Hardy KBP270 Installation And Operating Instructions Manual Download Page 2

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Summary of Contents for KBP270

Page 1: ...el KBP270 Model KBP270 HARDY MANUFACTURING COMPANY INC 12345 ROAD 505 PHILADELPHIA MS 39350 PHONE 601 656 5866 FAX 601 656 4559 www hardyheater com HARDY MANUFACTURING COMPANY INC 12345 ROAD 505 PHILADELPHIA MS 39350 PHONE 601 656 5866 FAX 601 656 4559 www hardyheater com Rev 2 22 2014 ...

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Page 3: ...peration of this heater THIS MANUAL INCLUDES IMPORTANT SAFETY INFORMATION Your new heater should have the following 1 Owner s manual complete with installation and hook up instructions 2 Warranty return warranty card 3 A tube of silicone located in the firebox for shipping 4 2 double wall sections of Smoke stack with a trim ring and cap 5 Condenser stack with trim ring 6 Ash removal tool 7 Metal a...

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

Page 5: ... unit This unit must be wired by a qualified electrician in accordance with the National Electrical Code Never use any type of petroleum based product charcoal starter lighter fluid or any other flammable accelerant to start your unit Fuel wood pellets Never leave the door open always latch the door securely Always use proper care when installing operating and maintaining the unit Do not modify th...

Page 6: ...stic hot water needs How do the Thermostat Controls work The only visible addition to the heating system inside your home is the thermostat which is located next to your existing thermostat The two thermostats are installed so that if the outside pellet burning heater is not in operation your existing unit can be used to maintain your household temperature The wall thermostat which regulates the h...

Page 7: ...oke Stacks and Condenser Stack 11 2 7 Filling the Heater with Water 12 2 8 Priming the Pump 13 SECTION III Connection to Central Heating AC System 3 1 Connection to Central Unit with existing Blower Relay 14 15 3 2 Location of Heating Coil 16 17 SECTION IV Connection to Hydronic Heating Systems Baseboard 4 1 Connection to Hydronic System 18 SECTION V Plumbing Options for Domestic Water 5 1 Plate H...

Page 8: ...ly 24 7 8 Low Water Sensor 24 7 9 Process Control Module 24 7 10 Feed Auger Assembly 25 7 11 Stir Shaft Motor Assembly 25 7 12 Stir Shaft Assembly 25 SECTION VIII Heater Maintenance 8 1 Daily Maintenance 26 8 2 Weekly Maintenance 27 8 3 Extended Period Shut Down and Start Up 28 SECTION IX Appendix 9 1 Modes of Operation Flow Diagram 29 9 2 General Trouble Shooting Guide 30 9 3 Module Specific Trou...

Page 9: ...s For outdoor use only Electrical Rating 115 VAC 60 HZ 1PH MFS 20 AMP MCA 20 AMP Clearance to Combustibles Top Rear Sides 18 Chimney Connector 18 Front 48 Flooring Non Combustible Water Capacity KBP270 Holds Approximately 40 Gallons of Water Heater Dimensions Description Width Depth Height Weight KBP270 31 75 48 636 lbs ...

Page 10: ...dard Components Legend Part No Description 1 2007 30 Complete Feed Auger Assembly 2 2007 40 Process Control Module 3 2007 45 System Control Switch 4 2004 96 Control Switch Cover 5 2007 10 Firebox Door and Frame Assembly 6 3107 37 Outside Weather Resistant Insulated Cover F o Water 2 3 4 5 6 1 ...

Page 11: ...y 10 502 00 Taco 009 Bronze Circulator 11 607 12 3 4 Brass Ball Valve 12 1100 28 Low Water Switch 13 1100 27 Automatic Water Fill Solenoid 14 2006 21 Stir Motor Assembly 15 2000 53 Process Control Relay 16 2000 55 Process Control Relay Socket 17 810 30 3 4 x 11 75 Raupex Pex A Pipe 18 810 32 3 4 x 2 5 Raupex Pex A Pipe 19 2007 13 Air Power Transmission Assy 20 2004 00 GFCI 7 9 10 11 11 12 13 14 15...

Page 12: ...s Legend Part No Description 21 2007 11 Firebox Burn Chamber Assembly 22 2007 24 Stir Rod Combustion Air Distribution Assy 23 2007 20 Front Bearing assembly 24 2007 70 Front Bearing Hi Temp Assy 25 2007 12 Heat Particulate Recovery Module 26 2007 50 Firebrick Assy 27 608 36 1 Brass Union Fitting 25 21 24 23 22 26 27 ...

Page 13: ... 22 Feed Auger Motor Assy 6 rpm 33 2007 35 Feed Auger Motor Mount Assy 34 2007 37 Feed Auger Drive Assy 35 2007 34 Feed Auger Hopper Tube Assy 36 660 10 2 Union Fitting 37 2007 33 Feed Auger Tube 38 2007 38 Feed Auger Flighting 39 2007 49 Feed Auger Conduit Assy 1 2 Heater Component Parts Model KBP270 Feed Auger Components 30 31 32 33 34 35 36 37 38 39 ...

Page 14: ...NG CO INC MODEL KBP270 PAGE 6 F o Water 1 2 Heater Component Parts Model KBP270 continued Optional Component Parts Legend Part No Description 40 2007 85 Optional Day Hopper Assy 41 2007 86 Optional Tank Frame Assy 40 41 ...

Page 15: ... for installation of the furnace with the optional Hardy Day Hopper Assembly and or Hardy Tank Frame Assembly If you will be using an alternate Fuel hopper then you will need to adjust the dimensions accordingly On the plumbing end of the heater you will need to bring up through the pad a 4 water tight chase pipe to route your water lines and electrical lines from the structure to be heated to the...

Page 16: ... the 4 water tight pipe or other insulation means for a standard installation An additional pipe may be required if more than 1 zone or location is to be heated If more than one location is to be heated a second 4 or single 6 watertight pipe or other insulation means will need to be installed underground for the water lines and thermostat wires of the second location This pipe will run from the re...

Page 17: ...o the LINE Terminals on the GFCI Receptacle located on the rear of the furnace The breaker installed at the power source should be a 20 amp GFCI 2 4 Wiring Diagram 11 10 9 8 7 6 5 4 3 2 1 4 1 5 12 8 9 14 13 MAIN HOT BK MAIN NEUTRAL W EARTH GROUND G 100 BK 101 W 101 W 101 W 100 BK 200 BK 201 R 202 O 203 BL WATER LEVEL SENSOR 204 BK Auto Water Fill 205 BL Combustion Blower 206 R Main Feed Auger 207 ...

Page 18: ... from the heating system is connected to the 3 4 Tee fitting as shown in diagram below Item 2 Water pipes must be designed for hot water service ex copper cpvc or Pex A Pipes should be installed in a 4 watertight pipe or some other type of insulating means to prevent heat loss from heater to heating system Use only copper brass or stainless steel fittings Do not use galvanized or black iron 2 Supp...

Page 19: ...oot sections of smoke stack The trim collar should be slid down the smoke stack until it rests on the outside cover The condenser stack must also be installed in the condenser stack opening The trim collar should be slid down the condenser stack until it rests on the outside cover DO NOT SEAL THE CONDENSER STACK TO THE WATER TANK CONDENSER STACK OPENING THIS IS THE WATER TANK VENT F Water Condense...

Page 20: ...per million of chloride salt in the water as acceptable for drinking experience has shown that chloride levels as low as 45 parts per million will eventually cause stress corrosion cracking in stainless steel tanks when water is heated It is therefore required to use rain water or bottled water with chloride content of less than 15 parts per million or test the water supply for chloride to assure ...

Page 21: ... INC MODEL KBP270 PAGE 13 2 8 Priming the Pumps Once the furnace has been filled with water you will need to prime the pumps You will need to open the pump valve Item 1 and the return valve Item 2 1 2 Pump Valve Return Valve ...

Page 22: ...arked R and the white wire to the screw terminal marked W At the Central air handler where you added the relay connect the white wire that is going to the new heat only wall thermostat to terminal 7 of the new relay along with a short jumper wire that will connect to terminal 6 of the new relay Next find the red wire going from the air handler control wiring to the original wall thermostat Cut thi...

Page 23: ...15V 24V TR TC R1 R2 T2 FS 1 2 4 5 6 7 8 R2 R2 R2 TG CONNECTION DIAGRAM SCHEMATIC DIAGRAM G R LOW VOLTAGE FIELD WIRING White Red White Red Green Green Red Legend R1 existing blow er relay R2 new control relay FS existing thermostat T2 New thermostat TC terminal strip C connection TR terminal strip R connection TG terminal strip G connection R existing thermostat R connection G existing thermostat G...

Page 24: ...e following diagrams and pictures 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 25: ... PAGE 17 3 2 Location of Heating Coil continued Air Flow Air Flow Air Must be Filtered before passing through Heating Coil Vertical Flow System Air Flow Air Flow Air Must be Filtered before passing through Heating Coil Horizontal Flow System ...

Page 26: ...he Hardy Outside Pellet Burning Heater to an existing Hydronic system is by installing a p n 300 01 40 plate heat exchanger w 1 fittings into the return line of the existing boiler system Run 2 1 potable hot water lines from the wood furnace to the existing boiler system Connect these lines to the plate heat exchanger so that the water flow of the furnace is opposite of that from the boiler system...

Page 27: ...plate heat exchanger and pump can be added This plate heat exchanger will provide preheated water to the domestic hot water The preferred method is to mount a plate heat exchanger at the water heater and connect it as shown in the following picture The pump will circulate heater water through the plate continuously The cold water supply will need to be connected to the opposite side of the plate h...

Page 28: ...ized Biofuel Burning Hydronic Heater Fuel must be stored in a clean dry environment and should be protected from contact with moisture like rain condensation etc Normal humidity will not harm the pellets This heater has two basic modes of operation Burn Mode Shut Down Mode Each Mode of operation is determined by the Process Control Module The Process Control Module constantly monitors the systems ...

Page 29: ...th the recommended type of fuel Fuels not suited for the heater type will result in poor and erratic performance and could possibly damage the heater Open shut off gate located in the hopper distribution tube by sliding the T handle out Some maintenance procedures will require the gate to be closed to shut off the supply of fuel Activate the system control switch located just below the process con...

Page 30: ...lower Assy and the Stir Rod Combustion Air Distribution Assy will be off To prevent overheating the pump will run continuously The heater will remain in this mode of operation until the tank water temperature reaches 170º F At this point the heater will enter into the Burn Mode of operation and all systems will be active F o Water Process Control Module System Control Switch Shut Off Gate 6 2 Burn...

Page 31: ...ays of operation a high moisture content is still evident the heater should be shut down and checked for leaks 7 4 Improper Burning Improper burning during the normal operation of the heater is normally caused by lack of combustion air or fuel in the firebox chamber First verify the Feed Auger Assembly is engaged and operating Open the Firebox Door and carefully view the fuel inlet located in the ...

Page 32: ...ace is in the burn mode 7 8 Low Water Sensor The low water switch signals a low water condition in the Process Control Module The Process Control Module will activate the automatic water fill valve assembly until the low water condition no longer exists The heater will not operate if a low water condition exists 7 9 Process Control Module Each mode of operation is determined by the Process Control...

Page 33: ...e the correct amount of fuel for the heater to operate properly 7 11 Stir Shaft Motor Assembly The Stir Shaft Motor Assembly serves as a power transmission to the Firebox Stir Shaft Assembly The Stir Motor operates on a cycle as determined by the Process Control Panel 7 12 Stir Shaft Assembly The Stir Shaft Assembly distributes fuel evenly throughout the firebox and also through its orifices provi...

Page 34: ...There is a minimal amount of maintenance that has to be done for proper operation of your new unit 8 1 Daily Maintenance 1 Make sure you have adequate fuel in the hopper 2 Open the front door and check for any accumulation of ash If ash has started to accumulate remove it according to instructions for ash removal in the weekly maintenance section 8 2 ...

Page 35: ...emove ash build up from the front and interior surfaces of the Firebox Burn Chamber Do not attempt to clean the Firebox Burn chamber while the unit is running 5 Open the front door Visually check the stir shaft to make sure that all the air fingers are open with no restrictions If restrictions are present you will need to remove the stir shaft and clean the Stir fingers and orifices refer to Stir ...

Page 36: ...er surfaces of the Heat Particulate recovery chambers with a shop vacuum to remove any ash or fuel left 8 Once the heater is cleaned you can reassemble and install the Feed auger assembly and the stir shaft assembly Start up of heater after extended shut down 1 Fill the hopper with fuel 2 Verify tank water levels Fill as needed according to Section 2 7 3 Visually check entire heater for physical d...

Page 37: ...ARDY MANUFACTURING CO INC MODEL KBP270 PAGE 29 Section IX APPENDIX 9 1 Modes of Operation Flow Diagram N Water Temp Y water Temp 170 F 172 F N Y Y water Temp N 170 F Initial Start Up Burn Shut Down Mode ...

Page 38: ...ontrol Module Contact Local Dealer Stir Shaft not operating properly Refer to section 9 4 Stir Shaft maintenance Stir Shaft Assy section of Module specific troubleshooting section 9 3 Defective Process Control Module Contact Local Dealer Poor Heater Performance No Heat Output at coil water temp 170ºF Pump not circulating water Refer to Section 9 4 Pump Troubleshooting also see Circulating Pump sec...

Page 39: ...er Power at motor connection but Combustion Blower does not operate Defective blower Test Blower with supplied test cord If blower does not operate then replace see section 9 4 Defective Process Control Relay Defective Process Control Module Contact Local Dealer Stir shaft finger orifices blocked Clear orifices see section 9 4 Excessive Ash buildup in Firebox Chamber Remove Ash Buildup from firebo...

Page 40: ...excessive accumulation of Ash in Firebox X X Section VIII 8 1 8 2 Remove Ash accumulation from outer surfaces of Heat Particulate recovery chambers X Section VIII 8 2 Remove Ash accumulation from Firebox X Section VIII 8 2 Verify Stir Rod Finger Orifices are open with no restrictions Remove and clean orifices as required X Section VIII 8 2 Also See Stir shaft Removal Section Stir Shaft Cleaning Se...

Page 41: ... Connector It will be the connector identified with Blue Tape 3 Remove the Lock Nut from the Auger Conduit Connector and remove from Hull Assembly 4 Using a 7 16 socket wrench or other suitable tool Loosen and remove the qty 4 Hex nut from the underside of Feed Auger Hopper Top as Shown 5 Loosen the 2 Union located just in front of the Auger Hopper Warning Heater should be shut down and allowed am...

Page 42: ...ll the assembly toward you as shown Completely remove the assembly from the Furnace 7 Remove the Auger by rotating the Assemby counterclockwise until the assembly is disengaged from the Auger Adapter Fitting located on the Rear of the Furnace 8 Pull the assembly away from Furnace Adapter coupling and then pull through the Hull Opening Use caution when pulling the assembly through the Hull Opening ...

Page 43: ... aside 3 To remove the motor assembly from the Auger Hopper Tube Assembly rotate the Motor Assembly in a counterclockwise rotation 4 When the threads on the Motor Assembly Coupling are disengaged from the Auger Tube Assembly the Motor and Flighting can be completely removed from the tube by pulling toward you 5 To Remove the Auger Drive Shaft and Flighting Assemblies Loosen the Motor Set Screw usi...

Page 44: ...d set aside 8 Pull the Drive Shaft and Flighting assemblies from the Motor Mount Housing 9 To remove the flighting from the Drive Shaft loosen the flighting clamp using a 7 16 wrench as shown Loosen the screws until the flighting will rotate out of the clamp To reinstall rotate the flighting under the clamp and turn until the end of the flighting contacts the shaft collar Then tighten the 7 16 set...

Page 45: ...When the set screw is in this location disconnect power to the motor 4 Loosen the set screw using an 7 16 wrench Slightly pull back on the motor assembly and remove from the stir shaft coupling Set the motor aside in an area to prevent damage Care should be taken to prevent damage to the cooling impeller on the rear of the motor 5 Remove the 7 16 set screw and 3 4 shaft collar and set aside 6 Whil...

Page 46: ...hown When the set screw is in this location disconnect power to the motor 4 Loosen the set screw using an 7 16 wrench Slightly pull back on the motor assembly and remove from the stir shaft coupling Set the motor aside in an area to prevent damage Care should be taken to prevent damage to the cooling impeller on the rear of the motor 5 Remove the 7 16 set screw and 3 4 shaft collar and set aside 6...

Page 47: ...ris Remove any debris from shaft air orifices using a small pointed object 4 Using a 5 16 drill bit and drill remove any Stir Finger orifice obstructions as shown 5 Clean the exterior surfaces of the Stir Shaft using a wire brush A rotating brush mounted on a drill will allow for easier removal of buildup on the shaft 6 Remove rust from bearing end of stir shaft drive rod as shown using a wire bru...

Page 48: ...across the two capacitor leads The meter should immediately read 0 Ohms then slowly drift to infinity Reverse the test leads and check meter reading The test procedure is the same for a digital multimeter except 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 ...

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