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Hardy LC300, Installation And Operating Instructions Manual

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Hardy LC300 Installation And Operating Instructions Manual Download Page 13

(MODEL LC300, LC500 & LC2500) 

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TABLE OF CONTENTS 

 

 
SECTION I:   

General Information

 

 

  1-1 Specifications ............................................................ 1-2 

 

1-2 Heater Component Parts Model LC300 ....................... 3 

 

1-3 Heater Component Parts Model LC500 ....................... 4 

 

1-4 Heater Component Parts Model LC2500 ..................... 5 

 
 

 

SECTION II:   

Installation of Heater 

 

 

2-1 Location of Heater ..................................................... 6-7 

 

  2-2 Chimney Connection .................................................... 7 

 

  2-3 Hull Removal ................................................................ 8 

 

  2-4 Set-Up of Grates ..................................................... 9-10 

 

  2-5 Location of Plumbing & Electrical Lines ..................... 11 

 

  2-6 Connection of Power to Heater .................................. 12 

 

  2-7 Wiring Diagram ..................................................... 13-14 

 

SECTION III:

   Plumbing Instructions 

 

  3-1  Instructions for forced air systems ............................. 15 

 

  3-2  Location of heating coil ......................................... 16-17 

 

  3-3  Instructions for Hydronic systems ......................... 18-19 

 

  3-4  Instructions for Water Heater Hookups LC300 , LC500,  

 

   

& LC2500 .................................................................. 20 

 

  3-5  Replacing Hull ........................................................... 21 

 

  3-6  Filling the Heater with water ...................................... 22 

 
SECTION IV:  

Connection to Central Heating/AC System 

 

  4-1 Connection to Central Unit 

 

   

with Existing Blower Relay ................................... 23-24 

 

  4-2  Connection to Central Unit 

 

 

with Existing Blower Relay Diagram  ......................... 25 

 
SECTION V: 

Heater Operation

 

 

5-1 Firing the Heater ........................................................ 26 

 

5-2  Water Temperature ................................................... 26 

 

5-3  Moisture in the Firebox .............................................. 26 

 

5-4  Wood Usage .............................................................. 27 

 

5-5  Improper Burning ....................................................... 27 

 

5-6  Ash Removal ............................................................. 27 

 

5-7  Ash Disposal ............................................................. 27 

 

5-8  Creosote Formation and Removal ............................. 28 

 

 

 

 

Summary of Contents for LC300

Page 1: ...PERATING INSTRUCTIONS FOR THE HARDY LIGHT COMMERCIAL OUTSIDE WOOD BURNING HEATER Model LC300 LC500 LC2500 HARDY MANUFACTURING COMPANY INC 12345 ROAD 505 PHILADELPHIA MS 39350 PHONE 601 656 5866 FAX 601 656 4559 www hardyheater com Rev 3 25 2015 ...

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

Page 3: ...ty 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 LC300 has two I beams and three cast iron grates located in the firebox LC500 has one I beam two channels and six grates located in the firebox LC2500 has one air tube two channels and six grates located in firebox 6 Shovel located in the fire...

Page 4: ...following 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: ...e with 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 ...

Page 6: ... MODEL LC300 LC500 LC2500 iv Safety Labels Read all safety labels on this unit Name Plate Supplement 5 X 10 not shown actual size ...

Page 7: ...L SECOND 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 CONNEC...

Page 8: ... MODEL LC300 LC500 LC2500 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 LC300 LC500 LC2500 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 LC300 LC500 LC2500 viii THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 11: ...nstructions 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 building not ...

Page 12: ...need for heat it turns the water pump on to circulate the hot water through the coil and also turns the blower on inside your central unit to force air across the hot coil This forces hot air into your central duct system The outside heater has a hot water thermostat which senses the water temperature of the unit If the water is not as hot as the thermostat setting then the combustion air intake i...

Page 13: ...lumbing Instructions 3 1 Instructions for forced air systems 15 3 2 Location of heating coil 16 17 3 3 Instructions for Hydronic systems 18 19 3 4 Instructions for Water Heater Hookups LC300 LC500 LC2500 20 3 5 Replacing Hull 21 3 6 Filling the Heater with water 22 SECTION IV Connection to Central Heating AC System 4 1 Connection to Central Unit with Existing Blower Relay 23 24 4 2 Connection to C...

Page 14: ...n Maintenance 33 34 7 3 In Season Maintenance 34 35 7 4 Post Season Maintenance 35 SECTION VIII Appendix 8 1 General Trouble Shooting Guide 36 43 8 2 Circulator Maintenance Instructions 44 45 8 3 Damper Solenoid Replacement Instructions 46 8 4 Low Water Switch Replacement Instructions 47 48 8 5 Draft Blower Replacement Instructions 49 50 8 6 Automatic water fill Replacement Instructions 51 52 8 7 ...

Page 15: ...ront 48 Flooring Non Combustible Water Capacity LC300 Holds Approximately 100 Gallons of Water LC500 Holds Approximately 130 Gallons of Water LC2500 Holds Approximately 160 Gallons of Water Heater Dimensions Description Width Depth Height Weight LC300 120 000 BTU 30 52 59 650 lbs LC500 180 000 BTU 40 52 59 850 lbs LC2500 250 000 BTU 40 60 59 1000 lbs Firebox sizes Description Width Depth Height LC...

Page 16: ...extra ports on your heater Heater Rating LC300 120 000 BTU LC500 180 000 BTU LC2500 250 000 BTU 120 000 2 69 WOOD LC300 1 07 1 1 Specifications Electrical Options 0 Without a Pump 1 Standard Pump 2 2nd Pump Relay 3 3rd Pump Relay 4 Without a Pump for Heating System and with Circulating Hot Water 5 With a Standard Pump for Heating System and with Circulating Hot Water 6 With 2nd Pump and Relay and ...

Page 17: ...Cap 9 2000 48 1 2 Well Fitting 10 2000 08 Honeywell Aqua stat 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 20...

Page 18: ...le 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 16 100 CFM Blower Lid 24 2004 28 Plastic Romex Connector 25 607 42 3 4 Boiler Drain 26 ...

Page 19: ...30 CFM Blower 10 300 02 Plate Exchanger 11 600 10 1 2 Brass elbow 12 810 00 1 2 Overflow pipe 13 607 42 3 4 Male Boiler Drain Valve 14 700 05 3 4 x 10 SS Flex Line 15 700 18 3 4 x 18 SS Flex Line 16 900 80 1 1 2 Copper Supply 17 900 85 1 1 2 Copper Pump Supply 18 900 90 1 1 2 Copper Return 19 607 47 1 1 2 Brase Ball Valve 20 607 45 1 Brass Ball Valve 21 607 12 3 4 Brass Ball Valve 22 607 00 1 2 Br...

Page 20: ...k flush with the 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 wood 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 cove...

Page 21: ...er for loading wood 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 a...

Page 22: ...oved 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 door the rectangular piece of stain...

Page 23: ...dy model LC500 there will be two channel beams and one I beam with the ends cut at a 45 degree angle There will also be six grates Stand the channel beams on edge with the open side to the inside and slide them over against the sides of the firebox The I beam will need to be set on edge with the longer edge on top and placed in the center of the firebox The grates may then be placed on either side...

Page 24: ...lide the 3 8 steel plate in the firebox across the air tube and channel beams under the drop down section of the fire box against the back wall Install the grates across the air tube and the channel beams inline and end to end in front of the 3 8 steel plate Stand the steel flame baffle up with the 5 support legs on the bottom facing the front of the heater The openings should be facing and pushed...

Page 25: ...tight pipe or other insulation means for a standard installation 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 ...

Page 26: ...ine side of 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 recept...

Page 27: ...ROUND 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 Models LC300 LC500 CONNECTION...

Page 28: ...TOR 4 6 R3 BM 1 PM SOL1 GFCI L1 L2 SCHEMATIC DIAGRAM LEGEND GFCI GROUND FAULT CIRCUIT INTERRUPTER R3 CIRCULATOR PUMP RELAY PM WATER CIRCULATOR PUMP M1 RECIRCULATOR PUMP T1 DAYTON AQUASTAT BM1 DAMPER BLOWER MOTOR SOL1 DAMPER SOLENOID SOL2 WATER SOLENOID F1 LOW WATER SWITCH L1 LOW WATER LIGHT R F1 L1 SOL2 1 2 3 4 5 6 7 8 R BM 1 SOL1 R3 PM M1 RECIRCULATOR ZONE CIRCULATOR SOL2 F1 T1 Dayton thermostat ...

Page 29: ...y 4 in diagram 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 ...

Page 30: ...ting Coil The following diagrams on this page and the following page show various methods of installing the heating coil in a 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 31: ... Supply Return Air Flow Air Flow Air Must be Filtered before passing through Heating Coil Supply Return Air Flow Air Flow Air Must be Filtered before passing through Heating Coil Vertical Flow System Horizontal Flow System 3 2 Location of Heating Coil continued ...

Page 32: ...le for 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...

Page 33: ...ng boiler aqua stat wiring By adding a normal open circuit into the existing aqua stat wiring you can leave the boiler aqua stat set at the original factory setting Set the new low voltage wall thermostat approximately 3 degrees below the wood heat thermostat If the heater were to get behind for any reason the boiler can come on and help maintain the building temperature EXISTING BOILER AQUASTAT 7...

Page 34: ... flowing in the opposite direction for maximum efficiency The alternate method would be to mount the plate heat exchanger on the back of the heater 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 o...

Page 35: ... tank opening The trim should slide 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 the outer hul...

Page 36: ...ater or your water supply with chloride content of less than 15 parts per million 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 chloride content of your local water supply exceeds the specifications mentio...

Page 37: ...electrical usage or cause your blower motor to over heat and burn out Remove the cover on the new wood 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 a...

Page 38: ...tside to the wood heater Take the green wire that is going outside to the Hardy Hydronic 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 transfor...

Page 39: ...N TR TERMINAL STRIP R CONNECTION 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...

Page 40: ...dually add more split wood and gradually increase the size of the wood Once a bed of coals has been established you can use larger wood 5 2 Water Temperature Mounted on the back of the heater is an aqua stat 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 set aqua stat temperature normally around 170 to 175 degrees...

Page 41: ...the coals and create air holes in the coal bed Check the smoke stack for creosote build up Also on the H4 H5 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 efficiency and can...

Page 42: ...te The creosote vapors condense in the relatively cool chimney flue of a slow burning fire As a result creosote residue accumulates on the flue lining When ignited this creosote makes an extremely hot fire The chimney connector and chimney should be inspected at least twice monthly during the heating season to determine if a creosote buildup has occurred If creosote has accumulated it should be re...

Page 43: ...the reed switch and close the contacts allowing power to be applied to the water solenoid If this switch is working in an opposite order to this it will need to be tightened another 180 degrees to allow the switch to operate correctly Never add any additional load to this switch since it is only rated for 30 watts LOW WATER LIGHT P N H1100 30 115 VAC indicator light controlled by the float switch ...

Page 44: ...o 009 pump P N H502 50 with stainless steel body If the pump will not run first unplug the power cord then check the water pump relay The relay can be bypassed by moving the wire on terminal 6 to terminal 5 terminals 4 to 5 is normally closed and disconnecting the thermostat wire from terminal 8 Now plug the power cord back in This should supply 115 vac directly to the pump If the pump will still ...

Page 45: ... intake to the forced air draft blower The solenoid is controlled by the damper thermostat It should lift the cover when the forced air blower comes on and drop the cover after the blower goes off If the solenoid does not drop the cover when the blower goes off the solenoid should be replaced The forced air draft intake cover must be in place when the blower is not running or the heater will overh...

Page 46: ...r leaks Water leaks on heater components 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 VI in owners manual for approved procedures Ash Bin Keep ash bin from ash buildup Remove ashes b...

Page 47: ... year accidental overheating can occur and the water will evaporate The evaporation causes a concentration of chlorides salts and other minerals To protect your heater from this build up of chlorides salts and other minerals we recommend to drain your heater each year at time of startup for the heating season and refill with rain water or bottled water with a chloride concentration of less than 15...

Page 48: ...st remove old gasket completely Put a generous bead of silicone on the back side of the lid where it will be coming into contact with the square air tube going into the heater Place a piece of wax paper across the silicone to prevent it from sticking to anything other than the lid Spray the wax paper with a misting of water to allow the paper to become more flexible Close the lid down gently onto ...

Page 49: ...ates that could block the flow of air to the fire Check the smoke stack for creosote build up In the CL500 model there is a baffle plate mounted in the fire box directly below the smoke stack This baffle plate can be removed for cleaning This baffle plate is laying across two 2 pipes in the top of the fire box and can be slid to either side for removal Any obstruction of the exhaust gases or the s...

Page 50: ...r 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 Check electrical connections capacitor and motor winding for bad...

Page 51: ...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 ohm meter 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 termina...

Page 52: ...volts Level the mounting base Blow dust from sensing bimetal Adjust heat anticipator See owners manual connection instructions 3 If heater is up to temperature over 140 f 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 ohm meter to check contacts Connect ohm meter to terminals...

Page 53: ...s are secure 2 Clear air passages in cleanout and damper blower outlets 3 Clear blower wheel 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 If grates warp they can be turned over and allowed to straighten When removing ashes leave at least 1 of ashes in bottom of ash pan H...

Page 54: ...replace the liquid level switch No Heat Water Level is LOW Water temperature is HOT Main power supply and Ground Fault Interrupter Receptacle OK 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...

Page 55: ...pen 4 Damper aqua stat defective 5 Water lines connections leaking Excessive wood usage or Overheating boiling Heater water boils 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 water coil W...

Page 56: ...t should float up as the heater fills with water Check switch by pivoting float up and down to see if solenoid clicks and light goes on and off if not replace switch 2 If solenoid does click and the heater still overflows it could be stuck in open position remove and clean or replace Excessive wood usage 1 Defective liquid level switch 2 Solenoid valve stuck or corroded Excessive wood usage Or Ove...

Page 57: ...stack stopped up Remove smoke stack check flue out of top of heater clean both flue pipe and smoke stack Baffle Model LC500 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 S...

Page 58: ...n ball 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 mainten...

Page 59: ...r 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 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...

Page 60: ... from solenoid 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 ...

Page 61: ...her suitable 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 ...

Page 62: ...f the automatic 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 t...

Page 63: ...lamp Pull 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 blowe...

Page 64: ...x and set 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 Reconn...

Page 65: ...t the solenoid aside for later installation If you are not replacing the water fill valve then skip to step 8 3 Using an adjustable wrench loosen and remove the flex line fitting from solenoid assembly and set aside 4 Using an adjustable wrench or other suitable tool remove the automatic water fill assembly from heater Remove the brass elbow 1 2 x1 4 bushing and 1 4 close nipple from the assembly ...

Page 66: ...assembly This wil result in reduced water flow The brass elbow should point slightly forward 8 Using a pipe wrench or other suitable tool turn the tee approx 1 4 turn counter clockwise until the assembly is parallel with the rear of the furnace Reinstall the flex line fitting and tighten hand tight plus approx 1 2 turn Do not over tighten the flex line to prevent damage to the inner bushing 9 Slid...

Page 67: ...o make sure 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 thermos...

Page 68: ...e fitting into 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 per...

Page 69: ...push the wire 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 M...

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