INSTALLATION
AND
OPERATION MANUAL
The Horiz.on Stove
MODEL 500CC
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INDEX
I.
INSJALLAHON SECTION
INTRODUCT ION
PLANNING INSTALLATION .
ASSE~1BL
Y _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
CHIMNEy......... .. . 4
STOVEPIPE , .. , . , , . , , .. , . , . , , .,
5
TEMPERATURE PROBE. , , , , . . . . . . . . . .. 5
CLEARANCES , , , . , , , . . . ..
6
flOOR PROTECTION, , , , , , , , . . 7
WALL
PROTECTrON .....•............... , , , , , . 8
II.
OPERATION SECTION
OP-E
RAll ON , , , , .. , . , , , . .
9-
{WILDING FIRST FIRE. , , . . . . . . . . . . . . . . . . 11
FUELS , . . . . . . . . . .. . . . ..
t
2
ASH-HANDLING , , •.................. , . . . .. . . . .. .. .
12
CLEANING 8<GENERAL MAINTENANCE. .. , . , , , , .. , , , . . ..
t
3
TROUBLE SHOOTING , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WARRANTIES, , , .. , , .. , .. , . . . IS
-1-
SECTION'
PLANNING INSTALLATION
PLANNING YOUR STOVE INSTALLATION WILL HELP MAKE THE JOB GO SMOOTHLY AND SAFELY. WHILE
YOUR DOVRE APPLIANCE IS LISTED BY UL AND ULC, IT IS STILL IMPORTANT TO CHECK LOCAL AND
STATE BUILDING CODES BEFORE BEGINNING THE INSTALLATION. YOU MAY BE REQUIRED TO OBTAIN A
BUILDING PERMIT IN SOME AREAS. THIS CAN BE ACCOMPLISHED BY CONTACTING YOUR BUILDING
INSPECTOR.
IN ADDITION, WE RECOMMEND THAT YOU NOTIFY YOUR INSURANCE COMPANY REPRESENTATIVE AS
SOME HOMEOWNER'S INSURANCE COMPANIES REQUIRE AN INSPECTION OF YOUR INSTALLATION. THIS
CAN GIVE YOU THE ADDED SAFETY OF AN OUTSIDE OPINION OF THE INSTALLATION.
FINDING THE RIGHT LOCATION FOR YOUR STOVE IS A BIG PART OF THE PLANNING PROCESS. YOUR
STOVE IS A RADIANT ROOM HEATER AND DEPENDS ON GOOD AIR CIRCULATION TO MOVE THE HEAT
GENERATED. THEREFORE, A CENTRAL LOCATION IS BEST IF YOU ARE DEPENDING ON YOUR STOVE AS
THE PRIMARY HEAT SOURCE. IF YOUR STOVE IS TO BE A ZONE OR SECONDARY HEAT SOURCE, CONSIDER
PLACING IT IN A HARD- TO -HEAT AREA OR IN THE MAIN LIVING AREA. OF COURSE, IF YOU ARE GOING
TO USE AN EXISTING CHIMNEY, YOU MAY HAVE TO COMPROMISE SOMEWHAT ON THE LOCATION. IF THIS
IS GOING TO CAUSE TOO MUCH OF A PROBLEM, YOU MAY ELECT TO CONSTRUCT A NEW FACTORY-BUlL T
CHIMNEY INSTEAD. SEE THE SECTIONS ON WALL AND FLOOR PROTECTION ON PAGE 7 AND PAGE 8.
THE DOVRE HORIZON IS NOT APPROVED FOR INSTALLATION IN MOBILE HOMES.
OTHER RECCMMENDED READING FOR SOLID FUEL USERS ARE:
I. VIVIAN, WOOD HEAT
RODALE PRESS, 1976
ISBN 0-87857-149-3 PAPERBACK
2. SHELTON&.SHAPIRO, THE WooDBURNER'S ENCYCLOPEDIA
VERMONT CROSSROADS PRESS, 1977
ISBN 0-915248-08-5 PAPERBACK
3. SHELTON, SOLID FUELS ENCYCLOPEDIA
GARDEN WAY PUBLISHING, 1983
ISBN 0-88266-307-0 PAPERBACK
ASSEMBLY
SINCE A CAST IRON HEATER IS HEAVY, IT IS EASIER TO ASSEMBLE AND INSTALL WITH TWO PEOPLE.
BEFORE STARTING ASSEMBLY, PLACE THE UNIT NEAR THE FINAL POSITION, THEN FOLLOW THE
PROCEDURE BELOW:
I. OPEN THE STOVE AND REMOVE ALL PARTS AND ARTICLES PACKED INSIDE. OPEN THE BOX
FOUND IN THE UNIT, CHECK THE PARTS LIST AND INSPECT ALL PARTS AND THE CAST IRON
BODY FOR SHIPPING DAMAGE. CONTACT YOUR DEALER IF ANY IRREGULARITIES ARE
NOTICED. YOU SHOULD ALSO REMOVE THE GLASS DOOR, THE SIDE LOADING DOOR, GRATES,
LOO RETAINER, SIDE&.BACK BURN PLATES AND ASH PAN TO MAKE THE UNIT LIGHTER AND
EASIER TO MANUVER.
-2-
2. NOW GENTLY LAY THE UNIT ON ITS BACK AND ATTACH THE LEGS AND ASH LIP (SEE FIG.!).
3. INSTAll flOOR PROTECTION IF THE HEATER IS BEING PLACED ON A COMBUSTIBLE FLOOR.
REFER TO THE SECTION ON FLOOR PROTECTORS FOR REQUIRED MATERIALS AND SIZES.
4. LIFT -
DO NOT liLT ON THE CAST IRON LEGS-
THE UNIT TO THE UPRIGHT POSITION
AND PLACE IT ON THE FLOOR PROTECTOR.
5. REPLACE THE 3 BURN PLATES, LOO RETAINERS, GRATES, AND ASH PAN INSIDE THE STOVE
(SEE FIG. 2).
SIDE BURN
PLATE
BACK BURN
PLATES
LOG RETAINER
FIG. 2
FIG. 1
6. RETURN THE GLASS DOOR AND THE SIDE LOADING DOOR TO THEIR HINGES. ATTACH THE
4 SPRING HANDLES TO THE 3 DOOR LATCHES AND BYPASS DAMPER LEVER.
7. THE FLUE COLLAR IS LOCATED IN THE BOX THAT WAS INSIDE THE HEATER. FOR A TOP FLUE
EXIT, ATTACH THE COLLAR TO THE TOP OF THE HEATER WITH BOLTS AND NUTS PROVIDED.
FURNACE CEMENT MAY BE USED TO SEAL UNDER THE COLLAR (SEE FIG.3). SHOULD A REAR
FLUE EXIT BE NECE~RYJYOU WILL NEED TO REMOVE THE BACK SHEET METAL COVER
PLATE FROM THE BACK SHIELD. THE FLUE COLLAR IS THEN FASTENED TO THE BACK OF
THE UNIT WITH THE BOLTS AND NUTSPROVIDED,AS SHOWN IN FIG. 3. INSTALL THE CAST
IRON COVER PLATE ON THE TOP OF THE HEATER IN THE UNUSED FLUE OPENING BY PLACING
A BEAD OF FURNACE CEMENT AROUND THE EDGE AND PLACE THE COVER IN POSITION SO IT
SITS FIRMLY AGAINST THE CAST IRON. FOR ATTACHING THE COVER PLATE TO THE REAR OF
THE STOVE, YOU WILL ALSO NEED TO ATTACH THE FIXING BAR TO THE COVER PLATE WITH
THE BOLT AND WASHERS PROVIDED. SEE FIG. 4 FOR TOP COVER PLATE AND FIG. 5 FOR
REAR COVER PLATE INSTALLATION.
..
'.
-3-
i
(f)
I
I
1/4" BEAD
I
FURNACE CEM:NT
Q~
1/4" BEAD
I
FURNACE CEM:NT
?-§SS§\
TOP OR
BACK
PU.TE OPEN
I
I'li
/ COVER PLATE
.i'
y
FIG. 4
FIG. 5
FIG. 3
8. REMOVE THE TOP PLATE OF THE STOVE BY TAKING OUT THE TWO ALLEN HEAD CAP SCREWS
WITH THE ALLEN WRENCH PROVIDED. CHECK PLACEMENT&OPERATION OF THE INTERNAL
BYPASS AND COMBUSTOR PARTS, USING THE DIAGRAM IN FIG. 5.
LEFT DAMPER PLATE
RIGHT DAMPER PLATE
~\
\\
\
b ~
\
\
\
BY-PASS
CONTROL
LEVER
NOTE: REtv'lNEPAPER
PACKAGING MATERIALS
FROM THIS AREA BEFORE
LIGHTING FIRST FIRE.
CATALYTIC COMBUSTOR
FIG.6
9. INSTALL THE CHIMNEY CONNECTOR BETWEEN THE HEATER AND THE CHIMNEY.
-4-
CHIMNEYS
THE VENTING SYSTEM CONSISTS OF A CHIMNEY CONNECTOR AND A CHIMNEY. THESE GET EXTREMELY
HOT DURING USE. TEMPERATURES INSIDE THE CHIMNEY MAY EXCEED 2000 DEGREES IN THE EVENT
OF A CREOSOTE FIRE. TO PROTECT AGAINST THE POSSIBILITY OF A HOUSE FIRE, THE CHIMNEY
CONNECTOR AND CHIMNEY MUST BE PROPERLY INSTALLED AND MAINTAINED. A THIMBLE MUST BE
USED WHEN A CONNECTION IS MADE THROUGH A COMBUSTIBLE WALL TO A CHIMNEY. A CHIMNEY
SUPPORT PACKAGE MUST BE USED WHEN A CONNECTION IS MADE THROUGH THE CEILING TO A
PRE-FABRICATED CHIMNEY. THESE ACCESSORIES ARE ABSOLUTELY NECESSARY TO PROVIDE SAFE
CLEARANCES TO COMBUSTIBLE WALL AND CEILING MATERIAl.
OF COURSfITHE CHIMNEY IS RESPONSIBLE FOR VENTING OUT SMOKE AND GASES. THIS IS DONE BY
CHIMNEY DRAFT. DRAFT IS A FUNCTION OF THE HEIGHT AND DIAMETER OF A CHIMNEY FLUE
COMBINED WITH FLUE TEMPERATURE VERSUS OUTSIDE AIR TEMPERATURE. A WARM CHIMNEY WILL
DRAW BETTER ON A COLD DAY THAN ON A MILD DAY. THE AMOUNT OF DRAFT IN YOUR CHIMNEY MAY
ALSO BE DEPENDENT ON LOCAL GEOGRAPHY, NEARBY OBSTRUCTIONS, AND OTHER FACTORS.
THE HORIZON MINIMUM DRAFT REQUIREMENT IS -.055 WATER COLUMN INCHES. TOO MUCH DRAFT
MAY CAUSE EXCESSIVE TEMPERATURE IN THE HEATER AND MAY DAMAGE THE CATALYTIC COMBUSTOR.
INADWUATE DRAFT MAY CAUSE BACKPUFFING INTO THE ROOM AND "PLUGGING" OF THE CHIMNEY OR
THE CATALYST.
1
HE NFPA, AND MOST LOCAL CODES, STATE THAT
CHIMNEYS MUST BE THE REQUIRED HEIGHT ABOVE
THE ROOF OR OTHER OBSTRUCTIONS FOR SAFETY
AND FOR PROPER DRAFT OPERATION. THE
REQUIREMENT IS THAT THE CHIMNEY MUST BE AT
I.fAST 3 FEET HIGHER THAN THE HIGHEST POINT
WHERE IT PASSES THROUGH THE ROOF AND AT
LEAST 2 FEET HIGHER THAN THE HIGHEST PART OF
THE ROOF OR STRUCTURE THAT IS WITHIN10FEET
OF THE CHIMNEY, MEASURED HORIZONTALLY.
EXISTING t1ASONRY CHIMNEYS MAY BE APPROPRIATE FOR YOUR UNIT IF THE CHIMNEY FLUE DOES NOT
SERVE ANY OTHER APPLIANCE. A DOVRE UNIT REQUIRES A MINIMUM 6UDIAMETER FLUE. IF YOU ARE
PLANNING TO USE AN EXISTING CHIMNEY, FIRST HAVE IT CLEANED AND INSPECTED BY A QUAliFIED
PROFESSIONAL TO INSURE THAT IT IS ACCEPTABLE TO THE LOCAL AUTHORITIES AND IS IN OOOD
CONDITION.
DO NOT CONNECT YOUR UNIT TO AN UNLINED CHIMNEY.
FLUE GASES COULD
PENETRATE INTO THE HOUSEIAND THERE IS A DANGER OF EXPOSING NEARBY WOODEN MEMBERS OF
THE HOUSE TO HIGH TEMPERATURE, DUE TO POSSIBLE DRIED AND CRACKED MORTAR JOINTS.
~RNIN6
STATEMENT:
THE CHIMNEY FLUE CONNECTED TO A DOVRE UNIT MUST
NOT BE USED TO VENT ANY OTHER COAL, GAS, OIL, OR WOODBURNING APPLIANCE, AS
THIS MAY ALLOW HARMFUL ~ES INTO THE HOUSEHOLD AIR SUPPLY.
-IF YOUR CHIMNEY NEEDS REPAIR, CALL A CHIMNEY MASON. SHOULD YOU DECIDE TO BUILD A NEW
MASONRY CHIMNEY, CALL A QUALIFIED MASON AND BE SURE IT IS BUILT TO COMPLY WITH LOCAL
CODES, OR NFPA
#211.
CHIMNEY HEIGHT
r
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