Hardy KB165 Installation And Operating Instructions Manual
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Hardy KB165 Installation And Operating Instructions Manual

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INSTALLATION AND
INSTALLATION AND

OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS
THE HARDY
THE HARDY
OUTSIDE WOOD
OUTSIDE WOOD
BURNING HEATER
BURNING HEATER
Model – KB165
Model – KB165
HARDY MANUFACTURING
HARDY MANUFACTURING
COMPANY, INC.
COMPANY, INC.
12345 ROAD 505
12345 ROAD 505
PHILADELPHIA, MS 39350
PHILADELPHIA, MS 39350
PHONE: (601) 656-5866
PHONE: (601) 656-5866
FAX: (601) 656-4559
FAX: (601) 656-4559
www.hardyheater.com
www.hardyheater.com
FOR
FOR
Rev. 5/7/2015

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Summary of Contents for Hardy KB165

  • Page 1: Operating Instructions

    INSTALLATION AND OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS THE HARDY THE HARDY OUTSIDE WOOD OUTSIDE WOOD BURNING HEATER BURNING HEATER Model – KB165 Model – KB165 HARDY MANUFACTURING HARDY MANUFACTURING COMPANY, INC. COMPANY, INC. 12345 ROAD 505 12345 ROAD 505 PHILADELPHIA, MS 39350...
  • Page 2 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 3 INTRODUCTION Thank you for purchasing the KB165 which is certified to the EPA 2015 Emission Standards. The KB165 is an all stainless steel Hardy Outside Wood Fired Hydronic Heater. It represents the result of many years of Hardy experience and the input of Hardy customers in the production of a top quality heater.
  • Page 4 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, Inc. HARDY MANUFACTURING COMPANY, INC.

  • Page 5: Safety Precautions

     Always use proper care when installing, operating and maintaining the unit.  Do not modify the unit.  Do not substitute repairs which can be provided by your dealer, distributor, or Hardy Manufacturing Co. Inc. Failure to heed this warning, any additional warnings on the unit, or instructions contained in this manual may result in an accident causing personal injury and/or loss of warranty.
  • Page 6 THIS PAGE INTENTIONALLY LEFT BLANK (MODEL KB165)
  • Page 7 2 feet Chimney height should be 2 feet above roof line. Residence served by furnace Minimum of 100 feet 7. Always remember to comply with all applicable state and local codes. Outdoor Furnace Manufacturers Caucus (MODEL KB165)
  • Page 8 THE HARDY OUTSIDE WOOD FIRED HYDRONIC HEATER How does an outside heater heat my home? The Hardy outside wood fired hydronic heater is designed to save the most energy and provide the most comfortable heating available. It heats your home by heating a stainless steel tank filled with water, which surrounds the firebox of the outside heater.
  • Page 9 Person(s) is/are also responsible for operation in a manner that does not create a public or private nuisance condition. The distance and stack height Hardy Mfg. recommends and the requirements in any applicable laws or other requirements may not always be adequate to prevent nuisance conditions due to terrain or other factors.

  • Page 10: Table Of Contents

    4-1 Connection to Hydronic System ......... 18 SECTION V: Plumbing Options for Domestic Water 5-1 Plate Heat Exchanger for Domestic Hot Water ..19 SECTION VI: Heater Operation 6-1 Firing the KB165 ............20 6-2 Loading the KB165 ............ 21 (MODEL KB165) viii...
  • Page 11 10-9 Blower ..............44 10-10 Bypass Damper ..........45-46 10-11 Door Seals ............47-49 10-12 Fire Box Door Latch Adjustment ....... 50-51 SECTION Xl: Heater Repair Parts 11-1 Heater Repair Parts ..........53 Warranty Card Copy ............55 (MODEL KB165)

  • Page 13: Section I

    SECTION I GENERAL INFORMATION This manual describes the installation and operation of The Hardy, Model KB165 Wood Fired Hydronic Heater, certified to the EPA 2015 Emission Standards. This heater meets the 2015 U.S. Environmental Protection Agency's crib wood emission limits for wood heaters sold between May 15, 2015 and May 15, 2020.

  • Page 14: Specifications

    18” Front 48” Flooring Non Combustible Electrical Rating 115 VAC/ 60 HZ / 1PH MFS-20 AMP, MCA-20 AMP Water Capacity KB165 – Holds Approximately 130 Gallons of Water Heater Outside Dimensions Model Width Depth Height Weight KB165 - 150,000 BTU 34”...

  • Page 15: Heater Component Parts

    SMD 1/2” Float Switch 2004.00 Ground Fault Interrupter Receptacle 2004.30 Terminal Block Assy. 508.50 Taco 008 SS pump 502.50 Taco 009 SS Pump 2002.69 1TDR6 Blower 7165.45 Air Volume Box 2065.10 Temperature Logic Controller HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 3...
  • Page 16 Heater Component Parts Model KB165 Standard Components (continued) Inside of Air Volume Box Legend Part No. Description 2065.50 Turbulators 7165.99 Bypass Damper 2001.05 Damper Solenoid 7165.40 Air Tube Damper Assy. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 4...

  • Page 17: Heater Component Parts

    Standard Components (continued) Legend Part No. Description 3105.18 Secondary Air Distribution Plenum 3105.17 Fire Grates 2165.27 Back wall brick 2165.28 Side Brick 2165.31 Bottom Front & Back Bricks 7165.20 Primary Air Distribution Plenum HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 5...

  • Page 18: Installation Of Heater

    INSTALLATION OF HEATER Location of Heater The Hardy Heater is designed to operate outside the structure to be heated. The unit must be located a minimum of 10 feet from any structure. The heating unit should be installed on a concrete pad with a recommended minimum dimension of 34”W x 61”L x 4”D.

  • Page 19: Chimney Connection

    (Note: The supply and return lines must be at least 3/4” pipe. 1” pipe may be required for longer distances. Some hydronic applications also require 1” pipe.) 3. One #12/2 w/gnd NM type UF underground wire HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 7...

  • Page 20: Connection Of Power To Heater

    Receptacle located on the rear of the Heater. The breaker installed at the power source should be a 20 amp GFCI. Wiring Diagram This equipment must be installed in accordance with the National Electrical Code. ( See wiring diagram next page ) HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 8...
  • Page 21 120 V. Combustion Blower Switch Temperature Logic Control Indicator Light Blower Primary air damper solenoid Secondary air damper solenoid Lockout Relay Time delay relay TD 1 Time delay control Terminal Strip Water Solenoid HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 9...

  • Page 22: Plumbing Connections

    Heater with hull and stacks removed to show connections Hardy P/N 300.01 40 Plate Heat Exchanger with 1" fittings Taco 009 Taco 008 Supply Existing Return Boiler Close this valve Heat Heat Existing Zone Zone Pump HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 10...

  • Page 23: Installation Of Smoke Stacks And Condenser Stack

    Do not seal Condenser Stack Seal perimeter of Smoke Stack ring To Condenser Tank. to Heater Hull using Silicone Sealant. Seal perimeter of Condenser tank ring to Heater Hull using Silicone Sealant. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 11...

  • Page 24: Filling The Heater With Water

    45 parts per million. Call your Hardy dealer to obtain a chloride test on your water supply. If the chloride content of your local water supply exceeds the specifications mentioned above and necessitates the use of bottled or rain water, please do so to maintain the warranty of your heater .

  • Page 25: Priming The Pump

    Air Flow Supply Return Heater with hull and stacks removed to show connections Vertical Flow System Taco 009 Taco 008 Supply Air Must be Air Flow Filtered before passing through Heating Coil. Return HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 13...

  • Page 26: Section Iii: Connection To Central Heating/Ac System

    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 terminal #8 of the new relay. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 14...

  • Page 27: With Existing Blower Relay

    New thermostat terminal s trip C connection terminal s trip R connection terminal strip G connection existing thermostat R connection existing thermostat G connection terminal numbers of relay contacts HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 15...

  • Page 28: Location Of Heating Coil

    Return Air Package System Supply Air Supply Air Install and Insulate Heating Coil in supply side of system and in a protected environment HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 16...

  • Page 29: Location Of Heating Coil

    Vertical Flow System Air Must be Air Flow Filtered before passing through Heating Coil. Horizontal Flow System Supply Return Air Must be Air Flow Air Flow Filtered before passing through Heating Coil. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 17...

  • Page 30: Section Iv: Connection To Hydronic Heating Systems (Baseboard)

    This unit must be wired by a qualified electrician in accordance with the National Electrical Code. The preferred method for connecting the Hardy KB165 Hydronic Heater to an existing hydronic system is by installing a p/n 300.01 (40 plate heat exchanger w/ 1” fittings) into the return line of the existing boiler system.

  • Page 31: Plumbing Options For Domestic Water

    PLUMBING OPTIONS FOR DOMESTIC WATER Plate Heat Exchanger for Domestic Hot Water To add domestic hot water to the KB165 hydronic heater, a plate heat exchanger and pump can be added. This plate heat exchanger will provide preheated water to the domestic hot water.

  • Page 32: Section Vi: Heater Operation

    HEATER OPERATION Firing the KB165 Hardy Manufacturing recommends burning clean seasoned oak hardwood in this heater: Clean Wood means wood that has no paint, stains, or other types of coatings, and wood that has not been treated with preservatives, including but not limited to, copper chromium arsenate, creosote, or pentachlorophenol.

  • Page 33: Loading The Kb165

    Loading the KB165 The following steps should be completed to load the KB165 Hardy Heater: 1. Open the bypass damper (located on the right side of the firebox door). 2. Open the firebox door. 3. Flip the blower switch off (located on the right side of the heater), light will turn on. This will begin the off delay timer that is set for 8 minutes.

  • Page 34: Section Vii: Service Information

    Fuel Usage Hardy Manufacturing recommends the use of clean seasoned oak (hardwood). Any fuels other than those specified will result in poor and erratic heater performance. This heater is designed to use a minimum amount of fuel but as with any heater of this type fuel usage is based upon the required load and temperature requirements.

  • Page 35: Air Volume Box

    This prevents short cycling of the unit. 7-13 Time Delay Relay The time delay relay is energized by the timer. It turns off the control power to draft dampers and the blower. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 23...

  • Page 36: Moisture Content Of Wood

    6. Take several different readings and average them. 7-15 Fuel Usage Hardy Manufacturing recommends the use of clean seasoned oak hardwood. Any fuels other than this will result in poor and erratic heater performance. This heater is designed to use a minimum amount of fuel but as with any heater of this type fuel usage is based upon the required load and temperature requirements.

  • Page 37: Section Viii: Heater Maintenance

    SECTION VIII HEATER MAINTENANCE The Hardy heater is designed for ease of operation and ease of service. There is a minimal amount of maintenance that has to be done for proper operation of your new unit. Weekly Maintenance The following steps should be completed weekly to clean the KB165 Hardy Heater: 1.

  • Page 38: Monthly Maintenance

    Monthly Maintenance The following steps should be completed monthly to clean the KB165 Hardy Heater: 1. Burn down wood in the firebox to a coal bed. 2. Open the bypass damper (located on the front right side of the heater).

  • Page 39: Extended Period Shut Down And Start Up

    2. Confirm all door gasket seals are clean and secured to form an air tight seal onto the door frame. 3. Refer to Section 6-1 & 6-2 instructions HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 27...

  • Page 40: Appendix

    6. Open the air volume box on the back of the heater and make sure that the top and bottom air inlets are clear of any creosote. 7. Verify that the dampers and blower are operating properly. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 28...
  • Page 41 Change out solenoid if powered up and not operating Check and seal any leakage around the air Air leakage volume box Inspect the foam gasket and replace as needed Bad air volume box gasket HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 29...
  • Page 42 1 on the terminal strip and each of the Time Delay Control connections on the time delay control for 120 If power is on one terminal but not on the other replace time delay control. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 30...

  • Page 43: Component Service / Replacement Procedure

    Remove the 1/2" ball valve, the 1/4" X 1/2" brass bushing, and the 1/4" close nipple from old valve. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 31...

  • Page 44: Water Solenoid Valve

    This will result in reduced or no water flow through the valve. Replace solenoid coil onto the valve assembly and splice the wiring together with suitable size wire nuts. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 32...

  • Page 45: Low Water Float Switch

    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. Arrow HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 33...

  • Page 46: Low Water Float Switch

    HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 34...

  • Page 47: Pump

    Gently pull the pump motor housing toward you and turn so you can view pump impellar. Rotate the pump impellar by hand. If the impellar will not spin freely then replace the cartridge. Reassemble in reverse order. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 35...

  • Page 48: Pump

    If the the pump does not show continuity across the two power wires or if either power wire shows continuity to ground the winding is defective and the pump should be replaced. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 36...

  • Page 49: Damper Solenoid

    Disconnect wires from damper solenoid. Remove retaining clip from connecting pin in the yoke assembly. Remove connecting pin from yoke assembly. Straighten ends of cotter pin through upper end of the connecting rod. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 37...
  • Page 50 Mount new solenoid and reinstall connecting rod and yoke assembly in the reverse order that they where removed. Check for proper mechanical operation by lifting solenoid plunger by hand to see that travel up and down is smooth. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 38...

  • Page 51: Damper Solenoid Bracket

    Replace gasket with the new gasket provided and mount the new solenoid bracket in the reverse order of removal. Remount the damper solenoid and connection rod assembly following steps in section 10-4 Damper Solenoid. Reconnect wiring. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 39...

  • Page 52: Air Volume Box Seal

    Using a caulking gun apply a bead of silicone caulk to the inside edge of the foam gasket. Also apply a bead of silicone caulk to the outside edge of the foam gasket. Allow the silicone to cure before closing door. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 40...

  • Page 53: Lockout Relay / Time Delay Relay

    To replace either relay, pull the old relay straight out from the relay socket. Insert the new relay into the relay socket, being sure to align the relay connecting pins with the corresponding slots in the relay socket. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 41...

  • Page 54: Temperature Logic Controller

    You must depress the front edge of the locking tab. slide rearward Slide the temperature logic controller out the hull. Feed the wiring harness of the new temperature logic controller back through the hull. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 42...
  • Page 55 Push forward Reconnect the 3 Pin & Socket connectors on the wiring in the rear of the temperature logic controller. Take care to match the wiring on these connectors. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 43...

  • Page 56: Blower

    Replace the gasket with the new gasket supplied and bolt the new blower to the air volume box. Wire the power cord to the new blower motor. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 44...

  • Page 57: Bypass Damper

    Open the flue box door on the right side of the heater. Remove the pin clip on the damper arm where it is connected to the pull rod connectors. Pull the pin out of the damper arm. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 45...

  • Page 58: Bypass Damper

    Clean off the bypass damper face. Reseal the mouth of the bypass channel with silicone and 1" flat fiberglass rope gasket material. And remount the by pass damper in the reverse order of removal. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 46...

  • Page 59: Door Seals

    Wire brush the seal area. Using a caulking gun lay a small bead of silicone in the bottom of the seal groove. Starting at one corner insert the 5/8" X 64" silicone impregnated fiberglass rope. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 47...
  • Page 60 Follow the same procedure for the ash door seal as you would for the fire box door seal with the exception that you will use a standard white 5/8" X 48" fiberglass rope. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 48...

  • Page 61: Door Seals

    Follow the same procedure for the Flue door seal as you would for the combustion door seal with the exception that you will use a 1/4" X 1" X 66" flat fiberglass rope. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 49...

  • Page 62: Fire Box Door Latch Adjustment

    Tighten the inside nuts on the latch adjustment bolts. You should only adjust these approximately one complete revolution at a time. To decrease tension loosen both inside nuts on the latch adjusting bolt. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 50...

  • Page 63: Fire Box Door Latch Adjustment

    Step # Operation Description Visual Aids/Comments Hazardous Voltage! Disconnect Power to Heater prior to performing this maintenance operation. Tighten both outside nuts on the latch adjustment bolt. Replace both acorn nuts and tighten. HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 51...
  • Page 64 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 65: Section Xl: Heater Repair Parts

    Bottom front & back bricks ( see section 1-2) 7165.20 Primary air distribution plenum ( see section 1-2) 2000.53 Lockout relay 2000.52 Honeywell relay 607.12 3/4” Ball valve 810.00 1/2” Overflow pipe 2000.31 Dwyer Thermo Well HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 53...
  • Page 66 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 67: Warranty Card Copy

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

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