Hardy KB165, Installation And Operating Instructions Manual

Page 1: ...C 12345 ROAD 505 PHILADELPHIA MS 39350 PHONE 601 656 5866 FAX 601 656 4559 www hardyheater com INSTALLATION AND OPERATING INSTRUCTIONS FOR THE HARDY OUTSIDE WOOD BURNING HEATER Model KB165 HARDY MANUFACTURING COMPANY INC 12345 ROAD 505 PHILADELPHIA MS 39350 PHONE 601 656 5866 FAX 601 656 4559 www hardyheater com Rev 5 7 2015 ...

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Page 3: ... installation and operation of this heater THIS MANUAL INCLUDES IMPORTANT SAFETY INFORMATION Your new heater should have the following 1 Owner s manual complete with installation and hook up instructions 2 Warranty return warranty card 3 A tube of silicone located in the firebox for shipping 4 2 double wall sections of smoke stack with a trim ring and cap 5 Condenser stack with trim ring 6 Ash sho...

Page 4: ...ANY 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 Company...

Page 5: ...um based product charcoal starter lighter fluid or any other flammable accelerant to start your unit Fuel Clean seasoned oak hardwood Clean wood means wood that has no paint stains or other types of coatings and wood that has not been treated with preservatives including but not limited to copper chromium arsenate creosote or pentachlorophenol Never leave the door open always latch the door secure...

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Page 7: ...ions for recommended loading times and amounts 5 STARTERS Do not use lighter fluids gasoline or chemicals 6 LOCATION It is recommended that the unit be located with due consideration to the prevailing wind direction 7 Always remember to comply with all applicable state and local codes Outdoor Furnace Manufacturers Caucus Furnace should be located no less than 100 feet from any residence not served...

Page 8: ...ds How do the Thermostat Controls work The only visible addition to the heating system inside your home is the thermostat which is located next to your existing thermostat The two thermostats are installed so that if the outside wood burning heater is not in operation your existing unit can be used to maintain your household temperature The wall thermostat which regulates the heat from the outside...

Page 9: ...e this wood heater in a manner inconsistent with operating instructions in this manual Operation in a manner inconsistent with the owner s manual will void the warranty EPA s Burnwise Program http www epa gov burnwise How to Use a Moisture Meter Video http www youtube com watch v jM2WGgRcnm0 EPA offers tips on how to properly use a moisture meter to test firewood before using in a wood burning sto...

Page 10: ... 7 Installation of Smoke Stacks and Condenser Stack 11 2 8 Filling the Heater with Water 12 2 9 Priming the Pump 13 SECTION III Connection to Central Heating AC System 3 1 Connection to Central Unit with Existing Blower Relay 14 15 3 2 Location of Heating Coil 16 17 SECTION IV Connection to Hydronic Heating Systems Baseboard 4 1 Connection to Hydronic System 18 SECTION V Plumbing Options for Domes...

Page 11: ...ION VIII Heater Maintenance 8 1 Weekly Maintenance 25 8 2 Monthly Maintenance 26 8 3 Extended Period Shut Down and Start Up 27 SECTION IX Appendix 9 1 General Trouble Shooting Guide 28 30 SECTION X Component Service Replacement Procedure 10 1 Water Solenoid Valve 31 32 10 2 Low Water Float Switch 33 34 10 3 Pump 35 36 10 4 Damper Solenoid 37 38 10 5 Damper Solenoid Bracket 39 10 6 Air Volume Box S...

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Page 13: ... ineffective and cause smoke Wood Dimension Condition 22 to 24 in Length 30 Moisture or less Cured between 6 to 9 months Any round wood over 7 in diameter must be split at least once Wood Load Capacity 10 to 15 pounds cubic ft Firebox is approximately 13 Cubic Feet Wood weight is approximately 130 to 195 pounds SECTION I GENERAL INFORMATION This manual describes the installation and operation of T...

Page 14: ...del wood fired hydronic heater has a preset forced air draft fan that requires no draft adjustments Draft is the force of air drawn from outside the heater and pushed throughout the various chambers before finally exiting through the smoke flue stack Excess ash or creosote buildup can hinder this process causing the heater to under perform and produce excess emissions Normal maintenance at schedul...

Page 15: ...No Description 1 1100 00 Water Solenoid Valve Assembly 2 1100 28 SMD 1 2 Float Switch 3 2004 00 Ground Fault Interrupter Receptacle 4 2004 30 Terminal Block Assy 5 508 50 Taco 008 SS pump 6 502 50 Taco 009 SS Pump 7 2002 69 1TDR6 Blower 8 7165 45 Air Volume Box 9 2065 10 Temperature Logic Controller 7 6 5 4 3 2 1 9 8 ...

Page 16: ...E 4 1 2 Heater Component Parts Model KB165 Standard Components continued Legend Part No Description 10 2065 50 Turbulators 11 7165 99 Bypass Damper 12 2001 05 Damper Solenoid 13 7165 40 Air Tube Damper Assy 12 11 10 Inside of Air Volume Box 13 ...

Page 17: ... KB165 Standard Components continued Legend Part No Description 14 3105 18 Secondary Air Distribution Plenum 15 3105 17 Fire Grates 16 2165 27 Back wall brick 17 2165 28 Side Brick 18 2165 31 Bottom Front Back Bricks 19 7165 20 Primary Air Distribution Plenum 17 14 16 15 17 19 18 ...

Page 18: ...e installed on a concrete pad with a recommended minimum dimension of 34 W x 61 L x 4 D On the plumbing end of the heater you will need to bring up through the pad a 4 water tight chase pipe to route your water lines and electrical lines from the structure to be heated to the furnace Reference the illustration below for pad layout and ideal placement of 4 pipe Concrete Pad Top View 4 pipe should b...

Page 19: ...or a standard installation An additional pipe may be required if more than one zone or location is to be heated If more than one location is to be heated a second 4 or single 6 water tight pipe or other insulation means will need to be installed underground for the water lines and thermostat wires of the second location This pipe will run from the rear of the unit to the location to be heated Cont...

Page 20: ...tall a 20 amp circuit with 12 2 W Gnd NM Type UF wire from the power source through the 4 watertight pipe or other means to the heater This wire will connect to the LINE Terminals on the GFCI Receptacle located on the rear of the Heater The breaker installed at the power source should be a 20 amp GFCI 2 5 Wiring Diagram This equipment must be installed in accordance with the National Electrical Co...

Page 21: ...itch N 120 V R1 R2 TD1 R1 BL S1 R2 CBS Combustion Blower Switch TLC Temperature Logic Control IL Indicator Light BL Blower S 1 Primary air damper solenoid S 2 Secondary air damper solenoid R 1 Lockout Relay R 2 Time delay relay TD 1 Time delay control TS Terminal Strip WS Water Solenoid 13 13 14 14 8 12 12 4 1 2 3 4 5 6 7 8 9 10 11 WS ...

Page 22: ...Item 2 Existing Boiler Heat Zone Heat Zone Existing Pump Close this valve Heater with hull and stacks removed to show connections Hardy P N 300 01 40 Plate Heat Exchanger with 1 fittings 1 2 Taco 009 Taco 008 Return Supply Water pipes must be designed for hot water service ex copper cpvc or Pex A Pipes should be installed in a 4 water tight pipe or some other type of insulating means to prevent he...

Page 23: ...one is applied to prevent any water from entering the outside cover The condenser tank will also need to be sealed in this manner The application of silicone to these openings is illustrated by the diagram below After the silicone is applied you can install the two three foot sections of smoke stack The trim collar should slide down the smoke stack until it rests on the outside cover The condenser...

Page 24: ...s per million of chloride salt in the water as acceptable for drinking experience has shown that chloride levels as low as 45 parts per million will eventually cause stress corrosion cracking in stainless steel tanks when water is heated It is therefore required to use rain water or bottled water with chloride content of less than 15 parts per million or test the water supply for chloride to assur...

Page 25: ...e return valves on both pumps Plug the power cord for the small circulator pump into the GFCI receptacle and listen for the air bubbling back into the water tank Once you no longer hear air bubbling slowly close the supply valve above the pump until you hear a change in the sound the water makes as it flows through the pump Once you are satisfied that the pump is moving water open the supply valve...

Page 26: ...arked R and the white wire to the screw terminal marked W At the central air handler where you added the relay connect the white wire that is going to the new heat only wall thermostat to terminal 7 of the new relay along with a short jumper wire that will connect to terminal 6 of the new relay Next find the red wire going from the air handler control wiring to the original wall thermostat Cut thi...

Page 27: ... 115V 24V TR TC R1 R2 T2 FS 1 2 4 5 6 7 8 R2 R2 R2 TG CONNECTION DIAGRAM SCHEMATIC DIAGRAM G R LOW VOLTAGE FIELD WIRING White Red White Red Green Green Red Legend R1 existing blow er relay R2 new control relay FS existing thermostat T2 New thermostat TC terminal strip C connection TR terminal strip R connection TG terminal strip G connection R existing thermostat R connection G existing thermostat...

Page 28: ...d Insulate Heating Coil in supply side of system and in a protected environment Package System Supply Air 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 a forced air system ...

Page 29: ...cation of Heating Coil continued Supply Return Air Flow Air Flow Air Must be Filtered before passing through Heating Coil Supply Return Air Flow Air Flow Air Must be Filtered before passing through Heating Coil Vertical Flow System Horizontal Flow System ...

Page 30: ...ed by a qualified electrician in accordance with the National Electrical Code The preferred method for connecting the Hardy KB165 Hydronic Heater to an existing hydronic system is by installing a p n 300 01 40 plate heat exchanger w 1 fittings into the return line of the existing boiler system Run 2 1 potable hot water lines from the wood heater to the existing hydronic system Connect these lines ...

Page 31: ...d pump can be added This plate heat exchanger will provide preheated water to the domestic hot water The preferred method is to mount a plate heat exchanger at the water heater and connect it as shown in the following drawing The pump will circulate heater water through the plate continuously The cold water supply will need to be connected to the opposite side of the plate heat exchanger and flowi...

Page 32: ... leave main heating pump unplugged to allow heater to reach operating temperature quicker 4 Open the bypass damper located on the front right side of the heater 5 Put paper in the firebox over the grates 6 Add approximately 10 lbs of small kindling on top of the paper 7 Light the paper and then close the firebox door 8 Let it burn between 15 to 20 minutes 9 Open the firebox door and add 6 to 8 sti...

Page 33: ...ined in the closed container until all cinders have thoroughly cooled 5 Rake the coals around in the firebox making sure all air holes in the back air tube are open with the provided fire poker 6 Confirm that the two 2 holes in the fire grates are open 7 Load the heater firebox with the amount of wood needed for your application For Example Using an average load of approximately 74 000 BTU HR the ...

Page 34: ...box This is normal and should not cause alarm 7 4 Improper Burning Improper burning during the normal operation of the heater is normally caused by lack of combustion air or fuel in the firebox chamber 7 5 Ash Removal Ashes must be removed from inside the heater on a routine basis Excessive ash buildup inside the Firebox and recovery chambers will reduce heating efficiency Remove ashes with the pr...

Page 35: ...er condition exists 7 10 Temperature Logic Controller The Temperature Logic Controller monitors water temperature as well as water level of the heater 7 11 Low Water Lockout Relay The low water lockout relay turns all combustion systems off until the heater fills with water 7 12 Timer delay on break When the Temperature Logic Controller satisfies or the control switch is switched off it begins tim...

Page 36: ...ak hardwood Any fuels other than this will result in poor and erratic heater performance This heater is designed to use a minimum amount of fuel but as with any heater of this type fuel usage is based upon the required load and temperature requirements Using seasoned hardwood instead of wood with high moisture content or softwood will allow the unit to operate more efficiently at high burn rates a...

Page 37: ... of ashes should be placed on the ground away from any combustible materials pending final disposal The ashes should be retained in the closed container until all cinders have thoroughly cooled 6 Stir the coal bed in the firebox with the provided fire poker 7 Poke out the holes in the grates verifying the loose powder ash has been raked down through the grates with the provided fire poker 8 Load t...

Page 38: ...e ground away from any combustible materials pending final disposal The ashes should be retained in the closed container until all cinders have thoroughly cooled 10 Close the ash door 11 Open the upper right hand side flue box door on the heater 12 Remove the tubulators out of each 2 tube 13 Push the provided 1 75 flue brush down each hole 14 Put the tubulators back in each 2 tube 15 Close the rig...

Page 39: ...tem control switch also turn off supply breaker from power source 4 Perform normal monthly maintenance schedule see monthly maintenance schedule section 8 2 Start Up of Heater After Extended Shut Down 1 Verify no creosote ash or other debris is obstructing air flow into or out of the combustion air blower air distribution tubes secondary heat recovery tubulators or smoke stacks 2 Confirm all door ...

Page 40: ...d 3 Open the ash door and empty the ashes in the ash drop 4 Take out the turbulators in the top right side chamber of the heater and brush out the tubes with the 1 75 flue brush provided 5 Clean out the bottom left side chamber with the shovel provided 6 Open the air volume box on the back of the heater and make sure that the top and bottom air inlets are clear of any creosote 7 Verify that the da...

Page 41: ...e burned Burning soft wood Soft wood will not form a coal bed you can mix soft wood with hardwod or either burn the right moisture hardwood Unit smokes Clean primary and secondary air tubes in the air volume box Make sure the air holes in the primary air tube are open Perform the weekly maintenance section 7 Unit is dirty Perform weekly maintenance section 7 Combustion blower Clean blower wheel fo...

Page 42: ...ill no power replace switch Float switch Check to see if low water light is illuminated on the temperature logic control Check to see if heater is full of water add water if needed Change the float if the heater is full of water and the float will not open Lockout relay Check with volt meter for power between terminals 1 and 7 on the terminal strip for 120 vac If power is there and relay is not en...

Page 43: ...coil away from valve as shown 3 To continue in changing the whole water fill assembly you need to use an adjustable wrench and a back up wrench Note the fitting above the valve is a swivel fitting and can be turned to remove valve 4 Remove the 1 2 ball valve the 1 4 X 1 2 brass bushing and the 1 4 close nipple from old valve Hazardous Voltage Disconnect Power to Heater prior to performing this mai...

Page 44: ... for the valve to function properly Apply pipe thread sealant to the threads of the fittings removed in the previous steps 7 Install the fittings and the new valve assembly on the furnace in reverse of steps used to remove Care should be taken to make sure no excess pipe sealant gets into the mesh screen during assembly This will result in reduced or no water flow through the valve 8 Replace solen...

Page 45: ...rom the furnace 4 Looking at the wrench flats on the switch there are two directional arrows located on the side as shown For the switch to operate correctly it will have to be oriented with the arrow pointed down when installed Make sure the heater has cooled down before attempting to change out the float Open the tank drain valves until the water level is below the float switch Arrow Hazardous V...

Page 46: ...ch is oriented with the arrow pointing down 6 Connect new switch wiring to existing wiring using suitable wire nut 7 Reconnect power to furnace On models with the automatic water fill option allow the unit to fill above the float switch If the automatic water fill and low water indicator does not turn on or if it turns on but does not shut off when the water reaches the correct level the switch is...

Page 47: ...ent water flow 2 Loosen and remove the four 4 7 16 screws from the pump motor housing 3 Gently pull the pump motor housing toward you and turn so you can view pump impellar 4 Rotate the pump impellar by hand If the impellar will not spin freely then replace the cartridge 5 Reassemble in reverse order Hazardous Voltage Disconnect Power to Heater prior to performing this maintenance operation ...

Page 48: ...ll show some resistance then return to OL open line To replace Capacitor cut away existing wire nut connectors Strip leads and connect with wire nut connector suitable for two 2 16 AWG wires 3 Replace cover Testing Pump Motor Winding 1 Disconnect power cord from motor wiring Using an Ohm meter or continuity tester check the continuity across each power wire and also check each power wire to ground...

Page 49: ...nts 1 Disconnect wires from damper solenoid 2 Remove retaining clip from connecting pin in the yoke assembly 3 Remove connecting pin from yoke assembly 4 Straighten ends of cotter pin through upper end of the connecting rod Hazardous Voltage Disconnect Power to Heater prior to performing this maintenance operation ...

Page 50: ...stalled on new damper solenoid 6 Using a 5 16 nut runner remove all mounting screws 7 Mount new solenoid and reinstall connecting rod and yoke assembly in the reverse order that they where removed Check for proper mechanical operation by lifting solenoid plunger by hand to see that travel up and down is smooth Hazardous Voltage Disconnect Power to Heater prior to performing this maintenance operat...

Page 51: ...4 Damper Solenoid 3 With a 5 16 nut runner remove the 3 mounting screws from the sides and bottom of the damper solenoid bracket assembly 4 Replace gasket with the new gasket provided and mount the new solenoid bracket in the reverse order of removal 5 Remount the damper solenoid and connection rod assembly following steps in section 10 4 Damper Solenoid 6 Reconnect wiring Hazardous Voltage Discon...

Page 52: ...al 2 Using a self adhesive 1 2 X 1 2 X 62 foam gasket line the inside of the door 3 Using a caulking gun apply a bead of silicone caulk to the inside edge of the foam gasket 4 Also apply a bead of silicone caulk to the outside edge of the foam gasket 5 Allow the silicone to cure before closing door Hazardous Voltage Disconnect Power to Heater prior to performing this maintenance operation ...

Page 53: ...s Comments 1 To replace either relay pull the old relay straight out from the relay socket 2 Insert the new relay into the relay socket being sure to align the relay connecting pins with the corresponding slots in the relay socket Hazardous Voltage Disconnect Power to Heater prior to performing this maintenance operation ...

Page 54: ...temperature logic controller there is a mounting clip that must be depressed and held to slide off the rear of the temperature logic controller You must depress the front edge of the locking tab 3 Slide the temperature logic controller out the hull 4 Feed the wiring harness of the new temperature logic controller back through the hull Depresshere slide rearward Hazardous Voltage Disconnect Power t...

Page 55: ...cover plate 6 Slide the mounting clips back onto the temperature logic controller untill they hold the controller firmly in place 7 Reconnect the 3 Pin Socket connectors on the wiring in the rear of the temperature logic controller Take care to match the wiring on these connectors Front of controller Pushforward Hazardous Voltage Disconnect Power to Heater prior to performing this maintenance oper...

Page 56: ... any on the blower wheel 2 Remove cover on blower motor wiring box Disconnect power cord wires from the motor wires 3 Unbolt the 4 1 4 bolts that mount the blower to the Air volume box and remove the old gasket 4 Replace the gasket with the new gasket supplied and bolt the new blower to the air volume box 5 Wire the power cord to the new blower motor Replacing blower Cleaning blower Hazardous Volt...

Page 57: ...Comments 1 Open the Bypass damper 2 Open the flue box door on the right side of the heater 3 Remove the pin clip on the damper arm where it is connected to the pull rod connectors 4 Pull the pin out of the damper arm Hazardous Voltage Disconnect Power to Heater prior to performing this maintenance operation ...

Page 58: ...the bypass damper 6 Clean the old gasket from the mouth of the bypass channel 7 Clean off the bypass damper face 8 Reseal the mouth of the bypass channel with silicone and 1 flat fiberglass rope gasket material And remount the by pass damper in the reverse order of removal Hazardous Voltage Disconnect Power to Heater prior to performing this maintenance operation ...

Page 59: ...brush the seal area 3 Using a caulking gun lay a small bead of silicone in the bottom of the seal groove 4 Starting at one corner insert the 5 8 X 64 silicone impregnated fiberglass rope Replacing Fire Box Door Gasket Allow heater to burn out all wood and coals before performing this procedure Hazardous Voltage Disconnect Power to Heater prior to performing this maintenance operation ...

Page 60: ...edge of the door 6 Fill in any voids with silicone Allow to cure before closing door 1 Follow the same procedure for the ash door seal as you would for the fire box door seal with the exception that you will use a standard white 5 8 X 48 fiberglass rope Replacing Fire Box Door Gasket Replacing Ash Door Gasket Hazardous Voltage Disconnect Power to Heater prior to performing this maintenance operati...

Page 61: ...of 1 8 4 Starting at one edge lay the 1 4 X 1 X 40 flat rope gasket on top of the silicone and work all the way around the door Press the rope onto the silicone to assure good adhesion 1 Follow the same procedure for the Flue door seal as you would for the combustion door seal with the exception that you will use a 1 4 X 1 X 66 flat fiberglass rope Replacing Combustion Door Gasket Replacing Flue D...

Page 62: ...nt bolts 4 Tighten the inside nuts on the latch adjustment bolts You should only adjust these approximately one complete revolution at a time 5 To decrease tension loosen both inside nuts on the latch adjusting bolt After replacing door gaskets you may need to adjust the door latch tension Allow heater to burn out all wood and coals and to cool down before attempting this procedure Hazardous Volta...

Page 63: ...oor Latch Adjustment continued Step Operation Description Visual Aids Comments 6 Tighten both outside nuts on the latch adjustment bolt 7 Replace both acorn nuts and tighten Hazardous Voltage Disconnect Power to Heater prior to performing this maintenance operation ...

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Page 65: ...see section 1 2 11 7165 99 Bypass damper see section 1 2 12 2001 05 Damper solenoid see section 1 2 13 7165 40 Air tube damper assy see section 1 2 14 3105 18 Secondary air distribution plenum see section 1 2 15 3105 17 Fire grate see section 1 2 16 2165 27 Back wall brick see section 1 2 17 2165 28 Side brick see section 1 2 18 2165 31 Bottom front back bricks see section 1 2 19 7165 20 Primary a...

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Page 67: ...All warranty claims are handled through local Hardy Dealers Contact Hardy Mfg Co Inc at 601 656 5866 to obtain contact information on local Hardy Dealers ...