIMUM  
CLEARANCE  
11 PCS  
(OPTIONAL PLENUM  
FAN CONTROL LOCATION)  
COLD AIR  
RETURN  
FURNACE PLENUM  
EXISTING FURNACE  
ANTI-BACKDRAFT  
FLAPPER  
SOLID FUEL  
FURNACE  
INSTALLATION E  
(U.S. ONLY)  
DUCT  
WORK  
2" MINIMUM  
CLEARANCE  
BAFFLE  
COLD AIR  
RETURN  
FURNACE PLENUM  
EXISTING FURNACE  
SOLID FUEL  
FURNACE  
21  
 
INSTALLATION F  
DUCT  
WORK  
2" MINIMUM  
CLEARANCE  
COLD AIR  
RETURN  
FURNACE PLENUM  
EXISTING FURNACE  
SOLID FUEL  
FURNACE  
INSTALLATION G  
DUCT  
WORK  
2" MINIMUM  
CLEARANCE  
CENTRAL  
FURNACE  
INSTALLATION  
COLD AIR  
RETURN TO  
FILTER BOX  
SOLID FUEL  
FURNACE  
22  
 
INSTALLATION H  
EXISTING OIL,  
ELECTRIC OR  
GAS FURNACE  
SOLID FUEL  
FURNACE  
(TOP VIEW)  
2" MINIMUM  
CLEARANCE  
EXISTING OIL,  
ELECTRIC OR  
GAS FURNACE  
SOLID FUEL  
FURNACE  
(FRONT VIEW)  
23  
 
TROUBLE SHOOTING TIPS FOR WARM AIR FURNACE  
LIST OF PROBLEMS  
POSSIBLE CAUSE  
SOLUTIONS  
1. Smoking when feed door  
is open.  
a) Insufficient Draft.  
b) Clogged chimney or chimney  
connector.  
a) Set Thermostat higher.  
b) Clean Chimney.  
c) Add raincap to chimney.  
c) Down draft in chimney.  
2. Furnace does not heat.  
3. Blower Does not run.  
a) Wood not seasoned and dry.  
b) Blower control set too low.  
c) Insufficient flue draft.  
a) Allow wood to season in a  
dry area for six months.  
b) Set blower control to higher  
temperatures. (See P. 14)  
c) Set flue draft. (See P. 9)  
a) Improperly wired.  
b) Bad blower control.  
c) Bad relay.  
a) Wire unit properly.  
b) Replace blower control.  
c) Replace relay.  
d) Bad blower motor  
d) Replace blower.  
4. No air from registers-  
fan running.  
a) Registers are closed.  
a) Open registers.  
b) Correct duct work install.  
c) Wire unit properly.  
b) Duct work improperly installed.  
c) Improper wiring between central  
furnace and this unit.  
5. Air from Registers is not hot  
6. Blower runs too long.  
a) Blower control is set too low.  
b) Bad blower control.  
a) Adjust blower control to  
higher setting. (See P. 14)  
b) Replace blower control.  
Blower control cut off set  
too low.  
Set blower control cut off to  
higher setting. (See P. 14)  
7. Blower does not run long  
enough.  
a) Blower control cut off set  
too high.  
b) Bad blower motor.  
a) Set blower control cut off to  
lower setting. (See P. 14)  
b) Replace Blower.  
8. Smoke and/or odor from  
registers when furnace  
is used for first time.  
Oil from furnace and duct  
work.  
The metal used in constuc-  
tion of the furnace and duct  
work has a light coating of  
oil. This should disappear  
after a short period of time.  
Once this burnoff has occur-  
red, is should not reoccur.  
9. Creosote build-up.  
a) Burning green wood (not  
seasoned or dry).  
a) Burn only seasoned wood.  
b) Thermostat setting too low  
for type fuel.  
b) Set thermostat higher to  
attain higher flue tempera-  
tures. This will aid in pre-  
venting build-up of creosote.  
10. Flame spillage when feed  
door is open.  
a) Insufficient draft.  
b) Smothering fire when adding  
fresh fuel.  
a) Set thermostat higher.  
b) Add fuel so as not to  
smother fire.  
24  
 

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