installation & operating manual - wordpress.com · 2014-01-24 · 9022101 contact your local...

3-90-233R23_10/13

Contact your local dealer with questions on installation, operation or service.

SAFETY NOTICEPlEASE rEAd ThIS ENTIrE mANuAl bEFOrE YOu INSTAll ANd uSE YOur NEw bOIlEr. FAIlurE TO FOllOw INSTruCTIONS mAY rESulT IN PrOPErTY dAmAgE, bOdIlY INjurY, Or EvEN dEATh.FOr rESIdENTIAl uSE IN ThE u.S. ANd CANAdA. IF ThIS PEllET bOIlEr IS NOT PrOPErlY INSTAllEd, A hOuSE FIrE mAY rESulT. FOr YOur SAFETY, FOllOw INSTAllATION dIrECTIONS. 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.CETTE guIdE d’uTIlISATION EST dISPONIblE EN FrANCAIS. ChEZ vOTrE CONCESSIONNAIrE dE hArmAN

SAvE ThESE INSTruCTIONS

Installation & Operating manual

model(s):HydroFlex 60 Pellet Boiler

NOTICE: SAVE THESE INSTRUCTIONS

hot glass will cause burns.• Donottouchglassuntilitiscooled• NEVERallowchildrentotouchglass• Keepchildrenaway• CAREFULLYSUPERVISEchildreninsameroomas

stove.• Alertchildrenandadultstohazardsofhightemperatures. high temperatures may ignite clothing or other

flammable materials.• Keepclothing,furniture,draperiesandotherflammable

materialsaway.

hOT SurFACES!

Glassandothersurfacesarehotduringoperation and cool down.

WARNING!

To obtain a French translation of thismanual, pleasecontactyourdealerorvisitwww.harmanstoves.com

Pourobtenirunetraductionfrançaisedecemanuel,s’ilvous plaît contacter votre revendeur ou visitezwww.harmanstoves.com

NOTE

2 3-90-233R23_10/13

hF60 Parts

HopperLid

OutsideAirKnockout(either side)

BoilerDrain(EitherSide)

HeatExchangeCleanout Cover

FluePipe-3”PelletVent

CombustionBlower

Temperature/PressureGauge

PressureReliefValve

FireboxDoor

Control Board

CombustionBlowerCover

CircuitBreaker

PowerCord

HeatingSystemSupply&Return(either side)

RemoteZoneControl/OATSensorTerminal

FireboxDraftTestPort

LevellingFeet

SideAccessPanel

1-Controlled&1-Un-controlled120VACOutlets

3

3-90-233R23_10/13

Pleasereadthisentiremanualbeforeyouinstallanduseyournewboiler.Failuretofollowinstructionsmayresultinpropertydamage,bodilyinjury,orevendeath.

SAvE ThESE INSTruCTIONS

hearth & home Technologies352MountainHouseRoad

Halifax,PA17032

Table of Contents

Options 4

Installation 5 venting 8 Plumbing 13 Electrical 19

Operation 25

maintenance 33

Troubleshooting 37

Specifications 38

wiring diagram 39

warranty 40

Testing label 42

Service Parts 43

Start-up Quick reference back Cover

= Contains updated information

harman Central heating Appliances are built and tested to be complete home heating solutions. As with any Central heat system, a backup heating system may be required in the event of power outages or during appliance service or maintenance.

dANgEr: rISk OF FIrE Or ExPlOSION - dO NOT burN gArbAgE, gASOlINE, drAIN OIl Or OThEr FlAmmAblE lIQuIdS IN ThIS APPlIANCE.wArNINg: rISk OF FIrE- dO NOT OPErATE wITh FuEl lOAdINg

Or ASh rEmOvAl dOOrS OPEN.- dO NOT STOrE FuEl Or OThEr

COmbuSTIblE mATErIAl wIThIN mArkEd INSTAllATION ClEArANCES.

- INSPECT ANd ClEAN ENTIrE vENTINg SYSTEm INCludINg All FluES ANd ChImNEY rEgulArlY.

4 3-90-233R23_10/13

Options

Inlet Cover part# 1-10-09542

DirectVentWallPassthroughItem#1-10-677177providesforsafepassingof the 3” or 4” pellet vent pipe through anoutsidewall,whileprovidingtheattachmentforoutsideair.Noextraholesneeded.

Standardmethodof attachingoutsideair.Besuretousetheinletcovertopreventbirdsand/orrodents fromentering the intakepipe.Thismethodrequiresaholetotheoutside,separatefromtheventpassage.

Outside Air Components

water Piping Supports- Item#2-00-232044B,securestotheboilerand gives the support needed for theexpansiontankandcirculator,whilekeepingthemataworkabledistancefromtheboiler.

Atmospheric Conversion-Item #1-00-232200, provides auto-matic fill, and converts the heatingsystem plumbing from pressurizedto a zero pressure system.Allowsfor installation into more placeswhere codes and standards restrict pressurizedsystems.

bulk Storage hopper-Item#1-00-73450,with1500lbpelletcapacity, it will automatically re-filltheunithopperwhenitfallsbelowacertain level.

5 3-90-233R23_10/13

1. Install3/4”MPTboilerdraininthefittingasshown.Eithersidecanbeutilized.Note:Ifusingthesupplyandreturnoneachside,eitheroneofthereturnsisgoingtoneedthe drain valve incorporated.

Note: Use Teflon pipe thread sealant or Teflon tape on All threads before connections are made.2. Installthe1/2”MPTtemperature/pressuregaugeinfitting

where shown.3. Locate and install the outside air temperature sensor.

LocationofthissensorshouldbeontheNorthsideofthehomeorbuildingandoutofdirectsunlight.Useacat3cableor18-2thermostatwiretoattachthesensortotheterminalslocatedbesidethecontrolboard.Thewirescanbeconnectedtothesensorwithwirenutsorbuttspliceconnectors.

Installation

boiler kit materials: (refer to page 3)Listofitemsshippedwiththeunit.

1-3/4”BoilerDrain1-3/4”SafetyReliefValve1-1/2”DualTemperature/PressureGauge1-OutdoorAirSensor2-PipingSupportBrackets1-ScraperTool4-1½”LevellingFeet.(page7)

Preparation For Installation:

Attach OutsideAirSensorHere

Bolt-DownBrackets:Usethebracketsfromtheoriginal packaging and atleast4bolts(notsupplied)to secure the unit in its permanentlocation.Recommended for all in-stallations.

Note:It is recommended that thelevelling feet be installed inall installations. The air space provided will help to prevent condensationortrappedmois-turewhichmayleadtorustonthebottomoftheunit.Thefeetcanbeadjustedusinga7/16”openendwrench.

6 3-90-233R23_10/13

Placement and System design:Thefirstthingthatneedstobedoneisdecidingwhereandhowtheboilerwillbeinstalled.Things that need to be taken into consideration are theintendeduseoftheboiler.Forexample,istheboilergoingtobeusedasasecondaryorbackupheatingsystem?Ifitistobeusedinconjunctionwithanexistingoilorgasboilersystemwillitbepipedinparallelorinseries?Theanswerstotheseandotherquestionscanbedeterminedbytalkingto your certified dealer or a qualifiedHVACor plumbingcontractor.Thiswillensure that theboiler is installedandpipedtobestaccommodateyourneedsandexpectations.Muchconsiderationmustbegiventotheventing.Duetolowexhaustgastemperatures,theboilershouldbeplacedwheretheventingsystemcanbeasshortaspossible.Payparticularattention to electrical connectionneedsand combustible/serviceclearancerequirements.Aftertheboilerissetintoplacetheventingcanbeinstalled.Makesureanyexhaustingdevicesorappliancesusedintheareaareinstalledsoasnottocreatenegativepressureintheroomwheretheboilerislocated.Thisboilermustnotbeinstalledinanareaorroomwherechemicalsorsolventsareusedorstoredinquantitiesabovethatofnormaluse.

Installation

Floor Protection: The striped area indicates theminimum required floorprotection area if the boiler is going to be placed on acombustible floor.Special Note: When installing on a protected floor, the levelling feet need to be adjusted so that the bottom of the unit is 1¼ inches off the floor protector (see illustration below). Thisboilerrequires46⅞”X29⅛”(48⅞X29⅛inCanada)ofnoncombustiblefloorprotectionasshownabove.16”(US)or18”(Canada)ofthefloorprotectionmustbeinfrontoftheboilerasshown,with6”extendingoneitherside.CSA/CANB366.1requiresfloorprotectionextending2”(50mm)underhorizontalsectionofchimneyconnector.Floorprotectionmustbeaminimumof26gaugesheetmetal.

Minimumnon-combustiblefloorprotectionarea

Levellingfeetmustbeadjustedtogive1¼inofclearancewheninstallingboileronaprotectedcombustiblefloor.

Note:Itisrecommendedthatthelevellingfeetbeinstalledinallinstallations. The air space provided will help to prevent condensationortrappedmoisturewhichmayleadtorustonthebottomoftheunit.Thefeetcanbeadjustedusinga7/16”openendwrench.This appliance is also approved for installation into a shop.

6” [1

52.4

mm

]

16” [406.4mm]US18”[457.2mm]CAN

29 1

/8” [

739.

78m

m]

46 7/8” [1190.63mm]US48 7/8” [1241.43mm]CAN

NON-COMBUSTIBLEFLOOR PROTECTION

46 7/8” [1190.63mm]US48 7/8” [1241.43mm]CAN

29 1

/8” [

739.

78m

m]

7 3-90-233R23_10/13

Installation

A

bC

d

minimum Clearances To Combustible materialsSidewall To Appliance A 6” (152 mm) mur latéral à l’Appareilbackwall To Appliance b 6” (152 mm) mur Arrière à l’AppareilStove Top To Ceiling C 16” (406 mm) haut du Poêle au PlafondStove Front To Combustibles d 48” (1219 mm) des Combustibles au devant du PoêleCombustibles To Pellet vent 3” (76 mm) matériaux Combustibles au Conduit de Fuméeminimum Alcove height 72” (1829 mm) hauteur de l’Alcôveminimum Alcove width 48” (1219 mm) largeur de l’Alcôveminimum Alcove depth 60” (1524 mm) Profondeur de l’Alcôve

wArNINg! rISk OF FIrE! Hearth&HomeTechnologiesdisclaimsanyresponsibilityfor,andthewarrantyandagencylistingwillbevoidedbythefollowingactions:dO NOT:• Installoroperateadamagedappliance• Modifytheappliance• InstallotherthanasinstructedbyHearth&HomeTechnologies• Operatetheappliancewithoutfullyassemblingallcomponents• Overfiretheappliance• InstallanycomponentorpartnotapprovedbyHearth&HomeTechnologiesImproperinstallation,adjustment,alteration,service,ormaintenancecancauseinjuryorpropertydamage.Forassistanceoradditionalinformation,consultaqualifiedinstaller,serviceagencyoryourdealer.

8 3-90-233R23_10/13

V =Vent Terminal A =Air Supply Inlet =Area where termination is mot permitted

Door

Sidewalk

FixedClosed

Openable

Openable FixedClosed

Inside CornerDetail

Porch orOpenable

Deck or Fixed

requirements for Terminating the ventingWARNING:Ventingterminalsmustnotberecessedintoawallorsiding.NOTE:OnlyPLventpipewallpass-throughsandfirestopsshouldbeusedwhenventingthroughcombustiblematerials.NOTE:Always take into consideration the effect theprevailingwinddirectionorotherwindcurrentswillcausewithflyashand/orsmokewhenplacingthetermination.In addition, the following must be observed:A.Theclearanceabovegrademustbeaminimumof12”.B.Theclearancetoawindowordoorthatmaybeopened

must be aminimumof 48” to the side, 48” below thewindow/door,and12”abovethewindow/door.

C.A 12” clearance to a permanently closedwindow isrecommendedtopreventcondensationonthewindow.

D.Theverticalclearancetoaventilatedsoffitlocatedabovetheterminalwithinahorizontaldistanceof2feet(60cm)fromthecenter-lineoftheterminalmustbeaminimumof18”.

E.Theclearancetoanunventilatedsoffitmustbeaminimumof12”.

F.Theclearancetoanoutsidecorneris11”fromcenterofpipe.

G.The clearance to an inside corner is 12”. If you see deposits developing on the wall, you may need to extend this distance to accommodate your installation conditions.

H.Aventmustnotbeinstalledwithin3feet(90cm)aboveagasmeter/regulatorassemblywhenmeasuredfromthehorizontalcenter-lineoftheregulator.

I.Theclearancetoserviceregulatorventoutletmustbeaminimumof6feet.

J.Theclearancetoanon-mechanicalairsupplyinlettothebuildingorthecombustionairinlettoanyotherappliancemustbeaminimumof48”.

K.Theclearancetoamechanicalairsupplyinletmustbeaminimumof10feet.

L.Theclearanceaboveapavedsidewalkorapaveddrivewaylocatedonpublicpropertymustbeaminimumof7feet.

M.Theclearanceunderaveranda,porch,deckorbalconymustbeaminimumof12inches. (See b. also)

NOTE: The clearance to vegetation and other exteriorcombustiblessuchasmulch is36”asmeasuredfromthecenteroftheoutletorcap.This36”radiuscontinuestogradeoraminimumof7feetbelowtheoutlet.CertainCanadianandorLocalcodesorregulationsmayrequiredifferentclearances.A vent shall not terminate directly above a sidewalk orpaveddrivewaywhichislocatedbetweentwosinglefamilydwellingsandservesbothdwellings.Onlypermitted ifveranda,porch,deck,orbalcony is fullyopenonaminimumof2sidesbeneaththefloor.

NOTE: where passage through a wall, or partition of combustible construction is desired, the installation shall conform to CAN/CSA-b365. (if in Canada)

Fig. 2

venting

9 3-90-233R23_10/13

10

Total Lineal Feet Combined Should Not Exceed 18' asmeasured from the outlet.

0

2

6

4

8

68 4 2

5

Altitude in Thousands of Feet

10

Maximum Horizontal Run 8'

10

5

7

6

9

8

18

15

4

The Total Lineal Feet Decreases as the Altitude Increases

ventingUseonly3”pelletventpipetoventyourpelletboiler.A combustion blower is used to extract the combustiongasesfromthefirebox.ThiscreatesanegativepressureinthefireboxandapositivepressureintheventingsystemasshowninFig.4.Thelongertheventpipeandmoreelbowsusedinthesystem,thegreatertheflowresistance,andthegreaterthechanceforcreosoteaccumulation.Becauseofthesefactswerecommendusingasfewelbowsaspossibleand18feetorlessofventpipe.Themaximumhorizontalrunshouldneverexceed8feet.Be sure to use wall and ceiling pass through fittings (which are approved for pellet vent pipe ) when going through combustible materials. Besuretouseastartingcollartoattachtheventingsystemtothestove.The starting collar must be sealed to the stove flue collar with high temp silicone caulking or aluminum tape, and screwed into the units’ flue collar in a minimum of three (3) places.due to low exhaust temperatures, increasing the diameter of the venting or exceeding the recommendations of the venting graph, is strongly discouraged.

Fig. 4

12”

36”

-

+

vent Pipe3” pellet vent pipe (also known as “L or PL” vent) isconstructed of two layers with air space between thelayers. This air space acts as an insulator and reduces the outsidesurfacetemperaturetoallowaminimumclearancetocombustiblesaslowas1inch.InCanadatheminimumclearancetocombustiblesis3inches.Checkwiththeventingmanufacturertobecertainofspecifiedclearances.Thesectionsofpipelocktogethertoformanairtightsealinmostcases;however,insomecasesaperfectsealisnotachieved.Forthisreasonandthefactthattheunitoperateswith a positive vent pressure, we specify that all joints within the structure should be secured with at least 3 screws, and sealed with silicone caulking.

venting

Fig. 3

Creosote - Formation and Need for removal -Whenwoodisburnedslowly,itproducestarandotherorganicvapors,whichcombinewithexpelledmoisturetoformcreosote.Thecreosotevaporscondenseintherelativelycoolchimneyflueofaslow-burningfire.Asaresult,creosoteresidueaccumulatesonthefluelining.Whenignited,thiscreosotemakesanextremelyhotfire.Thepelletventpipeshouldbeinspectedatleasttwicemonthlyduringtheheatingseasontodetermineifacreosotebuilduphasoccurred.Ifcreosotehasaccumulateditshouldberemovedtoreducetheriskofachimneyfire.Guidance on minimizing creosote formation and the need for periodic creosote removal:Thechimneyshouldbeinspectedduringtheheatingseasontodetermineifacreosotebuild-uphasoccurred.Ifasignificantlayerofcreosotehasaccumulated,1/8”(3mm)ormore,itshouldberemovedtoreducetheriskofachimneyfire.

NOTE: Use only 3” diameter type “L” or “PL” venting system. Be sure to inspect and clean exhaust venting system frequently.

10 3-90-233R23_10/13

Theminimumventconfigurationisa90o or Tee on a starter collaranda24”lengthhorizontalthroughanexteriorwall.Acapontheendshoulddirectthefluegasesdownandawayfromthestructure.SeeFig.5.Themaximumhorizontal length is 8 feet.The minimumtermination height above the exterior grade is 18”. Themaximumtotallengthofanyconfigurationis18feet*.*(seeventinggraphonpage10forexceptions)NOTE: Cleanout Tee’s should always be used on the transitions to horizontal pipe to allow easy access for cleaning.Theventinggraphallowsforone(1)90deg.orTeefittinginanyconfiguration.Ifmore90’s,T’s,or45’sareneededthetotallengthmustbeadjustedtoallowfortheaddedrestriction.Uptofour(4)additional90’s,Tee’s,orequivalent45’scanbeaddedaslongastheoveralllengthisadjustedinaccordancewiththevalueslistedbelow.(Seetheventinggraphonpage10.)EachVertical----90deg.orTsubtract2.5feetEachVertical----45deg. subtract1.5feetEachHorizontal-90deg.or Tsubtract5.0feetEachHorizontal-45deg. subtract2.5feet

venting

3” Type “L” or “PL” Vent pipe

Thisistheminimumventingconfiguration.NOTE:Astartingcollarisneededinordertoremovetheunits’cleanoutcover.

Fig. 5

Any exterior venting (vent pipe exposed to outside ambient temperatures) should be kept to a minimum, due to potential condensation problems. This is especially important in high humidity-cold weatherclimates,suchasmaritimeareas,lakeshores,andlowriver valleys.

venting Into An Existing Chimney TheboilermaybeventedintoanexistingmasonryorClassAmetalchimney,providingthatthechimneyislessthan20feetabovetheconnector.Aflueliner,nomorethan4-inchdiameter,mustbeinstalled,alongwithaterminationcapandtheproperflashingtosealtheexistingflue.The venting Can Not be installed in a chimney servinganother appliance.The chimney should be cleanedand/or inspected beforeinstallationoftheventliner.Due to low exhaust temperatures, and the increasedpossibilityofcondensationandcreosoteformation,additionalmeasuresmayneedtakentoincreasethefluetemperature.Onesuchmeasurewouldbetoremovethetworear-mostspiralbaffles,abovetheburnpot,fromtheirheatexchangetubes.Althoughsomeefficiencywillbe lost,an increasedfluetemperaturewillresult.The flue liner should be inspected frequently, duringoperation,tomonitoritsperformanceandcleanliness.

Otherexamplesofpossibleinstallationsoftheventing.

12”

36” 12”

36”


11 3-90-233R23_10/13

venting Installation

dO NOT INSTAll A FluE dAmPEr IN ThE ExhAuST vENTINg SYSTEm OF ThIS uNIT.

dO NOT CONNECT ThIS uNIT TO A ChImNEY FluE SErvINg ANOThEr APPlIANCE.

INSTAll vENT wAll PASS-ThrOughS AT ClEArANCES SPECIFIEd bY ThE vENT mANuFACTurEr.

INSTAllATION IS TO bE PErFOrmEd bY A QuAlIFIEd INSTAllEr.


INSTAllATION IS TO bE PErFOrmEd bY A QuAlIFIEd INSTAllEr.

NOTE: All installation clearances and restrictions must be adhered to.

To reduce probability of reverse drafting during a power failure, hearth & home Technologies strongly recommends:• Installingthepelletventwithaminimumverticalriseof

fivefeet.Preferablyterminatingabovetheroofline.• Installinganoutsideairconnectiontotheappliance.To prevent soot damage to exterior walls, and to prevent re-entry of soot or ash into the home:• Maintainspecifiedclearancestowindows,doorsandair

inlets,includingairconditioners.• Ventsshouldnotbeplacedbelowventilatedsoffits.• Avoidventingintoalcovelocations.• Ventsshouldnot terminateunderoverhangs,decksor

onto covered porches.• Maintain minimum clearance of 12” from the vent

terminationtotheexteriorwall.hearth & home Technologies assumes no responsibility for, nor does the warranty extend to, smoke damage caused by reverse drafting of pellet appliances under power failure conditions.NOTE: Read and follow all of the vent pipe manufacturers instructions on the proper installation and support of the vent pipe. Adhere to all clearances to combustibles.

dANgEr: rISk OF FIrE Or ExPlOSION - dO NOT burN gArbAgE, gASOlINE, drAIN OIl Or OThEr FlAmmAblE lIQuIdS IN ThIS APPlIANCE.wArNINg: rISk OF FIrE- dO NOT OPErATE wITh FuEl lOAdINg Or ASh

rEmOvAl dOOrS OPEN.- dO NOT STOrE FuEl Or OThEr COmbuSTIblE

mATErIAl wIThIN mArkEd INSTAllATION ClEArANCES.

- INSPECT ANd ClEAN ENTIrE vENTINg SYSTEm INCludINg All FluES ANd ChImNEY rEgulArlY.

WARNING!kEEP COmbuSTIblE mATErIAlS SuCh AS grASS, lEAvES, ETC. AT lEAST 3 FEET AwAY FrOm ThE POINT dIrECTlY uNdEr ThE vENT TErmINATION. (bETwEEN ThE vENT ANd ThE grOuNd)

CAUTION!kEEP COmbuSTIblES AwAY

FrOm FluE OuTlET.

12 3-90-233R23_10/13

NOTE: If outside air is installed, the inlet cover should not be placed in an area where drifting of snow or ice will build up, blocking the intake air supply.Hearth&HomeTechnologiesstronglyrecommendstheuseofoutsideairforallpelletboilerapplications.Per national building codes, considerationmust begivento combustion air supply for all appliances in the vicinityofthepelletboiler.Failuretosupplyadequatecombustionair forallappliancedemandsmay lead tobackdraftingofthoseappliances.ConsultwithyourHVACProfessionaltodeterminethatallcombustionairrequirementsaremet.when the appliance is side-wall vented:Theairintakeisbest locatedonthesameexteriorwallas,andlowerthantheexhaustventoutlet.when the appliance is roof vented:Theairintakeisbestlocatedontheexteriorwallorientedtowardstheprevailingwinddirection,duringtheheatingseason.TheOutsideAirIntakePipeisinsidetheRearCoverandtotherightofthefeedermotor.TheflexpipeismadetoslideinsidetheAirIntakePipe. SeeFig.8.Itshouldbeheldintoplacewithsilicone,foiltape,orahoseclamp.(notsupplied)Negative Pressure and Electrical Power FailureToreducetheprobabilityofback-draftingorburn-backinthepelletapplianceduringapowerfailure,theappliancemustbeabletodraftnaturallywithoutexhaustbloweroperation.Negativepressureinthehousewillresistthisnaturaldraftifnotaccountedforinthepelletapplianceinstallation.Heatrisesinthehouseandleaksoutatupperlevels.Thisairmustbereplacedwithcoldairfromoutdoorswhichflowsinto lower levels of the house.Vents and chimneys intobasementsandlowerlevelscanbecometheconduitforairsupply and reverse under these conditions.Theoutsideairsupplywillsupplymostofthedemandsofthepelletappliancetoresistback-drafting,butconsiderationmustbegiventothetotalhousedemand.Itmaybenecessaryto add additional ventilation to the space in which the pellet applianceislocated.ConsultwithyourHVACprofessionaltodeterminetheventilationdemandsforyourhouse.

Inlet Cover part# 1-10-08542

Installation

Fig. 6

Fig. 7

Outside Air Pipe knockout

Feeder Cover

rear Cover

Side Cover

Outside AirAlthoughstrongly recommended, theuseofoutsideair isoptional,exceptwhererequiredbylocalbuildingcodes.Toinstalloutsideair,usemetalflexpipe,part# 1-00-08543(25’roll)SeeFig.6.Thereisabreak-awayholeoneitherrearpanelwhichmustberemovedbeforeconnectingtheflexpipe.SeeFig.7.Thepipeshouldberunoutsideandterminate3feetormorebelowor1footormoretothesideoftheventpipeoutlet.Neverterminatetheoutsideairabovetheventpipeoutlet.Themaximumlengthofthispipeis15feet.Inletcoverpartnumber1-10-08542shouldbeusedtokeepbirds,rodentsetc.outoftheinletpipe.SeeFig.6.

during a loss of electrical power the hopper lid must be kept in a closed and latched position. Opening the lid while the combustion blower is non-operational will allow smoke into the home and potential overheating of the hopper and fuel. This can lead to a fire in the hopper.

Fig. 8Outside Air Inlet Pipe

13 3-90-233R23_10/13

Installation-Plumbing

BYPASS VALVE

SYSTEM SUPPLY 3/4"

* 3/4" NPT MALE PLUG

* BOILER DRAIN, 3/4" NPT MALE X 3/4" HOSE

TYPICAL BOILER HOT WATER PIPING SHOWING AIR REMOVAL SYSTEM, PROVISIONS FOR THE EXPANSION OF WATER AND THE AUTOMATIC COLD WATER SUPPLY. ALSO SHOWN BUT NOT NECESSARILY NEEDED IS THE BOILER BYPASS LINE. THE NECESSITY OF THIS LINE WILL BE DETERMINED BY THE INSTALLING CERTIFIED PLUMBER OR HVAC CONTRACTOR.

SHUT-OFF VALVE* AUTOMATIC AIR VENT

PIPE TO WITHIN 6" OF THE FLOOR OR A FLOOR DRAIN

UNION

* PRESSURE RELIEF VALVE

* TEMP/PRESSUREGAUGE

SHUT-OFF VALVE

UNION

SHUT-OFF VALVE

NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.

** THERMOMETER

PRESSURE REDUCING VALVE (PRV) OR COMBINATION PRV AND RELIEF VALVE

EXPANSION TANK (DIAPHRAGM TYPE)

SYSTEM RETURN 3/4"

3/4" BOILER BYPASS LINE (IF REQUIRED)

* ITEMS SUPPLIED ** OPTIONAL

CHECK VALVE (OR BACKFLOW PREVENTER IF REQUIRED)

** THERMOMETERAIR VENT

AIR SCOOP

SYSTEM SUPPLY 3/4"

COLD WATER SUPPLY 1/2"

NOTICE: When installing with the Atmospheric Conversion, all of the pressurized system components shown are not necessary. Air vents or bleeders should be removed from the plumbing system to prevent air from entering the lines.

NOTE: Cold return water temperature (Sustained temperatures below 140 degrees Fahrenheit) will lead to condensation or moisture in the firebox. This moisture can lead to creosote formation. To help minimize moisture and creosote, it is strongly recommended that some method of temperature balance is incorporated into the return system.

EXAMPLE OF A TYPICAL MULTI-ZONE HEATING SYSTEM WITH BOILER BYPASS AND INDIRECT DOMESTIC HOT WATER ZONE

SHUT-OFF VALVE




UNION

* AUTOMATIC AIR VENT

SYSTEM SUPPLY 3/4"



SHUT-OFF VALVE

UNION

DOMESTIC HOT WATER STORAGE HEATER WITH INTERNAL HEAT EXCHANGER

RETURN WATER

CHECK VALVE

OUT

IN

** THERMOMETER

SYSTEM RETURN 3/4"

** OPTIONAL

* ITEMS SUPPLIED

BOILER BYPASS CAN ALSO BE DONE WITH A 3-WAY MIXING VALVE AND CAN BE CONTROLLED MANUALLY OR WITH AN AUTOMATIC ACTUATING MOTOR. IF SO, THE TWO BALANCING VALVES ARE NOT NEEDED


BALANCING VALVE

CHECK VALVE

EXPANSION TANK, AIR REMOVAL AND COLD WATER SUPPLY

CIRCULATOR

HOTCOLD

** THERMOMETER

SYSTEM SUPPLY 3/4"

BYPASS (BALANCING) VALVE BOILER WATER SUPPLY WATER



14 3-90-233R23_10/13

boilers intended to be connected to an existing boiler or boiler system shall:1. Becapableofbeinginstalledwithoutinterferingwiththenormaldeliveryofheatedwaterfromtheoriginalboilertothe

radiationsystem.2. Becapableofbeinginstalledtooperateasintendedwithoutaffectingtheoperationoftheelectricalandmechanicalsafety

controlsoftheoriginalboiler.3. Provide,uponcompletionoftheinstallation,forachangeoverfromonefueltotheotherwithoutrequiringthemanual

adjustmentofanycontrolsorcomponentsotherthanthethermostats.4. Becompatiblewiththeoperationofaservicewater-heatingcoilwithintheoriginalboilerwithoutbypassingtheoperation

ofthesolid-fuelboiler.5. Haveprovisionforpreventing,oradequatewatercapacitywithintheboilertoprevent,damagetotheboilerfromlossof

circulationduetoelectricalpowerfailure.6. Be capable of being installedwithout changing the function of the control or rewiring of theoriginal boiler.Awiring

interconnectionispermitted.Theelectricalsystemofbothboilersshallbepoweredfromasinglebranchcircuitwithoutexception.

(CAN/CSA-B366.1-M91)7. PertainingtoCAN/CSA-B365-01,Haveaclearlylabelleddevice,locatedateachentrancetotheboilerarea,whichcan

bethrowntodiscontinueoperationtothefeedsystem.Anti-freeze and/or boiler water treatment: Thereisnorestrictiononthetypeofcommercialantifreezeused.Whenfillingtheboilerwatersystem,itisrecommendedthatsomeformofboilerwatertreatmentbeused.


EXAMPLE OF PIPING WITH AN INDEPENDENT CIRCULATOR SYSTEM CONNECTED TO AN EXISTING OPERATIONAL BOILER

* BOILER D

RAIN

, 3/4" NPT M

ALE X 3/4" H

OSE

* 3/4" NPT M

ALE PLU

G

RETURN 3/4"

SYSTEM SUPPLY





UNION

OUTUNION

SHUT-OFF VALVE

EXISTING BOILER

UNION

NOTE: NOT SHOWN IN THIS DRAWING ARE ALL OF THE ASSOCIATED PIPING AND CONTROLS THAT SHOULD ALREADY BE IN PLACE WITH THE EXISTING BOILER SYSTEM. FOR EXAMPLE, THE EXPANSION TANK, THE COLD WATER SUPPLY , AIR REMOVAL SYSTEM ETC... IT IS EXTREMELY IMPORTANT THAT THIS BOILER BE INSTALLED BY A QUALIFIED INSTALLER AND THAT ALL EXISTING CONTROLS AND SAFETY DEVICES ARE VERIFIED AS OPERATIONAL.

* ITEMS SUPPLIED

NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM. CIRCULATOR

SHUT-OFF VALVE

SHUT-OFF VALVE

UNION SUPPLY 3/4"

SYSTEM RETURN

UNION

IN

BALANCING VALVE

SHUT-OFF VALVEUNION

CIRCULATOR



15 3-90-233R23_10/13


EXAMPLE OF PIPING IN SERIES WITH AN EXISTING OPERATIONAL BOILER






UNION

SHUT-OFF VALVE

UNION




* ITEMS SUPPLIED

SYSTEM RETURN 3/4"

EXISTING BOILER

SHUT-OFF VALVE

SYSTEM SUPPLY 3/4"

OUT

IN



EXAMPLE OF PIPING IN PARALLEL WITH AN EXISTING OPERATIONAL BOILER



SYSTEM RETURN 3/4"

SYSTEM SUPPLY 3/4"





UNION

IN

UNION

SHUT-OFF VALVE

SHUT-OFF VALVE

EXISTING BOILER

BALANCING VALVE

UNION

BALANCING VALVE

UNIONOUT


* ITEMS SUPPLIED




16 3-90-233R23_10/13






UNION

SENSING BULB

SHUT-OFF VALVE

* ITEMS SUPPLIED

** OPTIONAL

** THERMOMETER

SYSTEM RETURN 3/4"

TYPICAL BOILER HOT WATER PIPING SHOWING AIR REMOVAL SYSTEM, PROVISIONS FOR THE EXPANSION OF WATER AND THE AUTOMATIC COLD WATER SUPPLY. ALSO SHOWN IS THE AUTOMATIC MIXING VALVE. THIS COULD ALSO BE DONE BY (2) CLOSELY SPACED TEE'S. THE PROPER PIPING FOR THE INTENDED USE WILL BE DETERMINED BY THE INSTALLING CERTIFIED PLUMBER OR HVAC CONTRACTOR.





SHUT-OFF VALVE

UNION

AIR VENTAIR SCOOP

** THERMOMETER

SYSTEM SUPPLY 3/4"



AUTOMATIC MIXING VALVE

SHUT-OFF VALVE




EXAMPLE OF TYPICAL TANKLESS DOMESTIC HOT WATER PIPING

MIXING VALVE

SAFETY RELIEF VALVE

FLOW REGULATOR WILL NEED TO MATCH THE GPM RATING OF THE DOMESTIC COIL.

CUSTOMER SUPPLIED SSPLATE HEAT EXCHANGER

DOMESTIC WATEROUTLET

DOMESTIC WATERINLET

SHUT-OFF VALVE

SHUT-OFF VALVE

OUTLET

INLET

HOSE BIB

HOSE BIB TO BACKFLUSH COIL IF NEEDED

FLOW REGULATOR

HIGH TEMPERATURE WATER ( IF NEEDED )


COLD WATER SUPPLY

MIXING VALVE SET TO DESIRED WATER TEMPERATURE.NORMALLY NOT MORE THAN 120 DEGREES.

ISOLATION VALVE

TEMPERED HOT WATER TO SHOWERS AND FAUCETS

17 3-90-233R23_10/13



MIXING VALVE SET TO DESIRED WATER TEMPERATURE.NORMALLY NOT MORE THAN 120 DEGREES.

TEMPERED HOT WATER FOR SHOWERS AND FAUCETS

FROM BOILER

CIRCULATOR

TO BOILER

EXAMPLES OF TYPICAL DOMESTIC HOT WATER STORAGE PIPING

EXAMPLE #1

TO BOILER

CIRCULATOR

FROM BOILER

COLD HOT

IN

OUT

EXAMPLE #2

MIXING VALVECOLD


HOT

IN

OUT

HIGHER TEMPERATURE WATER (IF NEEDED)

CAUTION: No domestic water temperature regulation shown

CAUTION: No domestic water temperature regulation shown


EXAMPLE OF A TYPICAL MULTI-ZONE HEATING SYSTEM WITH A SINGLE CIRCULATOR AND INDIVIDUAL ZONE VALVES


AIR VENT

SYSTEM RETURN 3/4"TO BOILER

FROM ADDITIONAL ZONES

SHUT-OFF VALVEUNION

AIR VENT (TYPICALLY INSTALLED IN THE HIGHEST ACCESSABLE LOCATION IN THE PIPING)

ZONE 1

ZONE 2

ZONE 3

FROM BOILERSYSTEM SUPPLY 3/4"

CIRCULATOR

ZON

E 2ZO

NE

1

TO ADDITIONAL ZONES

UNION

ZONE VALVE

BALANCING VALVE

ZON

E 3



18 3-90-233R23_10/13


AIR VENT (TYPICALLY INSTALLED IN THE HIGHEST ACCESSABLE LOCATION IN THE PIPING)

(LOW TEMPERATURE) RADIANT FLOOR HEAT

(LOW TEMPERATURE) RADIANT FLOOR HEAT

FROM BOILERSYSTEM SUPPLY 3/4"

SYSTEM RETURN 3/4"

HOT

THERMOSTATIC MIXING VALVE

TO BOILER

COLD

MIX UNION SHUT-OFF VALVE

NOTE: IF CIRCULATOR DOES NOT HAVE CHECK VALVE THEN A FLOW CONTOL VALVE WILL ALSO BE NEEDED AND INSTALLED IN THIS LOCATION

EXAMPLE OF A COMBINATION HIGH/LOW MULTI-ZONE HEATING SYSTEM WITH INDIVIDUAL ZONE CIRCULATORS

CIRCULATORS WITH INTEGRAL CHECK VALVE (SEE NOTE)

SHUT-OFF VALVE

(HIGH TEMPERATURE) BASEBOARD HEAT

ZON

E 1

ZON

E 2

ZON

E 3

AIR VENT

ZONE 1


ZONE 2

ZONE 3



EXISTING GAS / OIL FURNACE OR ELECTRIC HEAT PUMP

NOTE: NEVER INSTALL HOT WATERCOIL ON THE RETURN SIDEOF THE HEATING SYSTEM

* ITEMS SUPPLIED



* 3/4" NPT MALE PLUG PIPE TO WITHIN 6" OF THE FLOOR OR A FLOOR DRAIN

UNION


SHUT-OFF VALVE


SHUT-OFF VALVE

CIRCULATOR

RETURN AIR FLOW

SYSTEM RETURN 3/4"

HOT WATERHEATING COILTO BE SIZEDBY INSTALLER

EXAMPLE OF A TYPICAL FORCED HOT AIR HEATING SYSTEM WITH THE BOILER DIRECT TO AN IN DUCT HOT WATER COIL NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS

RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.




SYSTEM SUPPLY 3/4"

AIR VENT

AIR FLOW AIR FLOW

UNIONSHUT-OFF VALVE


FLOW CHECK

PURGE & BALANCE VALVE

(SIZED FOR TOTAL SYSTEM VOLUME)



19 3-90-233R23_10/13

Installation with A hot Air SystemElectrical interconnection of the HF60 to an existing heat pump, or fuel-fired hot air furnace: Interconnectionwithaheatpumpwillgenerallyrequireasecondthermostattobeinstalled.Itisrecommendedthatanewelectronicthermostatbeinstalledasclosetotheexistingthermostataspossible.Installingwithinonefootoftheexistingthermostatisrecommendedforeaseofinterconnectionandsimilartemperaturesensingability.Ifprogrammabilityisdesired,boththermostatsshouldhavethiscapability.Ifonlythenewthermostatisprogrammable,you’llneedtokeeptheexistingthermostatsetseveraldegreesbelowthelowestprogrammedtemperaturesettingofthenewthermostat.NOTE:Inthisconfiguration,iftheHF60cannotmaintainthedesiredthermostatsetting,theroomwillbeallowedtocooltothelowersetpointoftheexistingthermostatbeforeallowingtheheatpumptooperate.Specialnote:Eveniftheheatpumphasamulti-stagethermostat,itcannotbere-wiredtomakethefirststagecontroltheHF60,andthesecondstagecontroltheheatpump.Allmulti-stageheatpumpthermostatsareinterconnectedsothatthecompressorunitand/orthechangeoversolenoidactivatewiththefirststageonly.Controlling the existing furnace fan during overheat situation. Followingthewiringdiagramonthenextpage,youwillneedtosupplyandinstallapieceof18/3Thermostatwirebetweenthelow-voltagecontrolterminalstripontheupperleft-handsideoftheHF60’scontrolcover,tothelow-voltagecontroloftheexistingfurnace.Note: Some systems may have external terminals and some may have them enclosed within the unit. If the connections to the existing system need to be made internally, be sure to use the proper protective grommet or connector where passing through the cabinet of the existing unit. Ifthewiringuseddoesnotmatchthecoloringslisted,followthecorrespondingnumbersontheterminalstripstoensureproper connection.Step1.Disconnectelectricalpowertotheexistingheatingsystem.Step2. InstalltheabovementionedthermostatwirebetweenthetwosystemsStep3.Connectthethree(3)wirestotheHF60controlterminalstripasindicated.Step4.Removethegreenwirewhichcomesfromtheexistingthermostatandconnectstotheterminalmarked“G”onthe

existingsystemandspliceittothegreen(or#1)wirefromtheHF60.Step5.Connectthewhitewire(or#5)fromtheHF60tothe“G”terminaloftheexistingsystem.Thiswhitewireshouldbe

theonlywireconnectedto“G”.Step6.Now,thered(#3)wirefromtheHF60shouldbeaddedtothe“R”terminaloftheexistingsystem.Donotremoveor

replaceanyexistingwiresfrom“R”,justaddthisonetothem.Restorepowertotheexistingsystemonly.Usingtheexistingthermostat,increasethesettingtoverifythatthesystemworksasitdidpriortotheinterconnection.Increaseanddecreasethethermostatafewtimestoverifyproperreaction.Inthecaseofaheatpumpsystem,besuretheoutdoorcompressorunitisalsocycling.Notice:Mostcompressorshaveabuiltinlockouttimer(usually5minutes)soyoumayneedtowaitbetweenthermostatadjustmentstoverifyproperoperation.Onceyouarecertainthatnothingchangedwiththeoperationoftheexistingsystem,turntheexistingsystem’sthermostatdownfarenoughthatitwon’tcomeonduringthetest.ConnectpowertotheHF60,andturnonthecircuitbreakeronthefrontoftheunit.Withthecontrolinthe“OFF”position,turnthefeedadjusterknobto“Test”.WhentheOVERHEATSAFETYZONElightilluminates,thefanontheexistingsystemshouldcomeon.Besurethatthefanistheonlythingon.Thereshouldbenopowertothecompressorortheoilorgasburner.

20 3-90-233R23_10/13

Installation with A hot Air System

EXISTIN

G H

EAT PUM

P CO

NTR

OLS

LOW VOLTAGE 24 VAC COIL

O/A sensor terminals

in control cover

Through grommet

R2 RELAY

R1 RELAY

factory w

iring

to circu

lator o

utlet

The top three screws only

on the 5 pole terminal strip

1

6

4

5

3

8 7

LOW VOLTAGE

( by installer )

New T'stat Wire

34

1

6 5

8 7

Co

mp

ressor

Fan C

on

trol

24 VAC

ho

t

24 VAC

com

.

factory w

iring

HIGH VOLTAGE ( ORANGE) from control board

HIGH VOLTAGE ( N )

SPLICE ( by installer )

( by installer )

HIGH VOLTAGE ( L1 )

( by installer )

N

L

set 3° above existing t'stat

( by installer )

New T'stat Wire

Existing T'stat

set 3° below new t'stat

Existing T'statWiring

( by installer )

LOW VOLTAGE

SPLICE

RG C RG C

New T'stat

W1 O/B YL

Ch

ang

e-over valve

AU

X H

eat

Emerg

ency H

eat

SPLICE( by installer )

RED

WHITE

GREEN 1

5

3

L O/BW1 Y

( by installer )

L Y CG RO/BW1

Grainger# 2XC01- Omron LY2F 24V

Grainger#2XC02-Omron LY2F 120V

21 3-90-233R23_10/13

N

L

R CW1 G RW1 G C

set 3° below new t'stat set 3° above existing t'stat

24 VAC

com

.

24 VAC

ho

t

Heat C

on

trol

Fan C

on

trol

Existing T'statWiring

( by installer )

34

1

6 5

78

R2 RELAY

LOW VOLTAGE 24 VAC COIL

LOW VOLTAGE

LOW VOLTAGE

R1 RELAY

4

1

3

6 5

8 7

in control cover

Through grommet

HIGH VOLTAGE ( L1 )

HIGH VOLTAGE ( N )

HIGH VOLTAGE ( ORANGE) from control board

SPLICE

SPLICE

The top two screws only

on the 5 pole terminal strip

O/A sensor terminals

EXISTIN

G B

LOW

ER CO

NTR

OLS

to circu

lator o

utlet

New T'stat Wire

New T'stat Wire

( by installer )

( by installer )

factory w

iring

factory w

iring

( by installer )

( by installer )

( by installer )

Existing T'stat New T'stat

( by installer )



Installation with A hot Air System - fan only capable

22 3-90-233R23_10/13

Connection with a 2-wire hot air system

EXISTING BURNER / FAN SYSTEM

( GAS, OIL, ELECTRIC)

EXIS

TIN

G B

URN

ER /

FA

N S

YSTE

M

( GA

S, O

IL, E

LEC

TRIC

)

Exis

tin

g T

'sta

tN

ew T

'sta

t

120

VAC

FA

N W

IRIN

G

EXIS

TIN

G H

EAT

CO

NTR

OL

WIR

ING Neut

Hot

to fa

n c

on

tro

l

to fa

n m

oto

r

inp

ut

120

VAC

Neu

t

Return

Ho

tG

CR

24 V

AC

120

VAC

WH

ITE

RO

GER

S #

90-1

13

HO

NEY

WEL

L #

R828

5A10

48

J B

OX

MO

UN

TED

REL

AY

Ho

t

Neu

tR

etu

rn

N.O

. CO

NTA

CT

HotReturn

ENLA

RG

ED V

IEW

( by

inst

alle

r )

SPLI

CE

HIG

H V

OLT

AG

E ( O

RA

NG

E)

HIG

H V

OLT

AG

E ( N

)

to circulator outlet

R1 R

ELAY

R2 R

ELAY

factory wiring

6 4

8

5 3 1

7( b

y in

stal

ler )

( by

inst

alle

r )

( by

inst

alle

r )

HIG

H V

OLT

AG

E ( L

1 )

LOW

VO

LTA

GE

24 V

AC

CO

IL( b

y in

stal

ler )

New

T's

tat W

ire

8

6 4

7

5 13

L N

( by

inst

alle

r )

New

T's

tat W

ire

Exis

tin

g T

'sta

t Wir

e

thro

ug

h g

rom

met

INSI

DE

the

CO

NTR

OL

fro

m t

he

con

tro

l

Wit

h t

his

wir

ing

sch

emat

ic, t

he

over

hea

t

con

tro

l will

en

erg

ize

the

circ

ula

tor b

ut

will

po

wer

th

e fa

n o

n te

mp

erat

ure

ris

e.

no

t th

e fa

n re

lay.

Th

e ex

isti

ng

fan

co

ntr

ol

OV

ERH

EAT

SAFE

TY Z

ON

E

Gra

ing

er#2

XC02

Om

ron

LY

2F 1

20V

Gra

ing

er#2

XC01

Om

ron

LY

2F 2

4V

23 3-90-233R23_10/13

Connection with a wireless thermostatWIRELESS THERMOSTAT WIRING

2 AMP-CONTROLLEDCIRCULATOR OUTLET/AUX. DUMP ZONE

LT.BLUEVIOLET

R1 RELAY

6

4

8

LOW VOLTAGE

BROWN

BROWN

GREEN

WHITE5

3

7

LT. B

LUE

BR

OW

N

GRE

EN/Y

ELLO

W

GREEN/YELLOW

LT.BLUE

BROWN

GREEN/YELLOW

LT.BLUE

1.5 AMPAUX. OUTLETNON SWITCHED,CIRCUIT BREAKERPROTECTED

LT.BLUE to control board

BROWN to control board

VIOLET from control

ORANGE from control

N

L

1

RED

Grainger#2XC02Omron LY2F 120V

Installer SuppliedWireless T’stat

Receiver

( by INSTALLER )

18/2 THERMOSTAT WIRE

INSIDE EXISTING HVAC CONTROL SECTION

OUTSIDE AIR SENSOROUTSIDE AIR SENSOR

FAN/ZONE CONTRL

FAN/ZONE CONTRL

R2 RELAY

1 GREEN

78

4

6

3

5

GREEN

RED

EXISTING INTERNAL WIRING of HF60

LEFT SIDE OF CONTROL COVER

4 POLE TERMINAL STRIP

5BLUE

BLUE3

5N.O. contacts

R13

( by INSTALLER )

R CY O/BG

WIRENUT SPLICE

GREEN

L W1

EXISTING THERMOSTAT WIRE

EXTERNAL WIRING FOR UNITS WITH 4 POLE TERMINAL STRIP

WHITE

RED

WHEN USING AN RC T'STAT or OTHER DUAL T'STATS

Grainger #2XC01Omron LY2F 24V

24 3-90-233R23_10/13

Installationdraft Test ProcedureAftertheventingiscompleted,thefireboxdraftwillneedtobecheckedandpossiblyadjusted.Afterremovingtheplugboltfromthedrafthole(3/16”hexkeywrench)showninFig.9,insertthedraftmetertube.Thehopperlidmustbelatchedduringthistest.(Itisrecommendedthatthedraftmeterhaveascaleof0to1”WC.)Turnthefeedadjusterto“Test”.Thiswillstartthecombustionblowerandallowyou to checkand record theHighDraft______-IWCdate_______Themaximumdraftallowedis-.9”WaterColumn(-224Pa).ThereisnoadjustmentfortheHighDraft,otherthanre-positioningthecombustionblowerfanbladeonitsshaft,orachangeintheventingconfiguration.After the first 60 seconds the “Test” mode lowers thecombustionblowervoltagetotheLowBurnvoltage.Duringthisloweredvoltagecycle,thelow draft must be checked andadjustedifnecessary.Therecommendedlowdraftsettingshouldbebetween -.45and -.55 IWC.Dependingon theamountofverticalrise,itmaynotbepossibletogetalowdraftreadinginthisrange.Inthiscase,re-positioningthefanbladefurtheronthemotorshaftmaybehelpful. ThereisalowdraftvoltageadjustmentscrewlocatedthroughthesmallholetotherightoftheIgniterLight.SeeFig.10. AdjustedLowDraft is__________ -IWC.To increase thedraftinhigheraltitudes,HighAltitudekit#1-00-232059maybeneeded.don’t forget to turn the feed adjuster off of “Test”, and reinstall the draft test plug bolt into the boiler.

Fig. 9

“Test”

low draft Adjustment Pot

Fig. 10

draft Testing Port

high altitude kit #1-00-232059.Installthisringtoincreasedraftinhigheraltitudeinstallation locations.

CAUTION!hot while In Operation. do Not Touch. keep Children, Clothing And Furniture Away. Contact may Cause Skin burns. See Nameplate And Instructions.

keep doors Closed during Operation.

WARNING!

do Not Store Fuel or Other Combustible material within Installation Clearance Area.

WARNING!

risk of Fire - do Not Operate with the Flue draft Exceeding -.9” water Column (-224 Pa).

WARNING!

25 3-90-233R23_10/13

Power LightIndicates power to the control board. (Ready)

Status LightWill be lit anytime the unit is in operation.

Combustion Blower LightI n d i c a t e s P o w e r t o combustion blower

Feed Motor Light Indicates Power to the feed motor.

Max Temp dialThe “Max Temp Dial” is used to set the desired maximum operating temperature of the boiler.

7 blinks: Boilerwater overheat safety shut down (220DegreesF.)Thisrequiresamanualresetbycyclingthemainpoweroffforafewsecondsandre-connect.Explanation and Importance of the Overheat Safety ZoneWhen theunit is operatingatHighburn, andall demandfromtheheatingsystemstops, thecontrolwill reduce thefeedrateandshutdowncompletelyasnecessary.Thismaytakeseveralminutes,andtheremainingheatmaycausethewatertemperaturetorisetoover210degreesF.Whenthishappens,theOVERHEATSAFETYZONElightonthecontrolwillilluminateandtherelayR1isenergized.Thiswillclosecontacts#5and#3 (FanContactson the interconnectionPage20), andwill also energize the controlled circulatoroutlet,forthehotwaterdumpzone.Whenusingahotwatercoil inanairductsystem, if youdonotwantthelivingspaceheatedbeyondthethermostatsettingduringanoverheatdump,analternatedumpzonewillneedtobeinstalledandsomeinternalcontrolre-wiringwillbenecessary.

Feed adjusterSets the maximum feed rate

TestCombustion blower, feed motor and safety dump zone are fully energized for the first minute. Then, the combustion blower will stay on low.

Overheat Safety Zone LightIndicates that the boiler water temperature has reached 210 Degrees F.

Igniter LightIndicates power to the igniter

Lighting Mode SelectorSwitched between Auto and Manual lighting.

Mode Selector/Min Temp DialUsed to turn the boiler on or off and set the desired minimum operating temperature of the boiler.

Status light error messages:3 blinks:IndicatesthattheESP(ExhaustSensingProbe)hasgoneoutofrangetoomanytimes.Iftheunitisoperatingcorrectly,performamanualresetbycyclingthemainpoweroffat thecircuitbreakerforafewseconds.If the3blinkspersist, contact your service technician. 4 blinks:Indicatesmis-communicationwiththeaquastat,ortheaquastatisnotattachedproperly.Mayrequireamanualreset(turnoffpoweratcircuitbreaker).Notethatinsomeoptionalcontrolmethods,thisstatuswilloccurduringnormaloperationandresetautomatically.5 blinks:(InAutoLightModeOnly)Indicatesthattheigniterhasfailedtolightthefireafter40Minutes.Toreset -Turn theModeSelector/Min.Temp. toOFFandthenbacktothedesiredtemperature.6 blinks:Indicatesthatthecontrolhascalculatedpoororincompletecombustionoccurringfor25ormoreminutes.Asixblinkstatusmayoccurifthestoveisallowedtorunoutofpellets.Toreset,turnModeSelector/MinTempdialto“OFF”thenbackontothedesiredtemperature.Iftheunitwasnotoutofpellets,seeTroubleshootingsectionformoredetails.

Diagnostic PortFor maintenance only. Requi res specia l DDM monitor supplied to trained technicians exclusively.

Operation

label from unit control panel showing outlets

26 3-90-233R23_10/13

Setting The boiler Temperaturewithout the Outdoor Air Temp - Sensor InstalledTosetthemaximumboilerwatertemperature,simplyturntheMax.Temp.watertemperaturedialtothedesiredsetting.Thecontrolandtheboilerwillthenperformtoachieveandmaintainthesettemperature.TheMin. Temp. Knob is the boiler water temperatureminimum,orthelowesttemperaturethewaterwillgobeforetheunitre-starts.Turningtheknobfullycounterclockwiseisthe“OFF”position,while turningtheknobclockwise,pastthe140degreemarking,isthe“ON”position.with The Outdoor Air Temp - Sensor InstalledMaximumboilertempsettingisasdescribedabove,withtheaddedfeatureofautomaticmaximumwatertempcontrolledbytheOATsensor.TheMIN.TEMP.knob,inadditiontobeingthemodesetting(onoroff),alsohasthefunctionofsettingtheminimumboilerwater temperature.Thiswouldbe the lowestboilerwatertemperaturethatyouwanttohavebasedonthefollowingfactors;1. OutdoorAirTemperature(OAT)2. DomesticHotWaterUse a.HotWaterCoilOption b.IndirectHotWaterStorage3. OverallVolumeoftheHeatingSystemThe boiler is designed to withstand lower return water temperatures. However, extended return temperatures below 140 degrees F can cause condensation.NOTE: If the system is run at the lower temperature settings, conditions of the firebox, boiler tubes, secondary ash chamber and venting should be monitored closely. If any indications show excess condensation, the boiler water temperature will need to be increased until condensation does not occur.

Operation

Control board OperationAquastat Sensor-Thissensorislocatedbehindthecontrolpanel.This sensor, alongwith the outdoor air sensor, iswhatthecontrolboardusestoregulatetheburnratebasedon the observed conditions. (BoilerTemp.&OutdoorAirTemperature)Outdoor Air Temp - Sensor (OAT): This sensor is located outsidethebuilding(onthenorthsideofthehouseandoutofdirectsunlight).TheOutdoorAirSensorisusedtoperformhotwaterresetbasedonoutdoorairtemperatures.WhentheOATsensorisinstalled,at20°F.orbelow(outsidetemperature),theboilerwilloperateatthetemperaturesetontheMAX.TEMP.knob.Theboilerwatertemperaturewilldecreaseby1degreeF.forevery1degreeF.intemperaturerise(above20°)oftheoutdoorair.NOTE: Pellet Boiler Outdoor Air Reset Operation Graph located on page 28.

WATER TEMPERATURE

MAX. TEMP. MIN. TEMP.

27 3-90-233R23_10/13

OperationPe

llet B

oiler

Outd

oor A

ir Res

et Op

erati

on

Whe

n the

outdo

or se

nsor

is in

stalle

d, at

20° F

. or b

elow

OAT

(Outd

oor A

ir Tem

pera

ture)

, the

boile

r will

oper

ate at

the t

empe

ratur

e set

on th

e Max

imum

Temp

eratu

re kn

ob. T

he bo

iler w

ater

tempe

ratur

e will

decre

ase b

y 1 de

gree

for e

very

1 deg

ree i

n tem

pera

ture r

ise of

the O

utside

Air.

Exam

ple 1

OAT

Wate

r Tem

p De

gree

Cha

nge

Max s

et at

185o

65o

14

0o

-4

5°

Min s

et at

140o

60o

14

5o

-4

0°

55o

15

0o

-3

5°

50o

15

5o

-3

0°

45o

16

0o

-2

5o

40o

16

5o

-2

0o

35o

17

0o

-1

5o

30o

17

5o

-1

0o

25o

18

0o

-5

o

20o

18

5o

0

o

15o

18

5o

0

o

10o

18

5o

0

o

5o

185o

0°

0o

185o

Exam

ple 2

OAT

Wate

r Tem

p De

gree

Cha

nge

Max s

et at

180o

65o

15

0o

*

Min s

et at

150o

60o

15

0o

*

55o

15

0o

*

50o

15

0o

-3

0o

45o

15

5o

-2

5o

40o

16

0o

-2

0o

35o

16

5o

-1

5o

30o

17

0o

-1

0o

25o

17

5o

-5

o

20o

18

0o

0

o

15o

18

0o

0

o

10o

18

0o

0

o

5o

180o

0o

0o

180o

0o

* No c

hang

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oiler

temp

eratu

re af

ter re

achin

g mini

mum

setpo

int te

mper

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.

28 3-90-233R23_10/13

Starting A Fire Automatically1. Turn mode Selector to “OFF”.Thisresetsthecontrolinadditiontoturningitoff.

Operation

2. Clean burnpot with scraper.This is typically aweeklymaintenance procedure, but,dependingonthefuelbeingburned,mayneeddonemorefrequently.Cleaningtheburnpotwiththescraperwithasmallamountofnew fuel in thebottom isnotaproblem.First,scrapetheashesfromthefrontoftheburnpotintotheashpan.Thenscrapetheholegridsurfacedownwardintotheburnpot.Whenthestoveisignitedthesescrapingswillbepushedoutbythefeeder.CAuTION: wear heat-resistant gloves To Perform The Scraping Procedure.

3.Fill hopper with pellets.Beforerefillingthehopper,checkforexcessivefinesinthebottomofthehopper.Finesaresmallpiecesofbrokenpellets(sawdust).Finesdonotfloweasilyandoftenbuilduponthehopperfunnelbottomangles.Thesefinescanbepushedintothefeederopeningandthenfillthehopperwithpellets.Asthesystemworks,theywillbeburned.

Accesstheburnpotthroughthefireboxdoor.Scrapingcanbedonewhiletheunitisinoperation.*seecaution

29 3-90-233R23_10/13

4. If Starting After an Empty hopper, Turn Feed Adjuster to “TEST” (forone60secondcycle). Thiswillchargepelletsintotheaugertubeandalsoallowyoutocheckthemotorsforoperation.NOTE: The auger motor will not operate with any of the doors or hopper lid open.

5. Turn Feed Adjuster to #5. Ifthisisyourfirstfireoryouaretryinganewfuel,setthefeedadjusterto#5.Thissettingworkswellwiththeaveragewoodpellets,butmayneedadjustedforyourparticular fuel.Afteryouknowafeedratesettingthatworkswellforyourapplication,stickwiththatsetting.

NOTE: You know your feed rate is too highwhen:Theoverheatsafetyfeatureisenergizedeachtimetheheatingzonedemandturnsoffduringahighburn.OR,Ifunburnedorpartiallyburnedpelletsarefoundintheashpan.(thismayalsoindicateaneedforscrapingtheburnpot)If you need to keep the feed adjuster on it’s maximum setting, your unit is under-sized for the heating system. Continuous operation at maximum burn rate may cause pre-mature failure of the firebox baffles.Note: The firebox baffles (#1-10-232052) are considered to be a consumable item, and are therefore not covered by the product warranty.6. Flip the Igniter Switch up into the “AUTO” position.

due to low water temperature, the initial start will be a longer process than when the water temperature is closer to the minimum setting.

7. Turn the mAx. TEmP. dial onthecontrolboardtothedesiredtemperature.Thissettingmustalwaysbeatleast5°F.higherthantheMIN.TEMP.setting.

Operation

WATER TEMPERATURE

MAX. TEMP. MIN. TEMP.

WARNING!hOT whIlE IN OPErATION. dO NOT TOuCh. kEEP ChIldrEN, ClOThINg, ANd FurNITurE AwAY. CONTACT mAY CAuSE SkIN burNS.

30 3-90-233R23_10/13

8.Turn the mIN. TEmP. dial onthecontrolboardtothedesiredMinimumtemperature.Thiswillstartthelightingprocess if the temperature at the aquastat sensor isapproximately5°F.lessthanthesettemperatureontheMAXTEMP.dial.

9. Fill hopper with pellets and remove ashes as required.Type of Fuel -Usepelletizedwoodonly.Thelowertheashcontentof thepelletsthelesscleaningthatwillbeneededoftheheatexchangertubes.Thecleanerthesetubesarekept,themoreefficienttheboilerwillbe.

NOTE: Do not burn garbage, gasoline, naphtha, engine oil, or other inappropriate materials in this appliance.Store pellets in the manufacturer’s wrapping until needed to prevent pellets from absorbing moisture. do not store fuel within the appliance installation clearances, or within the space required for fueling, ash removal, and other routine maintenance operations.

Operation

lighting A Fire manuallyLightingthefiremanuallywillnotbenecessaryunlesstheignitionsystemfails.Follow steps 1 through 5 of the instructions for automatic lighting.6. Flip the Igniter Switch down intothe“MANUAL-LIGHT”

position.SeeFig.12.

7. Open the firebox door to access the burnpot.

8. Fill the burnpot with pellets as shown. SeeFig.14.Onlyfilllevelwiththefrontedge.

( ------- dO NOT OvErFIll ------- )

9. have matches or other ignition source ready.10. Turn mode SelectortodesiredMINTEMPsetting.Thiswill start the combustionblowerandallow the ESPtocontrolthefireinrelationtotheMAXTEMPDialsetting.(TheMAXTEMPdialsettingmustalwaysbesetabovetheMINTEMPsetting)OncethefireiswellestablishedtheMAXTEMPdialcanremainonanytemperaturesettingdesired.durINg mANuAl OPErATION:SPECIAl NOTE: when the Switch is set to manual ignite position, the boiler will function as in auto mode, except the fire will not be allowed to go out. It will only be allowed to go to a minimum burn rate between the times the aquastat is calling for heat. This rate is about 1.1 pound of fuel per hour. If used in manual mode, be sure there is an overheat dump in place. Note that if the overheat dump zone does not provide sufficient cooling, and the water temperature reaches 220 deg, the feed motor will be forced to shut off. because the unit is set on manual Ignition, it will not re-ignite when the water temperature cools below the settings.

Fig. 12

Fig. 13

Never attempt to start a fire if there is no power or if the combustion blower is not operating. Never open the hopper lid during a fire if there is no power or if the combustion blower is not operating.

Fig. 14

31 3-90-233R23_10/13

Operation

NOTE: Stirring the starting gel into the pellets usually allows the fire to become established quicker.CAuTION: Avapor flash couldoccur if toomuch time isallowedtopassbeforelightingthestartinggel.CAuTION:Caremustbe takennot togetstartinggelonyourhandsor clothing.Seriousburnscouldoccurduringthelightingprocess.CAuTION:Nevertrytoapplymorestartinggeltoanalreadyburningfire,orafirewithsmolderingpellets.“NEvEr uSE gASOlINE, gASOlINE-TYPE lANTErN FuEl, kErOSENE, ChArCOAl lIghTEr FluId, Or SImIlAr lIQuIdS TO STArT Or “FrEShEN uP “ A FIrE IN ThIS bOIlEr. kEEP All SuCh lIQuIdS wEll AwAY FrOm ThE uNIT whIlE IN uSE”.

STARTER GEL

Fig. 15

11. Apply starting gel as shown in Fig. 15

12. light The Starting gel with A match.13. Close The doors - Thefirewilllightandthecontrolwill

adjusttherateofburntotheproperlevel,accordingtotheMAXTEMPdialsetting.

Solid-fuelburningappliancesneedtobecleanedfrequentlybecausesoot, creosote, andashmayaccumulate. If yoususpectachimney/ventpipefiredothefollowing:1. Callthefiredepartment.2. Removefuelfromtheburnpotusingtheburnpotscraping

tool to scrape the pellets into the ash pan.3. Removetheashpanfromtheunitandtakeoutside.do

notplacetheashpanonacombustiblematerial.4. Turnoffcircuitbreakeratunit.5. Donotusetheunituntilaqualifiedpersonhasinspected

yourapplianceandventing.

Fig. 16

NOTICE: when burning the boiler in the manual ignition mode, there must be an overheat dump zone incorporated into the plumbing system.

Ifheatingdemandstopsduringmanualoperation,thecontrolwilltaketheunittolowburn.Ifnoheatisusedduringthistime,thewatertemperaturewillcontinuetorise.Whentheaquastat senses 220˚F, the feederwill be turned off andthefirewillgoout.Thiswillrequireamanualre-startofthesystem.(seepage26“7Blinks”)

32 3-90-233R23_10/13

burnpot Cleaning: Theburnpotshouldbecleanednolessthanonceaweek.Forbestoperationtheburnpotshouldbecleanedeverytimethehopperisfilledwithpellets.Thefiredoesnothavetobeouttoscrapetheburnpotalthoughit isrecommendedtheboilerbeonminimumburnatthetimeofcleaning.CAuTION: wear gloves To Prevent burns.Usetheflatendofthescraperprovidedtoscrapedownovertheholedsurfaceoftheburnpotgrate.SeeFig.17.It isnotnecessarytocleanoutthescrapingsfromthiscleaningbecausetheywillbepushedoutastheaugeroperates.Note: Make a special effort to scrape the bottom inside corners of the burnpot where the auger tube enters the burnpot. Carbon deposits can build up over time in this area that may cause a restriction to the flow of pellets into the burnpot.Note: The end of the scraper may need sharpened occasionally, for best results.Whilescrapingtheburnpot,youcanalsousethescrapertooltotaponeachofthevisibleheatexchangespirals.Thiswillhelptomaintainmaximumefficiencybetweencleanings.Cleaning the burnpot Air Chamber: Thisareaonlyneedstobecleanedtwiceaheatingseason,unless excessive buildup is noticed during scheduledcleanings.Thereisacoveronthefrontoftheburnpottogainaccesstotheairchamber.Thecoverisheldintoplacebytwothumbscrews.Loosen the thumbscrewsandremove thecover.SeeFig.19.Theairchambercanbecleanedofanyashthathasfallenthroughtheholesduringoperationandcleaning.NOTE: ALWAYS REMEMBER TO CLOSE THE CLEANOUT COVER AFTER CLEANING.Feeder Chamber (Fig. 20):This chambermaygetabuildupof fines from the feedermechanismmovement.Thisareashouldbecheckedandcleaned at least once a year.To remove the feeder cover:• Loosenthe5/16”wingnut.• Slidethecoveroffofthethreadedstudandliftupward.• Inspectandcleantheinnerchamberasnecessary.SeeFig.

20.• Thereisaremovableplateinthisareathatdeflectsfines

intotheauger.Toremovethisplate,rollitoutunderthepusherarm.

• Reinstallthecovermakingcertainit iscenteredonthefeederbodyandhand-tightenthewingnut.

maintenance

burnpot cleanout cover

Fig. 19

Fig. 20

Fines area

Feeder cover

Fig. 17

Scrapetheburnpottoremoveanycarbondeposits which mayhaveformed.

Scrapingcanbedonewhiletheboilerisin operation, accessedthroughthefireboxdooropening.Wearglovestoprotectfromburns.

33 3-90-233R23_10/13

maintenance

Soot and Flyash: Formation and Need for removalTheproductsofcombustionwill containsmallparticlesofflyash.Theflyashwillcollectintheexhaustventingsystemandrestricttheflowofthefluegases.Incompletecombustion,such as occurs during startup, shutdown, or incorrectoperationoftheboilerwillleadtosomesootformationwhichwillcollectintheexhaustventingsystem.Theexhaustventingsystemshouldbeinspectedatleasttwicemonthlyuntilanappropriatecleaningscheduleisdetermined.

Fig. 21

Inner refractory liningThefireboxandheatexchangertubeaccessareasarelinedwith high-temperature, fibrous ceramic insulation panels(muchlikespacecrafttiles).Thesurfaceofthesepanelsishardenedtoresistnormalwearfrombrushingwithanon-metalbrush.Thepanelsarenotdesignedtobecleanedwiththescraperorothersharpobjects.Cautionmustbetakenwhencleaningthesepanelsbecausedamagetothemisnotcoveredbythewarranty.Theashpanslidesintotheunitonarailsystem.Thiskeepstheashpanfromcontactingthesidesandfloorrefractorypanels.Cautionmustbetakentoensurethereisnothingonthefloorsurfacepriortoinsertingtheashpan.Ash removalIt is recommended to remove the asheswhen the boilerisnotinoperation.Thislessensthechancesofcomingincontactwithhotsurfaces.Ashescanberemovedwhileinoperationbut,extracaremustbetakenincludingwearingprotectivegloves.Open The Firebox doorSwingthelatchdownwardandopenthedoorasshowninfig.21.NOTE: Keep hopper lid, and firebox door closed during operation and maintain all seals in good condition. Air leaks will cause low draft conditions, which will result in feeder shutdown.disposal of Ashes:Ashesshouldbeplacedinasteelcontainerwithatightfittinglid.Theclosedcontainerofashesshouldbemovedoutdoorsimmediatelyandplacedonanon-combustiblefloororontheground,wellawayfromallcombustiblematerials,pendingfinaldisposal. Ifashesaredisposedofbyburial insoilorotherwiselocallydispersed,theyshouldberetainedintheclosed container until all cinders have thoroughly cooled.Otherwasteshallnotbeplacedinthiscontainer.

FireboxRefractoryLinings

34 3-90-233R23_10/13

maintenance

CAUTION: Cleaning of the heat exchangers, flue pipe, chimney, and combustion blower fan, is especially important at the end of the heating season to minimize corrosion during the summer months, caused by accumulated ash.

Thetabsgointotheslotsonthebaffleandthelatchflipsdownwardtosealattheangle.Liftthelatchandliftthebaffleoffofthetabsforremoval.Ashesfromtheheatexchangetubescanbecleaned from thisarea.Sliding thefirebrickfromonesidetotheotherwillallowmorespaceforbaffleremoval.CleaningTomaintainmaximum heating efficiency, this cleaningshouldbeperformedweeklyduring theburnseason.Thefrequencyofthiscleaningwillbedirectlyrelatedtothequalityandquantityoffuelbeingconsumed.Keepinmindthatthecleanertheheatexchangertubesarekept,thehighertheheattransferefficiencywillbe.Due to theeaseof restarting, it is recommended that theboilerbeturnedOFFforanhourbeforecleaning.Startbyremovingthetwofireboxbafflesasshownabove,thenreinstalltheashpan.Next,removethetopheatexchangercovertoexposetheheatexchangertubes.Vacuumthisupperexhaustchamber.Someofthetubescontainaspiralbafflewhichyoucanuseasacleaningdevice.Simplyworkthespiralupanddown,approximately6inches,toscrapetheinsidesurfaceoftheheatexchangetube(s).Theremoveddebriswillfalltotheashpanandontheangledchamberofthefirebox.Oncealltubesarecleaned,removetheashpanandcleantheremainderfromtheangles.Withawispbrush,paintbrushorasootvac,cleanthefireboxwallsandanyflyashthathasaccumulatedintheburnpot,orburnpotopening.Atthistimeyoucanscrapeandcleantheburnpotandfinescleanoutarea.Inspectallsealinggasketstoensureapropersealandre-installallcomponentsremovedforcleaning.

Tabs(2)

Slots(2)

Latch

SealingArea

Firebox Baffle Removal

Note: The firebox baffles (#1-10-232052) are considered to be a consumable item. Check for signs of warping or damage, and replace if necessary.CAuTION: For your safety, do not vacuum hot ashes or embers. Some portions will remain hot, long after shut-down. wear gloves to protect skin from burns.

Install theCleanoutCover LiftHandlebyusing the spring latchholes.InstalloneendoftheCleanoutCoverLiftHandleintothebackspringlatchholewhiletheothersidegetsplacedintotheonepositionedontheoppositesideaspicturedbelow.

Pullupwardslowly

AftertheCleanOutCoverhasbeenremovedyoucannowremovethe spirals. Using the Spiral Removal Tool, clamp through theopeninglocatedatthetopofeachspiralandslowlypullupwardasshownbelow.

35 3-90-233R23_10/13

maintenanceTheboilermuST be OFF at the circuit breaker, and COOl beforeyouattempttocleanthecombustionblower.Thewire to the combustion blower doesn’t need to bedisconnectedduringthecleaningprocess.Loosenthethree(3)thumbscrewsabout4turnseach.SeeFig.23.Holdthemotorheadwithonehandandtheblowerplatehandlewiththeotherhand.Pulloutwardontheplatehandleuntilthecompleteunitcomesloose.Nowrotatetheplatecounter-clockwiseabout1/8turn.Thiswillallowthecompleteassemblytoberemovedfromtheblowerchamber.Clean the blower fan blade and the blower plate sealingoverlap.SeeFig.24.NOTE: Be careful not to bend the fan blade, this will throw the fan blade out of balance or it may rub the inner chamber, which may affect the performance of the boiler. Any horizontal and vertical flue pipe directly above the unit should be cleaned at this timeNOTE: The horizontal flue pipe directly above the boiler is the first place fly ash will settle, due to the slowing of flue gas velocity through horizontal pipe. Cleaning of horizontal venting pipes is very important to the efficiency of this boiler.

NOTE: The exhaust probe sensing tip extends into this same area. CARE MUST BE TAKEN NOT TO DAMAGE THE ESP DURING CLEANING. Bending of the ESP will make it difficult to remove if it should become necessary. See Fig. 23.

Cleantheboilerblowerplatesealingoverlap.SeeFig24.Makesurethereisnoflyashbuildupthatmayblocktheeasyflowoffluegasesintothecombustionblowerinlethole.(Aflashlightmaybenecessary.)

Combustion blower CleaningRemovethecombustionblowercover.Therearetwolatchesthatholdtheshieldinplace(Fig.22).Flipthelatchesupandpulltheshieldawayfromtheboiler.

Fig. 24

SealingOverlap

5”DoubleBladedFan(standard)#3-21-502221

Fig. 22

Latch

Blower Cover

Fig. 23ThreeThumbScrews

Theexhaustsensingprobe(ESP)islocated

here.

CAUTION!Inspect flue pipes, flue pipe joints and flue pipe seals regularly to ensure that smoke and flue gases are not entering the home.

36 3-90-233R23_10/13

Special Instructions/ Power Failure

Minimizing Smoke During Loss of Power Using Battery Back-upHarman® strongly recommends installing battery back-up to minimize entry of smoke into the room in the event of power loss.

Your pellet/biomass burning appliance relies on a combustion blower to remove exhaust. A power failure will cause the combustion blower to stop. This may lead to exhaust seeping into the room. Vertical rise in the venting may provide natural draft. It is, however, no guarantee against leakage.

There are two Harman® approved battery back-up options for your appliance:

Uninterruptible Power Supply (UPS) UPS battery back-ups are available online or at computer and office equipment stores. Your Harman® appliance with Rev E or later software available beginning in November 2010 may be plugged directly into a Harman® approved UPS:

• The APC (American Power Conversion) model #BX1500G and the TrippLite OMNIVS1500 are tested and approved. Other brands or models may not be compatible.

When power is lost, a fully charged UPS will power a safe, combustion blower only shut-down. Yourappliance will pulse the blower every few seconds to clear exhaust until the fire is out. NOTE: The UPS provides safe shut-down only. It is not intended for continued operation.

Your appliance will recognize when power is restored. What happens depends on ESP temperature and whether it is equipped with automatic ignition:

• In “Automatic” setting, units equipped with automatic ignition will respond to the set point and ESP temperature and resume normal operation.

• In “Manual” setting or for units without automatic ignition:• If the ESP is cool, the appliance will remain shut down.• If the fire is out and the ESP is still warm, the feeder may restart. Since the fire is out, the ESP

temperature will not rise. The unit will then shut-down, and may flash a six-blink status error. (See ESP error codes)

• If the fire is still burning, it will resume normal operation.

Contact your dealer if you have questions about UPS compatibility with your appliance.CAUTION! Always keep appliance doors and hopper lid closed and latched during operation and during power failures to minimize risk of smoke or burn-back.CAUTION! Use only Harman® approved battery back-up devices. Other products may not operate properly, can create unsafe conditions or damage your appliance.

37 3-90-233R23_10/13

RequirementsasspecifiedbyCAN/CSA-B366.1Operation of the hF60 during a Power Failure -Asupplyof120VACisrequiredforoperation.Intheeventofapowerfailure,theunitwillnotoperate.TheboilercanbepoweredalternativelyusingtheSurefire512BatteryBack-upsystem,oragenerator.Thegeneratormustbeproperlyfilteredtomaintainaconstantsinewaveof60cycle,withasteady120Voltoutput.

1/8” Fiberglass Gasket #3-44-232043

Door Glass #3-40-73363

1/4” White Ceramic Gasket #3-44-232073

Door Glass Cover Plate #2-00-232066

(4) #10-32 Nuts #3-30-8010321

Screen Plate #2-00-232016

Using a flat screwdriver, pry up and out to remove the screen plate. Remove the (4) 10-32 nuts with a 3/8” wrench or socket. Remove the cover plate, the broken glass, and the gaskets. Install a new 1/8” gasket, a new glass, and a new 1/4” white gasket. Re-install the cover plate. While making sure that everything is centered, tighten the (4) nuts to secure the glass. To install the screen plate, insert it into the slots at the top of the opening, then push in the bottom.

Screwdriver Slot

ASH DOOR GLASS REPLACEMENT

EXAMPLE OF PIPING IN ACCORDANCE WITH (CAN/CSA-B366.1)A POWER FAILURE HEAT DISSIPATION LOOP

TO NORMAL HEATING DEMAND

THE SOLENOID CAN BE POWERED FROM THE CONTROL PANEL OUTLET MARKED-

BASEBOARD MUST BE AT LEAST24" HIGHER THAN BOILER FORPROPER GRAVITY FLOW

MINIMUM OF 36" OF 3/4" FINNED BASEBOARD

120VAC,NORMALLY OPEN,FULL FLOW,SOLENOID VALVE or EQUIVALENT


SYSTEM RETURN 3/4"

PRV PIPE TO WITHIN 6" OF THE FLOOR OR A FLOOR DRAIN

SHUT-OFF VALVE

(HIGH TEMPERATURE) BASEBOARD HEAT

SYSTEM SUPPLY 3/4"

UNION

UNION

SHUT-OFF VALVE

Special Instructions/ Power Failure

38 3-90-233R23_10/13

FEEdEr dOES NOT FEEd1. Nopelletsinhopper.2. Fireboxdraftmaybetoolowforlowdraftpressureswitch

infeedercircuittooperate.Check for improperly closed doors,looseormissinggasketondoorsorhopperlid,orafaultypressureswitch.

3. Feedmotorwillnotrununtil theESPsenses170deg.F.Maybeyoudidnotputenoughpelletsintheburnpotbeforelightingthefiremanually.

4. Somethingisrestrictingflowinthehopperorcausingtheslideplatetostick.

5. Feedmotorhasfailed.PArTIAllY burNEd PEllETS1. Feedratetoohigh.2. Drafttoolow.(Checkburnpotclean-outslideanddoor

gasket).3. Burn pot or heat exchanger tubesmay need to be

cleaned.4. Combinationofalltheabove.5. #6 status blink:A6blinkcontrolboardstatusindication

is caused by poor or incomplete combustion. TheAutomaticIgnitioncircuitboardhastheabilitytotrackthecombustionthroughfeedsettingsandESPtemperatures.Whenthecontrolboardhascalculatedpoororincompletecombustion,itwillshutdowntheunitasasafetyfeature.(Poor or incomplete combustion is a contributor ofcreosotewhichmaycauseachimneyfire)

A6blinkstatusmaybecausedbyseveralthings:1. Blockedorpartiallyblockedflue.2. Blockedorpartiallyblockedinletair.

a. Backdraft damper on the inlet pipemay be stuckclosed.

b. Ifoutsideairisinstalled,theinletcovermaybeblocked.3. Theairchamberundertheburnpotmaybefilledwithfines

andsmallbitsofash.4. Theholesintheburnpotmaybegettingfilledwithashor

carbonbuildup.5. Combustionblowerfanmayneedcleaned.6. Thereisnofuelinthehopper.SmOkE SmEllSealtheventpipejointsandconnectiontounitwithsilicone.FIrE hAS gONE OuT1. Nopelletsinhopper.2. Draftsettingistoolow.3. Somethingisrestrictingfuelflow.4. Feedmotororcombustionblowerhasfailed.5. Powerfailureorblownfuse.6. Fireboxdoororhopperleftopen.

SmOkE IS vISIblE COmINg OuT OF vENT1. Air-fuelratioistoorich.

a. Feedratetoohigh.b. Drafttoolowcausedbyagasketleak.

lOw hEAT OuTPuT1. Feedratetoolow2. Drafttoolowbecauseofgasketleak.3. Poorqualityordamppellets4. Combinationof1and2.

Cleaning burn PotWheneveryourboiler isnotburning, take theopportunitytoscrapetheburnpottoremovecarbonbuildup.Avacuumcleanerishandytoremovetheresidue.be sure of no hot embers if you use a vacuum.Carbonbuildupcanbescrapedloosewiththefireburningusingthespecialtoolprovidedwithyourboiler.Scrapethefloorandsidesoftheburnpot.Thecarbonwillbepushedoutbytheincomingfuel.Alwayswearglovestodothis.removing AshesAshescanbe removedwhile inoperation,butextracaremustbetakenandalwaysweargloves.MaximumFeedAdjuster settingsarenot needed inmostcases.Operatinginthenormalrange(#4)isrecommendedwhenmaximum heat output is not required. The ESPpreventsthestovefrombeingover-fired.Keeptheboilerfreeofdustanddirt.

Fuel

Pelletfuelsareputinto3categoriesintermsofashcontent.Premiumat1%orless,Standardat3%orlessandallothersat3%ormore.TheHF60iscapableofburningall3categoriesofpellets,duetoapatentedfeederandburnpotsystem.It should be noted, however, that higher ash contentwillrequiremorefrequentashremoval,scrapingoftheburnpot,andmayprovidelessBTU’sperpound.Normally,standardandhighashpelletscostlessthanpremiumpelletsandcanbecosteffectivewhenburnedintheHF60.Themoisturecontentmustnotexceed8%.HighermoisturewillrobBTU’sandmaynotburnproperly.

Troubleshooting

helpful hints

39 3-90-233R23_10/13

Specifications

bTu Input range= 0, and 9350 to 60,000*0BTUifsystemissatisfied.Min.Burn=1.1poundperhourMax.Burn=7poundsperhour*8500BTUperpoundfiguresElectrical 120 vAC 60 hzCombustionblower 1.4AMPAugermotor .7AMPIgniterelement 2.3AMPControlboard .05AMPApproximateoperatingwattage .2KWHShippingWeight(IncludesPackaging) 525Lbs.duty Cycle 80% -Althoughthismodelisratedfor60,000BTUonhighburn,itisnotintendedtoremainonhighburncontinuously.

40 3-90-233R23_10/13

wiring diagram

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41 3-90-233R23_10/13

warranty

4021-645F02-18-13 Page1of2

hearth & home TechnologieslImITEd lIFETImE wArrANTY

Hearth&HomeTechnologies,onbehalfofitshearthbrands(”HHT”),extendsthefollowingwarrantyforHHTgas,wood,pellet,coalandelectrichearthappliancesthatarepurchasedfromanHHTauthorizeddealer.

wArrANTY COvErAgE:HHTwarrantstotheoriginalowneroftheHHTapplianceatthesiteofinstallation,andtoanytransfereetakingownershipoftheapplianceatthesiteofinstallationwithintwoyearsfollowingthedateoforiginalpurchase,thattheHHTappliancewillbefreefromdefectsinmaterialsandworkmanshipatthetimeofmanufacture.Afterinstallation,ifcoveredcompo-nentsmanufacturedbyHHTarefoundtobedefectiveinmaterialsorworkmanshipduringtheapplicablewarrantyperiod,HHTwill,atitsoption,repairorreplacethecoveredcomponents.HHT,atitsowndiscretion,mayfullydischargeallofitsobligationsundersuchwarrantiesbyreplacingtheproductitselforrefundingtheverifiedpurchasepriceoftheproductitself.Themaximumamountrecoverableunderthiswarrantyislimitedtothepurchasepriceoftheproduct.Thiswarrantyissubjecttoconditions,exclusionsandlimitationsasdescribedbelow.

wArrANTY PErIOd:Warrantycoveragebeginsonthedateoforiginalpurchase.Inthecaseofnewhomeconstruction,warrantycoveragebeginsonthedateoffirstoccupancyofthedwellingorsixmonthsafterthesaleoftheproductbyanindependent,authorizedHHTdealer/distributor,whicheveroccursearlier.Thewarrantyshallcommencenolaterthan24monthsfollowingthedateofproductshipmentfromHHT,regardlessoftheinstallationoroccupancydate.Thewarrantyperiodforpartsandlaborforcoveredcomponentsisproducedinthefollowingtable.Theterm“LimitedLifetime”inthetablebelowisdefinedas:20yearsfromthebeginningdateofwarrantycoverageforgasappliances,and10yearsfromthebeginningdateofwarrantycoverageforwood,pellet,andcoalappliances.Thesetimeperiodsreflecttheminimumexpectedusefullivesofthedesignatedcomponentsundernormaloperatingconditions.

Seeconditions,exclusions,andlimitationsonnextpage.

Parts Labor Gas Wood Pellet EPAWood Coal Electric Venting

X X X X X X X

AllpartsandmaterialexceptascoveredbyConditions,

Exclusions,andLimitationslisted

X X X Igniters,electroniccomponents,andglass

X X X X X Factory-installedblowersX Moldedrefractorypanels

X Firepotsandburnpots

5years 1year X X Castingsandbaffles

7years 3years X X X Manifoldtubes,HHTchimneyandtermination

10years 1year X Burners,logsandrefractory

LimitedLifetime 3years X X X X X Fireboxandheatexchanger

X X X X X X X Allreplacementpartsbeyondwarrantyperiod

WarrantyPeriod HHTManufacturedAppliancesandVenting

1Year

ComponentsCovered

3years

2 years

90Days

42 3-90-233R23_10/13

warranty

4021-645F02-18-13 Page2of2

wArrANTY CONdITIONS:• ThiswarrantyonlycoversHHTappliancesthatarepurchasedthroughanHHTauthorizeddealerordistributor.Alistof

HHTauthorizeddealersisavailableontheHHTbrandedwebsites.• ThiswarrantyisonlyvalidwhiletheHHTapplianceremainsatthesiteoforiginalinstallation.•ThiswarrantyisonlyvalidinthecountryinwhichtheHHTauthorizeddealerordistributorthatsoldtheappliance

resides.• Contactyourinstallingdealerforwarrantyservice.Iftheinstallingdealerisunabletoprovidenecessaryparts,contact

thenearestHHTauthorizeddealerorsupplier.Additionalservicefeesmayapplyifyouareseekingwarrantyservicefromadealerotherthanthedealerfromwhomyouoriginallypurchasedtheproduct.

• Checkwithyourdealerinadvanceforanycoststoyouwhenarrangingawarrantycall.Travelandshippingchargesforpartsarenotcoveredbythiswarranty.

This warranty is void if:• Theappliancehasbeenover-firedoroperatedinatmospherescontaminatedbychlorine,fluorine,orotherdamaging

chemicals.Over-firingcanbeidentifiedby,butnotlimitedto,warpedplatesortubes,rustcoloredcastiron,bubbling,crackinganddiscolorationofsteelorenamelfinishes.

• Theapplianceissubjectedtoprolongedperiodsofdampnessorcondensation.• Thereisanydamagetotheapplianceorothercomponentsduetowaterorweatherdamagewhichistheresultof,but

notlimitedto,improperchimneyorventinginstallation.

lImITATIONS OF lIAbIlITY:• Theowner’sexclusiveremedyandHHT’ssoleobligationunderthiswarranty,underanyotherwarranty,expressor

implied,orincontract,tortorotherwise,shallbelimitedtoreplacement,repair,orrefund,asspecifiedabove.InnoeventwillHHTbeliableforanyincidentalorconsequentialdamagescausedbydefectsintheappliance.Somestatesdonotallowexclusionsorlimitationofincidentalorconsequentialdamages,sotheselimitationsmaynotapplytoyou.Thiswarrantygivesyouspecificrights;youmayalsohaveotherrights,whichvaryfromstatetostate.EXCEPTTOTHEEXTENTPROVIDEDBYLAW,HHTMAKESNOEXPRESSWARRANTIESOTHERTHANTHEWARRANTYSPECIFIEDHEREIN.THEDURATIONOFANYIMPLIEDWARRANTYISLIMITEDTODURATIONOFTHEEXPRESSEDWARRANTYSPECIFIEDABOVE.

wArrANTY ExCluSIONS:Thiswarrantydoesnotcoverthefollowing:• Changesinsurfacefinishesasaresultofnormaluse.Asaheatingappliance,somechangesincolorofinteriorand

exteriorsurfacefinishesmayoccur.Thisisnotaflawandisnotcoveredunderwarranty.• Damagetoprinted,plated,orenameledsurfacescausedbyfingerprints,accidents,misuse,scratches,melteditems,

orotherexternalsourcesandresiduesleftontheplatedsurfacesfromtheuseofabrasivecleanersorpolishes.• Repairorreplacementofpartsthataresubjecttonormalwearandtearduringthewarrantyperiod.Theseparts

include:paint,wood,pelletandcoalgaskets,firebricks,grates,flameguides,batteriesandthediscolorationofglass.• Minorexpansion,contraction,ormovementofcertainpartscausingnoise.Theseconditionsarenormalandcom-

plaintsrelatedtothisnoisearenotcoveredbythiswarranty.• Damagesresultingfrom:(1)failuretoinstall,operate,ormaintaintheapplianceinaccordancewiththeinstallation

instructions,operatinginstructions,andlistingagentidentificationlabelfurnishedwiththeappliance;(2)failuretoinstalltheapplianceinaccordancewithlocalbuildingcodes;(3)shippingorimproperhandling;(4)improperopera-tion,abuse,misuse,continuedoperationwithdamaged,corrodedorfailedcomponents,accident,orimproperly/incorrectlyperformedrepairs;(5)environmentalconditions,inadequateventilation,negativepressure,ordraftingcausedbytightlysealedconstructions,insufficientmake-upairsupply,orhandlingdevicessuchasexhaustfansorforcedairfurnacesorothersuchcauses;(6)useoffuelsotherthanthosespecifiedintheoperatinginstructions;(7)installationoruseofcomponentsnotsuppliedwiththeapplianceoranyothercomponentsnotexpresslyauthorizedandapprovedbyHHT;(8)modificationoftheappliancenotexpresslyauthorizedandapprovedbyHHTinwriting;and/or(9)interruptionsorfluctuationsofelectricalpowersupplytotheappliance.

• Non-HHTventingcomponents,hearthcomponentsorotheraccessoriesusedinconjunctionwiththeappliance.• Anypartofapre-existingfireplacesysteminwhichaninsertoradecorativegasapplianceisinstalled.• HHT’sobligationunderthiswarrantydoesnotextendtotheappliance’scapabilitytoheatthedesiredspace.Informa-

tionisprovidedtoassisttheconsumerandthedealerinselectingtheproperappliancefortheapplication.Consider-ationmustbegiventoappliancelocationandconfiguration,environmentalconditions,insulationandairtightnessofthe structure.

43 3-90-233R23_10/13

Testing label

OMNI-Test Laboratories, Inc.Report #/Rapport #135-O-20-6.2, #135-O-20b-6.2

Certifi ed for U.S.A. and CanadaCertifi é pour les États-Unis et le Canada

BARCODE LABEL008Serial No.No de série:

hydroFlex 60LISTED PELLET FUEL CENTRAL OR SUPPLEMENTARY FURNACES FOR RESIDENTIAL USE

APPAREIL DE CHAUFFAGE CENTRAL OU SUPPLÉMENTAIRE ENREGISTRÉ DE GRANULÉS COMBUSTIBLES POUR USAGE DANS LES RÉSIDENCES

Tested October 2008 to CAN/CSA-B366.1-M91 and UL 391-2006

Install and use only in accordance with the manufacturer’s installation/operting instructions. Refer to authorities having jurisdiction for proper installation. Contact local building or fi re offi cials about restrictions and installation inspection in your area. If there are no applicable local codes, follow ANSI/NFPA 211 and CAN/CSA B365. Special precaustions are required for passing the chimney through a a combustible wall or ceiling.

Inspect and clean exhaust venting system frequently in accordance with the manufacturer’s instructions. Use a 4” diameter type “L” or “PL” venting system.

Testé en October 2008 à CAN/CSA-B366.1-M91 and UL 391-2006

Installez et utilisez en accord avec les instructions d’installation et d’opération du fabricant. Référez-vous à des professionnels avec autorité dans l’installation. Contactez le bureau de la construction.ou le bureau des incendies au sujet des restrictions et de l’inspection dans votre voisinage.

S’il n’y a pas de codes locaux, suivez alors ANSI/NFPA211 et CAN/CSA B365. Prenez des précautions spéciales lorsque vous faites passer une cheminée à travers un mur ou un plafond combustibles. Inspectez et nettoyez le sustème de ventilation fréquemment en accord avec les instructions du fabricant. Utilisez un système de ventilation de 4” de diamètre de type “L” ou “PL”.

modelmodèle

hF60

FuelCombustible

Pelletgranulés

Chimney Connector Sizegrandeur du Tuyau de Cheminée

3”

bTuh/kw Input Pelletrendement des granulés bTuh/kw

60,000 bTuh (17.4 kw)

Electrical ratingClassifi cation Électrique

120v, 4.45, 60 hz

maximum Overcurrent ProtectionProtection maximum du Courant

20 AmP

date of manufacture / date de fabrication2013 2014 2015 jAN FEb mAr APr mAY juN jul Aug SEP OCT NOv dEC

Made in the U.S.A. / Fait aux États-UnisDo Not Remove or Cover This Label/Ne pas enlever ou recouvrir cet étiquette

Manufactured by/Fabriqué par: Hearth & Home Technologies, Inc.352 Mountain House Road - Halifax, PA 17032

Harman HydroFlex 60 Pellet BoilerLabel measures: 7.5" high X 6.5"wide

SidewalltoApplianceBackwalltoApplianceCombustibletoPelletVentStoveToptoCeilingAlcoveHeightalcoveWidthAlcoveDepthCombustiblesfromStoveFront

ClearancestoCombustibles/EspacesLibresauxCombustibles

6”(152mm)6”(152mm)3”(76mm)16”(407mm)72”(1829mm)48”(1220mm)60”(1524mm)48”(1220mm)

MurLatéralàAppareilMurArrièreàAppareilMatériauxCombustiblesauConduitdeFuméeHautduPoêleauPlafondHauteurdel’AlcôveLargeurdel’AlcôveProfondeurdel’AlcôveDesCombustiblesauDevantduPoêle

*At16”ofpipelengthdistancefromthefluecollarwhilemaintaininglistedclearancesfromappliancebody.Untuyaudegrandeurdedistancede16”del’ouvertureduventilateurdoitêtreenaccordavecl’espacelibrementionnédel’appareilmême.

NE PAS CONNECTEr CET APPArEIl À uN TuYAu dE ChEmINÉE SErvANT uN AuTrE APPArEIldANgEr! risque de feu ou d’explosion. Ne pas brûler des ordures, de

l’essence. du pétrole, de l’huile moteur ou autres matériaux inappropriés.

ATTENTION! Ne pas opérer si la porte du combustible ou la porte de la cuvette des cendres sont ouvertes. Ne pas placer le combustible et les matières combustibles à l’intérieur de l’espace désignée pour l’installation.

ATTENTION! Chaud lors de l’opération.

NE PAS toucher. gardez les enfants, les vêtements, les meubles et les matériaux combustibles loin de l’espace désignée pour l’installation.

le plancher de l’espace désigné pour l’installation doit ê fait de matière non-combustible, et 6” devant la poerte de déplacement de cendre.

dans le cas d’un manque d’électricité:

Consultez le manuel du propriétaire pour remettre la fournaise en marche lorsque l’electricité ést revenue.

dO NOT CONNECT ThIS uNIT TO A ChImNEY FluE SErvINg ANOThEr APPlIANCEdANgEr! risk of Fire or Explosion - do not burn garbage, gasoline,

naphtha, engine oil, or other inappropriate materials.

wArNINg! DO NOT operate with fi re chamber or ash removal doors open. dO NOT store fuel or other combustible material within installation clearance area.

CAuTION! hot while in operation.

dO NOT touch. keep children, clothing, furniture and other combustible material out of the installation clearance area.

Flooring must be a non-combustible material covering the installation clearance area, and 6” in front of the ash removal door.

In the event of loss of electrical power:

Consult owner’s manual for restarting your furnace after power is restored.

U.S. ENVIROMENTAL PROTECTION AGENCYThis model is exempt from EPA certifi cation under 40 CFR 60.531

by defi nition [Wood Heater (A) “air-to-fuel ratio”].

rev dP.N. 3-90-232

Essentialpartsandsubassembliesprovidedforfieldassemblyareasfollows/Piècesessentiellesetsous-assembléeprocuréespourl’assemblagesontlessuivantes:

(1)1/2”Dualtemperature/PressureGauge/(1)DoubleindicateurTempérature/Pression1/2” (1)3/4”SafetyReliefValve/(1)SoupapedeSécurité3/4”

(1)3/4”BoilerDrain/(1)RobinetdeVidange3/4” (1)OutdoorairSensor/(1)SondeExtérieure

SAmPlE lAbEl, rEFEr TO u

NIT lAbEl

FOr SAFETY INFOrmATIO

N.

3-90-233R23_10/13

Service Parts hF60beginning manufacturing date: july 2009

Ending manufacturing date: Active

Part number list on following page.

1

3

2

4

5

6

78

11

16

1721

2232

3334

36

35

37

23

2524

38

39

4041

42 43

44

45

46

47

48

4951

53

54

55

56 5758

59

60

61

19

52

50

2018

26

27

28

3031

29

19

1213

14

15

10

9

hydrofl ex 60 Central heat

1-90-232000

10/13

3-90-233R23_10/13



IMPORTANT:THISISDATEDINFORMATION.Partsmustbeorderedfromadealerordistributor.hearth and home Technologies does not sell directly to consumers.Providemodelnumberandserialnumberwhenrequestingservicepartsfromyourdealerordistributor.

Stockedat depot

ITEm description COmmENTS PArT NumbEr1 PlumbingSupportKit-Qty.2req. 1-10-2320442 FiretubeCleanoutDoorAssembly 1-10-232060A

FiretubeLift&CleanKit 1-00-2321203 DraftSectionRefractorySide Qty2req 3-40-2320544 1/4-20x1-1/2"WingscrewwithCollar Pkgof10 3-31-782124-10 Y5 DraftSectionWeldment 1-10-232011W6 1/2"FoamInsulationWrapAround 3-44-2320897 1/2"FoamInsulation 3-44-2320888 HopperAssembly 1-10-232034A Y

Gasket,HopperLid 10Ft 1-00-00248 YGasket,HopperThroat 3-44-677185 YGasket,HopperTop 20Ft 1-00-375501 YHopperLidAssembly 1-00-232038

9 FeederShieldRear 2-00-232039B Y10 1"FoilFacedFiberglassInsulation 3-44-23208511 ULFeederAssembly refer to feeder assembly page12 DifferentialSwitch 3-20-6866 Y13 Tempco450WIgniter 1-00-10450 Y14 1"FoilFacedFiberglassInsulation 3-44-23208615 TubeCleanoutPlate Qty2req 2-00-232008B

16HopperStiffenerBracketLeft 2-00-232031-1BHopperStiffenerBracketRight 2-00-232031-2B

17 FireboxRefractorySide Qty2req 3-40-23201018 BurnPotScraper 3-99-7498

19 WaterJacketGasketCombustion 3-44-232094-1LongBottom 3-44-232094-2ShortBottom 3-44-232094-3

20 AirPump 3-20-02679 YFitting&Filter Pre008490076 1-00-02679 Y

21 1/4"CeramicPaperFeederInsulation 3-44-23207822 3/4"NPTSquarePlug Qty4req 3-10-0060023 FeederCoverLeft 2-00-232096B24 3/4"NPTBoilerDrain 3-10-0756025 OuterSkinLeft 2-00-232026B26 CombustionSectionWeldment 1-10-232005W27 SteelSleeveBushing3/8ODx1/2OAL 3-50-0522928 ElevatorBolt3/8-16x1-1/2" Qty4req 3-30-93716150129 FireboxCleanoutCoverRetainer Qty2req 2-00-232056B

Additionalservicepartnumbersonthefollowingpage.

3-90-233R23_10/13




Stockedat depot

ITEm description COmmENTS PArT NumbEr30 TubeCleanoutCoverPlate Qty2req 2-00-232052B Y31 TubeCleanoutLatch Qty2req 2-00-232009L32 3/8"FlexConnector Qty2req 3-20-100033 CeramicInsert Pkgof10 3-20-05238-10 Y34 FlameGuide 3-00-03000 Y35 BurnpotAssembly 1-10-232079A Y

CleanOutCover 2Sets 1-00-06623 YThumbScrew Pkgof10 3-31-782108-10 Y

36 CeramicInsertGasket 3-44-724114 Y37 CeramicInsertPlate 2-00-724104 Y38 BurnPotGasket 3-44-724115 Y39 FireboxRefractoryRear 3-40-232015 Y40 Firebrick 3-40-232093 Y41 FireboxRefractoryBottom 3-40-232006 Y42 AshPanAssembly 1-10-232049A Y43 AshDoorAssembly 1-10-232019A

AshDoorSpacerSetw/Gasket 1-00-232074Glass5.25x5.25 3-40-5555Refractory 3-40-232023TadpoleGasket,Glass 10Ft 1-00-00539 Y

44 ControlBoardPlateAssembly 1-10-232055ACircuitBoardw/Knobs&Shafts 1-00-06143 YKnob&Shaft Setof25 1-00-015605 YFuse,6AMP Pkgof5 3-20-49447-5 Y

45 Pressure/TemperatureGauge 3-10-78427 Y46 PlumbingAssembly 1-10-232080A

47 CombustionMotorCoverPreSN004490643 2-00-232028APostSN004490643 2-00-232028B

48 OuterSkinFront 2-00-232027B49 CombustionBlower 3-21-08639 Y

Blade5"Single 3-20-502221 YCombustionBlowerMount 1-10-73416CombustionMotorMountingScrews Pkgof100 1-00-53483208

50 ExternalRetainingRing 3-31-00435751 FlexConduitSupportBracket 2-00-232071B52 3/8"FlexConduit 1-00-25043 Y53 AshDoorHinge 2-00-232020L54 WaterJacketWeldment 1-10-232001W


3-90-233R23_10/13




Stockedat depot

ITEm description COmmENTS PArT NumbEr55 SpiralFireTubeBaffle Pkgof8 2-00-232053-8 Y56 ESPProbe 3-20-00844 Y

AquaTempSensorCable 3-20-72180 Y57 1/2"FoamInsulation 3-44-23208758 2"FiberglassInsulation Qty2req 3-44-23209059 FeederCoverRight 2-00-232097B Y60 OuterSkinRight 2-00-232025B61 SpringLatch Qty4req 3-31-00927 Y

3/8"-16x1/4"AlloySteelBlackOxideCupPointSSS Pkgof25 3-30-2014-25 Y3PositionTerminalBlock 3-20-03018 YAmtrolAirVent 3-10-70130Circuitbreaker10Amp(orange-on/offswitch) 3-20-334110 YDiagnosticDsplayModule 3-20-05401 Y

DDMReplacementCable 1-00-05402DifferentialSwitch 3-20-6866 YDisconnect,Female Pkgof25 1-00-00959 YDraftMeterAssembly 1-00-00637 Y

DraftMeterBolt&Tube 1-00-04004HighAltitudeIntakeReduction 1-00-232059Label,Caution 3-90-08416Labels,Caution&Danger Pkgof10 1-00-200408541PowerCord 3-20-39685 YRelay,8Pin 3-20-29202 YRopeGasket,3/8"4Strand 30Ft 1-00-00888 YSafetyReliefValve 3-10-77382 YSiliconeTubing,1/4" 5Ft 1-00-5113521 YSiliconeTubing,1/8" 5Ft 1-00-5113574 YSwelllatch&Spacer 1-00-199110 YTouchUpPaint,PrepaintAerosol 3-42-7737WiringHarness 3-20-232076 Y


3-90-233R23_10/13




Stockedat depot

ITEm description COmmENTS PArT NumbEr11 ULFeederAssembly 1-10-232108A

11.1 PelletFeederGearMotor,6RPM 3-20-09302 YFeedMotorFanBlade Pkgof3 3-20-09302-3 Y

11.2 ULFeederCam 3-31-3014 Y11.3 FeederAirCrossoverKit 1-00-67900 Y

9MMSiliconeTube 5Ft 1-00-511427 Y11.4 PelletAirIntakeAssembly 1-10-06810A11.5 GasketFeederAirIntake Pkgof6 3-44-72224-6 Y11.6 ULFeederAirIntake 1-10-23211411.7 GasketUltraAirIntake Pkgof10 3-44-677160-10 Y11.8 UltraFeederWeldment 1-10-72226S Y11.9 ULFeederPusherArm 1-10-677187W Y

11.10 FinesDefl ector No longer available 2-00-677138-1011.11 Gasket,ULFeederCover Setof2 1-00-677122 Y11.12 SlidePlateAssembly 1-10-677121A Y11.13 ULFeederAugerAssembly 3-50-00565 Y11.14 BearingFlangew/Hardware 1-00-04035 Y11.15 ULFeederGearMotorBracketw/Grommet 1-00-247406 Y11.16 ULFeederCamBlock 3-00-677154 Y

Grommet,MotorBracket Pkgof12 3-31-2761-12HopperSwitchFeederFitting Setof2 1-00-142818 YPillowBlock Pkgof4 3-31-3614087-4 Y

#11 Feeder Asembly

11.711.6

11.511.4

11.3

11.2

11.1 11.16 11.15

11.8

11.911.10

11.11

11.12

11.1311.14

49 3-90-233R23_10/13

Service & maintenance log

Date Of Service Performed By Description Of Service

50 3-90-233R23_10/13

Service & maintenance log

Date Of Service Performed By Description Of Service

Proudly Printed On 100% Recycled Paper

At Harman, we build each product to a standard, not a price.This powerful heating appliance boasts uncompromising attention to detail and helps preserve our planet by using environmentally responsible fuels.

(Signature of Boxer)

Your premium quality hearth product designed and assembled by the experienced and skilled members at Harman in Halifax, PA, USA.

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installation & operating manual - wordpress.com · 2014-01-24 · 9022101 contact your local...

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