Hardy H3, Installation And Operating Instructions Manual

Page 1: ...ATION AND OPERATING INSTRUCTIONS FOR THE HARDY OUTSIDE WOOD BURNING HEATER Model Model Model Model H3 H5 H6 H3 H5 H6 H3 H5 H6 H3 H5 H6 HARDY MANUFACTURING COMPANY INC 12345 ROAD 505 PHILADELPHIA MS 39350 PHONE 601 656 5866 FAX 601 656 4559 www hardyheater com Rev 01 06 ...

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Page 3: ...llation and Hook Up Instructions 2 Warranty Return Warranty Card 3 A tube of silicon located in the firebox for shipping 4 Smoke stack and condenser tank stack both with trim located in firebox for shipping 5 Three cast iron grates located in firebox 6 Two I beam 2 Channel Beams located in firebox 7 Shovel located in the firebox for shipping 8 Stainless steel panel and insulation that will be loca...

Page 4: ...PANY INC 12345 ROAD 505 PHILADELPHIA MS 39350 PHONE 601 656 5866 www hardyheater com Please keep this manual with all other important papers The information in this manual is necessary for the installation operation and proper use of this unit If you should ever have a problem or question please refer to this manual or have it available when you call your Hardy Dealer or Hardy Manufacturing Compan...

Page 5: ... electrician in accordance with the National Electrical Code x Never use any type of petroleum product petroleum based product charcoal starter lighter fluid or any other flammable accelerant to start your unit x Always open the ash door bottom before you open the firebox door top x Never leave the doors open always latch the doors securely x Always use proper care when installing operating and ma...

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Page 8: ...ted neat the existing thermostat The two thermostats are installed so that if the outside wood heater is not in operation you existing unit will automatically take over to maintain your household temperature The wall thermostat which regulates the heat from the outside heater performs two functions when it senses your need for heat according to your temperature setting it turns the water pump on t...

Page 9: ...isting Blower Coil 14 16 3 2 Location of Heating Coil 17 18 SECTION IV Connection to Hydronic Heating Systems Baseboard 4 1 Connection to Hydronic System with existing 24 Volt Transformer 19 20 4 2 Typical Diagram for Plumbing Hydronic System 21 SECTION V Plumbing Options for Domestic Hot Water 5 1 Option 1 Plate Heat Exchanger for Domestic Water located at Hot Water Heater 22 23 5 2 Option 2 Plat...

Page 10: ...N VII Service Information 7 2 Water Circulation System 28 7 3 Temperature Control System 29 7 4 Preseason Heater Maintenance 30 7 5 Trouble Shooting Guide 31 35 SECTION VII Repair Parts 36 MODEL H3 H5 H6 viii ...

Page 11: ...ector 18 Front 48 Flooring Non Combustible Water Capacity H3 Holds Approximately 100 Gallons of Water H5 Holds Approximately 130 Gallons of Water H6 Holds Approximately 60 Gallons of Water HEATER DIMENSIONS Description Wide Depth Height Weight H3 120 000 BTU 30 52 59 650 lbs H5 180 000 BTU 40 52 59 850 lbs H6 100 000 BTU 30 40 51 475 lbs FIREBOX SIZES Description Wide Depth Height H3 120 000 BTU 2...

Page 12: ...ignates that you have a 120 000 Btu heater The 1 in the second section designates that you have a standard pump The 0 in the last section designates that your heater is without domestic hot water The 7 in the last section designates that you have extra ports on your heater On H3 H5 and H6 models domestic hot water is only available through the use of externally mounted heat exchanger kits Heater R...

Page 13: ...rass nipple 11 607 12 3 4 Brass ball valve 12 502 40 3 4 Bronze flange 13 502 08 Taco 009 Bronze pump w power cord for H3 H5 Models 508 09 Taco 008 Bronze pump w power cord for H6 Model 14 2000 52 Relay 15 2001 00 Dormeyer damper solenoid 16 2004 16 Receptacle box 17 2004 00 GFCI Receptacle 18 3200 12 Jack chain 19 2002 04 60 CFM blower w lid for H6 Model 2002 16 100 CFM blower w lid for H3 Model ...

Page 14: ...for loading wood and removing ashes The space between the rear of the unit and the outside cover will allow a 4 water tight pipe or other means to insulate the plumbing and electrical lines to run directly into the ground The outside cover can be removed by lifting it off the water tank on all four corners This will allow you easy access for the connection of the plumbing and electrical lines Plea...

Page 15: ...its through this cut out to allow connections to the unit The unit sits on the slab with the rear of the water tank flush or even with the front side of the cutout The outside cover of the heater can be removed by lifting it from the water tank on all four corners This will allow you east access for the plumbing and electrical connections Outside Hull Water Tank Concrete Pad Condenser Stack Pump R...

Page 16: ...taking it out With the back door removed using a 5 16 wrench remove the 8 metal screws that are located below the back door There are four on each side that hold the panel in place After the crews are removed the panel should come out easily and allow access to the bottom of the unit to make plumbing and electrical connections The second method is the removal of the entire cover With the back and ...

Page 17: ...wn in the picture below The grates can now be placed on the I beams in line and side to side The picture below shows the proper way for grates to be installed These grates are designed to be turned over if they warp On Hardy H5 models there is a stainless steel flame baffle 15 x 10 This flame baffle is inserted in the firebox across the 3 4 stainless steel pipes located directly below the smokesta...

Page 18: ...more than 1 zone is to be heated or more than 1 location is to be heated then an additional pipe or insulation must be installed underground This pipe will run from the rear of the unit to the location to be heated Inside the 4 inch watertight pipe be the 2 water line thermostat wire and electrical supply wire The listing below describes each line and their function 1 One water supply line to heat...

Page 19: ...ew on the line side of the GFCI receptacle 5 Connect the white wire to the silver screw on the line side of the GFCI receptacle 6 Connect the bare copper wire to the green screw on the GFCI receptacle 7 After the wiring is complete check the receptacle with a circuit tester to determine if the polarity is correct and to make sure the ground is connected Press the test button on the GFCI receptacle...

Page 20: ...HARDY MANUFACTURING CO INC MODEL H3 H5 H6 PAGE 10 Section II 2 6 Wiring Diagrams H3 H5 H6 This equipment must be installed in accordance with the National Electrical Code ...

Page 21: ...ll carry the return water from the heating system is connects to the 3 4 brass tee located at the bottom left hand corner of the heater noted by 4 in diagram Water pipes must be designed for hot water service ex Copper cpvc or Pex Pipes should be installed in a 4 watertight pipe or some other type of insulating means to prevent heat loss from heater to heating system Use only copper brass or stain...

Page 22: ... smokestack until it sits on the outside cover The condenser stack must also be installed in the condenser stack opening The trim must also sit snugly upon the outside cover DO NOT SEAL THE CONDENSER TANK TO THE CONDENSER TANK LID THIS IS THE WATER TANK VENT AND MUST NOT BE SEALED There are certain parts of the country that have high enough levels of chloride in the water to be harmful to stainles...

Page 23: ...he water tank directly into the condenser tank area This switch will activate a low warning light mounted into the side of the outer hull The water level in the heater needs to be high enough to operate low water switch and turn off the low water warning light Seal between the cover and the tank lid collar Seal between the condenser tank and heater cover Condenser tank Do not fill past this point ...

Page 24: ...o use this option then only a two wire conductor is required bypassing the low temperature sensor 4 Connect a jumper wire from the other side of the low temperature sensor to terminal 7 of the water pump relay R 3 and also connect the green wire to terminal 7 of R 3 If two wires are used then one is connected to terminal 7 and the other to terminal 8 5 Inside the house A Install the new wood heati...

Page 25: ...2 E Also connect a jumper wire from terminal 7 of R 2 to terminal 6 of R 2 9 Locate the existing central unit blower relay R 1 A Locate the wire running from the existing thermostat to the blower relay coil Disconnect this wire from the existing blower relay coil and connect it to terminal 5 of the new blower relay R 2 B Connect a jumper wire from the existing blower relay coil the point that you ...

Page 26: ...HARDY MANUFACTURING CO INC MODEL H3 H5 H6 PAGE 16 Section III 3 1 Connection to Central Unit with existing Blower Relay continued ...

Page 27: ...NG CO INC MODEL H3 H5 H6 PAGE 17 Section III 3 2 Location of Heating Coil The following diagrams and pictures on this page and the following page show various methods of installing the heating coil in forced air system ...

Page 28: ...HARDY MANUFACTURING CO INC MODEL H3 H5 H6 PAGE 18 Section III 3 2 Location of Heating Coil continued 3 SUPPLY TO HEATING SYSTEM 4 HEATING SYSTEM RETURN ...

Page 29: ...eating system in the house This wire must be rated for underground use or be run inside a pvc pipe The colors normally used are red and white 2 At the heater connect the white wire to terminal 8 of the water pump R 3 3 Connect the red wire to terminal 7 of the water pump relay R 3 4 In the house locate the existing pump relay Connect the red wire of the two conductor thermostat wire to the coil of...

Page 30: ...HARDY MANUFACTURING CO INC MODEL H3 H5 H6 PAGE 20 Section IV 4 1 Connection to Hydronic System with Existing 24 Volt Transformer continued ...

Page 31: ...tight pipe or some other type of insulating means to prevent heat loss from heater to heating system Use only copper brass or stainless steel fittings Do not use galvanized or black iron Turn off the makeup water for the existing system Manual filling of the wood heater or the electric fill option will supply makeup water for the wood heater and the existing hydronic Close all automatic air vents ...

Page 32: ... water supply going to the heating system see plumbing diagram Install a tee into the supply line from the pump One side of this tee will go straight to the heating system the other side will go to the unit port of the zone valve The main port of the zone valve will go to one side of the plate heat exchanger The other port on the same side of the plate heat exchanger will go back to the return por...

Page 33: ...Water located at Hot Water Heater 3 WAY ZONE VALVE ALLOWS THE WATER TO FLOW FROM THE BYPASS PORT TO THE MAIN PORT WHEN IT IS OFF WHEN THE VALVE IS ENERGIZED IT WILL DIVERT THE WATER THROUGH THE HEATING SYSTEM TO THE UNIT PORT AND OUT THE MAIN PORT DANGER WATER TEMPERATURE OVER 125 CAN CAUSE SEVER BURNS INSTANTLY ...

Page 34: ...w the pump and will be connected to the pump with a stainless steel flex line This pump will be wired to run continuously The domestic water hooks up on the opposite side of the plate heat exchanger The direction of domestic water flow is reversed from that of the heater water flow The cold water supply will go into the bottom port and the hot water back to the home hot water heater will connect t...

Page 35: ...lled on the rear of the heater It will also require a cold water supply line run to the heater The electric water valve is mounted on a 1 4 nipple in the upper right corner on the rear of the heater This will leave 1 2 hookup When hooking up your domestic water supply make sure a cutoff valve is installed and flexible connections to remove the screen for annual cleaning See illustration below ...

Page 36: ...sh door The fire in the heater must be out to seal the door With door still mounted on the heater scrape the old silicone out of the groove Run a small bead of silicone in the groove of the door Start installing the rope at the top edge if the wide groove next to the hinges running down the hinge side and continue around the door Run the rope past the starting point to the bottom of the hinge side...

Page 37: ...amper has been open for at least 15 minutes remove one of the screws in the damper lid If the problem continues remove the other screw Remove the screws only if you are absolutely sure the fire is going out 6 1 Ash Removal Ashes must be removed before they build up to the level of the grates Failure to keep the ash bin cleaned out will result in warped grates The buildup of ashes in the firebox sh...

Page 38: ...ump P N H502 00 WARNING When working with electrical circuits use caution to avoid electrical shock with bronze body If the pump will not run first unplug the power cord then check the water pump relay The relay can be bypassed by disconnecting the wire terminal 6 and the connecting to terminal 5 terminals 4 to 5 is normally closed remove the thermostat wire from terminal 8 and plug the power cord...

Page 39: ...s solenoid lifts the cover off the intake to the forced air draft blower The solenoid is controlled by the damper thermostat It should lift the cover when the forced air blower comes on and drop the cover after the blower goes off If the solenoid does not drop the cover when the blower goes off the solenoid should be replaced The forced air draft intake cover must be in place when the blower is no...

Page 40: ...ict the amount of combustion air entering the heater Check the seal on the clean out lid to assure a good air tight seal is still established Lift the damper lid on the draft blower and inspect the blower wheel for any build up of lint dust creosote or any other substance that could effect the performance of the draft blower Spray the damper lid hinge and the damper solenoid plunger with WD 40 or ...

Page 41: ...e at least 1 2 to 1 of ashes in bottom of ash pan to protect the bottom from burnout 5 Damper Draft System and Smoke stack Check at least every two weeks for build up of ash tar or any other material that could restrict the amount of air flow required Oil the blower motor bearings prior to each heating season with 10 to 20 drops of electric motor oil 6 Door Seals Check firebox door and ash door se...

Page 42: ...es connected to the motor terminals to test the motor independent of electrical connections Check for ground and continuity with ohmmeter The insulator of the windings should show no breakage If it does replace pump Pump does run 1 Defective 24 volt transformer 2 Defective wall thermostat heater 3 Defective low temperature sensor 4 Defective pump relay 1 Located at existing central unit If 115 120...

Page 43: ...y and ground fault interrupter receptacle OK Water tempera ture is COLD Heater Stack 1 Ash and Creosote Buildup 1 Clean heater stack of any ash and creosote buildup On H4 models make sure the baffle plate is clear of ash and creosote buildup Make sure baffle is in place otherwise heat will be lost up the stack 1 When bypassing aquastat if solenoid does not lift the lid off the intake to the forced...

Page 44: ...cleaning kit 5 Bleed air from hot water coil NO HEAT Blowing cold air in house Water temperature is HOT Power OK Excessive wood usage Or Overheating boiling Heater water boils Symptom Popoff valve is relieving 1 Doors open 2 Defective door seals 3 Damper blower lid stuck open 4 Damper aquastat defective 5 Water lines connections leaking 1 Close all doors and make sure they are securely fastened 2 ...

Page 45: ...e fill system If heater tank still overfills then remove heater hull and lid to check domestic water coil for leaks repair or replace Excessive wood usage Or Overheating boiling Improper Burning Grates Grates stopped up Clear grate of ash buildup If grates are warped turn over Air intake Damper blower clogged Clean damper blower assembly Air tube inspection lid Air tube clogged Lift inspection lid...

Page 46: ...nipple 11 607 12 3 4 Brass ball valve 12 502 40 3 4 Bronze flange 13 502 08 Taco 009 Bronze pump w power cord for H3 H5 Models 508 09 Taco 008 Bronze pump w power cord for H6 Model 14 2000 52 Relay 15 2001 00 Dormeyer damper solenoid 16 2004 16 Receptacle box 17 2004 00 GFCI Receptacle 18 3200 12 Jack chain 19 2002 04 60 CFM blower w lid for H6 Model 2002 16 100 CFM blower w lid for H3 Model 2002 ...