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Hardy C3 Installation And Operating Instructions Manual

Outside coal burning heater
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INSTALLATION AND
OPERATING INSTRUCTIONS
FOR
THE HARDY
OUTSIDE COAL
BURNING HEATER
Model – C3 & C5
Model – C3 & C5
HARDY MANUFACTURING
COMPANY, INC.
12345 ROAD 505
PHILADELPHIA, MS 39350
PHONE: (601) 656-5866
FAX: (601) 656-4559
www.hardyheater.com
Rev. 3/25/2015

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  • Page 1 INSTALLATION AND OPERATING INSTRUCTIONS THE HARDY OUTSIDE COAL BURNING HEATER Model – C3 & C5 Model – C3 & C5 HARDY MANUFACTURING COMPANY, INC. 12345 ROAD 505 PHILADELPHIA, MS 39350 PHONE: (601) 656-5866 FAX: (601) 656-4559 www.hardyheater.com Rev. 3/25/2015...
  • Page 2 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 3 Thank you for purchasing the original all stainless steel Hardy Outside Coal Burning 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. With the purchase of this Hardy Heater, you can now appreciate the high degree of craftsmanship and reliability that have made The Hardy the leader in the Outside Coal Burning Heater field.
  • Page 4 Please fill in the following information Hardy Model Serial Number Date of Purchase Date of Installation Dealer Purchased from Dealer Address Dealer Phone Number HARDY MANUFACTURING COMPANY, INC. 12345 ROAD 505 PHILADELPHIA, MS 39350 PHONE: (601) 656-5866 www.hardyheater.com (MODEL C3 & C5)

  • Page 5: Safety Precautions

    Failure to heed this warning or any additional warnings on the unit may result in an accident causing personal injury. Safety Labels and Rating Labels Read all safety labels on this unit 5” X 3.5” C3-1-07 120,000 2.69 COAL (MODEL C3 & C5)
  • Page 6 Safety Labels Read all safety labels on this unit Name Plate Supplement 5” X 10” (not shown actual size) (MODEL C3 & C5)
  • Page 7 SCHEM ATIC DIAGRAM GFCI LEGEND GFCI GROUND FAULT CIRCUIT INTERRUPTER LIQUID LEVEL SWITCH WATER SOLENOID VALVE (OPTIONAL ON H3 & H5) CIRCULATOR PUMP RELAY WATER CIRCULATOR PUMP DAMPER AQUASTAT DAMPER BLOWER MOTOR DAMPER SOLENOID LOW WATER LIGHT (MODEL C3 & C5)
  • Page 8 Safety Labels Read all safety labels on this unit Warning label for Condenser Vent 5” X 3” Back Door label 5” X 3” (MODEL C3 & C5)
  • Page 9 Safety Labels Read all safety labels on this unit Warning label on front between doors 4” X 2 3/4” Field wiring label 2 3/4” X 1” Hot water label 2 3/4” X 1” (MODEL C3 & C5)
  • Page 10 THIS PAGE INTENTIONALLY LEFT BLANK (MODEL C3 & C5) viii...
  • Page 11 2 feet Chimney height should be 2 feet above roof line. Residence served by furnace Minimum of 100 feet 6. Always remember to comply with all applicable state and local codes. Outdoor Furnace Manufacturers Caucus (MODEL C3 & C5)
  • Page 12 THE HARDY OUTSIDE COAL BURNING HEATER How does an outside heater heat my home? The Hardy Outside Coal Burning 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 13: Table Of Contents

    3-1 Plumbing Instructions for Forced Air ......14 3-2 Location of Heating Coil ........15-16 3-3 Connecting to Existing Hydronic Systems .... 17-18 3-4 Plumbing for Domestic water C3 & C5 ...... 19 3-5 Replacing Hull ............20 3-6 Filling the Heater with Water ........21...
  • Page 14 8-2 Circulator Maintenance Instructions ...... 41-42 8-3 Damper Solenoid Replacement Instructions ....43 8-4 Low Water Switch Replacement Instructions ..44-45 8-5 Draft Blower Replacement Instructions ....46-47 8-6 Aquastat Replacement Instructions....... 48-50 SECTION IX: Warranty 9-1 Warranty ..............51 (MODEL C3 & C5)

  • Page 15: Section I

    Top, Rear, Sides 48” Chimney Connector 48” Front 48” Flooring Non Combustible Water Capacity C3 – Holds Approximately 100 Gallons of Water C5 – Holds Approximately 130 Gallons of Water Heater Dimensions Description Width Depth Height Weight C3 – 120,000 BTU 30”...
  • Page 16 The first section determines the rating of your heater. The second section determines electrical options. The last section determines the plumbing options. For example heater model number C3-1-07. The C3 designates that you have a 120,000 BTU heater. The 1 in the second section designates that you have a standard pump.

  • Page 17: Heater Component Parts Model C3

    Heater Component Parts Model C3 Part No. Description 600.10 1/2” Brass Elbow 810.00 1/2” Overflow Pipe 1100.28 Low Water Switch 602.16 3/4” Brass Tee 603.40 3/4” x Close Brass Nipple 600.30 3/4” Brass Elbow 604.32 3/4” Brass Cap 604.16 1/2” Brass Cap 2000.48...

  • Page 18: Heater Component Parts Model C5

    Plastic Romex Connector 25 607.42 3/4” Boiler Drain 26 2004.04 3’ 3 Wire Power Cord 27 2004.08 8’ 2 Wire Power Cord 28 2004.52 Electrical Mounting Panel 29 604.00 1/4” Brass Cap HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 4...

  • Page 19: Section Ii

    INSTALLATION OF HEATER Location of Heater The Hardy Heater is designed to be positioned outside the building to be heated. The unit must be located a minimum of 10 feet from the building. The unit should be installed upon a concrete pad. There are two typical options that we recommend.
  • Page 20 This will allow you easy access for the plumbing and electrical connections. Please see the Illustration below for details. Option 2 60.000 14.000 48.000 20.000 4.000 6.000 HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 6...

  • Page 21: Hull Removal

    Hull Removal After placing your new Hardy Heater upon the concrete pad, you are ready to continue the installation process. There are two methods to gain access to the rear of the heater to make plumbing and electrical connections. The first and easiest method is to remove the screw holding the back door panel in place.

  • Page 22: Set-Up Of Fire Brick

    Fire brick (4 1/2” X 9” X 2 1/4” thick) The first step is to install the 4 C3 - SS corner brick supports into the four corners of the firebox (see picture #1). Next install 5 fire brick standing up on end across the back of the fire box (see picture #2).
  • Page 23 Set-Up of Fire Brick (continued) The Hardy model C5 comes standard with shaker grates and fire brick. The shaker grates are set up in the firebox from the factory. The fire brick will need to be installed prior to filling the heater with water.
  • Page 24 The C5 heater has a stainless steel flame baffle (15” x 10”) in . This flame baffle is inserted in the firebox across the 3/4” stainless steel pipes located directly below the smoke stack. Flame Baffle HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 10...

  • Page 25: Location Of Plumbing & Electrical Lines

    (All of these must be at least 3/4” pipe and may require 1” because of longer distances or some hydronic applications.) One 3 conductor thermostat wire. One #12/2 W/G UF underground romex wire. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 11...

  • Page 26: Connection Of Power To Heater

    If moisture is allowed into the Ground Fault Circuit Interrupter box, it will have a tendency to trip unwarranted. Measures should be taken to keep the box dry. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 12...

  • Page 27: Wiring Diagram

    Wiring Diagram LIQUID LEVEL SWITCH WATER VALVE Water valve GROUND FAULT Optional on CIRCUIT Models C3 & C5 INTERRUPTER CONNECTION DIAGRAM PUMP MOTOR RELAY OPTIONAL PUMP MOTOR RELAY SECOND HEATING ZONE DAMPER BLOWER DAMPER MOTOR AQUASTAT DAMPER SOLENOID GFCI SCHEMATIC DIAGRAM...

  • Page 28: Section Iii: Plumbing Instructions

    Do not use galvanized or black iron. Air Flow Heater with Hull and stacks removed to show connections. Vertical Flow System Air Must be Air Flow Filtered before passing through Heating Coil. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 14...

  • Page 29: 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 C3 & C5) PAGE 15...
  • Page 30 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 C3 & C5) PAGE 16...

  • Page 31: Connecting To Existing Hydronic Systems

    Connecting to Existing Hydronic Systems The preferred method for connecting the Hardy 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. This will allow the existing boiler to remain a pressurized system.
  • Page 32 3 degrees below the home heat thermostat. If the heater were to get behind for any reason the boiler can come on and help maintain the home temperature. Wiring to add Hardy Heater to exsisting hydronic heating system. EXISTING...

  • Page 33: Plumbing For Domestic Water C3 & C5

    Plumbing for Domestic Water C3 & C5 To add domestic hot water to the Model C3 & C5 heaters, a plate heat exchanger and pump can be added. This plate heat exchanger will provide preheated water to the domestic hot water. The preferred method is to mount a plate heat exchanger at the water heater and connect it as shown in the following picture.

  • Page 34: Replacing Hull

    Seal perimeter of Smoke Stack ring Seal perimeter of Condenser tank to Heater Hull using Silicone Sealant. ring to Heater Hull using Silicone Sealant. Do not fill past this point. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 20...

  • Page 35: Filling The Heater With Water

    45 ppm. The use of water in the water tank that exceeds 45 ppm shall void the warranty. Call your Hardy dealer to get a chloride test on your water supply. Fill your heater with water through the condenser stack opening or when you supply power to the heater if the heater has the automatic fill option it will fill itself.

  • Page 36: Section Iv: Connection To Central Heating/Ac System

    7 of the water pump relay (R-3) and also connect the green wire to terminal 7 of R-3. If only two wires are used then one is connected to terminal 7 and the other to terminal 8. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 22...
  • Page 37 Insure that the volt amp rating of the existing 24 volt transformer is not exceeded when the relays in the coal heating system are energized. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 23...

  • Page 38: Typical Wiring Diagram

    NEW CONTROL RELAY NEW THERMOSTAT LOW TEMPERATURE SENSOR EXISTING THERMOSTAT TERMINAL STRIP "C" CONNECTION TERMINAL STRIP "R" CONNECTION TERMINAL STRIP "G" CONNECTION EXISTING THERMOSTAT CONNECTION EXISTING THERMOSTAT CONNECTION QUICK CONNECT TERMINALS HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 24...

  • Page 39: Heater Operation

    You build a fire in the Hardy Heater the same way you would in any other coal heater. Start out with paper and wood kindling. Once you have the paper lit gradually add the kindling.

  • Page 40: Fuel Usage

    Allow the ashes and broken clinkers to fall through the grates and remove with provided shovel. This insures that the grates are clear. Always remove all ashes and clean out any buildup of creosote when the heater is not in use. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 26...

  • Page 41: Section Vi: Service Information

    (reassemble and try again) or the problem is the electrical winding or capacitor. Use an ohm meter to check the winding and capacitor. If the capacitor is defective, replace it. If the electrical winding is defective, replace the complete pump. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 27...

  • Page 42: Temperature Control System

    The motor should be oiled at the beginning of each heating season. When the heater is not in use, the power cord for the blower should be unplugged. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 28...

  • Page 43: Section Vii: Heater Maintenance

    Door Seals > Check firebox door and ash door seals occasionally for damage or obstructions that would affect an airtight seal. Preseason Maintenance > Review preseason heater maintenance section in owners manual prior to each heating season. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 29...

  • Page 44: Preseason Maintenance

    Preseason Maintenance The Hardy Heater is designed for ease of operation and ease of service. There is maintenance that has to be done for proper operation of your new unit. Each year before the heating season begins, you should check your heater to insure that everything is ready for the heating season.

  • Page 45: In Season Maintenance

    It is recommended that you check this water level at least once a week while the heater is in operation. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 31...

  • Page 46: Post Season Maintenance

    On the C5 model remove and clean the baffle plate in the top of the fire box, clean out the smoke stack. Ashes left in the firebox for extended periods can cause corrosion and shall void the warranty. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 32...

  • Page 47: Section Viii: Appendix

    Bad connections possibly Liquid Level Check electrical to ground. Switch, Low connections for bad water light. connections or corrosion. Clean, dry and then retest for proper operation. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 33...
  • Page 48 Check for ground and continuity with ohmmeter. The insulator of the windings should show no breakage. If it does, replace pump HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 34...
  • Page 49 4. Check relay terminals #7 & #8 for 24 volts. If 24 volts is present, use ohmmeter to check contacts. Connect ohmmeter to terminals #4 & #6. If no reading replace relay. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 35...
  • Page 50 On C5 model make sure the baffle plate is clear of ash and creosote buildup. Make sure baffle is in place, otherwise heat will be lost up the stack. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 36...
  • Page 51 – replace solenoid valve. 2. Water filter 2. Remove filter screen from 1/2” bushing in end of 1/2” ball valve, clean or replace. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 37...
  • Page 52 4. Check temperature setting on aquastat. Should be 170ºF. If aquastat is allowing blower to run until water boils, replace aquastat. 5. Repair or replace all lines or connections that are leaking. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 38...
  • Page 53 If heater tank still overfills then remove heater hull and lid to check domestic water coil for leaks, repair or replace. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 39...
  • Page 54 Fire box 1. Initial or yearly 1. Fire box walls will Fire box start up sweat and water will run down sides, this should clear up in about a week. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 40...

  • Page 55: Circulator Maintenance Instructions

    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 C3 & C5) PAGE 41...
  • Page 56 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 C3 & C5) PAGE 42...

  • Page 57: Damper Solenoid Replacement Instructions

    There should be tension in the chain when the flapper is Chain should be straight above in the down position. Damper Flapper. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 43...

  • Page 58: Low Water Switch Replacement Instructions

    Using an adjustable wrench or other suitable tool install the switch in the tank. Do not overtighten. Make sure the switch is oriented with the arrow pointing down. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 44...
  • Page 59 If the light does not go out the switch is possibly oriented incorrectly. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 45...

  • Page 60: Draft Blower Replacement Instructions

    Start inner screw but do not tighten. Position blower over gasket. Tighten inner screw to hold blower in position, then install and tighten the two outer screws. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 46...
  • Page 61 Connect power wires and install plastic cable tie if available. Verify blower is firmly attached to flange and damper flapper will lift freely. Reconnect power to furnace. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 47...

  • Page 62: Aquastat Replacement Instructions

    If the well fitting does not require replacement then skip to step # 10. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 48...
  • Page 63 Tighten the two well clamp screws. Do not over tighten the clamp screws. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 49...
  • Page 64 Reconnect power to furnace. If the water level was lowered to install a new well fitting, MAKE SURE THE FURNACE IS FILLED WITH WATER TO THE CORRECT LEVEL BEFORE OPERATING HEATER. HARDY MANUFACTURING CO., INC (MODEL C3 & C5) PAGE 50...

This manual is also suitable for:

C5

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