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Installation & Operating Manual
VF3000 Coal Stoker Boiler
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3 Contents Introduction 4 Specifications 5 Hot W ater Coil 5 W arnings 6 Packing List 7 Assembly 8 V enting 1 1 Installation 14 V erti-Flow™ Stoker Contr ol 17 Operation 19 Feed Adjustment 19 Maintenance 20 T r oubleshooting 22 Aquastat Installation 23 Feeder Parts List 25 W iring Diagram 26 Service Parts 27 W arranty 29
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4 Introduction The VF 3000 Stoker Boiler features our patented Verti-Flow™ Coal Feeder. The VF 3000 has a 5,000 to 95,000 BTUrange 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 mor
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Specifications/Hot Water Coil Hot W ater Coil T o install a hot water coil: 1. Removethe blank plate covering the water coil opening. 2. Insert the coilinto the boiler as shown.Be sure to puta new gasket around the coil plate. 3. Tighten allbolts evenly . 4. Fill the boiler and check for leaks before and afterthe boileris upto temperature. Rust caused by a leak can reduce the life ofthe boiler. 5. A temperingvalve may be installed betweenthe i
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Warnings Never sleep in the same r oom 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
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7 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 r equir ed for unit completion, the Feeder and Hopper ar e sold as separate items. Pressure Relief Valve Adapter Plate Temp/Pressure Gauge Aquastat-(3 Pieces) and Sensor (2) Grate Inserts Firebricks Combustion Blower Grate Holder with Gasket
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Assembly Top Left Side Hopper Support Front Door Blank Boiler Hopper - Sold separately Cleaning Rod Spring Handle Adapter Right Side Plate Baffle Clean out slide Base Jacket Flue Pipe Base Ash Tub Flue Plate The VF3000 is reversible as to which end the Ash Door hopper and flue pipe are located. Therefore, a decision must be madeas to which waywill work best for your situation. If you woud like to have the flue to the right and the hopper to the left, make sure
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9 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
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10 Assembly Fig. 4 Fig. 3 Grates and Fir ebrick 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 Snugthese bolts only. for expansion. The grate inserts can also be installed or removed after the feederis in place. Place the two firebricks on the grate angle and make the two bolts snug on theadapter plate as shown. Ap
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11 Venting Chimney Connectors and Chimneys No part of the chimney connector may pass through draft an attic or roof space, closet or other concealed space, Draft is widely misunderstood. It is important that you, or through a floor or ceiling. Whenever possible, avoid the stove operator, realize that draft is a variable effect, passing the connector through a combustible wall; if you not a given quantity. Stoves and chimneys do not have must, use an approved wall pass-through, described d
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12 Venting Non-combustible cover, one side only.If two coversare used, each must be mounted Hole witha minimum Closest on non-combustiblespacers clearance of 18" (450 mm) Combustible Minimum 2" (50mm) at least 7/8" (21mm) away between connectorand wall. Material Clearanceto Brick from the wall. Minimum 12" Liner (300mm) toBrick FireClay Thimble Chimney 1" (25mm) Connector Clearance Masonry Chimney Built to NFPA 211 Specifications. Minimum 12" (300mm)
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13 Venting 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 dis
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14 Installation Aquastat and W iring 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 loca- tion. 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
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1 Installation Fresh water in-with Heated domestic water AirScoop automatic fill SystemReturn System Supply Tempering Valve Expansion Tank Temp./ Pressure Gauge AquaSensor 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 recommendhaving experienced personneldo the plumbing. This is only one of many layouts possible. Cirulat
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1 Installation 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 of3 sheet metal screws. Draft T est Pr ocedur e Attach a draft meter to the vent pipeon the boiler side of the barometric damper (if installed). Wit
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COMPONENT RECEPTACLES - ON SIDE MAX LOAD MAX LOAD MAX LOAD 0.5 A 0.75 A 1.25 A 17 Verti-Flow™ Stoker Control VERTI - FLOW ™ STOKER CONTROL V erti-Flow ™ Stoker Contr ol 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 op- eration of the timer. One in
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1 Verti-Flow™ Stoker Control The V erti-Flow™ Stoker Contr ol How to operate the Stoker Contr ol The top receptacle (0.5 A) provides power to the coal There are four operator interfaces on the Stoker Con- feeder motor. Thus, the plug from the coal feeder motor trol. The operator interfaces are: one (1) rocker switch shouldbe inserted into this receptacle. andthree (3) 16-position rotary switches. The center receptacle (0.75
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19 Operation FILL THE BOILER AND PLUMBING SySTEM WITH W A TER PRIOR T O LIGHTING! Starting a fir e 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
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20 Maintenance Ash Removal W ith each hopper of coal that is burned, approximately one ash pan full of ashes must be removed. Failure to re- move ashes will result in a blocked grate and the fire will not burn properly. Remember, the ash pan will be hot, so Spring alwayswear protective gloves. handle 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
