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Owner's Installation and Operation Manual
Model HB1440E
Wood Only Central Furnace
Report No. 0215WH055S
This unit is certified UL-391(R2014)
U.S. ENVIRONMENTAL PROTECTION AGENCY
Certified to comply with the 2016 particulate
emission standards. Not approved for sale after
May 15, 2020
Installation is to be preformed by a
qualified installer.
SAVE THESE INSTRUCTIONS
United States Stove Company
227 Industrial Park Rd.
852854-3901F
South Pittsburg, TN 37380
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Summary of Contents for Hotblast HB1440E
- Page 1 Owner’s Installation and Operation Manual Model HB1440E Wood Only Central Furnace Report No. 0215WH055S This unit is certified UL-391(R2014) U.S. ENVIRONMENTAL PROTECTION AGENCY Certified to comply with the 2016 particulate emission standards. Not approved for sale after May 15, 2020 Installation is to be preformed by a qualified installer. SAVE THESE INSTRUCTIONS United States Stove Company 227 Industrial Park Rd.
- Page 2 CAUTION: • Power source not controlled by furnace main disconnect. • Respect all local and national codes when installing this unit. • This unit is not to be connected to a chimney flue serving another appliance. • This unit is designed to burn solid hardwood only. 49” 24-1/16” 34” 2” 40” 34”...
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Page 3: Specifications
Volume: 5.2 cubic feet Cubic Feet: Door Opening: Width x Height: 11.6” X 11.5” Weight (lbs): 509lbs This manual describes the installation and operation of the Hotblast, HB1440E wood heater. This heater meets the 2016 U.S. Environmental Protection Agency’s emission limits for wood heaters sold after May 15, 2016. Under specific EPA test conditions this heater has been shown to deliver heat at a rate of 18,850 – 56,000 BTU/hr. This heater achieved a particulate emissions rate of 0.39 lb/mmBtu when tested to method CSA B415.1-10 (*and an overall 0215WH055E efficiency of 62.6 %). The maximum overall heat output of this heater was tested to be 89,000 Btu/hr. - Page 4 Safety • WARNING: Do not operate with fuel loading or ash removal doors open. • Do not connect this unit to a chimney flue serving another appliance. • WARNING DANGER: Risk of fire or explosion. Do not burn garbage, gasoline, naphtha, motor oil, or other inappropriate materials. Do not use chemicals or fluids to start the fire. • WARNING: Risk of fire. Do not operate with flue draft exceeding .060” water column/14.93 Pascals. Do not operate with fuel loading and ash removal doors open. Do not store fuel or other combustible materials within marked installation clearances. Inspect and clean flues and chimney regularly. • CAUTION: Hot surfaces. Keep children away. Do not touch during operation. • The heat exchanger, flue pipe, and chimney must be cleaned regularly to remove accumulated creosote and ash. Ensure that the heat exchanger, flue pipe, and chimney are cleaned at the end of the heating season to minimize corrosion during the summer months. The appliance, flue pipe, and chimney must be kept in good condition. These instructions also apply to a draft inducer if used. To prevent flame or smoke spillage, the slide baffle must be pulled out and the fuel loading door left cracked for 10 seconds prior to opening door fully. Load fuel carefully or damage may result. • Hot while in operation. Keep children, clothing and furniture away. Contact may cause skin burns. • Do not use chemicals or fluids to ignite the fire. • Do not leave the furnace unattended when the door is slightly opened. • Do not burn garbage, flammable fluid such as gasoline, naphtha or motor oil. • Always close the door after the ignition. • Consult your municipal building department or fire officials about permits, restrictions and installations requirements in your area. • INSPECT FLUE PIPES, FLUE PIPE JOINTS, AND FLUE PIPE SEALS REGULARLY TO ENSURE THAT SMOKE AND FLUE GASES ARE NOT DRAWN INTO, AND CIRCULATED BY, THE AIR-CIRCULATION SYSTEM. • CAUTION: CLEAN OUT OF THE HEAT EXCHANGER, FLUE PIPE CHIMNEY, AND DRAFT INDUCER, IF USED, IS ESPECIALLY IMPORTANT AT THE END OF THE HEATING SEASON TO MINIMIZE CORROSION DURING THE SUMMER MONTHS, CAUSED BY ACCUMULATED ASH.
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Page 5: Tools And Materials Needed For Installation
Unpacking And Preassemble UNPACKING 1. Remove all packaging from the furnace. 2. Remove the supplied parts from the furnace. BRICK ALIGNMENT Inspect for any damage. Ensure that the bricks and ash plug are positioned correctly and not broken (see illustration for proper brick arrangement). Proper Fire Brick Alignment TOOLS AND MATERIALS NEEDED FOR INSTALLATION The following is a list of tools and materials needed to install your furnace. • 7/16” socket wrench. • 5/16” socket (Best if using a power drill and a socket bit). • Pair of pliers or channel-locks. -
Page 6: Furnace Installation
Furnace Installation INSTALLATION OPTIONS The installation of this furnace includes supplying electrical power, return (fresh air) ductwork, and supply air ductwork. This furnace may be installed in two different configurations. 1. Stand alone wood furnace 2. Add-on wood furnace See kit installation section in this manual to ensure proper assembly, installation and operation of your new furnace. -
Page 7: Floor Protector Requirements
MAINTENANCE CLEARANCES Your furnace has recommended minimum maintenance clearance requirements. These clearances insure that there is adequate room to preform maintenance and service your furnace. DO NOT store fuel within the specified clearances. See the table and diagram below to determine the clearances for your furnace. Dimension Inch mm Maintenance Clearance (Front) 24 Maintenance Clearance (Left) Maintenance Clearance (Right) 24 Maintenance Clearance (Rear) MAINTENANCE CLEARANCE FLOOR PROTECTOR The furnace must be placed on solid concrete, solid masonry, or when installed on a combustible floor, on a floor protector. The floor protector is required to provide heat, live ember, and ash protection and must be of a non- combustible, continuous solid surface to protect against infiltration of live embers and ash. Floor protection must have and R-Value of at least 2.8. Refer to floor protector manufacturer’s instructions for installation directions. The floor protector or non combustible floor must extend under the furnace and beyond each side as shown below. Back wall Dimension Inch Front Flue rear Left Right Flue Side FLOOR PROTECTOR REQUIREMENTS... -
Page 8: Duct Work Installation
Duct Work Installation We strongly recommend that the hot air ductwork be installed by a home heating specialist. If doing the installation yourself, before you decide which installation will best suit your needs, consult a qualified heating technician and follow his recommendations as to the safest and most efficient method of installation. This furnace can be installed in three ways, as a stand alone unit, parallel, and in series with an existing furnace. SUPPLY AIR (HOT AIR) PLENUM The warm-air supply duct shall be constructed of metal in accordance with NFPA 90B, 2-1.1. The plenums installed to the furnace shall be constructed of metal in accordance with NFPA 90B, 2-1.3. -
Page 9: Air Filter Replacement
CENTRAL INSTALLATION Air Filter Replacement... -
Page 10: Accessory Installation
Accessory Installation ASSEMBLY OF FURNACE THERMODISC Your furnace requires the following items to be assembled or installed by the service person: THERMODISC COVER Blowers and Blower Controls Electrical Connections 1. Remove all parts from the unit (blowers, thermodisc, and all wiring) and inspect for damage, including the firebrick as some 4” ELECTRICAL breakage could occur during shipment. JUNCTION BOX 2. Install the thermodisc on rear of furnace cabinet with the two screws provided. Mount the conduit assembly from the junction box to the thermostat bracket. Crimp the two female terminals BLOWERS... -
Page 11: Electrical Installation
Electrical Installation All electrical connections should be done by a qualified electrician It is recommended to connect the furnace to its own 15 amp 120 Volt circuit from the house power supply 105°C NOTE: Wire leads from the distribution blower are usually BOTH BLACK. Makes no difference which leads from the motor(s) connects to the corresponding leads coming out of the conduit. -11-... -
Page 12: Importance Of Proper Draft
Chimney Installation CHIMNEY Your wood furnace may be hooked up with a factory built or masonry chimney, matching the diameter of the exhaust. If you are using a factory built chimney, it must comply with UL 103 or CSA-B365 standard; therefore it must be a Type HT (2100°F). It is extremely important that it be installed according to the manufacturer’s specifications. If you are using a masonry chimney, it is important that it be built in compliance with the specifications of the National Building Code. It must be lined with fire clay bricks, metal or clay tiles sealed together with fire cement. (Round flues are the most efficient). The interior diameter of the chimney flue must be identical to the furnace smoke exhaust. A flue which is too small may cause draft problems, while a large flue favors rapid cooling of the gas, and hence the build-up of creosote and the risk of chimney fires. Note that it is the chimney and not the furnace which creates the draft effect; your furnace’s performance is directly dependent on an adequate draft from your chimney. Do not connect this unit to a chimney flue serving another appliance. The following recommendations may be useful for the installation of your chimney: • It must rise above the roof at least 3’ (0.9m) from the uppermost point of contact. • The exterior portion should be double or triple wall pipe to ensure proper draft. • The chimney must exceed any part of the building or other obstruction within a 10’ (3.04m) distance by a height of 2’ (0.6m). -
Page 13: Masonry Chimney
MASONRY CHIMNEY Ensure that a masonry chimney meets the minimum standards of the National Fire Protection Association (NFPA) by having it inspected by a professional. Make sure there are no cracks, loose mortar or other signs of deterioration and blockage. Have the chimney cleaned before the furnace is installed and operated. When connecting the furnace through a combustible wall to a masonry chimney, special methods are needed as explained in the “Combustible Wall Chimney Connector Pass-Throughs” Section. -13-... -
Page 14: Combustible Wall Chimney Connector Pass-Throughs
COMBUSTIBLE WALL CHIMNEY CONNECTOR PASS-THROUGHS Method A. 12” (304.8 mm) Clearance to Combustible Wall Member: Using a minimum thickness 3.5” (89 mm) brick and a 5/8” (15.9 mm) minimum wall thickness clay liner, construct a wall pass-through. The clay liner must conform to ASTM C315 (Standard Specification for Clay Fire Linings) or its equivalent. Keep a minimum of 12” (304.8 mm) of brick masonry between the clay liner and wall combustibles. The clay liner shall run from the brick masonry outer surface to... -
Page 15: Chimney Connector
CHIMNEY CONNECTOR Your chimney connector and chimney must have the same diameter as the furnace outlet. If this is not the case, we recommend you contact your dealer in order to insure there will be no problem with the draft. The furnace pipe must be made of aluminized or cold roll steel with a minimum thickness of 0.021” or 0.53 mm. It is strictly forbidden to use galvanized steel. Your connector should be assembled in such a way that the male section (crimped end) of the pipe faces down. Attach each of the sections to one another with three equidistant metal screws. Seal the joints with furnace cement. The pipe must be short and straight. All sections installed horizontally must slope at least 1/4 inch per foot, with the upper end of the section toward the chimney. Any installation with a horizontal run of furnace pipe must conform to NFPA 211. You may contact NFPA (National Fire Protection Association) and request the latest edition of the NFPA Standard 211. -
Page 16: Factory Built Chimney
FACTORY BUILT CHIMNEY When a metal prefabricated chimney is used, the manufacturer’s installation instructions must be followed. You must also purchase (from the same manufacturer) and install the ceiling support package or wall pass-through and “T” section package, firestops (where needed), insulation shield, roof flashing, chimney cap, etc. Maintain proper clearance to the structure as recommended by the manufacturer. The chimney must be the required height above the roof or other obstructions for safety and proper draft operation. -16-... -
Page 17: Air Controls
OPERATING THE PRIMARY AND SECONDARY AIR SETTINGS Primary air- is the driving air supply that feeds the fire in the heater. This air is introduced through the damper in the feed door to sustain the combustion. Secondary air – is the air supply that is typically introduced above the fire to effectively “re-burn” the smoke created in the primary combustion before the exhaust gasses exit the stove. This air is preheated before being injected into the heater so it can react with (re-burn) the smoke when they mix. When increasing the amount of primary air supplied to the heater, the secondary should also be increased as well to ensure a clean burn. Rear Pilot/Tertiary Air – The air that is introduced at the back of the firebox and is to help sustain heat in the secondary air to help ensure a cleaner burn. Start up: During Start-up the Primary and the Secondary air adjustments should be in the fully open or the “High” FULLY CLOSED setting positions. This allows for the maximum amount of combustion air during the initial start-up to insure the Primary Air Damper fastest and cleanest start-up. These settings should remain open until the stove has heated up and an adequate... -
Page 18: Do Not Burn
Operation The top down method of fire building is recommended for this appliance. After making sure that the stove air intake controls are fully open (open all three air controls to there maximum setting). Place the largest pieces of wood on the bottom, laid in parallel and close together. Smaller pieces are placed in a second layer, crossways to the first. A third layer of still smaller pieces is laid crossways to the second, this time with some spaces between. Then a fourth layer of loose, small kindling and twisted newspaper sheets tops off the pile. Higher efficiencies and lower emissions generally result when burning air dried seasoned hardwoods, as compared to softwoods or to green or freshly cut hardwoods. DO NOT BURN: 1. Garbage; 10. Salt water driftwood or other previously salt water 2. Lawn clippings or yard waste; saturated materials; 3. Materials containing rubber, including tires; 11. Unseasoned wood; or 4. Materials containing plastic; 12. Paper products, cardboard, plywood, or 5. Waste petroleum products, paints or paint particleboard. The prohibition against burning thinners, or asphalt products;... -
Page 19: Testing Your Wood
NOTICE: To minimize the risk of smoke spillage when opening the door with a fire in your furnace, crack the door open no more than 1” and wait for at least 10 seconds before opening it more to allow pressure stabilization inside the furnace. Smaller pieces of wood will dry faster. All logs exceeding 6” in diameter should be split. The wood should not be stored directly on the ground. Air should circulate through the cord. A 24” to 48” air space should be left between each row of logs, which should be placed in the sunniest location possible. The upper layer of wood should be protected from the elements but not the sides. TESTING YOUR WOOD When the furnace is thoroughly warmed, place one piece of split wood (about five inches in diameter) parallel to the door on the bed of red embers. Adjust all air controls to there maximum settings and close the door. If ignition of the piece is accomplished within 90 seconds from the time if was placed in the furnace, your wood is correctly dried. If ignition takes longer, your wood is damp. If your wood hisses and water or vapor escapes at the ends of the piece, your wood is soaked or freshly cut. Do not use this wood in your furnace. Large amounts of creosote could be deposited in your chimney, creating potential conditions for a chimney fire. THE FIRST FIRES The fresh paint on your furnace needs to be cured to preserve its quality. Once the fuel charge is properly ignited, only burn small fires in your furnace for the first four hours of operation. Never open the air control’s more than necessary to achieve a medium burn rate. -
Page 20: Ash Disposal
OPERATION Controlled combustion is the most efficient technique for wood heating because it enables you to select the type of combustion you want for each given situation. The wood will burn slowly if the wood furnace air intake control’s are adjusted to reduce the oxygen supply in the combustion chamber to a minimum. On the other hand, wood will burn quickly if the air control’s are adjusted to admit a larger quantity of oxygen in the combustion chamber. Real operating conditions may give very different results than those obtained during testing according to the species of wood used, its moisture content, the size and density of the pieces, the length of the chimney, altitude and outside temperature. WARNINGS: • Never over fire your furnace. If any part of the furnace starts to glow red, over firing is happening. Readjust the air intake control at a lower setting. • The installation of a log cradle or grates is not recommended in your wood furnace. Build fire directly on firebrick. • Never put wood above the firebrick lining of the firebox. RELOADING Once you have obtained a good bed of embers, you should reload the unit. In order to do so, open the air controls to maximum a few seconds prior to opening the furnace’s door. Then proceed by opening the door very slowly. Then bring the red embers to the front of the furnace and reload the unit. For optimal operation of your wood furnace, we recommend you to operate it with a wood load approximately equivalent to the 3/4 of the height of fire bricks. It is important to note that wood combustion consumes ambient oxygen in the room. In the case of negative pressure, it is a good idea to allow fresh air in the room, either by opening a window slightly or by installing a fresh air intake system on an outside wall. Creosote - Formation and Need for Removal - When wood is burned slowly, it produces tar and other organic vapors, which combine with expelled moisture to form 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. The chimney connector and chimney should be inspected at least twice monthly during the heating season to determine if a creosote build-up has occurred. If creosote has accumulated (3mm or more), it should be removed to reduce the risk of a chimney fire. -
Page 21: Over Firing
CAUTIONS: • Ashes could contain hot embers even after two days without operating the furnace. • The ash pan can become very hot. Wear gloves to prevent injury. • Never burn the furnace with the ash trap open. This would result in over firing the furnace. Damage to the furnace and even house fire may result. TAMPER WARNING This wood heater has a manufacturer-set minimum low burn rate that must not be altered. It is against federal regulations to alter this setting or otherwise operate this wood heater in a manner inconsistent with operating instructions in this manual. VISIBLE SMOKE The amount of visible smoke being produced can be an effective method of determining how efficiently the combustion process is taking place at the given settings. Visible smoke consist of unburned fuel and moisture leaving your stove. Learn to adjust the air settings of your specific unit to produce the smallest amount of visible smoke. Wood that has not been seasoned properly and has a high wood moisture content will produce excess visible smoke and burn poorly. Use the included moisture meter to insure your wood has a 20% or less moisture content. EFFICIENCY Efficiencies can be based on either the lower heating value (LHV) or the higher heating value (HHV) of the fuel. The lower heating value is when water leaves the combustion process as a vapor, in the case of wood stoves the moisture in the wood being burned leaves the stove as a vapor. The higher heating value is when water leaves the combustion process completely condensed. In the case of wood stoves this would assume the exhaust gases are room temperature when leaving the system, and therefore calculations using this heating value consider the heat going up the chimney as lost energy. Therefore, efficiency calculated using the lower heating value of wood will be higher than efficiency calculated using the higher heating value. In the United States all wood stove efficiencies should be calculated using the higher heating value. The best way to achieve optimum efficiencies... -
Page 22: Maintenance
Maintenance Your wood furnace is a high efficiency furnace and therefore requires little maintenance. It is important to perform a visual inspection of the furnace every time it is emptied, in order to insure that no parts have been damaged, in which case repairs must be performed immediately. Inspect and clean the chimney and connector pipe periodically for creosote buildup or obstructions. GASKET It is recommended that you change the door gasket (which makes your furnace door air tight) once a year, in order to insure good control over the combustion, maximum efficiency and security. To change the door gasket, simply remove the damaged one. Carefully clean the available gasket groove, apply a high temperature silicone sold for this purpose and install the new gasket. You may light up your furnace again approximately 24 hours after having completed this operation. This unit’s feed door uses a 3/4” diameter rope gasket. This unit’s ash door uses a 1/2” diameter rope gasket. PAINT Only clean your furnace with a dry soft cloth that will not harm the paint finish. If the paint becomes scratched or damaged, it is possible to give your wood furnace a brand new look by repainting it with a 1200° F heat resistant paint. For this purpose, simply scrub the surface to be repainted with fine sand paper, clean it properly, and apply thin coats (2) of paint successively. AIR TUBES The air tubes assembled in this unit are designed to provide an accurate mix of secondary air to insure the highest efficiency. Any damage or deterioration of these tubes may reduce the efficiency of combustion. The air tubes are held in position by either screws or snap pins. Locate these to either side of the tube and remove to allow the tube to be removed and replaced. -
Page 23: Replacement Parts
Replacement Parts Part No. Description Part No. Description 22761 Ring, Flue Collar 68217 Feed Door Assy. (1500) 40246 Flue Collar, 6” C.i. 610499 Tertiary Damper Assy. 88032 Gasket, Flue Collar 27901 Tertiary Damper Shield 27883 Cabinet Back 89574 Handle, Spring 25562 Cabinet Top 891098 Handle Assembly 891214 Stub Collar, 8” 610496 Assembly, Ash Door 25467 Cabinet Side 610498 Ash Pan... - Page 24 Replacement Parts Part No. Description 68234 Assy, Blower/T’stat Brkt. 68231-1 Fan Cntrl Cord Assy 80131 4 X 4 Junction Box 80232 Supply Cord 68231-2 Fan Cntrl Cord Assy 80594 Blower Assembly 89319 Blower Gasket 68231-3 Fan Cntrl Cord Assy 22140 Control Mounting Bracket 80714 F140 Thermodisc 80231 Cover, Junction Box In order to maintain warranty, components must be replaced using original manufacturers parts purchased through your dealer or directly from the appliance manufacturer.
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Page 25: Service Record
Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider: Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. -
Page 26: Limited Warranty
Limited Warranty Warm Air Furnace The operation of this heater in a manner inconsistent with the owner’s manual will void the warranty and is also against federal regulations. United States Stove Company warrants to the original purchaser its heating products against premature failure of any component due to workmanship, quality, or materials as follows: TIME PERIOD: Firebox ............................ - Page 27 Notes...
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Page 28: How To Order Replacement Parts
How to order Replacement Parts This manual will help you obtain efficient, dependable service from your stove, 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 stove. 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 ________________________________________________________________________________ 4. The serial number _________________________________________________________________________________ United States Stove Company 227 Industrial Park Road South Pittsburg, TN 37380 (800) 750-2723 www.usstove.com...
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