Installation & Operating manual
The bio-Flow 60
(bh60) Pellet boiler
dANgEr: rISk OF FIrE Or ExPlOSION
- dO NOT burN gArbAgE, gASOlINE,
drAIN OIl Or OThEr FlAmmAblE
lIQuIdS IN ThIS APPlIANCE.
wArNINg: rISk OF FIrE
- dO NOT OPErATE wITh FuEl
lOAdINg Or ASh rEmOvAl dOOrS
OPEN.
- dO NOT STOrE FuEl Or OThEr
COmbuSTIblE
mATErIAl wIThIN
mArkEdINSTAllATIONClEArANCES.
-
INSPECT ANd ClEAN ENTIrE
vENTINg SYSTEm INCludINg All
FluES ANd ChImNEY rEgulArlY.
r10
SAFETY NOTICE
PlEASE rEAd ThIS ENTIrE mANuAl bEFOrE YOu INSTAll ANd uSE YOur NEw bOIlEr. FAIlurE TO FOllOw
INSTruCTIONS mAY rESulT IN PrOPErTY dAmAgE, bOdIlY INjurY, Or EvEN dEATh.
FOr rESIdENTIAl uSE IN ThE u.S. ANd CANAdA.
IF ThIS PEllET bOIlEr IS NOT PrOPErlYINSTAllEd,AhOuSE FIrE mAYrESulT. FOrYOur SAFETY, FOllOw INSTAllATION
dIrECTIONS.
CONTACT lOCAl buIldINg Or FIrE OFFICIAlS AbOuT rESTrICTIONS ANd INSTAllATION INSPECTION
rEQuIrEmENTS IN YOur ArEA.
CONTACT YOur lOCAlAuThOrITY (SuChAS muNICIPAl buIldINg dEPArTmENT, FIrE dEPArTmENT, FIrE PrEvENTION
burEAu, ETC.) TO dETErmINE ThE NEEd FOr A PErmIT.
CETTE guIdE d’uTIlISATION EST dISPONIblE EN FrANCAIS. ChEZ vOTrE CONCESSIONNAIrE.
SAvE ThESE INSTruCTIONS
manual #3-90-233h
bh60 Parts
Flue Pipe - 3”
Pellet Vent
Combustion Blower
Cover
Hopper Lid
Heat Exchange
Cleanout Cover
Pressure Relief
Valve
Temperature/
Pressure Gauge
Heating System
Supply & Return
(either side)
Combustion Blower
Remote Zone
Control / OAT
Sensor Terminal
Control Board
Power Cord
Outside Air
Knockout
(either side)
Circuit Breaker
Side Access
Panel
Boiler Drain
(Either Side)
1- Controlled &
1-Un-controlled
120VAC Outlets
Firebox Door
Firebox Draft
Test Port
Levelling Feet
3
Table of Contents
Options
5
Installation
venting
6
9
Plumbing
Electrical
14
20
Operation
26
33
38
39
40
41
42
43
maintenance
Troubleshooting
Specifications
wiring diagram
warranty
Testing label
Service Parts
Start-up Quick reference back Cover
Please read this entire manual before you install and use
your new boiler. Failure to follow instructions may result in
property damage, bodily injury, or even death.
SAvE ThESE INSTruCTIONS
hearth & home Technologies
352 Mountain House Road
Halifax, PA 17032
4
Options
Outside Air Components
Flex pipe part#
1-00-08543
(25')
Inlet Cover part#
1-10-08542
Direct Vent Wall Passthrough
Standard method of attaching outside air. Be sure to
use the inlet cover to prevent birds and/or rodents
from entering the intake pipe. This method requires a
hole to the outside, separate from the vent passage.
Item # 1-10-677077 provides for safe passing of
the 3” pellet vent pipe through an outside wall,
while providing the attachment for outside air. No
extra holes needed.
water Piping Supports-
Bulk Storage Hopper-
Item # 2-00-232044B, secures to the boiler
and gives the support needed for the
expansion tank and circulator, while keeping
them at a workable distance from the boiler.
Item # 1-00-73450, with 1500 lb
pellet capacity, it will automatically
re-fill the unit hopper when it falls
below a certain level.
Atmospheric Conversion-
Item # 1-00-232200, provides
automatic fill, and converts the
heating system plumbing from
pressurized to a zero pressure
system. Allows for installation into
more places where codes and
standards restrict pressurized
systems. Circuit Board Dipswitch
#6 must be “ON” when installed.
5
Installation
Preparation For Installation:
Boiler Kit Materials: (Refer to page 3)
List of items shipped with the unit.
1 - 3/4” Boiler Drain
1. Install 3/4” MPT boiler drain in the fitting as shown. Either
side can be utilized. Note: If using the supply and return on
each side, either one of the returns is going to need the drain
valve incorporated.
Note: Use teflon pipe thread sealant or teflon tape onALL
threads before connections are made.
1 - 3/4” Safety Relief Valve
1 - 1/2” Dual Temperature/Pressure Gauge
1 - Outdoor Air Sensor
2 - Piping Support Brackets
1 - Scraper Tool
2. Install the 1/2” MPT temperature/pressure gauge in fitting
where shown.
4 - 1½” Levelling Feet. (page 7)
3. Locate and install the outside air temperature sensor.
Location of this sensor should be on the North side of the
home or building and out of direct sunlight. Use a cat3 cable
or 18-2 thermostat wire to attach the sensor to the terminals
located beside the control board. The wires can be connected
to the sensor with wire nuts or butt splice connectors.
Attach Outside Air
Sensor Here
Note:
It is recommended that the
levelling feet be installed
in all installations. The air
space provided will help to
prevent condensation or
trapped moisture which may
lead to rust on the bottom of
the unit.
Bolt-Down Brackets:
Use the brackets from
the original packaging
and at least 4 bolts (not
supplied) to secure the
unit in its permanent
location.
The feet can be adjusted
using a 7/16” open end
wrench.
Recommended for all
installations.
6
Installation
Minimum non-combustible floor protection area
Placement and System design:
The first thing that needs to be done is deciding where
and how the boiler will be installed.
NON-COMBUSTIBLE
FLOOR PROTECTION
Things that need to be taken into consideration are the
intended use of the boiler. For example, is the boiler
going to be used as a secondary or backup heating
system? If it is to be used in conjunction with an existing
oil or gas boiler system will it be piped in parallel or
in series? The answers to these and other questions
can be determined by talking to your certified dealer
or a qualified HVAC or plumbing contractor. This will
ensure that the boiler is installed and piped to best
accommodate your needs and expectations.
46 7/8”[1190.63mm]US
48 7/8”[1241.43mm]CAN
16”[406.4mm]US
18”[457.2mm]CAN
Much consideration must be given to the venting. Due
to low exhaust gas temperatures, the boiler should
be placed where the venting system can be as short
as possible. Pay particular attention to electrical
connection needs and combustible/service clearance
requirements.
After the boiler is set into place the venting can be
installed.
46 7/8”[1190.63mm]US
48 7/8”[1241.43mm]CAN
Make sure any exhausting devices or appliances used
in the area are installed so as not to create negative
pressure in the room where the boiler is located.
Floor Protection:
The striped area indicates the minimum required floor
protection area if the boiler is going to be placed on
a combustible floor. Special Note: When installing
on a protected floor, the levelling feet need to be
adjusted so that the bottom of the unit is 1¼ inches
off the floor protector (see illustration below). This
boiler requires 46⅞” X 29⅛” (48⅞ X 29⅛ in Canada)
of non combustible floor protection as shown above.
16” (US) or 18” (Canada) of the floor protection must
be in front of the boiler as shown, with 6” extending on
either side. CSA/CAN B366.1 requires floor protection
extending 2” (50mm) under horizontal section of
chimney connector. Floor protection must be a minimum
of 26 gauge sheet metal.
This boiler must not be installed in an area or room
where chemicals or solvents are used or stored in
quantities above that of normal use.
NOTICE: For installations above 3000 ft. elevation,
or any installation using the atmospheric conversion,
circuit board dipswitch #6 must be in the “ON” position.
Note: It is recommended that the levelling feet be
installed in all installations. The air space provided will
help to prevent condensation or trapped moisture which
may lead to rust on the bottom of the unit.
The feet can be adjusted using a 7/16” open end
wrench.
Levelling feet must be adjusted
to give 1¼ in of clearance when
installing boiler on a protected
combustible floor.
This appliance is also approved for installation
into a shop.
7
Installation
C
b
A
d
minimum Clearances To Combustible materials
Sidewall To Appliance A
6” (152 mm)
6” (152 mm)
mur latéral à l’Appareil
mur Arrière à l’Appareil
haut du Poêle au Plafond
backwall To Appliance b
Stove Top To Ceiling
C
16” (406 mm)
48” (1219 mm)
3” (76 mm)
Stove Front To Combustibles d
Combustibles To Pellet vent
minimum Alcove height
minimum Alcove width
des Combustibles au devant du Poêle
matériaux Combustibles au Conduit de Fumée
hauteur de l’Alcôve
72” (1829 mm)
48” (1219 mm)
60” (1524 mm)
largeur de l’Alcôve
minimum Alcove depth
Profondeur de l’Alcôve
wArNINg! rISk OF FIrE! Hearth & Home Technologies disclaims any responsibility for, and the warranty
and agency listing will be voided by the following actions:
dO NOT:
•
•
•
•
•
•
Install or operate a damaged appliance
Modify the appliance
Install other than as instructed by Hearth & Home Technologies
Operate the appliance without fully assembling all components
Overfire the appliance
Install any component or part not approved by Hearth & Home Technologies
Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage.
For assistance or additional information, consult a qualified installer, service agency or your dealer.
8
venting
H. A vent must not be installed within 3 feet (90 cm)
Requirements for Terminating the Venting
WARNING: Venting terminals must not be recessed
into a wall or siding.
NOTE: Only PL vent pipe wall pass-throughs and
fire stops should be used when venting through com-
bustible materials.
NOTE: Always take into consideration the effect
the prevailing wind direction or other wind currents
will cause with flyash and /or smoke when placing the
termination.
In addition, the following must be observed:
A. The clearance above grade must be a minimum of
18”.1
B. The clearance to a window or door that may be
opened must be a minimum of 48” to the side, 48”
below the window/door, and 12” above the window/
door.1
C. A 12” clearance to a permanently closed window is
recommended to prevent condensation on the window.
D. The vertical clearance to a ventilated soffit located
above the terminal within a horizontal distance of 2 feet
(60 cm) from the center-line of the terminal must be a
minimum of 18”.
above a gas meter/regulator assembly when measured
from the horizontal center-line of the regulator.1
I. The clearance to service regulator vent outlet must be
a minimum of 6 feet.1
J. The clearance to a non-mechanical air supply inlet
to the building or the combustion air inlet to any other
appliance must be a minimum of 48”.1
K. The clearance to a mechanical air supply inlet must
be a minimum of 10 feet.1
L. The clearance above a paved sidewalk or a paved
driveway located on public property must be a minimum
of 7 feet.1,2
M. The clearance under a veranda, porch, deck or
balcony must be a minimum of 12 inches.1,3 (See B. also)
NOTE: The clearance to vegetation and other exte-
rior combustibles such as mulch is 36” as measured from
the center of the outlet or cap. This 36” radius continues
to grade or a minimum of 7 feet below the outlet.
1Certain Canadian and or Local codes or regulations
may require different clearances.
2A vent shall not terminate directly above a sidewalk
or paved driveway which is located between two
single family dwellings and serves both dwellings.
3Only permitted if veranda, porch, deck, or balcony is
fully open on a minimum of 2 sides beneath the floor.
E. The clearance to an unventilated soffit must be a
minimum of 12”.
F. The clearance to an outside corner is 11” from center
of pipe.
G. The clearance to an inside corner is 12”. If you see
deposits developing on the wall, you may need to extend
this distance to accomodate your installation conditions.
NOTE:Where passage through a wall, orpartition of
combustible construction is desired, the installation
shall conform to CAN/CSA-B365. (if in Canada)
Fig. 2
= Air supply inlet
= Vent terminal
= Area where terminal is not permitted
9
venting
Venting
18
Use only 3” pellet vent pipe to vent your pellet boiler.
4
Fig. 3
5
15
10
5
A combustion blower is used to extract the combustion
gases from the firebox. This creates a negative pressure in
the firebox and a positive pressure in the venting system as
shown in Fig. 4. The longer the vent pipe and more elbows
used in the system, the greater the flow resistance, and the
greater the chance for creosote accumulation. Because of
these facts we recommend using as few elbows as possible
and 18 feet or less of vent pipe. The maximum horizontal
run should never exceed 8 feet.
6
7
8
9
10
10
8
The Total Lineal Feet
Decreases as the
Altitude Increases
6
4
2
0
Be sure to use wall and ceiling pass through fittings
(which are approved for pellet vent pipe ) when going
through combustible materials. Be sure to use a starting
collar to attach the venting system to the stove. The starting
collar must be sealed to the stove flue collar with high
temp silicone caulking or aluminum tape, and screwed
into the units’flue collar in a minimum of three (3) places.
8
6
4
2
Total Lineal Feet Combined
Should Not Exceed 18' as
measured from the outlet.
Maximum Horizontal Run 8'
Due to low exhaust temperatures, increasing the diameter
of the venting or exceeding the recommendations of the
venting graph, is strongly discouraged.
NOTE:Use only 3” diameter Pellet venting system.
Be sure to inspect and clean exhaust venting system
frequently.
Vent Pipe
3” pellet vent pipe (also known as “PL” vent) is constructed
of two layers with air space between the layers. This air space
actsasaninsulatorandreducestheoutsidesurfacetemperature
to allow a minimum clearance to combustibles as low as 1
inch. In Canada the minimum clearance to combustibles is
3 inches. Check with the venting manufacturer to be certain
of specified clearances.
Fig. 4
The sections of pipe lock together to form an air tight seal
in most cases; however, in some cases a perfect seal is not
achieved. For this reason and the fact that the unit operates
with a positive vent pressure, we specify that all joints
within the structure should be secured with at least 3
screws, and sealed with silicone caulking.
+
-
Creosote - Formation and Need for Removal - When wood is burned slowly, it produces tar and other organic vapors,
which combine with expelled moisture to form creosote. 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 pellet vent pipe 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 removed to reduce the risk of a chimney fire.
Guidance on minimizing creosote formation and the need for periodic creosote removal: The chimney should be inspected
during the heating season to determine if a creosote build-up has occurred. If a significant layer of creosote has accumulated,
1/8” (3mm) or more, it should be removed to reduce the risk of a chimney fire.
10
Venting
venting
The minimum vent configuration is a 90o or Tee on a starter
collar and a 24” length horizontal through an exterior wall.
Acap on the end should direct the flue gases down and away
from the structure. See Fig. 5.
This is the minimum venting configuration. NOTE: A starting
collar is needed in order to remove the units’ cleanout cover.
The maximum horizontal length is 8 feet. The minimum
termination height above the exterior grade is 18”. The
maximum total length of any configuration is 18 feet*.
* (see venting graph on page 10 for exceptions)
NOTE: Cleanout Tee’s should always be used on the
transitions to horizontal pipe to allow easy access for
cleaning.
3” Type “L” or
“PL” Vent pipe
The venting graph allows for one(1) 90 deg. or Tee fitting
in any configuration.
If more 90’s, T’s, or 45’s are needed the total length must
be adjusted to allow for the added restriction.
Up to four (4) additional 90’s, Tee’s, or equivalent 45’s
can be added as long as the overall length is adjusted in
accordance with the values listed below. (See the venting
graph on page 10.)
Fig. 5
Each Vertical ---- 90 deg. or T subtract 2.5 feet
Each Vertical ---- 45 deg.
Each Horizontal - 90 deg. or T subtract 5.0 feet
Each Horizontal - 45 deg. subtract 2.5 feet
subtract 1.5 feet
Venting Into An Existing Chimney
The boiler may be vented into an existing masonry or Class
A metal chimney, providing that the chimney is less than 20
feet above the connector. A flue liner, no more than 4-inch
diameter, must be installed, along with a termination cap and
the proper flashing to seal the existing flue.
The venting Can Not be installed in a chimney serving
another appliance.
Other examples of possible installations of the venting.
The chimney should be cleaned and/or inspected before
installation of the vent liner.
Any exterior venting (vent pipe exposed to outside
ambiant temperatures) should be kept to a
minimum, due to potential condensation problems.
This is especially important in high humidity-cold
weather climates, such as maritime areas, lake shores,
and low river valleys.
Due to low exhaust temperatures, and the increased
possibility of condensation and creosote formation, additional
measures may need taken to increase the flue temperature.
One such measure would be to remove the two rear-most
spiral baffles, above the burn pot, from their heat exchange
tubes. Although some efficiency will be lost, an increased
flue temperature will result.
The flue liner should be inspected frequently, during
operation, to monitor its performance and cleanliness.
NOTE: Use only 3” diameterPellet venting system.
Be sure to inspect and clean exhaust venting system
frequently.
11
venting Installation
To reduce probability of reverse drafting during
a power failure, Hearth & Home Technologies
strongly recommends:
INSTALLATION IS TO BE PERFORMED BY
A QUALIFIED INSTALLER.
•Installing the pellet vent with a minimum vertical rise
of five feet. Preferably terminating above the roof line.
NOTE: All installation clearances and restrictions
must be adhered to.
•Installing an outside air connection to the appliance.
To prevent soot damage to exterior walls, and to
prevent re-entry of soot or ash into the home:
INSTALLATION IS TO BE PERFORMED BY A
QUALIFIED INSTALLER.
•Maintain specified clearances to windows, doors and
air inlets, including air conditioners.
DO NOT INSTALL A FLUE DAMPER IN THE
EXHAUST VENTING SYSTEM OF THIS UNIT.
•Vents should not be placed below ventillated soffits.
•Avoid venting into alcove locations.
DO NOT CONNECT THIS UNIT TOACHIMNEY
FLUE SERVING ANOTHER APPLIANCE.
•Vents should not terminate under overhangs, decks or
onto covered porches.
•Maintain minimum clearance of 12” from the vent
termination to the exterior wall.
INSTALL VENT WALL PASS-THROUGHS AT
CLEARANCES SPECIFIED BY THE VENT
MANUFACTURER.
Hearth
&
Home Technologies assumes no
responsibility for, nor does the warranty extend to,
smoke damage caused by reverse drafting of pellet
appliances under power failure conditions.
NOTE: Read and follow all of the vent pipe
manufacturers’instructions on the proper installation
and support of the vent pipe. Adhere to all clearances
to combustibles.
WARNING
KEEP COMBUSTIBLE MATERIALS SUCH
AS GRASS, LEAVES, ETC. AT LEAST 3 FEET
AWAY FROM THE POINT DIRECTLY UNDER
THE VENT TERMINATION. (BETWEEN THE
VENTAND THE GROUND)
CAUTION
KEEP COMBUSTIBLES AWAY
FROM FLUE OUTLET.
12
Installation
NOTE: If outside air is installed, the inlet cover should not
be placed in an area where drifting of snow or ice will build
up, blocking the intake air supply.
Inlet Cover part#
1-10-08542
Hearth & Home Technologies strongly recommends the use
of outside air for all pellet boiler applications.
Per national building codes, consideration must be given
to combustion air supply for all appliances in the vicinity
of the pellet boiler. Failure to supply adequate combustion
air for all appliance demands may lead to backdrafting of
those appliances. Consult with your HVAC Professional to
determine that all combustion air requirements are met.
Fig. 6
Outside Air Pipe
Knockout
When the appliance is side-wall vented: The air intake is
best located on the same exterior wall as, and lower than the
exhaust vent outlet.
When the appliance is roof vented: The air intake is best
located on the exterior wall oriented towards the prevailing
wind direction, during the heating season.
Rear Cover
Side Cover
The Outside Air Intake Pipe is inside the Rear Cover and to
the right of the feeder motor. The flex pipe is made to slide
inside the Air Intake Pipe. See Fig. 8. It should be held into
place with silicone, foil tape, or a hose clamp. (not supplied)
Feeder Cover
Fig. 7
Negative Pressure and Electrical Power Failure
To reduce the probability of back-drafting or burn-back in the
pellet appliance during a power failure, the appliance must
be able to draft naturally without exhaust blower operation.
Negative pressure in the house will resist this natural draft if
not accounted for in the pellet appliance installation.
Heat rises in the house and leaks out at upper levels. This air
must be replaced with cold air from outdoors which flows into
lower levels of the house. Vents and chimneys into basements
and lower levels can become the conduit for air supply and
reverse under these conditions.
Outside Air Inlet Pipe
Fig. 8
The outside air supply will supply most of the demands of
the pellet appliance to resist back-drafting, but consideration
must be given to the total house demand. It may be necessary
to add additional ventilation to the space in which the pellet
appliance is located. Consult with your HVAC professional
to determine the ventilation demands for your house.
Outside Air
Although strongly recommended, the use of outside
air is optional, except where required by local building
codes. To install outside air, use metal flex pipe, part
# 1-00-08543 (25’ roll) See Fig. 6. There is a break-
away hole on either rear panel which must be removed
before connecting the flex pipe. See Fig. 7. The pipe
should be run outside and terminate 3 feet or more
below or 1 foot or more to the side of the vent pipe
outlet. Never terminate the outside air above the vent
pipe outlet. The maximum length of this pipe is 15
feet. Inlet cover part number 1-10-08542 should be
used to keep birds, rodents etc.out of the inlet pipe.
See Fig.6.
during a loss of electrical power the hopper lid
must be kept in a closed and latched position.
Opening the lid while the combustion blower
is non-operational will allow smoke into the
home and potential overheating of the hopper
and fuel. This can lead to a fire in the hopper.
13
Installation-Plumbing
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER
MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.
TYPICAL BOILER HOT WATER PIPING SHOWING AIR REMOVAL SYSTEM, PROVISIONS FOR THE
EXPANSION OF WATER AND THE AUTOMATIC COLD WATER SUPPLY. ALSO SHOWN BUT NOT
NECESSARILY NEEDED IS THE BOILER BYPASS LINE.THE NECESSITY OF THIS LINE WILL BE
DETERMINED BY THE INSTALLING CERTIFIED PLUMBER OR HVAC CONTRACTOR.
NOTICE: When installing with the Atmospheric Conversion, all of the pressurized system
** THERMOMETER
components shown are not necessary. Air vents or bleeders should be removed from the
AIR VENT
plumbing system to prevent air from entering the lines. Control dipswitch #6 must be“ON”.
AIR SCOOP
SYSTEM SUPPLY 3/4"
SYSTEM SUPPLY 3/4"
SHUT-OFF
VALVE
* AUTOMATIC AIR VENT
* TEMP/PRESSURE
GAUGE
COLD
WATER
PRESSURE REDUCING
SHUT-OFF
VALVE
CHECK VALVE (OR
BACKFLOW
PREVENTER IF
REQUIRED)
SUPPLY 1/2"
* PRESSURE RELIEF VALVE
VALVE (PRV) OR
COMBINATION PRV AND
RELIEF VALVE
BYPASS
VALVE
UNION
EXPANSION TANK
(DIAPHRAGM TYPE)
* 3/4" NPT MALE
PLUG
3/4" BOILER
BYPASS LINE (IF
REQUIRED)
PIPE TO WITHIN
6" OF THE FLOOR
OR A FLOOR
DRAIN
** THERMOMETER
UNION
SYSTEM RETURN 3/4"
SHUT-OFF VALVE
* BOILER DRAIN,
3/4" NPT MALE
3/4" HOSE
X
NOTE: Cold return water temperature (Sustained temperatures below 140 degrees
Fahrenheit) will lead to condensation or moisture in the firebox.This moisture can
lead to creosote formation.To help minimize moisture and creosote, it is strongly
recommended that some method of temperature balance is incorporated into the
return system.
* ITEMS SUPPLIED
** OPTIONAL
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER
MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.
EXAMPLE OF A TYPICAL MULTI-ZONE HEATING SYSTEM WITH BOILER BYPASS AND INDIRECT
DOMESTIC HOT WATER ZONE
NOTICE: When installing with the Atmospheric Conversion, all of the pressurized
EXPANSION TANK, AIR REMOVAL AND COLD WATER SUPPLY
system components shown are not necessary. Air vents or bleeders should be
removed from the plumbing system to prevent air from entering the lines.
Control dipswitch #6 must be“ON”.
** THERMOMETER
BALANCING VALVE
CHECK VALVE
SYSTEM SUPPLY 3/4"
SYSTEM SUPPLY 3/4"
COLD
HOT
* AUTOMATIC AIR VENT
BOILER BYPASS CAN ALSO BE DONE WITH A 3-WAY
MIXING VALVE AND CAN BE CONTROLLED MANUALLY
OR WITH AN AUTOMATIC ACTUATING MOTOR. IF SO,
THE TWO BALANCING VALVES ARE NOT NEEDED
* TEMP/PRESSURE
GAUGE
SHUT-OFF VALVE
DOMESTIC HOT
WATER STORAGE
HEATER WITH
INTERNAL HEAT
EXCHANGER
CIRCULATOR
* PRESSURE RELIEF VALVE
BOILER WATER
SUPPLY WATER
BYPASS (BALANCING) VALVE
UNION
RETURN WATER
* 3/4" NPT MALE PLUG
IN
PIPE TO WITHIN 6" OF THE FLOOR OR A
FLOOR DRAIN
OUT
** THERMOMETER
UNION
SYSTEM RETURN 3/4"
SHUT-OFF VALVE
CHECK VALVE
* BOILER DRAIN, 3/4" NPT MALE X
3/4" HOSE
NOTE: Cold return water temperature (Sustained temperatures below 140 degrees
Fahrenheit) will lead to condensation or moisture in the firebox.This moisture can
lead to creosote formation.To help minimize moisture and creosote, it is strongly
recommended that some method of temperature balance is incorporated into the
return system.
* ITEMS SUPPLIED
** OPTIONAL
14
Installation-Plumbing
Boilers intended to be connected to an existing boiler or boiler system shall:
1. Be capable of being installed without interfering with the normal delivery of heated water from the original boiler to the
radiation system.
2. Be capable of being installed to operate as intended without affecting the operation of the electrical and mechanical safety
controls of the original boiler.
3. Provide, upon completion of the installation, for a change over from one fuel to the other without requiring the manual
adjustment of any controls or components other than the thermostats.
4. Be compatible with the operation of a service water-heating coil within the original boiler without bypassing the operation
of the solid-fuel boiler.
5. Have provision for preventing, or adequate water capacity within the boiler to prevent, damage to the boiler from loss of
circulation due to electrical power failure.
6. Be capable of being installed without changing the function of the control or rewiring of the original boiler. A wiring
interconnection is permitted. The electrical system of both boilers shall be powered from a single branch circuit without
exception.
(CAN/CSA-B366.1-M91)
7. Pertaining to CAN/CSA- B365-01, Have a clearly labelled device, located at each entrance to the boiler area, which can
be thrown to discontinue operation to the feed system.
Anti-freeze and/or boiler water treatment:
There is no restriction on the type of commercial antifreeze used. When filling the boiler water system, it is recommended
that some form of boiler water treatment be used.
EXAMPLE OF PIPING WITH AN INDEPENDENT CIRCULATOR SYSTEM
CONNECTED TO AN EXISTING OPERATIONAL BOILER
NOTICE: When installing with the Atmospheric Conversion, all of the
pressurized system components shown are not necessary. Air vents or
bleeders should be removed from the plumbing system to prevent air
from entering the lines. Control dipswitch #6 must be“ON”.
NOTE: NOT SHOWN IN THIS DRAWING ARE ALL OF THE
ASSOCIATED PIPING AND CONTROLS THAT SHOULD
ALREADY BE IN PLACE WITH THE EXISTING BOILER
SYSTEM. FOR EXAMPLE,THE EXPANSION TANK,THE
COLD WATER SUPPLY , AIR REMOVAL SYSTEM ETC... IT IS
EXTREMELY IMPORTANT THAT THIS BOILER BE
INSTALLED BY A QUALIFIED INSTALLER AND THAT ALL
EXISTING CONTROLS AND SAFETY DEVICES ARE
VERIFIED AS OPERATIONAL.
SYSTEM SUPPLY
BALANCING VALVE
SUPPLY 3/4"
UNION
UNION
IN
SHUT-OFF
VALVE
* AUTOMATIC AIR VENT
* TEMP/PRESSURE
GAUGE
* PRESSURE RELIEF VALVE
EXISTING
BOILER
UNION
CIRCULATOR
PIPE TO WITHIN
6" OF THE
FLOOR OR A
FLOOR DRAIN
OUT
SHUT-OFF VALVE
UNION
UNION
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER
MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.
SHUT-OFF
VALVE
CIRCULATOR
SYSTEM RETURN
SHUT-OFF VALVE
UNION
RETURN 3/4"
NOTE: Cold return water temperature (Sustained temperatures below 140 degrees
Fahrenheit) will lead to condensation or moisture in the firebox.This moisture can
lead to creosote formation.To help minimize moisture and creosote, it is strongly
recommended that some method of temperature balance is incorporated into the
return system.
* ITEMS SUPPLIED
15
Installing Duct
Installation-Plumbing
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED
INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND
LOCATION WITHIN THE PIPING SYSTEM.
EXAMPLE OF PIPING IN SERIES WITH
AN EXISTING OPERATIONAL BOILER
NOTICE: When installing with the Atmospheric Conversion, all of the pressurized
system components shown are not necessary. Air vents or bleeders should be
removed from the plumbing system to prevent air from entering the lines.
Control dipswitch #6 must be“ON”.
SYSTEM SUPPLY 3/4"
NOTE: NOT SHOWN IN THIS DRAWING ARE ALL OF THE
ASSOCIATED PIPING AND CONTROLS THAT SHOULD
ALREADY BE IN PLACE WITH THE EXISTING BOILER SYSTEM.
FOR EXAMPLE,THE EXPANSION TANK,THE COLD WATER
SUPPLY , AIR REMOVAL SYSTEM ETC... IT IS EXTREMELY
IMPORTANT THAT THIS BOILER BE INSTALLED BY A
QUALIFIED INSTALLER AND THAT ALL EXISTING CONTROLS
AND SAFETY DEVICES ARE VERIFIED AS OPERATIONAL.
OUT
IN
* AUTOMATIC AIR VENT
* TEMP/PRESSURE
GAUGE
SHUT-OFF VALVE
* PRESSURE RELIEF VALVE
UNION
EXISTING BOILER
* 3/4" NPT MALE PLUG
PIPE TO WITHIN 6" OF THE FLOOR OR A
FLOOR DRAIN
UNION
SYSTEM RETURN 3/4"
SHUT-OFF VALVE
* BOILER DRAIN, 3/4" NPT MALE X 3/4" HOSE
NOTE: Cold return water temperature (Sustained temperatures below 140 degrees
Fahrenheit) will lead to condensation or moisture in the firebox.This moisture can
lead to creosote formation.To help minimize moisture and creosote, it is strongly
recommended that some method of temperature balance is incorporated into the
return system.
* ITEMS SUPPLIED
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER
MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.
EXAMPLE OF PIPING IN PARALLEL WITH
AN EXISTING OPERATIONAL BOILER
NOTICE: When installing with the Atmospheric Conversion, all of
the pressurized system components shown are not necessary.
Air vents or bleeders should be removed from the plumbing
system to prevent air from entering the lines. Control dipswitch
#6 must be“ON”.
SYSTEM SUPPLY 3/4"
BALANCING
VALVE
BALANCING
VALVE
NOTE: NOT SHOWN IN THIS DRAWING ARE ALL OF THE
ASSOCIATED PIPING AND CONTROLS THAT SHOULD
ALREADY BE IN PLACE WITH THE EXISTING BOILER
SYSTEM. FOR EXAMPLE,THE EXPANSION TANK,THE
COLD WATER SUPPLY , AIR REMOVAL SYSTEM ETC... IT IS
EXTREMELY IMPORTANT THAT THIS BOILER BE
INSTALLED BY A QUALIFIED INSTALLER AND THAT ALL
EXISTING CONTROLS AND SAFETY DEVICES ARE
VERIFIED AS OPERATIONAL.
UNION
UNION
OUT
* AUTOMATIC AIR VENT
* TEMP/PRESSURE
GAUGE
IN
* PRESSURE RELIEF VALVE
UNION
EXISTING
BOILER
* 3/4" NPT MALE PLUG
PIPE TO WITHIN
6" OF THE
FLOOR OR A
FLOOR DRAIN
SHUT-OFF
VALVE
SYSTEM RETURN 3/4"
SHUT-OFF VALVE
UNION
* BOILER DRAIN, 3/4" NPT MALE
X 3/4" HOSE
NOTE: Cold return water temperature (Sustained temperatures below 140 degrees
Fahrenheit) will lead to condensation or moisture in the firebox.This moisture can
lead to creosote formation.To help minimize moisture and creosote, it is strongly
recommended that some method of temperature balance is incorporated into the
return system.
* ITEMS SUPPLIED
16
Installing Duct/Air Conditioning
Installation-Plumbing
TYPICAL BOILER HOT WATER PIPING SHOWING AIR REMOVAL SYSTEM, PROVISIONS FOR THE
EXPANSION OF WATER AND THE AUTOMATIC COLD WATER SUPPLY. ALSO SHOWN IS THE AUTOMATIC
MIXING VALVE.THIS COULD ALSO BE DONE BY (2) CLOSELY SPACED TEE'S.THE PROPER PIPING FOR THE
INTENDED USE WILL BE DETERMINED BY THE INSTALLING CERTIFIED PLUMBER OR HVAC CONTRACTOR.
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER
MOUNTING POSITION AND LOCATION WITHIN THE PIPING SYSTEM.
NOTICE: When installing with the Atmospheric Conversion, all of the
** THERMOMETER
pressurized system components shown are not necessary. Air vents or
AIR VENT
bleeders should be removed from the plumbing system to prevent air
from entering the lines. Control dipswitch #6 must be“ON”.
AIR SCOOP
SYSTEM SUPPLY 3/4"
AUTOMATIC
MIXING VALVE
SHUT-OFF
VALVE
SHUT-OFF VALVE
* AUTOMATIC AIR VENT
COLD WATER
SUPPLY 1/2"
* TEMP/PRESSURE
GAUGE
EXPANSION TANK
(DIAPHRAGM TYPE)
* PRESSURE
RELIEF VALVE
UNION
CHECK VALVE (OR BACKFLOW
PREVENTER IF REQUIRED)
PRESSURE REDUCING VALVE
(PRV) OR COMBINATION PRV
AND RELIEF VALVE
* 3/4" NPT MALE PLUG
PIPE TO WITHIN 6" OF THE
FLOOR OR A FLOOR DRAIN
** THERMOMETER
SENSING BULB
UNION
SHUT-OFF VALVE
SYSTEM RETURN 3/4"
* BOILER DRAIN, 3/4" NPT
MALE X 3/4" HOSE
NOTE: Cold return water temperature (Sustained temperatures below 140 degrees
Fahrenheit) will lead to condensation or moisture in the firebox.This moisture can
lead to creosote formation.To help minimize moisture and creosote, it is strongly
recommended that some method of temperature balance is incorporated into the
return system.
* ITEMS SUPPLIED
** OPTIONAL
EXAMPLE OF TYPICAL TANKLESS DOMESTIC HOT WATER PIPING
TEMPERED HOT WATER TO
HIGH TEMPERATURE WATER
SHOWERS AND FAUCETS
( IF NEEDED )
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER
MOUNTING POSITION AND LOCATION WITHIN THE PIPING
SYSTEM.
CUSTOMER SUPPLIED SS
PLATE HEAT EXCHANGER
MIXING VALVE
SHUT-OFF VALVE
MIXING VALVE SET TO DESIRED WATER TEMPERATURE.
NORMALLY NOT MORE THAN 120 DEGREES.
INLET
DOMESTIC WATER
OUTLET
HOSE BIB TO BACKFLUSH COIL IF NEEDED
OUTLET
DOMESTIC WATER
INLET
SAFETY RELIEF VALVE
SHUT-OFF VALVE
ISOLATION VALVE
FLOW REGULATOR
HOSE BIB
COLD WATER SUPPLY
FLOW REGULATOR WILL NEED TO MATCH THE GPM RATING OF THE DOMESTIC COIL.
17
Installation-Plumbing
EXAMPLES OF TYPICAL DOMESTIC HOT WATER STORAGE PIPING
EXAMPLE #2
EXAMPLE #1
CAUTION: No domestic water
temperature
CAUTION: No domestic water
temperature
HIGHER
regulation shown
TEMPERATURE
WATER (IF NEEDED)
regulation shown
FROM BOILER
FROM BOILER
TEMPERED HOT WATER FOR
SHOWERS AND FAUCETS
COLD
HOT
COLD
HOT
MIXING VALVE
MIXING VALVE SET TO DESIRED WATER TEMPERATURE.
NORMALLY NOT MORE THAN 120 DEGREES.
DOMESTIC HOT
WATER STORAGE
HEATER WITH
INTERNAL HEAT
EXCHANGER
CIRCULATOR
DOMESTIC HOT
WATER
STORAGE
CIRCULATOR
HEATER WITH
INTERNAL HEAT
EXCHANGER
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED
INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND
LOCATION WITHIN THE PIPING SYSTEM.
IN
IN
TO BOILER
OUT
TO BOILER
OUT
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED
INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND
LOCATION WITHIN THE PIPING SYSTEM.
EXAMPLE OF A TYPICAL MULTI-ZONE HEATING SYSTEM WITH A SINGLE
CIRCULATOR AND INDIVIDUAL ZONE VALVES
NOTICE: When installing with the Atmospheric Conversion, all
of the pressurized system components shown are not
necessary. Air vents or bleeders should be removed from the
plumbing system to prevent air from entering the lines. Control
dipswitch #6 must be“ON”.
AIR VENT (TYPICALLY
INSTALLED IN THE HIGHEST
ACCESSABLE LOCATION IN
THE PIPING)
AIR VENT
BALANCING
VALVE
FROM ADDITIONAL ZONES
ZONE 1
ZONE 2
ZONE 3
ZONE VALVE
UNION
CIRCULATOR
TO ADDITIONAL ZONES
FROM BOILER
SHUT-OFF VALVE
UNION
SYSTEM SUPPLY 3/4"
TO BOILER
NOTE: Cold return water temperature (Sustained temperatures below
140 degrees Fahrenheit) will lead to condensation or moisture in the
firebox.This moisture can lead to creosote formation.To help minimize
moisture and creosote, it is strongly recommended that some method
of temperature balance is incorporated into the return system.
SYSTEM RETURN 3/4"
18
Installation-Plumbing
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS RECOMMENDED
INSTALLATION INSTRUCTIONS FOR THE PROPER MOUNTING POSITION AND
LOCATION WITHIN THE PIPING SYSTEM.
EXAMPLE OF A COMBINATION HIGH/LOW MULTI-ZONE HEATING SYSTEM
WITH INDIVIDUAL ZONE CIRCULATORS
NOTICE: When installing with the
Atmospheric Conversion, all of the
(HIGH TEMPERATURE) BASEBOARD HEAT
pressurized system components
shown are not necessary. Air vents or
(LOW TEMPERATURE) RADIANT FLOOR HEAT
bleeders should be removed from the
plumbing system to prevent air from
entering the lines. Control dipswitch
#6 must be“ON”.
(LOW TEMPERATURE) RADIANT FLOOR HEAT
AIR VENT
AIR VENT (TYPICALLY
INSTALLED IN THE HIGHEST
ACCESSABLE LOCATION IN
THE PIPING)
NOTE: IF CIRCULATOR DOES NOT HAVE
CHECK VALVE THEN A FLOW CONTOL
VALVE WILL ALSO BE NEEDED AND
INSTALLED IN THIS LOCATION
SHUT-OFF VALVE
CIRCULATORS WITH INTEGRAL
CHECK VALVE (SEE NOTE)
ZONE 3
ZONE 2
ZONE 1
MIX
UNION
SHUT-OFF VALVE
HOT
COLD
FROM BOILER
SYSTEM SUPPLY 3/4"
THERMOSTATIC
MIXING VALVE
NOTE: Cold return water temperature (Sustained temperatures below 140 degrees
Fahrenheit) will lead to condensation or moisture in the firebox.This moisture can lead to
creosote formation.To help minimize moisture and creosote, it is strongly recommended
that some method of temperature balance is incorporated into the return system.
TO BOILER
SYSTEM RETURN 3/4"
HOT WATER
HEATING COIL
TO BE SIZED
EXAMPLE OF A TYPICAL FORCED HOT AIR HEATING SYSTEM
WITH THE BOILER DIRECT TO AN IN DUCT HOT WATER COIL
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE
BY INSTALLER
NOTICE: When installing with the Atmospheric Conversion, all of the
pressurized system components shown are not necessary. Air vents
or bleeders should be removed from the plumbing system to prevent
air from entering the lines. Control dipswitch #6 must be“ON”.
PROPER MOUNTING POSITION AND LOCATION WITHIN THE
PIPING SYSTEM.
AIR VENT
AIR FLOW
AIR FLOW
FLOW CHECK
SYSTEM SUPPLY 3/4"
* AUTOMATIC AIR VENT
* TEMP/PRESSURE
GAUGE
* PRESSURE RELIEF VALVE
EXISTING
GAS / OIL
FURNACE
OR
PURGE & BALANCE
VALVE
SHUT-OFF
UNION
VALVE
ELECTRIC
HEAT
PUMP
RETURN
AIR FLOW
* 3/4" NPT MALE PLUG
PIPE TO
WITHIN 6" OF
THE FLOOR
OR A FLOOR
DRAIN
NOTE: NEVER INSTALL HOT WATER
COIL ON THE RETURN SIDE
OF THE HEATING SYSTEM
SHUT-OFF VALVE
CIRCULATOR
UNION
SYSTEM RETURN 3/4"
SHUT-OFF VALVE
* BOILER DRAIN,
3/4" NPT MALE
3/4" HOSE
X
COLD
WATER
SUPPLY 1/2"
* ITEMS SUPPLIED
CHECK VALVE (OR BACKFLOW
PREVENTER IF REQUIRED)
PRESSURE REDUCING VALVE
(PRV) OR COMBINATION
PRV AND RELIEF VALVE
EXPANSION TANK
(DIAPHRAGM TYPE)
(SIZED FOR TOTAL
SYSTEM VOLUME)
NOTE: Cold return water temperature (Sustained temperatures below 140 degrees Fahrenheit)
will lead to condensation or moisture in the firebox.This moisture can lead to creosote
formation.To help minimize moisture and creosote, it is strongly recommended that some
method of temperature balance is incorporated into the return system.
19
Installation with A hot Air System
Electrical interconnection of the BH60 to an existing heat pump, or fuel-fired hot air furnace:
Interconnection with a heat pump will generally require a second thermostat to be installed. It is recommended
that a new electronic thermostat be installed as close to the existing thermostat as possible. Installing within one
foot of the existing thermostat is recommended for ease of interconnection and similar temperature sensing ability.
If programmability is desired, both thermostats should have this capability. If only the new thermostat is
programmable, you’ll need to keep the existing thermostat set several degrees below the lowest programmed
temperature setting of the new thermostat. NOTE: In this configuration, if the BH60 cannot maintain the desired
thermostat setting, the room will be allowed to cool to the lower set point of the existing thermostat before allowing
the heat pump to operate.
Special note: Even if the heat pump has a multi-stage thermostat, it cannot be re-wired to make the first stage control
the BH60, and the second stage control the heat pump. All multi-stage heat pump thermostats are interconnected
so that the compressor unit and/or the changeover solenoid activate with the first stage only.
Controlling the existing furnace fan during overheat situation.
Following the wiring diagram on the next page, you will need to supply and install a piece of 18/3 Thermostat
wire between the low-voltage control terminal strip on the upper left-hand side of the BH60’s control cover, to the
low-voltage control of the existing furnace.
Note: Some systems may have external terminals and some may have them enclosed within the unit. If the
connections to the exisitng system need to be made internally, be sure to use the proper protective grommet
or connector where passing through the cabinet of the existing unit.
If the wiring used does not match the colorings listed, follow the corresponding numbers on the terminal strips
to ensure proper connection.
Step 1. Disconnect electrical power to the existing heating system.
Step 2. Install the above mentioned thermostat wire between the two systems
Step 3. Connect the three (3) wires to the BH60 control terminal strip as indicated.
Step 4. Remove the green wire which comes from the exisiting thermostat and connects to the terminal marked
“G” on the existing system and splice it to the green (or #1) wire from the BH60.
Step 5. Connect the white wire (or #5) from the BH60 to the “G” terminal of the existing system. This white wire
should be the only wire connected to “G”.
Step 6. Now, the red (#3) wire from the BH60 should be added to the “R” terminal of the existing system. Do not
remove or replace any existing wires from “R”, just add this one to them.
Restore power to the existing system only. Using the existing thermostat, increase the setting to verify that the
system works as it did prior to the interconnection. Increase and decrease the thermostat a few times to verify
proper reaction. In the case of a heat pump system, be sure the outdoor compressor unit is also cycling. Notice:
Most compressors have a built in lockout timer (usually 5 minutes) so you may need to wait between thermostat
adjustments to verify proper operation.
Once you are certain that nothing changed with the operation of the existing system, turn the existing system’s
thermostat down far enough that it won’t come on during the test. Connect power to the BH60, and turn on the
circuit breaker on the front of the unit. With the control in the “OFF” position, turn the feed adjuster knob to “Test”.
When the OVERHEAT SAFETY ZONE light illuminates, the fan on the existing system should come on. Be sure
that the fan is the only thing on. There should be no power to the compressor or the oil or gas burner.
20
Installation with A hot Air System
Existing T'stat
New T'stat
set 3° below new t'stat
set 3° above existing t'stat
W1 O/B
W1 O/B
L
Y
G
R
C
L
Y
G
R
C
SPLICE
( by installer )
Existing T'stat
Wiring
New T'stat Wire
( by installer )
LOW VOLTAGE
SPLICE
( by installer )
W1 O/B
L
Y
G
R C
Through grommet
in control cover
LOW VOLTAGE
LOW VOLTAGE 24 VAC COIL
( by installer )
New T'stat Wire
( by installer )
8
7
HIGH VOLTAGE ( L1 )
L
6
5
( by installer )
N
4
3
1
R2 RELAY
Grainger# 2XC01- Omron LY2F 24V
( by installer )
HIGH VOLTAGE ( N )
HIGH VOLTAGE ( ORANGE) from control board
8
7
SPLICE
( by installer )
6
5
4
3
1
R1 RELAY
Grainger#2XC02-Omron LY2F 120V
3
5
1
RED
WHITE
GREEN
O/A sensor terminals
The top three screws only
on the 5 pole terminal strip
21
Installation with A hot Air System - fan only capable
Existing T'stat
New T'stat
set 3° below new t'stat
set 3° above existing t'stat
W1 G
R
C
W1 G
R
C
SPLICE
( by installer )
New T'stat Wire
( by installer )
Existing T'stat
Wiring
LOW VOLTAGE
Through grommet
in control cover
LOW VOLTAGE
LOW VOLTAGE 24 VAC COIL
( by installer )
New T'stat Wire
( by installer )
8
7
HIGH VOLTAGE ( L1 )
L
6
5
( by installer )
N
4
3
1
R2 RELAY
Grainger#2XC01-
Omron LY2F 24V
( by installer )
HIGH VOLTAGE ( N )
HIGH VOLTAGE ( ORANGE) from control board
8
7
SPLICE
( by installer )
6
5
4
3
1
R1 RELAY
Grainger#2XC02-
Omron LY2F 120V
O/A sensor terminals
The top two screws only
on the 5 pole terminal strip
22
Connection with a 2-wire hot air system
EXISTING BURNER / FAN SYSTEM
( GAS, OIL, ELECTRIC)
n
e t R u r
e u N t
o t H
e t R u r
n
o t H
factory wiring
to circulator outlet
23
Connection with a wireless thermostat
WIRELESS THERMOSTAT WIRING
BROWN to control board
LT.BLUE to control board
BROWN
LT.BLUE
L
N
GREEN/YELLOW
Installer Supplied
Wireless T’stat
Receiver
ORANGE from control
VIOLET from control
GREEN/YELLOW
8
7
WHITE
RED
6
5
4
3
1
GREEN
R1 RELAY
Grainger#2XC02
Omron LY2F 120V
LOW VOLTAGE
LT.BLUE
BROWN
BROWN
1.5 AMP
AUX. OUTLET
NON SWITCHED,
CIRCUIT BREAKER
PROTECTED
2 AMP-CONTROLLED
CIRCULATOR OUTLET
/AUX. DUMP ZONE
EXTERNAL WIRING FOR UNITS WITH 4 POLE TERMINAL STRIP
WHEN USING AN RC T'STAT or OTHER DUAL T'STATS
INSIDE EXISTING HVAC CONTROL SECTION
EXISTING THERMOSTAT WIRE
WIRENUT SPLICE
8
7
R2 RELAY
Grainger #2XC01
Omron LY2F 24V
GREEN
6
5
RED
4
3
1
GREEN
GREEN
( by INSTALLER )
R
G
Y
O/B
C
L
W1
18/2 THERMOSTAT WIRE
( by INSTALLER )
4 POLE TERMINAL STRIP
LEFT SIDE OF CONTROL COVER
R1
RED
BLUE
3
5
FAN/ZONE CONTRL
FAN/ZONE CONTRL
3
5
N.O. contacts
WHITE
BLUE
OUTSIDE AIR SENSOR
OUTSIDE AIR SENSOR
EXISTING INTERNAL WIRING of HF60
24
Installation
Draft Test Procedure
After the venting is completed, the firebox draft will need
to be checked and possibly adjusted.After removing the
plug bolt from the draft hole (3/16” hex key wrench)
shown in Fig. 9, insert the draft meter tube. The hopper
lid must be latched during this test. (It is recommended
that the draft meter have a scale of 0 to 1” WC.)
Turn the feed adjuster to “Test”. this will start the
combustion blower and allow you to check and record
the High Draft ______ - IWC date _______ The
maximum draft allowed is -.9” Water Column (-224 Pa).
There is no adjustment for the High Draft, other than
re-positioning the combustion blower fan blade on its
shaft, or a change in the venting configuration.
After the first 60 seconds the “Test” mode lowers the
combustion blower voltage to the Low Burn voltage.
During this lowered voltage cycle, the Low Draft must
be checked and adjusted if necessary. The recommended
low draft setting should be between -.45 and -.55 IWC.
Depending on the amount of vertical rise, it may not be
possible to get a low draft reading in this range. In this
case, re-positioning the fan blade further on the motor
shaft may be helpful.
Draft
Testing Port
Fig. 9
“Test”
There is a low draft voltage adjustment screw located
through the small hole to the right of the Igniter Light.
See Fig. 10. Adjusted Low Draft is __________ -IWC.
To increase the draft in higher altitudes, kit #
1-00-232059 High Altitude Intake Reduction, may be
needed.
Don’t forget to turn the feed adjuster off of “Test”, and
Low Draft
Adjustment Pot
reinstall the draft test plug bolt into the boiler.
CAUTION: Hot While In Operation. Do
Not Touch. Keep Children, Clothing And
Furniture Away. Contact May Cause Skin
Burns. See Nameplate And Instructions.
Fig. 10
High altitude kit #1-00-232059.
Install this ring to increase draft in higher altitude
installation locations.
WARNING: Keep Doors Closed During
Operation.
WARNING: Do Not Store Fuel or Other
Combustible Material Within Installation
Clearance Area.
WARNING: Risk of Fire - Do Not Operate
With the Flue Draft Exceeding -.9” Water
Column (-224 Pa).
25
Operation
Power Light
Feed adjuster
Indicates power to the
control board. (Ready)
Sets the maximum feed rate
Test
Combustion blower, feed motor
and safety dump zone are fully
energized for the first minute.
Then, the combustion blower
will stay on low.
Status Light
Will be lit anytime the unit is
in operation.
Overheat Saftey Zone Light
Indicates that the boiler water
temperature has reached 210
Degrees F.
Lighting Mode Selector
Switched between Auto and
Manual lighting.
Mode Selector/Min Temp
Dial
Used to turn the boiler on
or off and set the desired
minimum operating
temperautre of the boiler.
Combustion Blower Light
Indicates Power to
combustion blower
Feed Motor Light Indicates
Power to the feed motor.
Diagnostic Port
For maintenance only.
Requires special DDM monitor
supplied to trained technicians
exclusively.
Igniter Light
Indicates power to the igniter
Max Temp dial
The “Max Temp Dial” is used to set the desired maximum operating temperature
of the boiler.
Status light error messages:
7 Blinks: Boiler water overheat saftey shut down. This
requires a manual reset by cycling the main power off for a
few seconds and re-connect.
3 Blinks: Indicates that the ESP (Exhaust Sensing Probe)
has gone out of range too many times. If the unit is operating
correctly, perform a manual reset by cycling the main power
off at the circuit breaker for a few seconds. If the 3 blinks
persist, contact your service technician.
Explanation and Importance of the OverHeat Safety Zone
When the unit is operating at High burn, and all demand from
the heating system stops, the control will reduce the feed
rate and shut down completely as necessary. This may take
several minutes, and the remaining heat may cause the water
temperature to continue to rise. When the water temperature
gets too high, the OVERHEAT SAFETY ZONE light on the
control will illuminate and the relay R1 is energized. This will
close contacts #5 and #3 (Fan Contacts on the interconnection
Page 20), and will also energize the controlled circulator
outlet, for the hot water dump zone.
4 Blinks: Indicates mis-communication with the aquastat, or
the aquastat is not attached properly. May require a manual
reset (turn off power at circuit breaker). Note that in some
optional control methods, this status will occur during normal
operation and reset automatically.
5 Blinks: (InAuto Light Mode Only) Indicates that the igniter
has failed to light the fire after 40 Minutes. To reset - Turn
the Mode Selector/Min. Temp. to OFF and then back to the
desired temperature.
When using a hot water coil in an air duct system, if you
do not want the living space heated beyond the thermostat
setting during an over heat dump, an alternate dump zone
will need to be installed and some internal control re-wiring
will be necessary.
6 Blinks: Indicates that the control has calculated poor or
incomplete combustion occurring for 25 or more minutes.
A six blink status may occur if the stove is allowed to run
out of pellets. To reset, turn Mode Selector/Min Temp dial
to “OFF” then back on to the desired temperature. If the unit
was not out of pellets, see Troubleshooting section, Page 38,
for more details.
label from unit control panel showing outlets
26
Operation
Setting The Boiler Temperature
Without the Outdoor Air Temp - Sensor Installed
To set the maximum boiler water temperature, simply
turn the Max. Temp. water temperature dial to the
desired setting. The control and the boiler will then
perform to achieve and maintain the set temperature.
The Min. Temp. Knob is the boiler water temperature
minimum, or the lowest temperature the water will
go before the unit re-starts. Turning the knob fully
counterclockwise is the “OFF” position, while turning
the knob clockwise, past the 140 degree marking, is the
“ON” position.
With The Outdoor Air Temp - Sensor Installed
Maximum boiler temp setting is as described above,
with the added feature of automatic maximum water
temp controlled by the OAT sensor.
The MIN. TEMP. knob, in addition to being the mode
setting (on or off), also has the function of setting the
minimum boiler water temperature. This would be the
lowest boiler water temperature that you want to have
based on the following factors;
WATER TEMPERATURE
1.) Outdoor Air Temperature (OAT)
2.) Domestic Hot Water Use
a.) Hot Water Coil Option
b.) Indirect Hot Water Storage
3.) Overall Volume of the Heating System
MAX. TEMP.
Control Board Operation
MIN. TEMP.
Aquastat Sensor - This sensor is located behind the
control panel. This sensor, along with the outdoor air
sensor, is what the control board uses to regulate the burn
rate based on the observed conditions. (Boiler Temp. &
Outdoor Air Temperature)
The boiler is designed to withstand lower return water
temperatures. However, extended return temperatures below
140 degrees F can cause condensation.
Outdoor Air Temp - Sensor (OAT): This sensor is
located outside the building (on the north side of the
house and out of direct sunlight). The Outdoor Air
Sensor is used to perform hot water reset based on
outdoor air temperatures.
When the OAT sensor is installed, at 20° F. or below
(outside temperature), the boiler will operate at the
temperature set on the MAX. TEMP. knob. The boiler
water temperature will decrease by 1 degree F. for
every 1 degree F. in temperature rise (above 20°) of the
outdoor air.
NOTE:
If the system is run at the lower temperature settings,
conditions of the firebox, boiler tubes, secondary ash chamber
and venting should be monitored closely. If any indications
show excess condensation, the boiler water temperature will
need to be increased until condensation does not occur.
NOTE: Pellet Boiler Outdoor Air Reset Operation
Graph located on page 28.
27
Operation
28
Operation
Starting A Fire Automatically
1. Turn Mode Selector to “OFF”.
This resets the control in addition to turning it off.
2. Clean Burnpot with scraper.
This is typically a weekly maintenance procedure, but,
depending on the fuel being burned, may need done
more frequently. Cleaning the burn pot with the scraper
with a small amount of new fuel in the bottom is not a
problem. First, scrape the ashes from the front of the
burn pot into the ash pan. Then scrape the hole grid
surface downward into the burn pot. When the stove is
ignited these scrapings will be pushed out by the feeder.
CAUTION: Wear Heat-Resistant GlovesTo Perform
The Scraping Procedure.
Access the burnpot through the firebox door. Scraping
can be done while the unit is in operation. *see caution
3. Fill Hopper with pellets.
Before refilling the hopper, check for excessive fines
in the bottom of the hopper. Fines are small pieces of
broken pellets (sawdust). Fines do not flow easily and
often build up on the hopper funnel bottom angles.
These fines can be pushed into the feeder opening and
then fill the hopper with pellets. As the system works,
they will be burned.
29
Operation
4. If Starting After an Empty Hopper, Turn Feed
Adjuster to “TEST” (for one 60 second cycle). This
will charge pellets into the auger tube and also allow
you to check the motors for operation. NOTE: The
auger motor will not operate with any of the doors
or hopper lid open.
5. Turn Feed Adjuster to #5.
If this is your first fire or you are trying a new fuel, set
the feed adjuster to #5. This setting works well with the
average wood pellets, but may need adjusted for your
particular fuel. After you know a feed rate setting that
works well for your application, stick with that setting.
NOTE: You know your feed rate is too high when:
The overheat safety feature is energized each time the
heating zone demand turns off during a high burn. OR,
If unburned or partially burned pellets are found in the
ash pan. (this may also indicate a need for scraping the
burn pot)
If you need to keep the feed adjuster on it’s maximum
setting, your unit is under-sized for the heating system.
Continuous operation at maximum burn rate may cause
pre-mature failure of the firebox baffles.
Note: The firebox baffles (#1-10-232052) are
considered to be a consumable item, and are
therefore not covered by the product warranty.
6. Flip the IgniterSwitch up into the “AUTO” position.
due to low water temperature, the initial start will be
a longer process than when the water temperature
is closer to the minimum setting.
WATER TEMPERATURE
7. Turn the MAX. TEMP. Dial on the control board to
the desired temperature. This setting must always be at
least 5° F. higher than the MIN. TEMP. setting.
WARNING: HOT WHILE IN OPERATION.
KEEP CHILDREN, CLOTHING, AND
FURNITURE AWAY. CONTACT MAY CAUSE
SKIN BURNS.
MAX. TEMP.
MIN. TEMP.
30
Operation
7. Open the firebox door to access the burnpot.
8. Turn the MIN. TEMP. Dial on the control board
to the desired Minimum temperature. This will start the
lighting process if the temperature at the aquastat sensor
is approximately 5° F. less than the set temperature on the
MAX TEMP. dial.
Fig. 13
9. Fill hopper with pellets and remove ashes as required.
8. Fill the burnpot with pellets as shown.
See Fig. 14. Only fill level with the front edge.
( ------- DO NOT OVERFILL ------- )
Type of Fuel
Use pelletized wood only. The lower the ash content of
the pellets the less cleaning that will be needed of the heat
exchanger tubes. The cleaner these tubes are kept, the more
efficient the boiler will be.
NOTE: Do not burn garbage, gasoline, naphtha, engine oil,
or other inappropriate materials in this appliance.
Store pellets in the manufacturer’s wrapping until needed
to prevent pellets from absorbing moisture. Do not store
fuel within the appliance installation clearances, or within
the space required for fueling, ash removal, and other
routine maintenance operations.
Fig. 14
9. Have matches or other ignition source ready.
Never attempt to start a fire if there is no power
or if the combustion blower is not operating.
10. Turn Mode Selector to desired MIN TEMP setting.This
will start the combustion blower and allow the ESPto control
the fire in relation to the MAX TEMPDial setting. (The MAX
TEMP dial setting must always be set above the MIN TEMP
setting) Once the fire is well established the MAX TEMPdial
can remain on any temperature setting desired.
Never open the hopper lid during a fire if there
is no power or if the combustion blower is not
operating.
Lighting A Fire Manually
DURING MANUAL OPERATION:
Lighting the fire manually will not be necessary unless
the ignition system fails.
SPECIAL NOTE: When the Switch is set to Manual
ignite position, the boiler will function as in auto mode,
except the fire will not be allowed to go out. It will only
be allowed to go to a minimum burn rate between the
times the aquastat is calling for heat. This rate is about
1.1 pound of fuel per hour. If used in manual mode, be
sure there is an overheat dump in place. Note that if the
overheat dump zone does not provide sufficient cooling,
and the water temperature continues to rise, the feed
motor will be forced to shut off. Because the unit is set
on Manual Ignition, it will not re-ignite when the water
temperature cools below the settings.
Follow steps 1 through 5 of the instructions for automatic
lighting.
6. Flip the Igniter Switch Down into the “MANUAL-
LIGHT” position. See Fig. 12.
Fig. 12
31
Operation
11. Apply starting gel as shown in Fig.15
12. Light The Starting Gel With A Match.
13. Close The Doors
Fig. 15
The fire will light and the control will adjust the rate of
burn to the proper level, according to the MAX TEMP
dial setting.
NOTE: Stirring the starting gel into the pellets usually
allows the fire to become established quicker.
CAUTION: Avapor flash could occur if too much time
is allowed to pass before lighting the starting gel.
NOTICE: when burning the boiler in the
manual ignition mode, there must be an
overheat dump zone incorporated into the
plumbing system.
CAUTION: Care must be taken not to get starting gel
on your hands or clothing. Serious burns could occur
during the lighting process.
CAUTION: Never try to apply more starting gel to an
already burning fire, or a fire with smoldering pellets.
If heating demand stops during manual operation, the
control will take the unit to low burn. If no heat is used
during this time, the water temperature may continue
to rise to the point at which the feeder will be turned
off and the fire will go out. This will require a manual
re-start of the system. (see page 26 “7 Blinks”)
“NEVER USE GASOLINE, GASOLINE-TYPE
LANTERN FUEL, KEROSENE, CHARCOAL
LIGHTER FLUID, OR SIMILAR LIQUIDS TO
START OR “FRESHEN UP “ A FIRE IN THIS
BOILER. KEEP ALL SUCH LIQUIDS WELL
AWAY FROM THE UNIT WHILE IN USE”.
Solid-fuel burning appliances need to be cleaned
frequently because soot, creosote, and ash may
accumulate. If you suspect a chimney/vent pipe fire do
the following:
1. Call the fire department.
2. Remove fuel from the burn pot using the burnpot
scraping tool to scrape the pellets into the ash pan.
3. Remove the ash pan from the unit and take outside.
Do not place the ash pan on a combustible material.
4. Turn off circuit breaker at unit.
Fig. 16
5. Do not use the unit until a qualified person has
inspected your appliance and venting.
32
maintenance
Burnpot Cleaning:
Scrape the burnpot to
remove any carbon
deposits which may
have formed.
The burnpot should be cleaned no less than once a week.
For best operation the burnpot should be cleaned every
time the hopper is filled with pellets. The fire does not have
to be out to scrape the burnpot although it is recommended
the boiler be on minimum burn at the time of cleaning.
Scraping can be done
while the boiler is in
operation, accessed
through the firebox
door opening. Wear
gloves to protect
from burns.
CAUTION: Wear Gloves To Prevent Burns.
Use the flat end of the scraper provided to scrape down over
the holed surface of the burnpot grate. See Fig. 17. It is
not necessary to clean out the scrapings from this cleaning
because they will be pushed out as the auger operates.
Note: Make a special effort to scrape the bottom inside
corners of the burnpot where the auger tube enters the
burnpot. Carbon deposits can build up over time in this
area that may cause a restriction to the flow of pellets into
the burnpot.
Note: The end of the scraper may need sharpened
occasionally, for best results.
Fig. 17
While scraping the burnpot, you can also use the scraper tool
to tap on each of the visible heat exchange spirals. This will
help to maintain maximum efficiency between cleanings.
Cleaning the Burnpot Air Chamber:
This area only needs to be cleaned twice a heating season,
unless excessive buildup is noticed during scheduled
cleanings.
There is a cover on the front of the burnpot to gain access to
the air chamber. The cover is held into place by two thumb
screws. Loosen the thumb screws and remove the cover. See
Fig. 19. The air chamber can be cleaned of any ash that has
fallen through the holes during operation and cleaning.
Burnpot
cleanout cover
NOTE: ALWAYS REMEMBER TO CLOSE THE CLEANOUT
COVER AFTER CLEANING.
Feeder Chamber (Fig. 20):
Fig. 19
This chamber may get a buildup of fines from the feeder
mechanism movement. This area should be checked and
cleaned at least once a year.
To remove the feeder cover:
• Loosen the 5/16” wing nut.
Fines area
• Slide the cover off of the threaded stud and lift upward.
• Inspect and clean the inner chamber as necessary. See Fig. 20.
• There is a removable plate in this area that deflects fines
into the auger. To remove this plate, roll it out under the
pusher arm.
• Reinstall the cover making certain it is centered on the feeder
body and hand-tighten the wing nut.
Feeder cover Fig. 20
33
maintenance
Inner Refractory Lining
The firebox and heat exchanger tube access areas are
lined with high-temperature, fibrous ceramic insulation
panels (much like spacecraft tiles). The surface of these
panels is hardened to resist normal wear from brushing
with a non-metal brush. The panels are not designed
to be cleaned with the scraper or other sharp objects.
Caution must be taken when cleaning these panels
because damage to them is not covered by the warranty.
The ash pan slides into the unit on a rail system.This keeps
the ash pan from contacting the sides and floor refractory
panels. Caution must be taken to ensure there is nothing on
the floor surface prior to inserting the ash pan.
Ash Removal
It is recommended to remove the ashes when the boiler
is not in operation. This lessens the chances of coming in
contact with hot surfaces. Ashes can be removed while
in operation but, extra care must be taken including
wearing protective gloves.
Firebox Refractory
Linings
Open The Firebox Door
Swing the latch downward and open the door as shown in
fig. 21.
Fig. 21
NOTE: Keep hopper lid, and firebox door closed during
operation and maintain all seals in good condition. Air
leaks will cause low draft conditions, which will result
in feeder shutdown.
Soot and Flyash: Formation and Need for
Removal
Disposal of Ashes:
Ashes should be placed in a steel container with a
tight fitting lid. The closed container of ashes should
be moved outdoors immediately and placed on a non-
combustible floor or on the ground, well away from all
combustible materials, pending final disposal. If ashes
are disposed of by burial in soil or otherwise locally
dispersed, they should be retained in the closed container
until all cinders have thoroughly cooled. Other waste
shall not be placed in this container.
The products of combustion will contain small
particles of flyash. The flyash will collect in the exhaust
venting system and restrict the flow of the flue gases.
Incomplete combustion, such as occurs during startup,
shutdown, or incorrect operation of the boiler will lead
to some soot formation which will collect in the exhaust
venting system. The exhaust venting system should
be inspected at least twice monthly until an apropriate
cleaning schedule is determined.
34
maintenance
Firebox Baffle Removal
Spirals can be used to scrape the heat
exchange tubes.
Silicone sealing
gasket
The tabs go into the slots on the baffle and the latch flips
downward to seal at the angle. Lift the latch and lift the baffle
off of the tabs for removal. Ashes from the heat exchange
tubes can be cleaned from this area. Sliding the firebrick
from one side to the other will allow more space for baffle
removal.
Inspect all sealing gaskets to ensure a proper seal and
re-install all components removed for cleaning.
Note:Thefireboxbaffles(#1-10-232052)areconsidered
to be a consumable item. Check for signs of warping
or damage, and replace if necessary.
Cleaning
To maintain maximum heating efficiency, this
cleaning should be performed weekly during the
burn season. The frequency of this cleaning will be
directly related to the quality and quantity of fuel
being consumed. Keep in mind that the cleaner the heat
exchanger tubes are kept, the higher the heat transfer
efficiency will be.
Due to the ease of restarting, it is recommended that
the boiler be turned OFF for an hour before cleaning.
Start by removing the two firebox baffles as shown
above, then reinstall the ash pan. Next, remove the top
heat exchanger cover to expose the heat exchanger
tubes. Vacuum this upper exhaust chamber. Some of
the tubes contain a spiral baffle which you can use as a
cleaning device. Simply work the spiral up and down,
approximately 6 inches, to scrape the inside surface of
the heat exchange tube(s). The removed debris will fall
to the ash pan and on the angled chamber of the firebox.
Once all tubes are cleaned, remove the ash pan and clean
the remainder from the angles.
CAUTION: For your safety, do not vacuum hot ashes
or embers. Some portions will remain hot, long after
shut-down. Wear gloves to protect skin from burns.
CAUTION: Cleaning of the heat exchangers, flue
pipe, chimney, and combustion blower fan, is
especially important at the end of the heating season
to minimize corrosion during the summer months,
caused by accumulated ash.
With a wisp brush, paint brush or a soot vac, clean
the firebox walls and any fly ash that has accumulated
in the burnpot, or burnpot opening.At this time you can
scrape and clean the burnpot and fines cleanout area.
35
maintenance
The boiler MUST be OFF at the circuit breaker, and
COOL before you attempt to clean the combustion
Blower Cover
blower.
The wire to the combustion blower doesn’t need to be
disconnected during the cleaning process.
Loosen the three (3) thumb screws about 4 turns each.
See Fig. 23. Hold the motor head with one hand and the
blower plate handle with the other hand. Pull outward
on the plate handle until the complete unit comes loose.
Now rotate the plate counter-clockwise about 1/8 turn.
This will allow the complete assembly to be removed
from the blower chamber.
Latch
Fig. 22
Theexhaust sensing
probe (ESP) is
located here.
Clean the blower fan blade and the blower plate sealing
overlap. See Fig. 24.
NOTE: Be careful not to bend the fan blade, this will
throw the fan blade out of balance or it may rub the
inner chamber, which may affect the performance of
the boiler. Any horizontal and vertical flue pipe directly
above the unit should be cleaned at this time
Three Thumb Screws
Fig. 23
NOTE: The horizontal flue pipe directly above the
boiler is the first place fly ash will settle, due to the
slowing of flue gas velocity through horizontal pipe.
Cleaning of horizontal venting pipes is very important
to the efficiency of this boiler.NOTE: The exhaust
probe sensing tip extends into this same area. CARE
MUST BE TAKEN NOT TO DAMAGE THE ESP
DURING CLEANING. Bending of the ESPwill make
it difficult to remove if it should become necessary.
See Fig. 23.
Sealing Overlap
Clean the boiler blower plate sealing overlap. See Fig
24. Make sure there is no fly ash buildup that may block
the easy flow of flue gases into the combustion blower
inlet hole. (A flashlight may be necessary.)
5” Double Bladed Fan
(standard) #3-21-502221
Fig. 24
CAUTION: Inspect flue pipes, flue pipe joints and
flue pipe seals regularly to ensure that smoke and
flue gases are not entering the home.
Combustion Blower Cleaning
Remove the combustion blower cover.There are two
latches that hold the shield in place (Fig. 22). Flip the
latches up and pull the shield away from the boiler.
36
Special Insructions/ Power Failure
Requirements as specified by CAN/CSA- B366.1
Operation of the HF60 During a Power Failure - A supply of 120 VAC is required for operation. In
the event of a power failure, the unit will not operate. The boiler can be powered alternatively using the
Surefire 512 Battery Back-up system, or a generator. The generator must be properly filtered to maintain
a constant sine wave of 60 cycle, with a steady 120 Volt output.
EXAMPLE OF PIPING IN ACCORDANCE
WITH (CAN/CSA-B366.1)
A POWER FAILURE HEAT DISSIPATION LOOP
TO NORMAL HEATING DEMAND
(HIGH TEMPERATURE) BASEBOARD HEAT
BASEBOARD MUST BE AT LEAST
24" HIGHER THAN BOILER FOR
PROPER GRAVITY FLOW
MINIMUM OF 36" OF 3/4" FINNED BASEBOARD
120VAC,NORMALLY OPEN,FULL FLOW,
UNION
SHUT-OFF VALVE
SOLENOID VALVE or EQUIVALENT
SYSTEM SUPPLY 3/4"
NOTE: ALWAYS REFER TO THE INDIVIDUAL COMPONENTS
RECOMMENDED INSTALLATION INSTRUCTIONS FOR THE PROPER
MOUNTING POSITION AND LOCATION WITHIN THE PIPING
SYSTEM.
UNION
SYSTEM RETURN 3/4"
SHUT-OFF VALVE
THE SOLENOID CAN BE POWERED
FROM THE CONTROL PANEL
OUTLET MARKED-
PRV PIPE TO WITHIN 6" OF THE
FLOOR OR A FLOOR DRAIN
1/8”Fiberglass Gasket #3-44-232043
Door Glass #3-40-73363
1/4”White Ceramic Gasket #3-44-232073
Door Glass Cover Plate #2-00-232066
(4) #10-32 Nuts #3-30-8010321
Screen Plate #2-00-232016
Screwdriver Slot
Using a flat screwdriver, pry up and out to remove the screen plate. Remove the (4) 10-32 nuts
with a 3/8”wrench or socket. Remove the cover plate, the broken glass, and the gaskets. Install
a new 1/8”gasket, a new glass, and a new 1/4”white gasket. Re-install the cover plate.While
making sure that everything is centered, tighten the (4) nuts to secure the glass.To install the
screen plate, insert it into the slots at the top of the opening, then push in the bottom.
37
Troubleshooting
FEEdEr dOES NOT FEEd
SmOkE IS vISIblE COmINg OuT OF vENT
1. No pellets in hopper.
1. Air-fuel ratio is too rich.
A. Feed rate too high.
B. Draft too low caused by a gasket leak.
lOw hEAT OuTPuT
2. Firebox draft may be too low for low draft pressure
switch in feeder circuit to operate. Check for
improperly closed doors, loose or missing
gasket on doors or hopper lid, or a faulty pressure
switch.
3. Feed motor will not run until the ESP senses 170
deg. F. Maybe you did not put enough pellets in
the burn pot before lighting the fire manually.
4. Something is restricting flow in the hopper or
causing the slide plate to stick.
1. Feed rate too low
2. Draft too low because of gasket leak.
3. Poor quality or damp pellets
4. Combination of 1 and 2.
helpful hints
5. Feed motor has failed.
PArTIAllY burNEd PEllETS
1. Feed rate too high.
Cleaning burn Pot
Whenever your boiler is not burning, take the
opportunity to scrape the burn pot to remove carbon
buildup. A vacuum cleaner is handy to remove the
residue. be sure of no hot embers if you use a
vacuum.
2. Draft too low. (Check burn pot clean-out slide and
door gasket).
3. Burn pot or heat exchanger tubes may need to
be cleaned.
4. Combination of all the above.
Carbon buildup can be scraped loose with the fire
burning using the special tool provided with your boiler.
Scrape the floor and sides of the burn pot. The carbon
will be pushed out by the incoming fuel. Always wear
gloves to do this.
5. #6 status blink: A 6 blink control board status
indication is caused by poor or incomplete
combustion. The Automatic Ignition circuit board
has the ability to track the combustion through
feed settings and ESP temperatures. When the
control board has calculated poor or incomplete
combustion, it will shut down the unit as a safety
feature. (Poor or incomplete combustion is
a contributor of creosote which may cause a
chimney fire)
removing Ashes
Ashes can be removed while in operation, but extra
care must be taken and always wear gloves.
Maximum Feed Adjuster settings are not needed
in most cases. Operating in the normal range (#4)
is recommended when maximum heat output is not
required. The ESP prevents the stove from being over-
fired.
A 6 blink status may be caused by several things:
1. Blocked or partially blocked flue.
2. Blocked or partially blocked inlet air.
a. Backdraft damper on the inlet pipe may be stuck
closed.
Keep the boiler free of dust and dirt.
b. If outside air is installed, the inlet cover may be
blocked.
3. The air chamber under the burnpot may be filled
with fines and small bits of ash.
4. The holes in the burnpot may be getting filled with
ash or carbon buildup.
5. Combustion blower fan may need cleaned.
6. There is no fuel in the hopper.
Fuel
Pellet fuels are put into 3 categories in terms of ash
content. Premium at 1% or less, Standard at 3% or
less and all others at 3% or more.
The BH60 is capable of burning all 3 categories
of pellets, due to a patented feeder and burn pot
system.
SmOkE SmEll
Seal the vent pipe joints and connection to unit with
silicone.
It should be noted, however, that higher ash content
will require more frequent ash removal, scraping of
the burn pot, and may provide less BTU’s per pound.
Normally, standard and high ash pellets cost less
than premium pellets and can be cost effective when
burned in the BH60.
FIrE hAS gONE OuT
1. No pellets in hopper.
2. Draft setting is too low.
3. Something is restricting fuel flow.
4. Feed motor or combustion blower has failed.
5. Power failure or blown fuse.
The moisture content must not exceed 8%. Higher
moisture will rob BTU’s and may not burn properly.
6. Firebox door or hopper left open.
38
Specifications
39
Wiring Diagram
wiring diagram
U G
W H I T E 1 3 P I N P L
R E D
U E . B T L L
C K A B L
W H I T E
G R E E N
G R E E N
W O
G R E E N / Y E L L
U E . B T L L
W O N B R
W O Y E L L
U E . B T L
C K A B L
C K A B L
U E . B T L L
G R E E N / Y E L L
W O
N.O.CONTACTS
LOW PRESSURE SWITCH
40
warranty
ECO-CHOICE™ LIMITED WARRANTY
Hearth & Home Technologies Inc., on behalf of its Heatilator® brand (”HHT”), extends the following warranty for all ECO-
CHOICE™ furnace and boiler products (“Products”) that are purchased from an HHT authorized dealer.
Warranty Coverage: Subject to the conditions, exclusions and limitations set forth below, HHT warrants to the original
owner of the Products, and to any transferee taking ownership of the Products at the site of original installation within two
years following the date of original purchase, that the Products will operate free from defects in material and workmanship
under normal conditions and use, as described in the operating instructions furnished with the Product, during the warranty
period described below. HHT will, at its option, repair or replace any Product covered by this warranty that is determined
to be defective in material or workmanship.
Warranty Period: The warranty period runs for six years, except for mechanical and electrical components, which are
warranted for three years. The warranty period begins on the earlier of: (i) the date of invoice for the Product; (ii) in the case
of new home construction, the date of first occupancy of the residence or six months after the date of sale of the Product by
an HHT authorized dealer, whichever occurs first; or (iii) the date 24 months following the date of Product shipment from
HHT, regardless of the invoice or occupancy date.
Warranty Conditions: This warranty applies only to Products: (i) installed, operated, and maintained as recommended in
the Product user’s manual; (ii) purchased through an HHT authorized dealer; (iii) while remaining at the site of original
installation; and (iv) that have not been altered after leaving the factory.
How to File a Claim: Claims must be made within the warranty period to the dealer who sold the Product. If that dealer
cannot provide the warranty service, contact the nearest HHT authorized dealer. Additional service fees may apply if you
are seeking warranty service from a dealer other than the dealer from whom you originally purchased the Product. Travel
and shipping charges for parts are not covered by this warranty.
Warranty Exclusions: This warranty does not cover the following: (1) consumable and normal wear items, including,
without limitation, flame guides, grates, coal bars, afterburner hoods, fire brick, gaskets, paint, glass discoloration, burnpot
housing weldments, burnpot grate weldments (pellet or corn), burnpot front plates (pellet or corn), burnpot front plate
locks, corn auger extensions, ceramic inserts, and ceramic insert plates; (2) noise caused by minor expansion, contraction
or movement of parts; (3) damage resulting from: (i) failure to install, operate or maintain the Product according to the
installation and operating instructions and listing agent identification label furnished with the Product; (ii) failure to install
the Product according to local building codes; (iii) shipping or improper handling; (iv) abuse, misuse, continued operation
with damaged, corroded or failed components, accident, or incorrectly performed repairs; (v) environmental conditions,
inadequate ventilation, negative pressure or drafting caused by tightly sealed construction, insufficient make-up air supply,
or handling devices such as exhaust fans or forced air furnaces or other such causes; (vi) use of fuels other than those
specified in the operating instructions; (vii) installation or use of components or accessories not supplied with the Product
or authorized and approved in writing by HHT; (viii) modification of the product not expressly authorized and approved by
HHT in writing; or (ix) interruptions or fluctuations of electrical power supply to the Product; (4) non-HHT components
or accessories used in conjunction with the Product; (5) the Products’ capability to heat a desired space; information is
provided to assist the consumer and the dealer in selecting the proper Product for the application; consideration must be
given to Product location and configuration, environmental conditions, insulation and air tightness of the structure; or (6)
additional or unusual utility bills incurred due to any malfunction or defect in Products.
Limitations of Liability: Repair or replacement in accordance with the provisions of this warranty will be the owner’s
exclusive remedy for and will constitute HHT’s sole obligation under this warranty, under any other warranty (express or
implied), or in contract, tort or otherwise. No employee, agent, dealer, or other person is authorized to give any warranty
on behalf of HHT. TO THE EXTENT ALLOWED BY LAW, HHT MAKES NO OTHER WARRANTY, EXPRESS
OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. HHT WILL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES ARISING
OUT OF DEFECTS IN OR USE OF THE PRODUCTS. Some states do not allow exclusions or limitation of incidental or
consequential damages, so these limitations may not apply to you. This warranty gives you specific rights; you also may
have other rights, which vary from state to state. The duration of any implied warranty is limited to the duration of the
warranty period specified herein.
41
Testing label
BH60
8
Wood Pellets
BH60
Flooring must be non-combustible material extending
16” (US) or 18”(CAN) in front of the ash removal d
e revêtement de sol doit être de l'étendre de matériel incombustible 6” aux
côtés, et 16” (USA) ou 18”(Canada) devant la porte d'enlèvement de cendre.
WAfire - Do not operate with the flue draft exceeding
-.9 in Water Column / -224Pa.
ATTENTION: Risque de feu -Ne fonctionnez pas avec l'ébauche
deconduite de cheminée excédant -.9 " colonne de l'eau / -224Pa.
Hearth & Home Technologies
352 Mountain House Road, Halifax, PA 17032
3-90-232H
42
Service Parts
bh105
beginning manufacturing date: july 2009
bioflow hydronic 105k Pellet boiler
Ending manufacturing date: Active
1
2
28
3
27
26
4
5
25
6
24
23
22
21
7
20
8
9
10
19
18
11
12
14
13
17
15
16
IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement
parts for your appliance please provide model number and serial number. All parts listed
in this manual may be ordered from an authorized dealer.
Stocked
at depot
ITEm
dESCrIPTION
COmmENTS
PArT NumbEr
1-10-72140A
3-44-677185
3-31-00927
1-10-07330
1-00-06143
1-00-015605
3-20-49447-5
2-00-72158B
3-20-6866
1
Hopper Assembly
Gasket, Hopper Throat
Hopper Lid Spring Latch
Control Board Plate, Studded w/label
Control Board
Y
Y
2
3
Y
Y
Y
Control Knob/Shaft
25 Sets
Pkg of 5
Fuse, 6 AMP
4
5
6
7
Feeder Cover Assembly
Differential Switch
Y
Red Nylon Knob
3-31-72196
1-10-72153A
Swing Plate Assembly
Additional service part numbers appear on following page.
04/12
Service Parts
bh60
beginning manufacturing date: may 2009
Ending manufacturing date: Active
IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement
parts for your appliance please provide model number and serial number. All parts listed
in this manual may be ordered from an authorized dealer.
Stocked
at depot
ITEm
description
Plumbing Support Kit - Qty. 2 req.
Firetube Cleanout Door Assembly
Draft Section Refractory Side
1/4-20 x 1-1/2" Wingscrew with Collar
Draft Section Weldment
COmmENTS
PArT NumbEr
1-10-232044-18
1-10-232060-18A
3-40-232054
1
2
3
4
5
6
7
8
Qty. 2 req.
Pkg of 10
3-31-782124-10
1-10-232011W
3-44-232089
Y
1/2" Foam Insulation Wrap Around
1/2" Foam Insulation
3-44-232088
Hopper Assembly
1-10-232034-18A
1-00-375501
Gasket, Hopper Top
20 Ft
Y
Y
Gasket. Hopper Throat
3-44-677185
9
Feeder Shield Rear
1-00-232039-18
3-44-232085
10
11
12
13
14
15
1" Foil Faced Fiberglass Insulation
UL Feeder Assembly
refer to feeder page
3-20-6866
Differential Switch
Y
Y
Tempco 450W Igniter
3-20-00450
1" Foil Faced Fiberglass Insulation
Tube Cleanout Plate
3-44-232086
Qty. 2 req.
Qty. 2 req.
2-00-232008B
2-00-232031-1B
2-00-232031-2B
3-40-232010
Hopper Stiffener Bracket Left
Hopper Stiffener Bracket Right
Firebox Refractory Side
16
17
18
Burn Pot Scraper
3-99-7498
3-44-232094-1
3-44-232094-2
3-44-232094-3
3-20-02679
19
Water Jacket Gasket
Long Bottom
Short bottom
20
21
Air Pump
Y
Y
Filter & Fitting
1-00-02679
1/4" Ceramic Paper Feeder Insulation
3/4" NPT Square Plug
3-44-232078
22
23
24
25
26
27
28
29
30
31
Qty. 4 req.
3-10-00600
Feeder Cover Left
1-00-232096-18
3-10-07560
3/4" NPT Boiler Drain
Outer Skin Left
1-00-232026-18
1-10-232005W
3-50-05229
Combustion Section Weldment
Steel Sleeve Bushing 3/8 OD x 1/2 OAL
Elevator Bolt 3/8-16 x 1-1/2"
Firebox Cleanout Cover Retainer
Tube Cleanout Cover Plate
Tube Cleanout Latch
Qty. 4 req.
Qty. 2 req.
Qty. 2 req.
Qty. 2 req.
3-30-937161501
2-00-232056B
2-00-232052B
2-00-232009L
Y
Additional service part numbers on the following page.
02/12
Service Parts
bh60
beginning manufacturing date: may 2009
Ending manufacturing date: Active
IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement parts for
your appliance please provide model number and serial number. All parts listed in this manual may
be ordered from an authorized dealer.
Stocked
at depot
ITEm
32
description
COmmENTS
Qty. 2 req.
PArT NumbEr
3-20-1000
3/8" Flex Connector
Ceramic Insert
33
Pkg of 10
3-20-05238-10
3-00-03000
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
34
Flame Guide
35
Burnpot Assembly
Clean Out Cover
Thumb Screw
1-10-232079A
1-00-06623
2 Sets
Pkg of 10
3-31-782108-10
3-44-724114
2-00-724104
3-44-724115
3-40-232015
3-40-232093
3-40-232006
1-10-232049A
1-00-232019-18
1-00-232074
3-40-5555
36
37
38
39
40
41
42
43
Ceramic Insert Gasket
Ceramic Insert Plate
Burn Pot Gasket
Firebox Refractory Rear
Firebrick
Firebox Refractory Bottom
Ash Pan Assembly
Ash Door Assembly
Ash Door Spacer Set w/Gasket
Glass 5.25 x 5.25
Refractory
3-40-232023
1-00-232055-18
1-00-06143
44
Control Board Plate Assembly
Control Board
Y
Y
Y
Fuse, 6 AMP
Pkg of 5
3-20-49447-5
3-10-78427
45
46
Pressure / Temperature Gauge
Plumbing Assembly
1-10-232080A
1-00-232028A-18
1-00-232028B-18
1-00-232027-18
3-21-08639
Pre 004510191
Post 004510191
47
Combustion Motor Cover
48
49
50
Outer Skin Front
Combustion Blower
Blade 5" Single
Y
Y
3-20-502221
3-31-004357
1-10-73416
External Retaining Ring
Combustion Blower Mount
Flex Conduit Support Bracket
3/8" Flex Conduit
51
52
53
54
55
56
57
58
59
60
2-00-232071B
1-00-25043
7 Ft
Y
Ash Door Hinge
2-00-232020L
1-10-232001W
2-00-232053-8
3-20-00844
Water Jacket Weldment
Spiral Fire Tube Baffle
ESP Probe
Pkg of 8
Qty. 2 req.
Y
Y
1/2" Foam Insulation
2" Fiberglass Insulation
Feeder Cover Right
Outer Skin Right
3-44-232087
3-44-232090
1-00-232097-18
1-00-232025-18
Additional service part numbers on the following page.
02/12
Service Parts
bh60
beginning manufacturing date: may 2009
Ending manufacturing date: Active
IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement
parts for your appliance please provide model number and serial number. All parts listed
in this manual may be ordered from an authorized dealer.
Stocked
at depot
ITEm
61
description
COmmENTS
Qty. 4 req.
PArT NumbEr
3-31-00927
Spring Latch
Y
Y
Y
Y
62
3/8"-16 x 1/4" Alloy Steel Black Oxide Cup Point SSS
Touch up Paint (RED)
Pkg of 25
3-30-2014-25
3-42-00018
Circuit breaker 10 Amp (orange - on/off switch)
High Altitude Intake Reduction
3-20-334110
1-00-232059
3-20-232076
Wiring Harness
Y
#11 Feeder Assembly
11.1
11.15
11.14
11.12
11.16
11.2
11.13
11.11
11.3
11.10
11.9
11.4
11.5
11.8
11.7
11.6
11
UL Feeder Assembly
1-10-232108A
3-20-09302
Pellet Feeder Gear Motor, 4RPM
Feed Motor Fan Blade
UL Feeder Cam
11.1
Y
Y
Y
Y
Y
Pkg of 3
3-20-09302-3
3-31-3014
11.2
11.3
Feeder Air Crossover Kit
9MM Silicone Tube
1-00-67900
5 Ft
1-00-511427
1-10-06810A
3-44-72224-6
1-10-72222
Pellet Air Intake Assembly
Gasket Feeder Air Intake
UL Feeder Air Intake
11.4
11.5
Pkg of 6
Pkg of 10
Y
11.6
Gasket Ultra Air Intake
Ultra Feeder Weldment
UL Feeder Pusher Arm
Fines Deflector
3-44-677160-10
1-10-72226S
1-10-677187W
11.7
Y
Y
Y
11.8
11.9
No longer available 2-00-677138-10
1-00-677122
11.10
11.11
11.12
11.13
11.14
11.15
11.16
Gasket, UL Feeder Cover
Slide Plate Assembly
Y
Y
Y
Y
Y
Y
1-10-677121A
UL Feeder Auger Assembly
Bearing Flange w/Hardware
UL Feeder Gear Motor Bracket w/Grommet
UL Feeder Cam Block
3-50-00565
1-00-04035
1-00-247406
3-00-677154
02/12
Notes
At Harman, we build each product to a standard, not a price.
This powerful heating appliance boasts uncompromising
attention to detail and helps preserve our planet by using
environmentally responsible fuels.
(Signature of Boxer)
Your premium quality hearth product designed and assembled
by the experienced and skilled members at Harman in Halifax,
PA, USA.
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