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Hardy C3 Installation And Operating Instructions Manual Download Page 54

HARDY MANUFACTURING CO., INC                      (MODEL C3 & C5)             PAGE  40 

8-1 

General Trouble Shooting Guide (continued)

 

COMPLAINT

 

AREA OF TROUBLE

 

POSSIBLE CAUSES

 

CORRECTIVE ACTION

 

Improper 
Burning 

Grates 

Grates stopped up 

Clear grate of ash 
buildup. If grates are 
warped, turn over. 

Air intake 

Damper blower 
clogged 

Clean damper blower 
assembly. 

Air tube inspection 
lid 

Air tube clogged 

Lift inspection lid and 
cleanout all obstructions. 

Smoke Stack 

Smoke stack 
stopped up 

Remove smoke stack, 
check flue out of top of 
heater, clean both flue 
pipe and smoke stack. 

Baffle 

(Model C5 Only)  
Baffle stopped up 

Remove baffle through 
the fire box door, clean 
baffle and flue area. 

Fire 

Fire going out 

If fire goes completely out 
remove one screw in 
blower lid. 

Forced air blower 
running but no draft 

1.  Solenoid not 

lifting lid 

2.  Creosote buildup 

1.  Replace solenoid. 
2.  See excessive 

fuelusage. 

Fire box 

Moisture In 
Fire box 

1.  Initial or yearly 

start up 

 

1.  Fire box walls will 

sweat and water will 
run down sides, this 
should clear up in 
about a week.  

 

Summary of Contents for C3

Page 1: ...ION AND OPERATING INSTRUCTIONS FOR THE HARDY OUTSIDE COAL BURNING HEATER HARDY MANUFACTURING COMPANY INC 12345 ROAD 505 PHILADELPHIA MS 39350 PHONE 601 656 5866 FAX 601 656 4559 www hardyheater com Model C3 C5 Rev 3 25 2015 ...

Page 2: ...THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 3: ...n and Hook Up Instructions 2 Warranty Return Warranty Card 3 A tube of silicone located in the firebox for shipping 4 Smoke stack and condenser tank stack both with trim located in the firebox for shipping 5 C3 has two I beams and Shaker grates located in the firebox C5 has two I beams and Shaker grates located in the firebox 6 box of Fire Brick and support pieces 7 Shovel located in the firebox f...

Page 4: ...ng information Hardy Model Serial Number Date of Purchase Date of Installation Dealer Purchased from Dealer Address Dealer Phone Number HARDY MANUFACTURING COMPANY INC 12345 ROAD 505 PHILADELPHIA MS 39350 PHONE 601 656 5866 www hardyheater com ...

Page 5: ...h the National Electrical Code Never use any type of petroleum product petroleum based product charcoal starter lighter fluid or any other flammable accelerant to start your unit Always open the ash door bottom before you open the firebox door top Never leave the doors open always latch the doors securely Always use proper care when installing operating and maintaining the unit Do not modify the u...

Page 6: ... MODEL C3 C5 iv Safety Labels Read all safety labels on this unit Name Plate Supplement 5 X 10 not shown actual size ...

Page 7: ...ND HEATING ZONE GROUND FAULT CIRCUIT INTERRUPTER L1 L2 DAMPER SOLENOID R LLS 4 6 R 3 4 6 R 3 T1 BM PM PM W V SOL GFCI L2 L1 LEGEND GFCI GROUND FAULT CIRCUIT INTERRUPTER LLS LIQUID LEVEL SWITCH WV WATER SOLENOID VALVE OPTIONAL ON H3 H5 R3 CIRCULATOR PUMP RELAY PM WATER CIRCULATOR PUMP T1 DAMPER AQUASTAT BM DAMPER BLOWER MOTOR SOL DAMPER SOLENOID R LOW WATER LIGHT HEATER WIRING DIAGRAMS CONNECTION D...

Page 8: ... MODEL C3 C5 vi Safety Labels Read all safety labels on this unit Warning label for Condenser Vent 5 X 3 Back Door label 5 X 3 ...

Page 9: ... MODEL C3 C5 vii Safety Labels Read all safety labels on this unit Warning label on front between doors 4 X 2 3 4 Field wiring label 2 3 4 X 1 Hot water label 2 3 4 X 1 ...

Page 10: ... MODEL C3 C5 viii THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 11: ...tions for recommended loading times and amounts 4 STARTERS Do not use lighter fluids gasoline or chemicals 5 LOCATION It is recommended that the unit be located with due consideration to the prevailing wind direction 6 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 serve...

Page 12: ... that passes through your heater and coil to heat your house How do the Thermostat Controls work The only visible addition to the heating system inside your home is the thermostat which is located near the existing thermostat The two thermostats are installed so that if the outside heater is not in operation your existing unit will automatically take over to maintain the household temperature The ...

Page 13: ... SECTION III Plumbing Instructions 3 1 Plumbing Instructions for Forced Air 14 3 2 Location of Heating Coil 15 16 3 3 Connecting to Existing Hydronic Systems 17 18 3 4 Plumbing for Domestic water C3 C5 19 3 5 Replacing Hull 20 3 6 Filling the Heater with Water 21 SECTION IV Connection to Central Heating AC System 4 1 Connection to Central Unit with Existing Blower Relay 22 23 4 2 Typical Wiring Di...

Page 14: ...eason Maintenance 30 31 7 3 In Season Maintenance 31 32 7 4 Post Season Maintenance 32 SECTION VIII Appendix 8 1 General Trouble Shooting Guide 33 40 8 2 Circulator Maintenance Instructions 41 42 8 3 Damper Solenoid Replacement Instructions 43 8 4 Low Water Switch Replacement Instructions 44 45 8 5 Draft Blower Replacement Instructions 46 47 8 6 Aquastat Replacement Instructions 48 50 SECTION IX W...

Page 15: ...ng 115 VAC 60 HZ 1PH MFS 15 AMP MCA 15 AMP Clearance to Combustibles Top Rear Sides 48 Chimney Connector 48 Front 48 Flooring Non Combustible Water Capacity C3 Holds Approximately 100 Gallons of Water C5 Holds Approximately 130 Gallons of Water Heater Dimensions Description Width Depth Height Weight C3 120 000 BTU 30 52 59 820 lbs C5 180 000 BTU 40 52 59 945 lbs Firebox sizes Description Width Dep...

Page 16: ...section determines the plumbing options For example heater model number C3 1 07 The C3 designates that you have a 120 000 BTU heater The 1 in the second section designates that you have a standard pump The 7 in the last section designates that you have extra ports on your heater Heater Rating C3 120 000 BTU C5 180 000 BTU C3 1 07 120 000 2 69 COAL 1 1 Specifications Electrical Options 0 Without a ...

Page 17: ...2000 48 1 2 Well Fitting 10 2000 08 Honeywell Aquastat 11 603 32 3 4 x 6 Brass Nipple 12 607 12 3 4 Brass Ball Valve 13 502 60 3 4 SS flange 14 502 50 Taco 009 SS Circulator 15 2004 40 Wire Connectors 16 1100 30 Low Water Light 17 2000 52 Honeywell Relay 18 2001 05 Damper Solenoid 19 2004 00 GFCI Receptacle 20 2004 16 Receptacle box 2 1 8 deep 21 3200 12 Jack Chain 22 3200 16 Key Ring 23 2002 16 1...

Page 18: ...7 12 3 4 Brass Ball Valve 13 502 60 3 4 SS flange 14 502 50 Taco 009 SS Circulator 15 2004 40 Wire Connectors 16 1100 30 Low Water Light 17 2000 52 Honeywell Relay 18 2001 05 Damper Solenoid 19 2004 00 GFCI Receptacle 20 2004 16 Receptacle box 2 1 8 deep 21 3200 12 Jack Chain 22 3200 16 Key Ring 23 2002 16 100 CFM Blower Lid 24 2004 28 Plastic Romex Connector 25 607 42 3 4 Boiler Drain 26 2004 04 ...

Page 19: ...ith end of the pad We recommend the pad to be 48 wide and 53 long minimum If you add extra length it will allow ample concrete in front of the heater for loading fuel and removing ashes The space between the rear of the unit and the outside cover will allow a 4 watertight pipe or other means to insulate the plumbing and electrical lines to run directly into the ground The outside cover can be remo...

Page 20: ...g fuel and removing the ashes The 4 watertight pipe or other means to insulate plumbing that runs underground exits through this cut out to allow connections to the unit The unit sits on the pad with the rear of the water tank flush or even with the front side of the cutout The outside cover of the heater can be removed by lifting it from the water tank on all four corners This will allow you easy...

Page 21: ... removed using a 5 16 wrench remove the eight metal screws that are located below the back door There are four on each side that hold the panel in place After the screws are removed the panel should come out easily and allow access to the bottom of the unit to make plumbing and electrical connections The second method is the removal of the entire cover With the back and the rectangular piece of st...

Page 22: ...C3 SS corner brick supports into the four corners of the firebox see picture 1 Next install 5 fire brick standing up on end across the back of the fire box see picture 2 Repeat this step for the front of the fire box Once you have the front and back of the firebox lined you can start on the side fire brick Lay one of the C3 SS brick spacer angles against each side of the firebox on top of the I be...

Page 23: ...all the 4 C5 SS corner brick supports into the four corners of the firebox see picture 1 Next install 3 firebrick standing up on end centered across the back and 2 firebrick stacked on their side on each end of the back row see picture 2 Repeat this step for the front Once you have the front and back of the firebox lined you can start on the side fire brick Lay the C5 SS side brick supports see pi...

Page 24: ...5 PAGE 10 2 3 Set Up of Fire Brick continued Flame Baffle The C5 heater has a stainless steel flame baffle 15 x 10 in This flame baffle is inserted in the firebox across the 3 4 stainless steel pipes located directly below the smoke stack ...

Page 25: ...tallation If more than one zone is to be heated or more than one location is to be heated then an additional pipe or insulation must be installed underground This pipe will run from the rear of the unit to the location to be heated Inside the 4 watertight pipe will be the four water lines thermostat wire and electrical supply wire The listing below describes each line and their function 1 One cold...

Page 26: ... the GFCI receptacle Connect the white wire to the silver screw on the line side of the GFCI receptacle Connect the bare copper wire to the green screw on the GFCI receptacle After the wiring is complete and power is applied check the receptacle with a circuit tester to determine if the polarity is correct and to make sure the ground is connected Press the test button on the GFCI receptacle The re...

Page 27: ...ZONE GROUND FAULT CIRCUIT INTERRUPTER L1 L2 DAMPER SOLENOID CONNECTION DIAGRAM R LLS 4 6 R3 4 6 R3 T1 BM PM PM W V SOL GFCI L1 L2 SCHEMATIC DIAGRAM LEGEND GFCI GROUND FAULT CIRCUIT INTERRUPTER LLS LIQUID LEVEL SWITCH WV WATER SOLENOID VALVE R3 CIRCULATOR PUMP RELAY PM WATER CIRCULATOR PUMP T1 DAMPER AQUASTAT BM DAMPER BLOWER MOTOR SOL DAMPER SOLENOID R LOW WATER LIGHT Water valve Optional on Model...

Page 28: ...ram These two 2 lines will go to the heat exchanger coil that mounts into the duct work of your forced air heating system For best results connect the line from the pump to the fitting of the heat exchanger closest to the side of the heat exchanger that the air is leaving Connect the return line to the heat exchanger on the side that the air is entering Water pipes must be designed for hot water s...

Page 29: ...oil The following diagrams on this page and the following page show various methods of installing the heating coil in forced air system Supply Air Return Air Install and Insulate Heating Coil in supply side of system and in a protected environment Package System Supply Air ...

Page 30: ... 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 3 2 Location of Heating Coil continued ...

Page 31: ...r continuous flow from the pump and return of the heater to the existing boiler system Connect these lines to the plate heat exchanger so that the water flow of the heater is opposite of that from the boiler system Bypass the relay on the pump to allow the pump on the heater to run continuous Water pipes must be designed for hot water service ex copper cpvc or Pex Pipes should be installed in a 4 ...

Page 32: ...circuit into the existing aquastat wiring you can leave the boiler aquastat set at the original factory setting Set the new low voltage wall thermostat approximately 3 degrees below the home heat thermostat If the heater were to get behind for any reason the boiler can come on and help maintain the home temperature EXISTING BOILER AQUASTAT 7 1 5 6 3 4 2 8 24 VOLT TRANSFORMER NEUTRAL 120 VOLT 40 VA...

Page 33: ...e direction for maximum efficiency The alternate method would be to mount the plate heat exchanger on the back of the furnace and connect the water heater to the plate the same way as in the preferred method with counter flowing waters Water pipes must be designed for hot water service ex copper cpvc or Pex Pipes should be installed in a 4 watertight pipe or some other type of insulating means to ...

Page 34: ... condenser stack opening The trim should be slid down the condenser stack until it sits on the outside cover You should have a piece of insulation and a stainless steel plate that you removed from the inside of the firebox earlier This will install between the firebox door and the ash door The insulation fits between the doors and the stainless steel plate will slide behind the door frames across ...

Page 35: ... supply for chloride to assure that the water supply does not exceed 45 ppm The use of water in the water tank that exceeds 45 ppm shall void the warranty Call your Hardy dealer to get a chloride test on your water supply Fill your heater with water through the condenser stack opening or when you supply power to the heater if the heater has the automatic fill option it will fill itself If the chlo...

Page 36: ...l usage or cause your blower motor to over heat and burn out Remove the cover on the new home heat thermostat to mount it on the wall There is a round dial visible with an adjustable pointer This is the heat anticipator The dial also has a series of numbers The pointer must be set to the highest number on the dial On the Honeywell model t 822 1016 the pointer is turned counter clockwise as far as ...

Page 37: ...green wire that is going outside to the heater and along with a short jumper wire appx 3 4 long connect to terminal 7 on the new relay that was added to the air handler Connect the other end of this jumper wire to terminal 6 of the relay Locate the low voltage transformer that is providing you with 24 volt power Find the common lead of this transformer and connect a wire to this lead and to termin...

Page 38: ...ECTION TG TERMINAL STRIP G CONNECTION R EXISTING THERMOSTAT CONNECTION G EXISTING THERMOSTAT CONNECTION QUICK CONNECT TERMINALS LEGEND 1 2 3 4 5 6 7 8 R C G W L1 L2 24 VOLTS R C G W 1 2 3 4 5 6 7 8 EXISTING TRANSFORMER EXISTING THERMOSTAT EXISTING BLOWER RELAY NEW RELAY NEW THERMOSTAT LOW TEMPERATURE SENSOR CIRCULATOR PUMP RELAY L1 L2 115V 24V TR TC R1 R2 R3 T2 LTS FS 1 2 4 5 6 7 8 7 8 R2 R2 R2 TG...

Page 39: ...he coal has ignited you can add more coal Do not fill coal above the fire brick 5 2 Water Temperature Mounted on the back of the Hardy Heater is an aquastat that controls the draft system of the heater to maintain a preset temperature When the fire has heated the water in the tank to the temperature the aquastat is set at normally around 170 to 175 degrees the draft damper and blower will shut dow...

Page 40: ...poker to stir the coals and create air holes in the coal bed Check the smoke stack for creosote build up Also on the C5 models there is a removable baffle plate directly below the smoke stack inside the firebox that will need to be removed and cleaned 5 6 Ash Removal Ashes must be removed from inside the heater on a routine basis Excessive ash buildup inside the Ash box will reduce heating efficie...

Page 41: ... in the home heat thermostat circuit to prevent the pump on the heater from running when the water in the heater is not hot The sensor has a set of contacts that close when the water rises to 110ºF and open when the water drops to 90ºF WATER PUMP RELAY P N H2000 52 WARNING When working with electrical circuits use caution to avoid electrical shock This is a Honeywell DPDT relay with a 24 volt coil...

Page 42: ...on to avoid electrical shock This solenoid lifts the cover off the intake to the forced air draft blower The solenoid is controlled by the damper thermostat It should lift the cover when the forced air blower comes on and drop the cover after the blower goes off If the solenoid does not drop the cover when the blower goes off the solenoid should be replaced The forced air draft intake cover must b...

Page 43: ...nents can cause electrical shorts damage to component parts and insulation Low Water Light Check the low water warning light each week for proper operation to avoid low water or over filling in heater with electric make up water systems See service information section in owners manual for proper checking procedures Ash Bin Keep ash bin from ash buildup Remove ashes before they build up to the leve...

Page 44: ...d check for any build up of ash tar or any other material that could restrict the amount of combustion air entering the heater Check the seal on the clean out lid to assure a good air tight seal is still established Lift the damper lid on the draft blower and inspect the blower wheel for any build up of lint dust creosote or any other substance that could affect the performance of the draft blower...

Page 45: ...ow the paper to become more flexible Close the lid down gently onto the air tube lift back up to check for a indent into the paper and silicone seal If indent has wrinkles in the paper gently lift the paper away from the silicone to straighten back out and set lid back down to form the seal again You may have to do this step a couple of times until you get a good seal Once the seal has been formed...

Page 46: ...ructions Raise the cleanout lid on the main air tube going into the back of the heater check for blockage such as ashes pushed into it when the ashes were shoveled out of the ash bin Check the grates for build up on top of grates that could block the flow of air to the fire Check the smoke stack for creosote build up In the C5 model there is a baffle plate mounted in the fire box directly below th...

Page 47: ...o protect from moisture 2 Remove cover and check the bare copper wire connected to the green screw for secure attachment Test Receptacle for proper operation Moisture or corrosion in electrical connections or windings Check electrical connections and windings for moisture or corrosion Clean or dry and then test for proper operation Pump Motor Corrosion in motor electrical connections or windings C...

Page 48: ...ump cartridge 2 Defective pump capacitor 3 Defective pump motor winding 1 Unplug pump Remove pump Pull cartridge from pump and spin impeller by hand If impeller will not spin replace cartridge 2 Use Ohmmeter When the meter is connected to the capacitor the needle should jump towards 0 ohms and slowly drift back to infinity Replace if defective 3 Disconnect the wires connected to the motor terminal...

Page 49: ... Check for 24 volts Level the mounting base Blow dust from sensing bimetal Adjust heat anticipator See owners manual connection instructions 3 Remove wires on sensor and connect to each other to bypass If pump runs replace low temperature sensor 4 Check relay terminals 7 8 for 24 volts If 24 volts is present use ohmmeter to check contacts Connect ohmmeter to terminals 4 6 If no reading replace rel...

Page 50: ...l of any lint ashes or creosote buildup Ash Bin Ash buildup in ash bin Clean out ash bin Ash bin should be cleaned out each week Ash buildup on grates can cause grates to warp When removing ashes leave at least 1 2 to 1 of ashes in bottom of ash pan NO HEAT Main power supply and ground fault interrupter receptacle OK Water temperature is COLD Heater Stack Ash and Creosote Buildup Clean heater stac...

Page 51: ... liquid level switch No Heat Water Level is LOW Water temperature is HOT Main power supply and Ground Fault Interrupter Receptacle OK Optional Water solenoid valve 1 Defective solenoid valve 2 Water filter 1 If water solenoid valve does not click when checking the liquid level switch but level indicator light does come on replace solenoid valve 2 Remove filter screen from 1 2 bushing in end of 1 2...

Page 52: ...efective 5 Water lines connections leaking Excessive fuel usage Or Overheating boiling Heater water boils Symptom Popoff valve is relieving 1 See area of trouble Pump Operation 2 Open or replace valves 3 Bleed lines if air is trapped non pressured lines require pump to be running 4 Disconnect the inlet and outlet of the hot water coil and clean with a scale remover solution 5 Bleed air from hot wa...

Page 53: ... solenoid does click and the heater still overflows it could be stuck in open position remove and clean or replace 4 Disconnect line to the electric water solenoid and turn off valve to system fill to assure no water enters tank from the fill system If heater tank still overfills then remove heater hull and lid to check domestic water coil for leaks repair or replace Excessive fuel usage Symptom P...

Page 54: ...uctions Smoke Stack Smoke stack stopped up Remove smoke stack check flue out of top of heater clean both flue pipe and smoke stack Baffle Model C5 Only Baffle stopped up Remove baffle through the fire box door clean baffle and flue area Fire Fire going out If fire goes completely out remove one screw in blower lid Forced air blower running but no draft 1 Solenoid not lifting lid 2 Creosote buildup...

Page 55: ... valves to prevent 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 o...

Page 56: ...pt the meter will 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...

Page 57: ...olenoid 3 Using a 5 16 wrench or other suitable tool remove the three screws holding the Damper Solenoid to the electrical panel 4 Install new damper solenoid in reverse order Make sure chain is straight above the flapper lifter as shown There should be tension in the chain when the flapper is in the down position Chain should be straight above Damper Flapper Remove Three Screw s Hazardous Voltage...

Page 58: ...table tool remove the float switch from the heater 3 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 4 Apply pipe joint compound liberally around the threads of the switch Using an adjustable wrench or other suitable tool install the swi...

Page 59: ...utomatic water fill and low water indicator mounted on side of hull does not turn off when the water reaches the correct level the switch is possibly not oriented correctly On units without the automatic water fill option fill the tank until the water level is above the float switch The low water light mounted on the left side of the hull should turn off when the water is at this level If the ligh...

Page 60: ...ll blower power wires through clamp Remove clamp by pressing on locking tang with a flat head screwdriver and pulling away from blower 3 Loosen and remove the three flange screws Remove blower from heater 4 Place new flange gasket onto blower flange Align holes on gasket with holes in flange Start inner screw but do not tighten 5 Position blower over gasket Tighten inner screw to hold blower in po...

Page 61: ...et aside Using pliers or other suitable tool remove the right knockout and install the plastic romex connector 8 Push blower power wires through connector Replace blower electrical box cover Using pliers press the wedge clamp into place 9 Connect power wires and install plastic cable tie if available 10 Verify blower is firmly attached to flange and damper flapper will lift freely 11 Reconnect pow...

Page 62: ...that the bulb has not been damaged during heater operation Make sure the bulb is not lodged in the well fitting If the bulb is lodged the well fitting will have to be replaced 4 Fold back the terminal block protector Loosen the two screws on the terminal block and remove the two thermostat wires Pull the wires through the wiring hole and lay aside 5 Loosen the two screws on the thermostat clamp Ge...

Page 63: ...to the rear of the furnace Use an adjustable wrench to tighten the fitting 9 Remove the cover from the new thermostat Loosen the two screws on the thermostat clamp Make sure the clamp is loose enough to slide over the notch in the well fitting 10 Slide the bulb into the well fitting Position the thermostat so that the thermostat well hole is centered over the well the thermostat is perpendicular t...

Page 64: ...e clamp into the wiring hole Using a flat head screwdriver tighten the two clamp screws 12 Verify the thermostat temperature setting is correct The correct value is written on the front cover The dial can be adjusted using a flat head screwdriver 13 Replace the cover and tighten the cover screw 14 Reconnect power to furnace If the water level was lowered to install a new well fitting MAKE SURE THE...

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