failing secondaries Clayton furnace

[NFN]

I have used my Clayton (US stove) wood furnace for 5 winters, essentially running it full time for 3-4 months per winter. Works great, but the secondary system is falling apart.

Two rectangular tube arms support the 4 secondary tubes which in turn support 1" thick ceramic fiber planks.

The rectangular tubes split open and are warping. Two secondary tubes fell down. I replaced the two tubes with rebar just to hold the ceramics planks up.

Yes, I know its a cheap stove, you get what you pay for yada yada. I monitor and control flue temperature, 300-500 degrees F.

My Questions are :

do the ceramic planks serve a purpose other than to give the secondaries a chance to burn?

If the rectangular tubes completely fail and I remove the ceramic planks, is that ok?

Is the secondary system repairable?

 

[brenndatomu]

The "ceramic plates" are called baffles, and yes, they are important...without the baffles, or the secondary air tubes, you have an old school "campfire in steel box" type wood furnace...much less efficient, and much dirtier burning.
If it's only 5 years old I'd think you could still order replacement parts for it.
What model is it? Have pics?

 

[NFN]

Thanks for your reply. It's a model cf700m. I think it was designed when secondaries were a new idea.

Actually I've used it 6 winters. Time flies.

I'm guessing the fire box was fully welded after the secondary system was installed inside, so the only access is through the door. Would require cutting the rectangular tubes and welding. Probably not feasible through the door. I reached out to US stove. No response yet.

Overall, the furnace has worked great, but the rectangular tubes are made of cheap steel. I hope the firebox itself is made of something better. That's what I get for using eBay!

 

[brenndatomu]

USSC is not known for quality...I doubt any of the steel in that machine is anything great.
Those secondary burn systems like that have been common since the 80s when the EPA first put emissions limits on wood stoves...wood furnaces however were not forced to clean up their act until 2017 though...at that point USSC just copied an existing design from a competitor (competitor had much better quality)
I would say any welder/fabricator worth his salt could cut out, replicate, and retrofit a replacement secondary air system...might have to buy the tubes themselves from USSC though, the size, location, and quantity of those holes is critical.
The baffles however can be replaced with aftermarket ceramic insulation board, if they need to be.

 

[brenndatomu]

This brand is who I am pretty sure they copied their design from...here's a link to the newest model...these guys are basically the company store and often put em on sale for $3500ish (w/free shipping) closer to spring

https://www.myfireplaceproducts.com/us/en/heaters/wood-furnaces/

 

[NFN]

Thanks. I'll check with a local chimney sweep to see if he knows of a wood furnace repair guy.

 

[NFN]

I heard from US Stove. Not helpful at all. Obviously didn't read my first communication. After I explained the problem again, the person offered no suggestions.

I would not purchase a US stove again. My furnace is sort of a beginners unit (although it is considerably more complex than a plain stove) and it was not expensive, but I didn't expect significant repairs after 6 winters. I would have guessed a 10+ year life.

 

[brenndatomu]

You made it at least 1 more year past anything I would have bet on!
I would have said 3-5 and toast!

 

[brenndatomu]

If you want 10 years, try the Heat Commander...if you want 20-30 (probably more like 30+) try a Kuuma Vaporfire

 

[R Henderson]

I heard from US Stove. Not helpful at all. Obviously didn't read my first communication. After I explained the problem again, the person offered no suggestions.

I would not purchase a US stove again. My furnace is sort of a beginners unit (although it is considerably more complex than a plain stove) and it was not expensive, but I didn't expect significant repairs after 6 winters. I would have guessed a 10+ year life.

I wasn't impressed with US stove either several years ago mom and dad had a regular stove of that brand and within the first year the top was warped, door required tightening about twice a week, second year the bottom grated burnt out, (mind you they didn't run it hard either) replaced grate with cut sections off a road grader blade. If I recall I think the blower died early on too. The king stove that it replaced was at least 25 years old and is actually still in use in dads shop while in the house the USSC is long gone.

As stated above if you have a relativity long burn season it may be worth looking at a heat commander or kuuma I upgraded this year from an old school furnace and my consumption has dropped significantly and much easier to keep going not having to babysit it.

 

[NFN]

Thanks. Hopefully I can hold my Clayton furnace together until spring and then take it apart to see if there are other issues. If it's fixable I will. If not, then I'll look into a heat commander or kuuma. Or a propane furnace. The thought of removing my Clayton and bringing in a new 600 pound wood furnace is not appealing.

 

[brenndatomu]

Or a propain furnace.

Fixed that spelling for you...