Harman VF3000 User manual

Installation & Operating Manual
VF3000 Coal Stoker Boiler
R4
SAFETY NOTICE
Please read this entire manual before you install and use your new room heater. Failure
to follow instructions may result in property damage, bodily injury, or even death.
FOR USE IN THE U.S. only. NOT SUITABLE FOR INSTALLATION IN MOBILE HOMES
IF THIS boiler IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT. FOR YOUR SAFETY, FOLLOW INSTALLATION DIRECTIONS. INSTalLATION should be performed by a qualified installer.
CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION
REQUIREMENTS IN YOUR AREA.
Contact your local authority (such as municipal building department, fire department, fire
prevention bureau, etc.) to determine the need for a permit.
this appliance is also approved for installation into a shop.
save these instructions.
# 3-90-70741
Contents
Introduction
4
Specifications 5
Hot Water Coil
5
Warnings
6
Packing List
7
Assembly 8
Venting 11
Installation
14
Verti-Flow™ Stoker Control 17
Operation
19
Feed Adjustment
19
Maintenance 20
Troubleshooting
22
Aquastat Installation
23
Feeder Parts List
25
Wiring Diagram
26
Service Parts 27
Warranty
29
Introduction
The VF 3000 Stoker Boiler features our patented Verti-Flow™ Coal Feeder. The
VF 3000 has a 5,000 to 95,000 BTU range and 250 lb. coal hopper capacity.
An aquastat is used to activate the feeder when more heat is needed to maintain the
set water temperature. When the Aquastat senses the water is at the set temperature the
feeder stops feeding coal. Now the Verti-flow™ Stoker Control takes over to maintain
a very low fire until more heat is needed.
Properly installed and maintained, your VF 3000 will heat your home for a lifetime.
Therefore, have your unit professionally installed. Consult with your Harman Dealer
regarding proper maintenence.
Specifications/Hot Water Coil
Hot Water Coil
To install a hot water coil:
1. Remove the blank plate covering the water coil opening.
2. Insert the coil into the boiler as shown. Be sure to put a new gasket around the coil plate.
3. Tighten all bolts evenly.
4. Fill the boiler and check for leaks before and after the boiler is up to temperature. Rust caused by
a leak can reduce the life of the boiler.
5. A tempering valve may be installed between the in and out pipes to reduce the maximum water
temperature at the tap. NOTE: This hot water coil is rated at 4 gallons per minute.
Warnings
Never sleep in the same room with any coal burning stove.
Always empty the hopper when not burning for more than a week. When left standing
for long periods with wet coal, the pusher block will rust and corrode, causing it to seize.
If the stoker is then turned “on”, damage to the pusher assembly and feed motor will
result. This will be considered neglect and will void the warranty on those parts. Always
check to see if moving parts are free before using if the unit has not been burned for a
period of time. This can best be determined by shaking the adjuster rod.
Freshly delivered coal is typically watered down to minimize dust when loading and
unloading. Wet rice coal does not flow as well as damp or dry coal, and may bind or
bridge in the hopper. We do not recommend loading your hopper with wet coal. If you
must burn wet coal, the feed rate will likely need increased, in order to get the same size
fire. As the wet coal in the hopper dries out, the feed rate will need decreased to avoid
over-feeding. Using wet coal, in an emergency, will likely not damage your stove as
long as it is hot and burning at the time. The damage is caused when the hopper has wet
coal in it when the stove is cold. This will cause rust and corrosion which is considered
neglect and will not be covered by the product warranty.
Appliance Placement: The VF3000 must be installed on a non-combustible floor.
The non-combustible floor must also extend a minimum of 18” in front of the firebox
door, and 8” to the sides. Maintain a minimum of 18” of clearance to combustible
walls, 24” to the ceiling and keep combustible materials a minimum of 36” away from
in front of the appliance.
This boiler may be connected to an existing boiler heating system. Inter-connection may
be done in a series or parallel configuration. Consult with your licensed plumber or HVAC
professional to determine the most effective installation for your heating needs.
This unit must be connected to a chimney capable of providing a -.04 minimum draft.
WARNING: If the chimney has no draft, coal gases may escape from the unit and stove
pipe. These gases are toxic and can be fatal. It is recommended that a CO detector be
installed to warn of this condition.
Packing List
Inside bag;
(2) Crimp -on terminals for Aqua
Sensor
(4) #8-32 X 1/2” screws and nuts to
mount the timer control box.
NOTE: Although required for
unit completion, the Feeder and
Hopper are sold as separate items.
Adapter Plate
Pressure Relief
Valve
Temp/Pressure
Gauge
Aquastat-(3 Pieces)
and Sensor
(2) Grate Inserts
Firebricks
Grate Holder
with Gasket
Combustion Blower
Assembly
Top
Left Side
Hopper
Support
Front
Door
Blank
Boiler
Hopper - Sold
separately
Cleaning Rod
Spring Handle
Adapter
Plate
Right Side
Baffle
Clean out slide
Base Jacket
Flue Pipe
Base
Ash Tub
Flue Plate
The VF3000 is reversible as to which end the
hopper and flue pipe are located. Therefore, a decision
must be made as to which way will work best for your
situation.
If you woud like to have the flue to the right and
the hopper to the left, make sure the gaskets are in place
on both the flue pipe and flue plate. Bolt the flue pipe
on the right end and the flue plate on the left end of the
base. Next, the baffle must be slid into place on the right
end with the center of the base. Note the baffle and flue
pipe must always be at the same end and opposite the
hopper.
Next, place the base jacket around the base and
clamp into place with the four clamping bolts on the
front of the base. The hole in the jacket goes around the
flue pipe.
Ash Door
Place 1/4” x 1” gasket around the flat edge on top
of the base. Now place the boiler on top of the base with
the feeder opening opposite the flue pipe. Place 1/4” x 1”
gasket around the door openings on the boiler. Bolt the
door mount on the front door opening with 5/16” x 1”
flat head bolts. Bolt the door blank on the rear opening
with 5/16” x 1” hex head bolts.
Now the outer jacket can be installed. The front
jacket with the coil hole must be installed first. Next,
the two sides which hold the front in place and then the
top which holds the sides in place.
Assembly
Hopper left, flue right
Hopper right, flue left
Feeder
Begin assembly by sliding the pusher block with the adjuster rod from the front through the slot shown
in Fig. 1. Be sure the pusher block is turned with the bolt hole to feed indicator side. Next, hold pusher block
in the most rearward position and slide the adjuster tube over the adjuster rod until it bottoms out on the pusher
block. Thread the adjuster, then the wing nut on the end of the adjuster rod.
Put gasket around the opening on the adapter plate. Slide the feeder through the plate and bolt together
with two 5/16 x 3/4” bolts. Next, install the grate holder.
Grate
Fig. 1
The grate is composed of four pieces: the grate holder,
(2) grate inserts, and firebrick angle. The firebrick angle
is bolted to the grate holder with (2) 3/8” x 1 1/4” bolts.
Before installing the grate holder, 3/8” round gasket must
be checked in the groove on the bottom side of the grate
holder, as shown in fig. 4. Check to be sure the gasket has
not been damaged. Locate the flange at the rear of the grate
holder into the slot on the feeder as shown at left. Bolt
the front end down snug with the 1/4” x 20 allen bolt and
nut provided. The rear end will be
Fig. 2
locked in place by the flange.
Before completely tightening the
bolt, be sure the grate holder is
back as far as possible and centered side to side on the feeder
opening.
Assembly
10
Fig. 4
Fig. 3
Snug these bolts only.
Grates and Firebrick
Lay the two grate inserts into the grate holder as
shown. Divide the spaces between the grates equally
and be sure they are not tight. The spaces are needed
for expansion. The grate inserts can also be installed or
removed after the feeder is in place.
Place the two firebricks on the grate angle and make
the two bolts snug on the adapter plate as shown.
Apply 1 inch flat gasket around the feeder opening
and insert the feeder and adapter plate into the boiler and
tighten. NOTE: You will need a 3/4” socket to do this.
Blower
Remove one of the screws on the intake screen, and
install the blower restrictor plate. Install the blower on
the bottom of the feeder by sliding it into the bracket as
far as it will go. NOTE: The bolt holes on the blower
flange are not used.
Control Box
Install the control box on mounting pad provided on
the side of the stoker with (4) #8-32 bolts and nuts.
Plug the gear motor into the top receptacle, and the
combustion blower into the middle receptacle on the
control box. The bottom receptacle is not used.
Hopper
Insert small end of hopper into the hopper slot on
the feeder. Push top of hopper under the hopper support,
causing the slot on the bottom side of the support to
hook onto the hopper. The hopper support will spring
up slightly for the hopper to go under. If you have difficulty getting the hopper under, you can raise the top
slightly.
The feed motor cover can now be installed.
Venting
Chimney Connectors and Chimneys
Draft
Draft is widely misunderstood. It is important that you,
the stove operator, realize that draft is a variable effect,
not a given quantity. Stoves and chimneys do not have
draft, yet draft is the key to your stove’s performance.
Draft is a force, produced by an operating stove and
the chimney to which it is attached. It is created by
hot gases rising up the chimney, creating a pressure
difference between the inside of your home and the
outside air. It continually moves fresh combustion air
into the stove, and hot exhaust gases out of the stove;
without this constant flow, the fire will go out.
Other factors, such as barometric pressure, winds,
the tightness of the home, the total inside chimney
volume, chimney height and the presence of venting
devices such as exhaust fans also play a role in maintaining an adequate draft. Low barometric pressures,
super insulated homes, and exhaust fans can reduce
draft; winds can play havoc with draft; and too large or
too small a chimney volume can cause reduced draft
due to the excessive cooling or not enough room to
vent the exhaust gases. Introducing outside air directly to the stove may help remedy a low draft problem.
Some signs of inadequate draft are smoking, odor,
difficulty in maintaining the fire, and low heat output.
Overdraft can be caused by a very tall chimney even
if it is the recommended size, and can cause overfiring of your stove. Signs of an overdraft include rapid
fuel consumption, inability to slow the fire, and parts
of the stove or chimney connector glowing red. It is
important that you follow the chimney guidelines in
this manual, including size, type, and height to avoid
draft problems.
When installed and operated according to this manual,
the appliance will produce enough hot gases to keep
the chimney warm so that adequate draft is maintained
throughout the burn cycle.
Chimney Connectors
In general, following these guidelines will ensure
compliance with all national and provincial codes; prior
to beginning your installation, check with your local
building code official(s) regarding any additional local
requirements or regulations which may influence the
design and placement of your venting system.
The VF3000 may be installed with (.6 mm) 24 gauge
chimney connector pipe. The size of the connector
should correspond to the size of the flue collar opening.
Do not use makeshift components.
11
No part of the chimney connector may pass through
an attic or roof space, closet or other concealed space,
or through a floor or ceiling. Whenever possible, avoid
passing the connector through a combustible wall; if you
must, use an approved wall pass-through, described
later in this section.
Assemble the connector beginning at the flue collar,
with the crimped ends pointing towards the stove (to
keep debris and creosote flakes inside the system).
Each joint, including the one to the stove’s flue collar
and the one to the chimney itself should be secured
with at least three sheet metal screws. Screws may be
a maximum of 3 inches apart. A 1-1/4" (32 mm) overlap
is required at each joint, including the flue collar attachment. No more than two 90 degree elbows should be
used, and the total length of connector should not exceed 10 feet (3m) All horizontal runs of connector must
have a minimum upward slope of 1/4" per foot (20 mm
per meter).
Wall Pass-thrus
Occasionally it is necessary to pass the chimney
connector through a combustible wall to reach the
chimney. Depending on your local building codes, and
the pertinent provincial or national codes, there are
several choices for accomplishing this safely. Before
beginning your installation, contact local officials, and
also the chimney connector and chimney manufacturer
for specific requirements.
Canada. Three methods are approved by the
Canadian Standards Association. The diagram shows
one method requiring an 18" (460 mm) air space
between the connector and the wall. It allows use of one
or two covers as described in the diagram. The other
two methods are described in detail in the current issue
of CAN/CSA B365, the national standard.
United States In the U.S., the national code is NFPA
211. While many localities adopt this standard, be sure
to check with local authorities before beginning your
installation.
The NFPA (National Fire Protection Association)
permits four methods for passing through a combustible
wall. A commonly used method to pass through a wall
directly to a masonry chimney is to clear a minimum
12"(305 mm) around the entire chimney connector, and
fill it with brick masonry which is at least 3.5"(90 mm)
thick. A fireclay liner, minimum 3/8" (9 mm) wall thickness
must run through the brick wall to the chimney liner (but
not beyond the inner surface of the liner). It must be
cemented in place with refractory cement. This method
is illustrated. For details on the other three options, refer
to the most recent edition of the NFPA 211 code.
Venting
12
Hole with a minimum
clearance of 18" (450 mm)
between connector and wall.
Non-combustible cover, one
side only. If two covers are
used, each must be mounted
on non-combustible spacers
at least 7/8" (21mm) away
from the wall.
Closest
Combustible
Material
Minimum 2" (50mm)
Clearance to Brick
Chimney Flue
Liner
1" (25mm)
Clearance
Minimum 12"
(300mm) to Brick
Fire Clay
Thimble
Chimney
Connector
Masonry Chimney Built to
NFPA 211 Specifications.
AN APPROVED CANADIAN
WALL PASS-THROUGH
The Chimney
This unit must be installed into a chimney approved
for use with solid-fuel appliances. In the U.S., it must
be connected to (1) a prefabricated chimney complying with the requirements for Type HT chimneys in
the Standard for Chimneys, Factory-Built, Residential
Type and Building Heating Appliances, UL 103, or (2)
a code-approved masonry chimney with a flue liner.
In Canada, this unit is listed for use with prefabricated chimneys tested and listed to the high temperature
(650 degrees C) chimney standard, ULC S-629, or
with a code approved masonry chimney.
The minimum recommended height for any chimney
is 16 ft (4.8 m) above flue collar height. A round flue
(either masonry or approved prefabricated), of either
6" (150 mm), 7" (180 mm) or 8" (200 mm) may be
used. For square or rectangular masonry chimneys,
nominal sizes of 8" x 8" or 8"x 12" (200mm x 200 mm,
200 mm x 300 mm) may be used.
Codes require that solid-fuel chimneys extend 3
ft (0.9 m) above the highest point at which they exit
from the roof. Then, the chimney must extend 2 ft.(6
m) above the highest point within a 10 ft (3 m) radius.
Thus, the 3 foot, 2 foot, 10 foot rule:
3ft. - Above roof exit point
2ft. - Higher than anything within10ft. of the chimney.
Minimum 12" (300mm)
to Combustibles
AN APPROVED U.S.
WALL PASS-THROUGH
Do not connect this unit to a chimney
flue servicing another appliance.
This VF3000 Is Approved To Burn
Anthracite “Rice” Coal Only.
More Than 10 ft. (3m)
10 ft. (3m)
2 ft. (0.6m) min.
Ridge
Height Necessary
Above Any Roof Surface Within 10ft. (3m)
3ft. (0.9m)
minimum
above
exit
point
Chimney
The 3-foot, 2-foot, 10 foot rule
Venting
13
Existing Masonry Chimneys
If you plan on using a pre-existing masonry chimney,
have it thoroughly inspected and cleaned. Any faults
which make the chimney unsafe and unusable must be
repaired prior to use. These can include improper height,
structural defects, blockages, inadequate clearance to
combustibles, unsealed openings into other rooms of
the house, signs of creosote or smoke leakage, a loose
or absent clean-out door, or absence of a liner.
Do not connect to any air distribution
duct or system
Venting to a Masonry Chimney
When connecting to a masonry chimney, several
provisions are standard. First, whether the chimney
connector is vented to the chimney through a thimble
or a breech pipe, neither must pass beyond the inner
surface of the chimney liner, and both must be firmly
cemented in place with refractory cement. (A thimble is
a masonry pipe which is inserted through the chimney
wall, and is frequently the preferred method; a breech
pipe is a piece of steel pipe used the same way.) In
Canada, a breech pipe has ridges or protrusions to lock
it firmly into the refractory cement. In either case, the
chimney connector vents to the chimney through the
thimble or breech pipe.
Using a thimble, the connector slides completely
inside the masonry to the inner edge of the flue liner,
and may be easily removed for chimney and connector
inspection. A breech pipe must extend at least 2" (50
mm) into the room, so the connector can be attached
with sheetmetal screws.
Do not burn any fuel other than coal. Never use highly
volatile substances in your stove, such as gasoline,
which could cause an explosion.
When solid fuels are burned completely, they produce
water and carbon dioxide. However, in long slow burns,
a substantial amount of carbon monoxide may be produced. If allowed to build up, carbon monoxide (which is
odorless) can prove fatally poisonous. Proper ventilation
and draft will prevent this from happening. If you smell
smoke, thoroughly ventilate your dwelling. Contact your
dealer to arrange for a draft test.
Other causes of poor ventilation or draft are icing,
Venting to a Masonry Fireplace Chimney
exhaust fans, a blocked outside air inlet, and room air
In some situations, a code compliant chimney origistarvation. If your stove is sluggish and you get occanally used for a masonry fireplace may be used to install
sional odor, check these possibilities and increase the
your stove. In addition to the requirements found in the
air flow in your home.
previous paragraphs, it is important to be aware that
all clearances must be met, including those from the
chimney connector to combustibles. Do not forget to
include floor protection in your plans. (See Clearances
and Floor Protection in this section.) Since many fireplaces have exposed wooden mantels and trim, pay
special attention to the clearances necessary to these
Installing to a Prefabricated Chimney
materials.
When venting your stove using a prefabricated chimIf your fireplace chimney is behind a combustible wall,
ney,
be sure to contact local building code authorities,
you must use an approved wall pass-through system
and
to
follow the manufacturer’s instructions exactly.
to gain access to the masonry chimney. The chimney
Use
only
the manufacturer’s parts; do not use makeshift
connector must enter the chimney at a place where it is
lined, and the fireplace must be made inoperable. For installation techniques. All prefabricated chimneys must
example, you might remove the damper, replacing it with be tested to either the U.S. or Canadian high-temperaa secure, airtight, noncombustible seal (removable for ture standards, UL 103 or ULC S629.
inspection); this also satisfies the requirement that no
room air must be allowed to enter the chimney.
14
Installation
Aquastat and Wiring
See page 23 for assembly and mounting details. Pay close attention to the jumper positioning inside
the A350 and S350 controls. Also note the sensor and its wire length when considering the mounting location. Remember that 212° f. is boiling temperature and must be avoided. Be sure to incorporate a means for
flowing water in the event of an over-heat condition. Coal can not just stop burning when there is no demand
for heat. Never fire a boiler with no water in the system. Serious consequences will result.
Installation
Fresh water in- with
automatic fill
15
Heated domestic water
Air Scoop
System Return
System Supply
Tempering Valve
Expansion Tank
Temp. / Pressure Gauge
Aqua Sensor Well
Pressure Relief
Aquastat
Circulator Pump
Boiler Drain
Basic Plumbing
This is a basic plumbing hook up. Your system may vary depending on many factors.
Therefore, we recommend having experienced personnel do the plumbing.
This is only one of many layouts possible. Cirulator pumps, zone valves, and thermostats are not supplied with the unit because the amount and type of these parts vary with every
system. It is best to have a professional plumber do the job.
Installation
16
Clearances
Installation
Place the boiler a minimum of 18” from a wall. The flue pipe must be at least 18” from
anything combustible. The rear of the hopper should be a minimum of 36” from the wall.
The boiler should be placed on a non-combustible floor. Secure all chimney connector pipe
joints with a minimum of 3 sheet metal screws.
Draft Test Procedure
Attach a draft meter to the vent pipe on the boiler side of
the barometric damper (if installed). With a fire established,
the chimney draft should be between -.04 and -.06 inches
of Water Column. If the flue draft exceeds these readings,
install and adjust the barometric damper accordingly.
DO NOT operate if the flue draft exceeds -.10 inches Water
Column ( -24.9 Pa).
Next, remove the allen head set screw from the center of
the firebox door and attach your draft meter. The firebox
draft should be -.04 to -.05 in W.C. Adjust the combustion
blower restrictor plate, closed to increase the draft or open
to decrease firebox draft.
Combustion Blower
Restrictor Plate
Verti-Flow™ Stoker Control
17
0.75 A
MAX LOAD
1.25 A
MAX LOAD
COMPONENT RECEPTACLES - ON SIDE
0.5 A
MAX LOAD
VERTI - FLOW ™
STOKER CONTROL
Verti-Flow™ Stoker Control
This section describes the features and operations
of the Harman Verti-Flow™ Stoker Control. The timers are
adjustable from 0 minutes to 15 minutes in 1 minute steps.
There are red lights on the front panel to show proper operation of the timer. One indicator shows power is applied
to the unit. The other three indicators show when power is
available at the adjacent receptacle.
The stoker control will be mounted on the side panel
of the feeder directly below the coal hopper. The three receptacles and switch will be facing forward while the power
cord, 3 AMP fuse access port and the thermostat connections
will be to the rear.
18
Verti-Flow™ Stoker Control
The Verti-Flow™ Stoker Control
The top receptacle (0.5 A) provides power to the coal
feeder motor. Thus, the plug from the coal feeder motor
should be inserted into this receptacle.
The center receptacle (0.75 A) provides power for the
combustion blower motor. Thus, the plug from the combustion blower should be inserted into this receptacle.
The bottom receptacle (1.25 A) is not used.
The thermostat connections on the back panel of the
stoker control are .25 inch male quick connect terminals.
The mating connectors (supplied) should be .25 inch
female quick connector terminals. The wire should be
no smaller than 22 gauge.
The thermostat connections should be connected to
the aquastat as shown on the wiring diagram.
The AC power cord should be the last connection made.
The power cord should be plugged into a 115 VAC / 60
hertz wall outlet, which has proper grounding available.
This 115 AC volt wall outlet should also be capable of
handling 3 amps of current because this is the maximum
amperage this unit will draw.
How to operate the Stoker Control
There are four operator interfaces on the Stoker Control. The operator interfaces are: one (1) rocker switch
and three (3) 16-position rotary switches.
The rocker switch is a power switch that controls only
the coal feeder motor. For normal operation this switch
should be placed in the “on” position. This switch’s
operation can be verified by a small red light above the
coal feeder receptacle being on when the switch is on.
The off position is used for lighting the fire.
The other three switches are the customer’s adjustments for the timers (on timer, off time, distribution
blower time). These switches can adjust each timer
individually from 1 minute to 15 minutes in 1 minute
increments. Do not set pilot mode timers to 0.
The “on” time and the “off’ time should be programmed to a minimum time that keeps the coal
burning during the maintenance cycling mode. The
distribution blower time should be set to 0. This is because the VF 3000 doesn’t have a distribution blower.
The Verti-Flow™ Stoker Control is also used on the Magnum Stoker which does use this timer.
Recommended timer settings to start are: “on” 4
minutes, “off” 12 minutes, extend timer 0 minutes.
You may find that these settings produce too much
heat in pilot mode. If so, you can reduce the “on”
time and increase the “off” time. However, we do not
recommend going below 4 minutes with the on time
for efficiency reasons.
Do not connect this unit to a chimney flue
servicing another appliance.
DANGER- Risk of Fire or Explosion;
DO NOT burn garbage, gasoline, drain oil or
other flammable liquids.
CAUTION- Hot While in Operation;
- Keep Children Away
- Do Not Touch
Operation
19
Fill the boiler and plumbing system with water prior to lighting!
Starting a fire
Feed Indicator
Fill the hopper with rice coal. With the aquastat calling
for heat, the coal will begin to feed onto the grate inside
the stove. This process can be accelerated by adjusting the
feed rate to the maximum position. When the coal starts
to come up out of the grate and is almost up to the area
where the holes start, turn the feed adjuster back about
2 turns and turn off the feed motor with the switch on
the side of the control box. Whether using wood pellets,
charcoal, or kindling and paper, mix your starter material
with the coal on the grates, for best results. Use a match
to light the fire or starting material.
After the coal is burning, the feed motor can be turned
on and the coal fire will continue to get larger. Fresh coal
will continue to be pushed onto the grate and ashes will
be pushed off the grate. The feed rate must be adjusted
so the coal is burned up and turned to ashes before the
coal gets to within one inch of the end of the grate. Too
high of a feed rate will push unburned coal off the coal
grate, therefore wasting fuel.
Feed Adjustment
The feed indicator on the side of the feeder shows how
far the pusher moves each stroke. There are dots above
the indicator spaced 1/8” apart. A movement of one dot
would give a low burn, two dots medium and three dots
high. Lock the adjuster with the wing nut after adjusting
feed rate.
After the fire is burning and the feed rate is adjusted,
you can now set the aquastat to the desired water temperature.
Maintenance
20
Ash Removal
With each hopper of coal that is burned, approximately
one ash pan full of ashes must be removed. Failure to remove ashes will result in a blocked grate and the fire will
Spring not burn properly. Remember, the ash pan will be hot, so
handle always wear protective gloves.
Ashes should be placed in a metal container with a tight
fitting lid. The closed container of ashes should be placed
on a non-combustible floor or on the ground, well away
from all combustible materials, pending final disposal. If the
ashes are disposed of by burial in soil, or otherwise locally
dispersed, they should be retained in the closed container
until all cinders have thoroughly cooled.
Weekly:
The small tray in the side of the stoker should be removed
and emptied.
The spring handle located at the center of the unit should
be cycled in and out several times. This action cleans the
interior of the heat exchanger and causes the dust to fall
into the ashpan.
Every 3 months:
Baffle slide
Slide open
The grate “clean-out” slide should be opened and reclosed
as shown in drawings below.
In the “closed” position, be sure the “grate clean-out”
plate slide is straight across as shown.
The easiest way to handle this slide is through the ash door with a poker inserted into the hole at the end. The
purpose of this operation is to let any ash build-up, under
the grate, fall into the ash tub.
This operation can be performed while the unit is burning. However, you should first lower the thermostat to
lower the stove temperature and be sure you are wearing
protective gloves.
Slide closed
Maintenance
The operation can also be performed when the unit is
not burning by lifting the grate inserts out and removing
the ash with a vacuum cleaner.
Remove baffle slide as shown and remove fly ash.
Annually:
21
Hopper Maintenance: Always empty the hop-
per when not burning for more than a week.
Pusher Block Maintenance: When left standing for long periods with wet coal, the pusher block
will rust and corrode, causing it to stop. If the stoker
is then turned “on”, damage to the pusher assembly
and feed motor will result. This will be considered
neglect and will void the warranty on those parts.
If the unit has not been burned for a period of time,
always check to see if moving parts are free before
using. This can best be determined by shaking the
adjuster rod.
The end of the heating season is the best time to perform
annual maintenance. Rust and corrosion can form much
faster in the high humidity of summer, so cleaning your
VF 3000 will prevent those damages.
1. Remove all coal from the hopper
2. Remove all ashes
3. Remove and clean flue pipe
4. Check chimney and clean if necessary
5. Remove hopper and check for rust at bottom edges.
If rust is found, remove it with a file or sandpaper then
paint the area with spray paint available at your Harman
dealer.
6. Check the feeder for rust and corrosion where the hopper fits into it.
7. Check pusher block to be sure it moves freely. This
can best be done by shaking the adjuster rod. If it does
not move freely, it should be removed and cleaned. Also
remove any rust or corrosion from the area where the
pusher block slides and spray with WD-40 or other rust
preventing spray. To remove pusher block, remove cover,
wing nut, adjuster and adjuster tube. Remove motor mount
Adjuster Rod
with motor in place and cord still attached. Swing pusher
assembly up as high as it will go. Remove feed indicator
from side with allen wrench. Now the pusher block can be
CAUTION:
removed. To reinstall, just reverse procedure. If the pusher
- Inspect flue pipes, joints, and seals regublock cannot be removed, call your Harman dealer.
larly to ensure that smoke and flue gases
are not drawing into the dwelling.
- Cleaning of the heat exchanger, flue pipe,
WARNING- Risk Of Fire;
chimney, and draft inducer if used, is espe- DO NOT Operate with flue draft exceeding cially important at the end of the heating
-.10 in Water Column (-24.9 Pa.)
season to minimize corrosion during the
- DO NOT operate with fuel loading or ash summer months caused by accumulated
removal doors open.
ash.
- DO NOT store fuel or other combustible - DO NOT use chemicals or fluids to start a
material within specified installation fire.
clearance areas.
- DO NOT burn garbage, gasoline, naptha,
- INSPECT and clean chimney flue system engine oil, or other inappropriate materials.
and chimney connectors regularly.
22
Troubleshooting
Feeding Problems
Wet Coal: Wet coal does not flow the same as dry coal,
therefore; the feed rate will change with wet coal. If
it is too wet, it may not feed at all. Wet coal can also
cause a sulfur odor.
Wrong Size Coal: The Verti-Flow™ System is designed to burn rice coal (or buckwheat coal if rice is
not available). If buckwheat coal is burned, raise the
draft setting from .04 to .06. Larger coal will not feed
or burn properly.
Hopper Blocked: Sometimes wood, paper, or other
foreign objects accidently end up in your coal bin and
can slow down or block the flow of coal. You may have
to empty the hopper to find the blockage.
Pusher Out of Adjustment: This can happen when
more than one person tend the stoker. One person does
not tell the others what adjustments were made.
Gas Odor Problems
Gas Alarm Goes Off or Sulfur Odor Exists: A sulfur
smell may be noticed when a door is opened during
operation with wet or damp coal. This is normal. However, it is not recommended that wet coal be used or
the doors be opened for more than a few seconds while
burning to inspect the fire or remove ashes.
Lack of Draft or a Down Draft in the chimney: These
will cause gases to escape from the unit. No unit will
function properly without draft. Any draft problem
should be corrected before use.
A draft inducer may be installed to increase
draft in marginal situations. The installation should
be performed by your dealer who is factory trained to
correct any problems on initial start up. After proper
installation, many years of trouble-free operation can
be expected.
Stoker Control Troubleshooting
Problem: No motors or lights will turn on.
Solution:
1. Check AC power cord to the stoker control
2. Check the 3 amp fuse on the side panel of the
stoker timer. (replace only with a 3 amp 3 ag slow
blow fuse.)
Problem: Lights on the stoker control are on, but motors will not operate.
Solution: Check the AC power plugs from the motors
(are they securely plugged into the correct outlet?)
Problem: One of the motors will not operate.
Solution: Check if the light above the receptacle is
lit. Check the AC power plug from the motor (is it
securely plugged into the correct outlet?”
Problem: The motors are cycling on and off, but not
in the correct order.
Solution: Check the AC power plugs from the motors
(are they securely plugged into the correct outlet?)
Problem: Coal feeder motor will not turn on.
Solution: Check if the red light is lit, if not, check if
the feeder motor switch is turned on.
Problem: The motors turn on and off as programmed,
but the water temperature is below the thermostat
setting.
Solution: Check the connections from the stoker
control to the aquastat.
AQUASTAT INSTALLATION
23
AQUASTAT INSTALLATION
(a350My350, s350)
1. Lay the din rail on a flat surface with the flat side down. Secure one end clamp on the left side.
2. From the right side, slide the A350 control onto the din rail. Slide the control to the left until it is
against the end clamp.
3. Repeat Step 2 with the Y350 power module, connecting it to the A350 control. NOTE: Be careful
when fastening the plug-together connecters located at the top of the controls.
4. Repeat Step 3 with the S-350 control, connecting it to the Y350 power module.
5. Install the other end clamp to the right side of the din rail.
6. Remove the covers on the three controls by using the four screws on each control. (A350, Y350,
S350)
7. Install the terminal box to the controls by using the three chase nipples and locknuts supplied with
the kit.
8. Mount the terminal box with controls to the boiler jacket or any other desired location by the four
holes in the terminal box.
9. Using two 8-32 nuts, install the terminal block over the studs located in the terminal box.
10. A350 Control: 1) Set the jumpers to the heat position. They may already be in this position. 2) Set
the differential to the desired set point. 3) Terminate the wires using the common and the normally
open terminals.
11. Y350 Control: 1) Terminate the power wiring using the 120 VAC terminals on the control. This
will be supplied from the terminal block located in the terminal box.
12. S350 Control: 1) Set the offset to the desired set point. 2) Set the differential to the desired set
point. 3) Set the jumpers to the cooling position. 4) Terminate the wiring using the common and the
normally open terminals.
13. Set the A350 control to the desired water temperature.
14. After locating and installing the sensor well and sensor, wire the sensor to the A350 control. The
terminals marked “sen” and “com” are located in the upper left-hand corner of the A350 control. Make
sure the sensor is inserted into the well fully and secured with a setscrew.
15. Reinstall the covers on the three controls
16. NOTE: Sensor wire can be lengthened up to 50 feet with standard 22 awg t-stat wire. Shielded
cable is generally not required for sensor wiring runs of less than 50 feet. However, if over 50 feet,
follow this guide:
WIRE GAUGE/SHIELDED CABLE LENGTH
14 awg.....................800 feet
16 awg.....................500 feet
18 awg.....................310 feet
20 awg.....................200 feet
22 awg.....................124 feet
24
AQUASTAT
Feeder Parts List
25
M
M
1. (2) grate inserts #4-00-00046
18. cam arm #3-50-00054
2. grate holder w/ angle #1-10-01000
19. dust tray #2-00-00055B
3. grate angle #3-00-00218
20. feed indicator #2-00-00056
4. feeder body #1-10-00687
21. cam bearing #3-31-3014
5. clean-out slide #2-00-00048P
22. gasket #1-00-43375
6. pusher arm #1-10-00025
A. (4) 1/4 x 1/2 #3-30-1252005013
7. (2) pillow block bearing #3-31-324122
B. (3) 1/4” nut #3-30-80252013
8. feed motor #3-20-60075
C. 3/8 x 1 #3-30-3037161002
9. capacitor #3-20-69654
D. (2) 3/8” washer #3-30-02003714
10. motor mount #1-10-00031P
E. (2) 3/8” nut #3-30-80371613
11. pusher block #3-50-00026
F. 1/4” x 1 1/4” Allen #3-30-3025201502
12. adjuster rod #2-00-08011
G. (4) 10-32 x 5/8” Allen #3-30-3010320622
13. adjuster tube #1-10-00050P
H. #10-32 screw and nut #3-30-608320501/8010321
14. adjuster #2-00-00051D
I. (1) 1/4” x 1/2” grade 8 #3-30-1252005014
15. wing nut #3-30-8131181
J. (3) 5/16” x 3/4” #3-30-1311807513
16. motor cover #2-00-00052P
K. (3) 5/16 nut #3-30-80311813
17. cam arm cover #2-00-00053P
L. (1) 1/4” x 5/8” button head #3-30-3125200622
M. (2) 3/8 x 1-1/2” #3-30-1371615013
26
Wiring Diagram & Fuel
Coal
Approved For Use With Anthracite Rice Coal Only.
Anthracite coal is “hard coal”, mined primarily
in the northeast United States. Rice coal, as shown
at right, is typically described as coal having no dimension larger than 3/8”. Other size coal may cause
feeding problems, and is therefore not recommended
for use in your VF3000.
It is best to buy your supply of coal when the
temperature is above freezing. This is because many
dealers put kerosene or fuel oil on the truck box and
calcium on the coal to keep it from freezing while it
is being transported. The calcium can promote rust
and the oil may cause an odor depending on what type is used.
It is best and most convenient to have a coal bin
inside and close to the boiler. The bin should have
drainage to allow the water to drain.
DO NOT store fuel within the specified clearance
area.
Rice Coal
VF3000
Service Parts
Service Parts diagram
Coal Stoker Boiler
Beginning Manufacturing date: n/a
ending Manufacturing date: active
1-70-03241
1
2
3
4
Part number list on following page.
01/10
Service Parts
VF3000
Service Parts list
Coal Stoker Boiler
Beginning Manufacturing date: n/a
ending Manufacturing date: active
1-70-03241
IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement
parts for your appliance please provide model number and serial number. All parts listed
in this manual may be ordered from an authorized dealer.
IteM
deSCrIPtIOn
COMMentS
Part nuMBer
Stocked
at harman MFg
1
Hopper assembly
1-00-4677373
2
Verti-flow coal feeder assembly
1-00-00004
Y
3
Timer control box
3-20-44322
Y
4
Feeder body weldment
1-10-00687
Y
5
Door handle
4-00-00042
Y
Aquastat replacement for White Rodgers
1-00-03500
Y
Ash pan (galvanized tub - 12 gallon/#1) (available locally)
3-41-01882
Bearing 3/8 ID X 1-1/8 OD
3-31-3014
Y
Blower 75cfm - 22 in cord
3-21-07522
Y
Capacitor 370 Vac motor run
3-20-69654
Y
Capacitor Holder Kit
3-20-36533
Cast grate insert (2 per)
4-00-00046D
Combustion blower restrictor plate
2-00-01023
Controller a350aa-2c
3-10-1350112
Y
2-00-00036
Y
Feeder cam block
3-50-00054
Y
Feeder cam block assembly
1-10-00102A
Y
Feeder dust tray
2-00-00055
Y
Fuse holder - (timer control box)
3-20-00900
Y
Gasket 1/2” Rope (ash pan door)
1-00-53500
Y
Gasket 1” w/adhesive - 1 ply (feeder gasket)
1-00-88100
Y
Gasket 1” w/adhesive - 2 ply (fire door)
1-00-88250
Y
Gearmotor-1/80hp - 4.5rpm
3-20-60075
Y
Grate angle
3-00-00218
Y
Grate holder assembly
1-10-01000
Y
Oil burner optional
1-00-01050
Oil to coal on/off control assembly
1-10-01205A
Y
3-31-324122
Y
Power supply y350r-1c
3-10-935071
Y
Pusher arm weldment
1-10-00025
Y
Pusher block w/all thread
3-50-00026
Y
Pusher block assembly w/tube
1-10-00099
Y
Sensor/a350 control appbc-25c (aquastat well sensor)
3-10-2992225
Y
Door latch
Pillow block - 3/4” flange
Spring handle - brass plate 1/2”
Stage module s350aa-1c
Qty 2 req
Qty 2 req
Qty 2 req
Qty 3 req
Y
3-40-00086-3
3-10-7350111
Thermostat-low voltage
3-20-12080
Well wel11a-601r
3-10-935111
Y
Y
01/10
Warranty
29
HARMAN™ CENTRAL HEATING PRODUCTS LIMITED WARRANTY
Hearth & Home Technologies Inc., on behalf of its Harman™ brand (”HHT”), extends the following warranty for all
Harman™ furnace and boiler products (“Products”) that are purchased from an HHT authorized dealer.
Warranty Coverage: Subject to the conditions, exclusions and limitations set forth below, HHT warrants to the original owner of the Products, and to any transferee taking ownership of the Products at the site of original installation
within two years following the date of original purchase, that the Products will operate free from defects in material
and workmanship under normal conditions and use, as described in the operating instructions furnished with the Product, during the warranty period described below. HHT will, at its option, repair or replace any Product covered by this
warranty that is determined to be defective in material or workmanship. Warranty Period: The warranty period runs for six years, except for mechanical and electrical components, which
are warranted for three years. The warranty period begins on the earlier of: (i) the date of invoice for the Product; (ii)
in the case of new home construction, the date of first occupancy of the residence or six months after the date of sale
of the Product by an HHT authorized dealer, whichever occurs first; or (iii) the date 24 months following the date of
Product shipment from HHT, regardless of the invoice or occupancy date.
Warranty Conditions: This warranty applies only to Products: (i) installed, operated, and maintained as recommended
in the Product user’s manual; (ii) purchased through an HHT authorized dealer; (iii) while remaining at the site of
original installation; and (iv) that have not been altered after leaving the factory.
How to File a Claim: Claims must be made within the warranty period to the dealer who sold the Product. If that
dealer cannot provide the warranty service, contact the nearest HHT authorized dealer. Additional service fees may
apply if you are seeking warranty service from a dealer other than the dealer from whom you originally purchased the
Product. Travel and shipping charges for parts are not covered by this warranty.
Warranty Exclusions: This warranty does not cover the following: (1) consumable and normal wear items, including, without limitation, flame guides, grates, coal bars, afterburner hoods, fire brick, gaskets, paint, glass discoloration,
burnpot housing weldments, burnpot grate weldments (pellet or corn), burnpot front plates (pellet or corn), burnpot
front plate locks, corn auger extensions, ceramic inserts, and ceramic insert plates; (2) noise caused by minor expansion, contraction or movement of parts; (3) damage resulting from: (i) failure to install, operate or maintain the
Product according to the installation and operating instructions and listing agent identification label furnished with the
Product; (ii) failure to install the Product according to local building codes; (iii) shipping or improper handling; (iv)
abuse, misuse, continued operation with damaged, corroded or failed components, accident, or incorrectly performed
repairs; (v) environmental conditions, inadequate ventilation, negative pressure or drafting caused by tightly sealed
construction, insufficient make-up air supply, or handling devices such as exhaust fans or forced air furnaces or other
such causes; (vi) use of fuels other than those specified in the operating instructions; (vii) installation or use of components or accessories not supplied with the Product or authorized and approved in writing by HHT; (viii) modification of the product not expressly authorized and approved by HHT in writing; or (ix) interruptions or fluctuations of
electrical power supply to the Product; (4) non-HHT components or accessories used in conjunction with the Product;
(5) the Products’ capability to heat a desired space; information is provided to assist the consumer and the dealer in
selecting the proper Product for the application; consideration must be given to Product location and configuration,
environmental conditions, insulation and air tightness of the structure; or (6) additional or unusual utility bills incurred
due to any malfunction or defect in Products. Limitations of Liability: Repair or replacement in accordance with the provisions of this warranty will be the owner’s
exclusive remedy for and will constitute HHT’s sole obligation under this warranty, under any other warranty (express
or implied), or in contract, tort or otherwise. No employee, agent, dealer, or other person is authorized to give any
warranty on behalf of HHT. TO THE EXTENT ALLOWED BY LAW, HHT MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. HHT WILL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES
ARISING OUT OF DEFECTS IN OR USE OF THE PRODUCTS. Some states do not allow exclusions or limitation
of incidental or consequential damages, so these limitations may not apply to you. This warranty gives you specific
rights; you also may have other rights, which vary from state to state. The duration of any implied warranty is limited
to the duration of the warranty period specified herein.
30
Notes
Notes
31