United States Stove 24AF Furnace User Manual
Contents
1. eee OE ehe 5 6 7 Installation 8 11 12 16 PROCESS ONL 17 WA 18 23 Trouble SHOGUING 24 hii qp O A 25 26 Enc d M 27 How Order Repair Parts E 28 USSC Page 3 Rules for the Safe Installation and Operation of Your Furnace Check local codes the installation must comply with strict conformance in regard to clearances The Furnace mustbe installed on a noncombustible floor Connect the furnace to tile lined insidemasonry chimney or approved insulated all fuel prefabricated chimney only Keep smoke pipe connection as short as possible using minimum 24 gauge pipe witha minimum 1 2 per foot rise from the flue collar to the chimney opening Be sure there is a sufficient supply of combustion air to the area where the furnace is to be located Do not over draft the furnace It is designed to operate at 04 to 06 inches of water column and must be set with a draft gauge to maintain a steady draft Do not use flammable liquids for starting a fire Do not store fuel or combustibles near the furnace Some areas of the furnace are hot and could cause an explosion and possible bodily or property damage Store all2. In each case care must be taken The outer masonry brick or block must be chipped away and the inner liner must be pierced The flue pipe or thimble is then inserted flush to the inside face of the tile liner NOT ANY FURTHER Use furnace cement or mortar to seal this connection When connecting the flue pipe make sure the attachment is se cure enough so down draft or puffs do not dislodge it USSC FACTORY BUI LT OR METAL CHI MNEYS If your home has an existing metal chimney the same rules apply as with masonry chimneys One thing to be espe cially aware of is that Class B chimneys are for gas appli ances only not solid fuel burners If purchasing a new package consult with the dealer He will provide the nec essary parts and instructions for installation INSTALLI NG A NEW CHI MNEY When installing a new chimney whether it be masonry or metal if possible it is recommended that it is placed within the house structure These chimneys remain warmer and in turn radiate this warmth into the house A chimney located outside the house is exposed to cold temperatures which encourages creosote build up and poor chimney draft CONNECTI NG STOVE PIPE TOA METAL CHI MNEY When using a metal chimney part of the installation pack age should include a stove pipe connector Follow the in structions provided with the chimney and its parts CHI MNEY DRAFT REGULATORS OPTI ONAL BAROMETRI C DAMPER These devices are use
3. 88033 3 8 ROPE GASKET FEED DOOR C21390 7 32 1 ROLL PIN FEED DOOR 24482 PRESSURE FLAP 88075 3 4 FLAT ROPE GASKET C21390 7 32 x 1 ROLL PIN PRESSURE FLAP 69326B FEED DOOR HANDLE ASSY 83379 1 4 20 x 1 BOLT 83261 1 4 20 LOCK NUT 24485 ASH DOOR 88033 3 8 ROPE GASKET 25047B ASHDOORHANDLE C21390 7 32 x 1 ROLL PIN ASH DOOR 83379 1 4 20 x 1 BOLT 83261 1 4 20 LOCK NUT 24382 SPINDAMPER 83471 5 16 18 x 1 3 4 CARR BOLT 83423 5 16 18 HEX LOCK NUT 69068 ASH DRAWER ASSY 24501 SMOKECURTAIN 83445 1 4 20 x 1 1 4 BOLT 83261 1 4 20 LOCK NUT 23787 SMOKE DOOR CLIP 89799 STUBCOLLAR 24528 DAMPER ROD 83874 1 8 DIA x 1 1 2 COTTER PIN 69321G CONTROL CENTER 69323 CONTROL CENTER STAINLESS STEEL 69097 FORCED DRAFT BLOWER ASSY 80129 THERMOSTAT 89574 SPRING HANDLE DAMPER ROD SHAKER 89849 HOOK SPRING HANDLE FEED ASH DOOR 69082 JUNCTION BOX ASSY 69069 SHAKERGRATEHANDLE 40369 SHAKERGRATEFRAME 40349 SHAKERGRATE 40366 FIREBOX LINER 24496 FRONTHEATPLATE 24487 FURNACEHEATPLATE 1 1 1 3 4 1 25 2 1 FT 2 1 1 1 1 29 1 2 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 2 2 1 1 2 2 2 1 1 89066 FIREBRICK
4. CAUTION Never use chemicals or fluids such as gasoline char coal lighter fluid drain oil or kerosene to light a fire in your furnace This would be like checking the level of gas in your car with a lighted match Page 21 3 Ignite the paper and close the door Do not attempt to open the door immediately after igniting the fire There could be a flame flash out 4 It willtake a few minutes for the fire to establish itself Once you have some good red hot burning coals add larger pieces of wood All Chimneys and hookups act differently After a while you will find out how your unit works best for starting 5 Pushin bypass damper after fire has progressed 6 Your furnace is capable of putting out many BTU s so don t fully load your furnace until you have become familiar with the operation of the furnace Keep in mind a full load will not always give you the best re sults for your needs Note With new steel there is a small amount of oil or dirt on the metal You may smell an odor This is normal during the first operation You may want to assemble the furnace out of doors and build a small fire in it to burn off this dirt and oil before installing the unit 7 When loading your furnace that has existing hot coals pull the bypass damper out and rake the red hot em bers over grate evenly Put a few smaller pieces of wood on the coals first then load up to the middle of the feed door 8 Set rheostat sett
5. Wood amp Coal Burning Furnace Owners Manual Models 24AF 24AG 24AZ TESTED TO UL 391 All installations must be made in accordance with local and state codes which may differ from this manual UNITED STATES STOVE COMPANY WARNOCK HERSEY 227 Industrial Park Road P O Box 151 wem South Pittsburg TN 37380 851224C CHIMNEY INSTALLATION Your new furnace must be installed into a Class A Chimney only This type of chimney consists of a flue lined brick chimney or an approved Class A all fuel factory built prefabricated type Any other installation guarantees an immediate fire hazard Do not install the furnace into the same chimney serving other appli ances When using 8 flue pipe the chimney should have an 8 to 10 round flue liner or 9 9 square liner The chimney should have a minimum height of 3 from the top of the chimney to the point at which it passes through the roof The top of the chimney must be at least 2 higher than the peak or the highest portion of the roof within 10 horizontally A chimney that rises within the house is better insulated than a chim ney that is located outside the house and exposed to the weather the north side of the house is the worst position Check manual for proper installation of flue pipe into chimney FURNACE INSTALLATION Install your furnace as close to the chimney as possible witha minimum of elbows no more than two and flue pipe run of no more than
6. 250146 CABINET TOP 25015 CABINET TOP STAINLESSSTEEL 25016G CABINETRIGHTSIDE 25017 CABINET RIGHT SIDE STAINLESS STEEL 25018G CABINET LEFT SIDE 25019 CABINET LEFT SIDE STAINLESS STEEL 25025B SIDE FILLER 25020G BOTTOM FRONT 25021 BOTTOM FRONT STAINLESS STEEL 891049 CATCH 891048 BALLSTRIKE 25022G CABINET DOOR 25023 CABINET DOOR STAINLESS STEEL 69318B TOP CABINET DOOR HINGE 69319B TOP CABINET DOOR HINGE a 2 m 0 p 851405 ASHLEY SCRIPT LOGO 25024B LINER CABINET DOOR 89943 DOORKNOB NOT SHOW C60456 1050 CFM DISTRIBUTION BLOWER Ry RT RT RT RI N S Page 9 Furnace location Before start It is very important you check with your dealer local fire department or building inspector They will be able to in form you of any state or local codes pertaining to the loca tion and installation of your furnace The ideal location for your furnace is centrally located in the basement This allows for an even heat distribution by having all the duct work approximately the same length Ideal locations cannot always be used for one reason or another therefore let s look at some alternatives If your home does not have a basement but a utility room or garage make sure there is enough space to maintain t
7. L z lt gt ZZZZZZ 2 7 22222277 JZZ 2 A CHIMNEY INSTALLATION With the chimney being the most important part to your installation great care should be given to its design MASONRY CHI MNEYS If your intention is to use an existing masonry chimney check first with your local building official to see if this is acceptable An older chimney in need of repair is the GREATEST fire hazard in any installation STOVE PI PE FLUE PI PE CONNECTI ON The flue pipe you should use is 6 or 8 24 gauge or heavier steel pipe When installing the flue pipe make sure all joints are se cured with at least three 3 sheet metal screws This includes the connection to the flue collar of the furnace For added protection use some high temperature furnace cement to seal each joint The stove pipe should slope upward to the chimney at a rate of 1 2 inch per foot Any horizontal runs of stove pipe should not exceed six 6 feet and it should be supported every four 4 feet Note Flue pipe should be attached inside the flue pipe collar to prevent creosote from running down onto electrical motors CONNECTI ON OF FLUE PI PE TO AMASONRY CHI MNEY When connecting flue pipe to a masonry chimney there are two ways to go 1 The flue pipe itself can be cemented into the chim ney or 2 A thimble can be used which is cemented into the chimney and the flue pipe fits into the thimble
8. establish threads then mount blower The electrical box on the blower should be facing downward Draft fan air intake cover should be set at a 20 opening about 1 2 opening DISTRIBUTION FAN After mounting the two 2 fans proceed to the fan control center NOTE The best maintenance for fan motors is to keep them clean exceptionally clean with 20W N detergent once a season willalso help but cleanliness is what prolongs motors life Two 2 drops on the draft blade four 4 drops in the distribution fan USSC 5a 5b Attaching furnace control center box To separate outer cover remove two 2 side screws and pull off black rheostat knob Attach box to left side facing feed door with four 4 self threading screws One screw in each corner NOTE Furnace control center is designed for left side attachment Should space prohibit such reversing shrouds for right side installation is possible however control wires from box will have to be ex tended Next attach the 4x4 junction box below the control center box using 2 self threading screws provided in Attach low voltage thermostat No 18 up to 30 ft run No 16 to 15ft Run purchase locally to terminal plate screws identified with letters G amp R Generally top row center bottom row right Snake wire through holes in top of box Replace outer covers amp control knob Under no circumstances should you attempt
9. do form the coal quality should be checked first and then all the above points should be reviewed and corrected SAFETY Whenever a loading door is opened the bypass damper should be opened first use a glove to protect you hand and the door should be cracked slightly for about ten 10 seconds to allow oxygen to enter and burn any combus tible gases that are present before fully opening Failure to do this could result in sudden ignition of the unburned gases when the door is opened With the exception of the start up period the ash pit door should never be left open Serious damage to the stove can occur from overheating In extreme cases this over heating could be the cause of an unfriendly fire Coal furnaces are subject to the same installation clear ance standards as wood furnaces Never burn coal in any furnace that does not have an airtight unified chimney system Coal furnaces should not be installed in any chimney that has had a history of back drafting or flow reversal Also coal furnaces should not be installed in any chimney hav ing an excessively large flue These conditions can cause improper draft resulting in carbon monoxide entering the house rather than being drawn up the chimney Remem ber coal gases are toxic Sulfur dioxide sulfur trioxide and other ions released from coal burning may corrode stainless and masonry chim neys and even terra cotta chimney liners and brick in nearby buildings C
10. furnace Ducting enter ing the existing plenum at an angle approximately 45 de grees will facilitate air flow from the furnace while divert ing air from the existing furnace Existing Furnace Furnace INSTALLATION 3 The baffle on this system should be made the full width of the furnace plenum in order to properly direct the air into the distribution ducts V 2 m Baffle Existing Furnace Furnace USSC Your fur esigned to be adde MA 5 duct E wo viande oper ih with orwithoutanother heateouree Clearance to Combustibles aneha a ils die Furnace to back wall 30 nie table ewa wo cting your furn Furnace to side wall 12 learan 2 Materials Your Furnace has been tested to determin ethe SAFE clear to combus tiblen material The clea are prin Pipe to side wall 18 en Hc ck of the fur rna e Fu to ceili 30 s page also s these minimum cleara e you follow t 2 choosing you 1 loc Ductwork to ceiling 18 6 1 Ke re um connection to a furnace must be con ted of metal NOTE INSTALLONLYONANON COMBUSTIBLEFLOOR Dem 30 The termin designed to without res discharge FLUE ONS Page 12 T Fr
11. 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 charge to the back being careful not to seal off the top Close the feed door but leave the spin damper open for a few minutes until the volatile gases have burned off It is not necessary to shake down the ashes each time you refuel your furnace Experience will be your best teacher BANKING THE FIRE For extended operation suchas over night you will need to bank the fire To do so heap coal up along the sides and back of the firebox so that the fire gradually burns it over a longer period of time You will also reduce the intensity of the fire without letting it go out Follow the same procedure as 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 for about 30 minutes Then close your damper to the point where the house does not be come too cold It is important that you begin banking early enough before retiring or leaving that you can make neces sary 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 damper to get a good draft through the grate 2 place a thin layer of dry coal over the entire top of the fire DO NOT POKE OR SHAKE THE FIRE AT THIS TIME 3 after the fresh coal has become well igni
12. into a metal container Coals can remain hot many hours after a fire is out Coal ashes should not be put on gardens as they do not contain beneficial minerals like wood ashes and may cause ground water pollution Coal produces considerably more ash than wood so the intervals between emptying are much shorter For equal heat output coal will produce seven 7 to ten 10 times more ash than wood CLINKERS Clinkers can occur in any coal furnace during the process of burning These are hard pieces of fused ash that form in the firebox They can become hard and large in size and therefore cannot be shaken through the grates in a coal stove When there is an appreciable accumulation the fire will go out because insufficient air is allowed to pass through the clinkers to the burning coal Once large clinkers have formed they can be removed only from above the grates This usually means the fire must be allowed to go out before they can be removed Clinkers formation can occur from a number of different causes or a combination of causes Some of these are Poor quality coal excess ash content and or too low a heat of fusion Too hot a fire too much draft Too shallow a bed of coals Too deep a bed of coals Excessive Shaking USSC Poking the fire from the top Too little air draft after a long hot fire caused by rapid adjustment of draft from a very high setting to alow setting If clinkers
13. oil before installing the unit During the first few fires heat may slightly warp the front and back panels This is normal and will not hamper your unit s operation DONOTCONNECTTHISUNITTO ACHIMNEYFLUESERV ING ANOTHER APPLIANCE BURN WOOD OR COAL ONLY IN MODEL DO NOT MIXOTHER THAN THEUSEOFWOOD TOSTART ACOAL FIRE DANGER Risk of Fire or Explosion Do not burn gar bage gasoline drain oil or other flammable liquids WARNING Risk of Fire Do not operate with flue draft exceeding 6 inches water column Do not operate with fuel loading or ash removal doors open Do not store fuel or other combustible material within marked installation clearances Inspect and clean flues and chimney regularly This Furnace Must Be nstalled By A Qualified nstaller Page 4 USSC How Your New Furnace Works Unlike conventional heating gas oil electric wood or coal heating requires more user attention Your furnace with its automatic combustion air blower alleviates the constant need for adjusting the burning rate common to other units on the market The fire however must be started and subsequent fuel added by the user Conventional heating system produce heat only when the thermostat calls for heat This way of heating is inefficient and often leaves part of the home either too hot or too cold Your furnace is designed to deliver heat as long as there is a fire in it The fire intensity is regulated by t
14. temperature is calling for or not call ing for heat Set thermostat at 80 degrees D Check to see if thermodisc 170 degrees left side is faulty Use match or lighter for click or jumper wire Problem Odor from first fire Solution The odor remains call your dealer immedi ately A defective weld can cause a fume leak Problem Excessive creosote Solution A Checkthe grade of wood you are burning B Make sure your unit is serviced by its own proper chimney check length of flue pipe and its connections D Make sure you are burning the smallest hot test fire to adequately heat your home Also see Solutions to Problem 1 Use a magnetic surface thermometer on flue pipe and operate between 300 and 400 degrees T Problem Poor sealaround unit door Solution Bend door latch in to tighten seals USSC Notes USSC Page 27 THIS MANUAL WILL HELP YOU OBTAIN EFFICIENT DEPENDABLE SERVICE FROM YOUR FURNACE AND ENABLE YOU TO ORDER REPAIR PARTS CORRECTLY KEEP THIS MANUAL IN A SAFE PLACE FOR FUTURE REFERENCE WHEN WRITING ALWAYS GIVE THE FULL MODEL NUMBER WHICH IS ON THE NAMEPLATE ATTACHED TO THE HEATER WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE FOLLOWING INFORMATION AS SHOWN IN THIS LIST 1 THE PART NUMBER 2 THE PART DESCRIPTION 3 THE MODEL NUMBER 24AF 71 24AG D 24AZ 7 4 THE SERIAL NUMBER UNITED STATES STOVE COMPANY 227 INDUSTRIAL PARK ROAD WARNOCK HERSEY PO BOX 1
15. to plug in main power cord until all wiring and covers are in place NOTE A ground power cord plug is pro vided however local codes may require fuse box mounting USSC Wall thermostat should be mounted on an upstairs in side wall no outside facing wall preferably near your existing thermostat For more specific information read the Honeywell instruction sheet provided with thermo stat Caution disconnect the power supply before in stalling NOTE Your wall thermostat and transfer re lay are mated Honeywell products for trouble free in stallation 8 Install top shroud if removed by simply placing shroud on to the top of unit push down check each corner for snug fit Page 15 CAUTION hotair plenum connection to a furnace must be constructed of metal 11 Installing Grates Install grates together slip shaker lug into hole and place grates into frame Grate arch faces upward Check out grate rotation by placing shaker handle on grate lug 3 4 Grates should ro 9 Installing collar to top To install hot air attaching tate freely collar simply bend all tabs right angle undershroud NOTE Grates are designed to withstand high tempera This may be possible with thumbs if not remove top tures however should you overfire the furnace you and use small hammer may fuse or melt grates This happens if furnace re ceives too much air caused by leaving the ash and feed doors ope
16. 1 420 LOCKNUT 23787 SMOKEDOORCLIP 89799 STUBCOLLAR 24528 DAMPERROD 83874 1 8DIA x1 1 2 COTTERPIN 69080 CONIROLCENTER 69097 FORCEDDRAFTBLOWER ASSY 80129 THERMOSTAT 89574 SPRINGHANDLE DAMPERROD SHAKER 89840 HOOKSPRINGHANDLE FEED ASHDOOR 69082 JUNCTIONBOXASSY 69069 SHAKERGRATEHANDLE 40369 SHAKERGRATEFRAME 40349 SHAKERGRATE 40366 HREBOXLINER 24496 FRONTHEATPLATE 24487 FURNACEHEATPLATE 89066 FIREBRICK 24488 CABINETTOP 24489 CABINETRIGHTSIDE 24490 CABINETLEFTSIDE C60456 1050 CFM DISTRIBUTION BLOWER USSC Page 7 E 1 8 ZZ aA 212 212 s 57 o N COIN O H s 2 2 72 A NOTSHOWN N S 37 Parts FOR MODEL S 24 0 24AZ QW 21 7 AUT _ mt m USSC Page 8 Parts USSC PART DESCRIPTION d 69315 FIREBOXWELDMENT C97999 WATER COIL COVER GASKET 24220 INSIDE COVER PLATE C23799 12x 3 4 TEKS SCREW 83236 1 4 20 x 3 4 HX SCREW 25085 FEED DOOR
17. 51 SOUTH PITTSBURG TN 37380 423 837 2100 www USSTOVE com Page 28 USSC
18. 56 DRAFT FAN 5 80392 20 USSC Control Box amp Electrical Component 10 BASIC FUNCTI ONS OF ELECTRICAL SYSTEM Wall mounted thermostat requests heat electrical contact occurs 2 Current is sent through relay rheostat 170 degrees thermo limit disk to activate draft fan 3 Relay electrical switching device Rheostat current voltage reducer increases or de creases draft fan R P M 170 degrees limit disk breaks off electrical current at 170 degrees limit disk Draft fan small fan that activates fire increasing fire temperature 4 Upon firebox temperature rise due to air from draft fan distribution fan is activated at approximately 110 degrees air temperature 600 CFM of air at 110 de grees 5 110volts main electrical line is sent to left side of 140 degrees thermo disk 8 prongs current passes through 140 degrees disk to 110 degrees disk Current simply waiting for 110 degrees so it can pass through and activate normal speed function of distribution fan blue wire 6 If 110 degrees firebox air temperature is not main tained snap disk terminates current to distribution fan Should firebox temperature air reach 140 degrees cur 7 rentis directed to activate high speed portion 1300 of air Current travel from prong 1 to prong 2 on 140 degrees disk to activate high speed portion black wire Distribution Capacitor Reduces amps required to ac 8 tivate distribution fan Va
19. 6 feet horizontally Also the flue pipe should contain a 1 2 rise per foot and NEVER installed closer than 18 from combustibles WOOD BURNING Install a manual flue pipe draft damper at a safe convenient location between your furnace and chimney COAL BURNING Install a barometric damper set at 05 Water Column AIR FLOW Solid Fuel furnaces produce much hotter air than oil or gas fired appliances so all clearances are mandatory AIR DUCT INSTALLATION This furnace provides a 12 round 113 sq in opening because of efficiency and general convenience United States Stove Company recommends a Parallel Furnace Installa tion with direct ducted feed or return air to your furnace NOTE Cold air duct intake must be at least 25 larger than hot air duct outlet FURNACE ASSEMBLY U S Stove provides easy step by step pictures therefore the fur nace assembly procedure should be understandable FI RING YOUR FURNACE Start on a conservative basis Your new furnace when properly fired with hard dry wood will achieve approximately 6 to 8 hours of burn time per load of wood much longer with coal If the furnace is being fired hot constantly with full flames and only provides a 3 hour burn cycle the furnace is being overfired Possibly your heating requirements are too much for the size of furnace purchased Certainly allowing your existing furnace to assist in extremely cold weather is no crime Re member your furnace can be
20. EEL IS COMMON AGGRESSIVE BUT GENTLE FIRING CAN MINIMIZE WARPAGE e There is no substitute for dry hard wood Wood requires 6 months to a year to air dry to 25 moisture content or less Don t throw heavy wet wood into your Jensen it could crack the firebox and bricks eTreat your furnace with the proper respect and it will reward you with much comfort and a lifetime of central heat USSC Welcome to the world of solid fuel heating Your new furnace has been designed and built with a high grade of materials and the strictest regard to quality Before you start installing your new furnace take the time to read these installation and operating instructions We have prepared them for your benefit to save time and provide some helpful knowledge on wood and coal burning Save the instructions for future use It won t take long for you to realize the benefit of solid fuel heating however maintenance is the key to a long lasting relationship with your new furnace These instructions can help you now as well as in the future Note This owners manual is provided for Forced Air add on furnaces United States Stove Company is constantly developing and improving its product line therefore we reserve the right to change specifications without notice Table Of Contents General Rules esee ehe tee iae etre fe eet a As 4 E
21. R ILLUSTRATION PURPOSES ONLY ACTUAL PRODUCTS MAY LOOK DIFFERENTLY Domestic Hot Water Coil Part 11WCK ITT USSC Page 19 WIRING DIAGRAM ROOM NOTE RHEOSTAT IS ADJUSTABLE IN CASE OF LOW VOLTAGE TURN COUNTERCLOCKWISE UNTIL BLOWER WILL RUN BUT NOT STALL WHEN POWER IS RETURNED TO UNIT ORANGE RHEOSTAT PT 80090 5 ve 0350 3 BLACK LOCATED ON LEFT OF BOX 2 as PT4 80388 THERMOSTAT THERMAL DISC DISTRI BUTI ON FAN 1 HI SPEED PT 80389 ENERGIZES WHEN UNIT IS FIRED AGGRESSIVELY ONLY 2 LOW SPEED PT 80388 ADJUSTABLE IN APPROX 5 DEGREE STEPS A LOW SETTING TURNS BLOWER ON SOONER Ro wit tate here h flat blade screwdriver THERMAL DI SC FAN ADJUSTMENT DRAFT FAN 3 HI LIMIT PT 80390 DE ENERGIZES WHEN UNIT REACHES TEMPERATURES OF APPROX 170 DEGREES LOCATED ON RIGHT SIDE TOP 1 PT 80389 LOCATED ON RIGHT SIDE BOTTOM BLACK WHITE T PURPLE BLACK GREEN 120 VAC 60 Hz 15 5 PURPLE WHITE NOTE WIRES FROM BLACK BLACK DISTRIBUTION FAN RUN DIRECTLY INTO BLUE BLUE THE 4 x 4JUNCTI ON ORANGE BOX 8 u 2 1 2 5 z NOTE CAP OFF RED DISTRIBUTION WIRE WITH A FAN WIRE NUT PT C604
22. ashes in a metal container with a tight sealing lid and allow ashes to cool before disposing of them possibly a week Familiarize yourself with the furnace s solid fuel burning characteristics before leaving unit unattended for long pe riods of time The loading door and ash door must be tightly closed dur ing furnace operation to insure safety and efficiency CAUTION The furnace has hot surfaces Keep Children Away Do not touch during operation General Rules In the event of a chimney fire call the fire depart ment then be sure the furnace doors are closed tightly and the power to the unit is turned off The furnace is designed to burn air dried wood and coal at predetermined firing rate Over firing could result in dam age to the heat exchanger and cause dangerous opera tion Over firing occurs when the ash door is left open during operation or a highly volatile fuel such as large amounts of small kindling is used Note This action voids all warranty Follow a regular service and maintenance schedule of the furnace and chimney for efficient and safe operation Do not leave the ash door open when the fire is burning Do not let ashes build up closer than 2 to the grate With new steel there is asmall amount of oil or dirt on the metal You may smell an odor This is normal during the first operation You should assemble the furnace out of doors and build a small fire in it to burn off this dirt and
23. bring the coal up to the top of the front liner not above Be sure you have closed your ash door Before adding further fuel be sure you leave a red spot of glowing coals in the center of the firebox to insure that you have not smothered the fire and to help ignite the Page 23 gases given off by the new charge A deep charge will give a more even heat and a longer fire but it may take one to two hours before the whole bed is fully ignited When the fire is well established and the room is becoming warm partially close the dampers You will have to experi ment with your particular setting of the damper and con trols as your chimney provides the draft necessary to not only exhaust the smoke but to pull combustion air into the heater as well and no two chimney s perform the same Leave the ash pit damper at 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 anew 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 re charged Only when the coal is burned down to half its original depth is it time to add fresh coal When doing so open your stove pipe damper which will allow the fire to burn off any accumulated gases Open the feed door and with a small rake
24. coal BURNING BITUMINOUS Once your kindling and wood fire has produced a bed of well established coals start adding coal in layers allowing each to ignite before adding more Bituminous has 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 fire box 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 USSC and produce less smoke Once the fire is WELL ESTAB LISHED coal to the center of the firebox forming the cone Burning in this fashion allows heat to drive off the volatile gases and turbulence created increases the burn efficiency You will have to experiment with your particular setup as no two chimney s or installations are going to be the same Just remember to allow enough secondary air to enter the firebox 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 espe cially if it has caked over or formed a crust But be careful not to mix the coal as this increases the chances of forming clinkers When shaking the grate s be gentle Just a few short movements is better than a lot of agitation The ob jective 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
25. d to help maintain adequate chimney draft automatically They should be installed according to their instructions and set at 04 to 06 inches of water column MANUAL DAMPER RECOMMENDED FOR ADDED SAFETY Theseare used to control chimney draft manually and should be installed in a convenient place between furnace and chimney In the event of a chimney fire it should be closed reducing air to the chimney fire A combination of both barometric damper and manual damper may be used If this is the case install the manual damper between the barometric damper and the chimney VENTI LATI ON FOR YOUR FURNACE There are many appliances which require make up air to operate However with a combustion air draft fan make up air is not usually necessary with your wood furnace If your home is sealed exceptionally well use a 3 or 4 diameter duct vented to the outside and terminating in the vicinity of the combustion air draft fan Also it is possible for your fans to draw in furnace smoke if there is only dead airin the area Note It s highly recommended that a cold air return system be utilized Simply attach a 14 round to a filter box adapter and attach to cold air return Also a cold air return increases motor life Page 13 NOTE Your furnace may come partially pre assembled but in the case that it is not follow the instruc tions below Prior to assembling place the unit in the general vicinity of the installatio
26. damaged if fired continually at extremely high temperatures and this procedure will void your warranty CAUTI ON OVERFI RI NG YOUR FURNACE VOI DS WARRANTY Page 2 OVER FIRING This generally occurs when the following procedures are not fol lowed ash door is open even partially open the feed door pressure relief flap is open the feed door is open or the manual draft spinner is open Open the ash and feed doors only when in attendance never leave the furnace unattended when doors are open This furnace has an automatic draft fan so use the manual draft with a specific purpose Also an overfilled ash drawer can cause grate warpage keep ash drawer clean Don t use furnace if distribution fan isn t functioning properly and keep air filter clean Draft fan opening should be set at 1 2 open as a point of start depending on condition of fuel U S Stove recommends a very active fire at all times for maximum results but only as instructed SOME HELPFUL HI NTS Your furnace will hold logs approximately 2 shorter than the length of the firebox Don t force in oversized logs e Unsplit dry logs will provide longer burn time than split logs Don t ever try to burn trash or garbage Keep flue pipe stack temperature between 300 and 400 degrees This will reduce creosote build up A magnetic surface thermometer can be obtained from your dealer Weather is the most important determinant in how you operate your furnace assu
27. he room thermostat high or low the fire continues to pro duce heat This heat is continuously distributed throughout the home by a distribution blower This constant supply of heat is uniform and prevents drafts USSC How WARNING Note Improper firing Wood or coal over firing oc curs when the ash door is left open during operation or a highly volatile fuel is used Coal that exceeds the fire brick line will cause overfiring this type of op eration will immediately void any warranty Page 5 Parts FOR MODEL S 24AF TAVAN N NN N i 7 gt ya 2 Y da i x N USSC Page 6 Parts PART DESCRIPTION 69072 FIREBOXWELDMENT 97999 WATERCOILCOVERGASKET 24220 INSIDECOVERPLATE C23799 12x3 4 TEKSSCREW 83236 1 4 20x3 4 HXSCREW 25085 FEEDDOOR 88033 3 8 ROPEGASKET FEED DOOR C21390 7 32x1ROLLPIN FEED DOOR 24482 PRESSUREFLAP 88075 3 4FLATROPEGASKET 21390 7 32x1ROLLPIN PRESSURE FLAP 69077 FEEDDOORHANDLE ASSY 83379 1 420x1BOLT 83261 1 4 20LOCKNUT 24485 ASHDOOR 88033 3 8ROPEGASKET 24486 ASHDOORHANDLE 21390 7 32x1ROLLPIN ASH DOOR 83379 1 420x1BOLT 83261 1 420LOCKNUT 24382 SPINDAMPER 83471 5 16 18x1 3 4 CARR BOLT 83423 5 1618HEXLOCKNUT 69068 ASHDRAWERASSY 24501 SMOKECURTAIN 83445 1 4 20x1 1 4 BOLT 83261
28. he required clearances stated on the label located on the furnace Also read about combustion air INSTALLATION 1 With this installation a back draft damper optional is in serted into the heat run before the plenum of the existing furnace to prevent air from the existing furnace to blow back into the furnace when it is not in use When back damper is employed it should be located as close to the existing furnace plenum as practical Optional it 1 Draft N amper Existing Furnace Furnace Page 10 Installation Chimney location is also critical The furnace must be placed as close as possible to the chimney You want the chimney connector smoke pipe to have a minimum of elbows two 2 orless Also the chimney connector should not have to run more than six 6 feet to the chimney CAUTION The warm air supply outlet of the Fur nace should not be connected to the cold air re turn inlet of the central furnace because a possibil ity exists of components of the central furnace over heating and causing the central furnace to operate other than as intended After installation be sure the measured external static pres sure of the central and Furnace is not greater than those marked on the nameplates INSTALLATION 2 Extending the hot air duct from the furnace into the exist ing plenum will help direct the flow of air from the furnace as well as the flow in the existing
29. ing for type and condition of coal or wood Hard coal and wood requires more forced air than soft so experiment with dial setting Start with a center dial setting The draft fan cover also requires experimenting with Start with a 20 opening 9 Set the furnace thermostat for comfort Set the other thermostat 10 degrees lower 10 Use caution when opening loading door Avoid open ing loading door rapidly This could cause flames to flash out the door This occurs when there is unburned fuel and a large amount of gases on the top of the firebox When the door is opened oxygen is combined with the gases and ignites ASH REMOVAL Every morning when there is just a bed of hot embers shake the grate very very lightly Once every week or two depending on how much fuel you burn ashes should be removed Note A 2 to 3 bed of ashes will prolong wood burning and protect grates Page 22 CAUTION Never let ashes build up to grate level This will re duce the life span of your grate and void grate war ranty To remove ash pan simply open ash door and pull out your ash pan But remember the ash pan can get very hot Dump ashes in a metal container with a lid and place on a non combustible surface CAUTION Never use anything but a metal container to put your ashes in Every year fires are caused by emptying ashes into cardboard boxes or paper bags MAINTENANCE Keep chimney and flue pipe clean by cleaning at
30. least twice during a heating season CREOSOTE FORMATI ON 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 rela tively 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 The chimney connector and chimney should be inspected atleast twice monthly during the heating season to deter mine if a creosote buildup has occurred If creosote has accumulated it should be removed to re duce the risk of a chimney fire CAUTION If you have a chimney fire we recommend the follow ing immediate actions 1 Alerteveryonein the house 2 Shutany furnace doors disconnect power to the unit and close any dampers This should take no longer than a few seconds Call the fire department USSC Keeping your chimney and stove pipe clean is the best in surance against chimney fires Note Smoke detectors and fire extinguishers should always be a part of your equip ment If you clean your own chimney and stove pipe we recom mended purchasing the equipment professionals use Wire brushes are available in enough sizes and shapes to be a snug fit inside any common flue Once a week let your furnace burn with ash door open for a maximum of fifteen minutes while in attendance This will hel
31. ming you have dry wood colder it is the stronger the draft warm weather reduces draft Set your draft fan rheostat and manual draft accordingly Open manual smoke damper only when starting the fire and when chimney draft is marginal Always place logs so air can flow between them Shake gently up to 10 o clock down to 8 o clock don t try to loose weight shaking down ashes Wood ash is useful as a fertilizer because it contains potassium ashes also decrease the acidity of the soil Coal ashes will provide good traction on ice or snow otherwise they are useless Always store ashes in a metal container with a lid Ashes are a good thermal insulator and will keep enough oxygen away so embers will not burn out e Never never let ashes accumulate up to grate level this will greatly reduce the life span of your grate Coal produces much more ash than wood Keep your chimney and flue pipe clean check monthly Smoke detectors and fire extinguishers should always be a part of your equipment e Never use chemicals or fluids such as gasoline charcoal lighter drain oil or kerosene to light a fire Oil the air fan motors yearly They do not contain bearings sleeves with felt Therefore keeping fan air clean is more important than oiling Turn on your regular furnace once every month to keep it tuned up Always shut the furnace down gradually to prevent excessive stress on steel WARPAGE OF ST
32. n This should help minimize handling damage to the unit after assembly Note If your basement can t handle a height of 7 8 you must lay the furnace on two 2 x 4 s to slide shrouds onto weldment Then stand furnace up 2 i be J ee 4 Unitside shrouds be assembleby slipping the side shrouds into place from the top down If they don t slide easily open up the lip of the sides with a large screw driver then add a little oil Sometimes a slight tapping with ablock of wood and hammer may quired but do not force When properly installed the electrical knock outs willbe at the top left side NOTE Should you wish to installa domestic hot water coil it should be secured to the right side prior to assembly Also the rear cast iron baffle must be fastened prior to shroud installation NOTE The furnace is partially prewired all that is re quired is the wiring of the distribution fan see wiring diagram page 18 and the wiring to wall the thermo stat REAR OF FURNACE Attaching the distribution fan First remove the four 4 bolts from the rear of the unit Secondly slide the distribution fan up to the rear of the furnace line up the 4 holes and reattach the bolts and tighten se curely Page 14 Attach the draft fan to the back of the weld on the throat 2 throat hole with 3 mounting holes It s best to use the self tapping screws without the draft fan to
33. n draft fan cover wide open and hot coals or ashes are excessive in ash pan 10 Install grate frame if not already installed Lay 12 Installing Firebrick Place 5 bricks on each side 10 the first grate frame on the side supports and slide to brick total The bricks tuck under firebox seem the back of the unit Then install the second grate frame to the front as shown in the picture above Page 16 USSC 13 Installing front and rear cast baffles heat plates NOTE Grate frames and brick will slide forward and backward to allow baffle to fit Install front cast baffle using two 2 5 16 bolts nuts amp washers 7 16 wrench will be needed Place the side of the baffle that has the two ribs against the front weld of the firebox Do not tighten bolts yet Place the rear cast baffle to the back of the firebox but do not attach the bolts at this time 15 Installing smoke damper rod to sliding smoke damper First insert rod through hole above feed door and push forward 14 Now slip the rear heat plate in behind the rear baffle 16 Nextworking through the flue hole behind furnace line Attach heat plate to the firebox by using two 2 5 16 bolts nuts amp washers First line up the top holes and tighten bolts Secondly line up the holes in the rear baffle and the heat plate with the firebox and attach by using two 2 5 16 bolts nuts amp washers Tighten all four 4 bolts NOTE to reach rear bolts you ma
34. oal with high sulfur content will de stroy chimneys especially fast if soot sits in the flue for extended lengths of time It is important to clean chim neys regularly Page 25 Trouble Shooting TROUBLE SHOOTI NG PROBLEM SOLVI NG FOR YOUR FURNACE 1 Problem Smoke puffs from furnace Solution Check chimney draft Check for blocked chim ney or flue pipe Use mirror to check chimney clearance Check ash pit if too full empty Make sure furnace room is not too airtight Make sure all chimney mortar connections are air tight Check clean out door Make sure it s airtight Check chimney for possible down draft caused by taller surrounding trees or objects Correct with proper chimney vent cap Check the possibility of cold chimney forcing cool gas blockage Remedy by properly insu lating chimney with noncombustible liner and non combustible insulation H Fuel may be too wet Make sure no other fuel burning devices are connected to the chimney impairing the draft UNS m Problem Inadequate heating being delivered to your home Solution Check home insulation is it adequate B Check hookup to furnace is it installed cor rectly review manual Coolairinlet may be inadequate or furnace room too airtight 14 inlet for 12 outlet D Your wood fuel may be too low grade Hard woods are recommended Make sure your hot air duct and other duct work is air
35. p minimize creosote buildup Also placing a surface magnetic thermometer on flue pipe is helpful to keep tem peratures at 300 to 400 degrees Duct temperatures should be 115 to 125 degrees at 12 above furnace BURNI NG COAL Your furnace is capable of burning both Bituminous and Anthracite coal Anthracite is perhaps the best coal fuel because its long even burn time high heat output and cleanliness make it a good choice for the home However keep in mind itis a much more difficult fuel to use requires more care and patience is not so widely available and is usually much more expensive than bituminous SIZE OF COAL Most sizes of Bituminous Coal will work in your New Furnace for best results we recommend large nut coal to small egg coal 1 3 4 dia to 4 dia When burning Anthracite use egg or broken with sizes between 2 5 16 thru 4 3 8 Note that it is important to the long life of your furnace to buy coal which has been sized and cleaned Cleaning insures removal of rocks and other materials Never use coal smaller than 1 or larger than 5 in diameter Small sized coal will smother the fire Too large a size of coal will not burn well STOVE OPERATION All coal fires should be started with wood which will allow the fire to get hot enough to ignite 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 addition of the
36. red coals fall into the ash pan Excessive shak ing wastes fuel and can expose the grate s to very high temperatures 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 burned off close the feed door and adjust your stove pipe damper Then adjust your thermostat 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 open the ash pit door and feed door place newspaper finely split kindling on the grate and light the paper Add larger hard wood after kindling is burning brightly 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 they 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
37. ristor Provides even flow of current to snap disk 9 prevents electrical surges provides longer life of snap disk Transformer Reduces voltage 110 volts to 12 volts for 10 thermostat usage Generally hums a bit The above is somewhat basic however it s offered so you can understand your furnaces electrical functions and en joy it more USSC ELECTRICAL COMPONENTS Wall Thermostat 110 degrees Adjustable Thermo Disk 140 degrees Thermostat 170 degrees Thermo Limit Disk Relay Transformer Air Distribution Fan Draft Fan Control Box Components Your new furnace is now completely assembled and ready to be installed Make sure you followed the sections on installation in the front of this manual OPERATI ON OF YOUR NEW WOOD BURNI NG FURNACE Check that your draft blower is in working order before lighting a fire cover setting 2076 open Do this by turning the room thermostat to a high tempera ture so that the draft blower turns on then turn the ther mostat back to proper setting thus turning the draft air blower off Should draftblower not function check to see if rheostat setting is on NOW PROCEED WITH LI GHTI RE 1 Pullbypass damper out opens up flue hole 2 Make sure your flue pipe damper is open Place sev eral pieces of crumpled paper in the center of your firebox Ina crisscross pattern place a couple of hand fuls of dry kindling wood then several small dry pieces of firewood
38. ted shake the grate just a little and you will be ready to refuel Page 24 DO NOT burn coke charcoal high volatile bituminous coal sub bituminous lignite or cannel coal sometimes called channel coal or candle coal NEVER burn wax or chemi cally impregnated sawdust logs their intended use is for fireplaces only NEVER fill your stove or furnace above the firebrick or cas iron liner SHAKING Shaking should be done only when there is a hot fire The frequency of shaking will depend on the degree of burning Shaking should be done at least once a day and preferably twice a day Best results from shaking the rocker grates will occur if short choppy strokes are used rather than long even strokes The amount of shaking is critical Too little or too much of both can result in the extinguishing ofa fire due to blocked air flow The proper amount normally occurs when red coals first start to drop through onto the bed of ashes No furnace ever should be poled from the top This can lead to clinker formation and compacting of the coal and ashes which results in clogged air passages USSC ASHES Ashes never should be allowed to accumulate in the ash pitso that they in any way impede the flow of combustion air to the fire Excess ash accumulation can cause the fire to go out and also can cause severe damage to the grates because of the absence of a cooling flow of air beneath them Ashes always should be emptied
39. tight If furnace room is warm but your home isn t check back draft dampers Is air inletto the blower open Check filters Fuel may be too wet Check draft blower cover setting 1 2 open ing J Rheostat setting is fully open m Problem Excess smoke flames coming out door when refueling Solution Open bypass damper Wait 15 seconds and open door slowly then refuel B Check length of flue pipe to chimney Your unit should be within six 6 feet of your chimney C sure chimney cap is not too close to the top of the chimney D Check chimney draft make sure chimney flue pipe is clean and chimney is of adequate height E Make sure you re not suffocating the fire with excess amounts of unburned fuel Page 26 4 6 7 9 Problem Distribution blower vibrating Solution Tighten Allen Screw on squirrel cage B Check for bad fan bearings C Also oil 3 4 drops of 20w non detergent oil Problem Distribution blower continues to run or will not run Solution A Check tosee if thermodisc 110 degrees top right side is faulty Use match or lighter for click or jumper wire B Check to see that blower is properly wired See Wiring and Assembly Instructions Problem Draft blower continues to run or will not run Solution Check rheostat switch for on position Check wiring B Check thermostat or thermostat wire for short C Make sure
40. y find iteasier to put your arm through the flue outlet rather than to reach through the feed door USSC up rod between the two posts on the sliding smoke damper Then line up the three 3 holes for cotter pin insertion this procedure will test your patience It s helpful to have a flashlight and another person posi tioning the rod Page 17 17 Reposition door latches feed and ash door For shipping purposes door latches are on backwards Unfasten 7 16 nuts reverse and snug fairly tight latches must move freely 18 Installing steel smoke shield Two 2 holes are pro vided above each corner of the feed door Slide the two 2 bolts supplied in the parts bag into the holes Next place the two 2 clips provided onto each bolt and then attach the two 2 nuts on each bolt Before tightening the bolts and nuts securely slide the smoke shield up under the clips lining them with the slots in the smoke shield Tighten the 2 bolts and nuts NOTE The smoke shield should be able to swing back and forth The smoke shield will help prevent smoke back puffing if you havea lazy flue Page 18 19 Attach flue pipe to flue collar Flue pipe 6 fits inside furnace flue collar Finish off with three 3 metal screws NOTE Flue pipe connections flow downward so creosote can return to furnace for burn up USSC Accessories Filter Box Part 24CRM NOTE DRAWINGS ARE FO
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