Hardy KBP270 User manual

INSTALLATION AND
OPERATING INSTRUCTIONS
FOR
THE HARDY
OUTSIDE WOOD
BURNING HEATER
Model – KBP270
Model – KBP270
HARDY MANUFACTURING
COMPANY, INC.
12345 ROAD 505
PHILADELPHIA, MS 39350
PHONE: [phone]
FAX: [phone]
www.hardyheater.com
HARDY MANUFACTURING
COMPANY, INC.
12345 ROAD 505
PHILADELPHIA, MS 39350
PHONE: [phone]
FAX: [phone]
www.hardyheater.com
Rev. 2/22/2014

THIS PAGE INTENTIONALLY LEFT BLANK

(MODEL KBP270)
i
INTRODUCTION
Thank you for purchasing our Hardy Outside Wood Pellet 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 Pellet burning Heater field. This
manual will provide you with a good basic understanding of the installation and
operation of this heater.
THIS MANUAL INCLUDES IMPORTANT SAFETY INFORMATION.
Your new heater should have the following:
(1) Owner’s manual complete with installation
and hook-up instructions
(2) Warranty & return warranty card
(3) A tube of silicone (located in the firebox for shipping)
(4) 2 double wall sections of Smoke stack with a trim ring and cap
(5) Condenser stack with trim ring
(6) Ash removal tool
(7) Metal ash removal pan
(8) Feed auger assembly
Should your heater not have any of these items or if you have any questions regarding
the operation or maintenance of your heater, please consult you local Hardy dealer.
Again, thank you for purchasing a Hardy Heater.
Sincerely,
Frank L. Moore
President
Hardy Manufacturing Co., Inc.

(MODEL KBP270)
ii
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: [phone]
www.hardyheater.com
Please keep this manual with all other important papers.
The information in this manual is necessary for the
installation, operation and proper use of this unit. If you
should ever have a problem or question please refer to
this manual or have it available when you call your Hardy
Dealer or Hardy Manufacturing Company, Inc.

(MODEL KBP270)
iii
SAFETY PRECAUTIONS
WARNING
Do not operate this equipment for other than its intended purpose nor other
than in accordance with the instructions contained in this manual and all other
instructions accompanying the unit.
For units covered by this instruction book, it is important to observe safety precautions
to protect yourself from possible injury. Among the many considerations, you are
advised to:
 Observe all safety stickers on the unit.
 This unit must be wired by a qualified electrician in accordance with the National
Electrical Code.
 Never use any type of petroleum based product, charcoal starter, lighter fluid, or any
other flammable accelerant to start your unit.
 Fuel: wood pellets.
 Never leave the door open, always latch the door securely.
 Always use proper care when installing, operating and maintaining the unit.
 Do not modify the unit.
 Do not substitute repairs which can be provided by your dealer, distributor, or Hardy
Manufacturing Co. Inc.
Failure to heed this warning or any additional warnings on the unit may result in an
accident causing personal injury and loss of warranty.

(MODEL KBP270)
iv
THE HARDY OUTSIDE PELLET BURNING HEATER
How does an outside heater heat my home?
The Hardy outside pellet 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.
The heater is a non pressurized boiler with an atmospheric vent. This hot water is then
circulated through underground hot water pipes to a water coil inside your existing
central duct system. The Hardy Heater can be connected to any existing hydronic
heating system that operates at 170 degrees Fahrenheit or less.
How does THE HARDY heat water for household use?
A plate heat exchanger (optional) is installed in the hot water circulator line. When you
open a hot water faucet inside your home, the cold water passes through the other
side of the heat exchanger and the water going to your hot water heater is preheated.
The only additional energy required is maintaining the hot water temperature. The
plate heat exchangers can be used for pools, dairies and other domestic hot water
needs.
How do the Thermostat Controls work?
The only visible addition to the heating system inside your home is the thermostat
which is located next to your existing thermostat. The two thermostats are installed so
that if the outside pellet burning heater is not in operation, your existing unit can be
used to maintain your household temperature. The wall thermostat which regulates the
heat from the outside heater turns the blower on inside your central unit to force air
across the hot coil. This forces hot air into your central duct system. The outside
heater has a Process Control Module which senses the water temperature of the unit.
This module cycles the heater on and off in order to maintain a preset water
temperature.
Where should an Outside Pellet Burning Heater be located?
The outside unit should be located at least 10 feet from your home so that all fire
danger is removed from your home. The unit may be installed as much as 100 feet
away and still heat your house and hot water. If the unit is located more than 100 feet
away, you may experience some heat loss on the water supplying your water heater.
Locate the outside pellet burning heater where it will be convenient for refueling. All
water and power lines are installed underground between the house and the outside
wood heater.

(MODEL KBP270)
v
TABLE OF CONTENTS
SECTION I: General Information
1-1 Specifications...............................................................1
1-2 Heater Component Parts ..........................................2-6
SECTION II: Installation of Heater
2-1 Location of Heater........................................................7
2-2 Location of Plumbing & Electrical Lines .......................8
2-3 Connection of Power to Heater ....................................9
2-4 Wiring Diagram ............................................................9
2-5 Plumbing Connections ...............................................10
2-6 Installation of Smoke Stacks and Condenser Stack 11
2-7 Filling the Heater with Water……………………………12
2-8 Priming the Pump ......................................................13
SECTION III: Connection to Central Heating/AC System
3-1 Connection to Central Unit
with existing Blower Relay....................................14-15
3-2 Location of Heating Coil .......................................16-17
SECTION IV: Connection to Hydronic Heating Systems (Baseboard)
4-1 Connection to Hydronic System.................................18
SECTION V: Plumbing Options for Domestic Water
5-1 Plate Heat Exchanger for Domestic Water ................19
SECTION VI: Heater Operation
6-1 Firing the Heater ........................................................20
6-2 Burn Mode.................................................................21
6-3 Shut Down Mode .......................................................22

(MODEL KBP270)
vi
TABLE OF CONTENTS continued
SECTION VII: Service Information
7-1 Water Temperature.................................................... 23
7-2 Fuel Usage ................................................................ 23
7-3 Moisture in Firebox .................................................... 23
7-4 Improper Burning ....................................................... 23
7-5 Ash Removal ............................................................. 23
7-6 Water Circulation System .......................................... 24
7-7 Combustion Air Blower Assembly…………………… . 24
7-8 Low Water Sensor ..................................................... 24
7-9 Process Control Module............................................. 24
7-10 Feed Auger Assembly.............................................. 25
7-11 Stir Shaft Motor Assembly ....................................... 25
7-12 Stir Shaft Assembly.................................................. 25
SECTION VIII: Heater Maintenance
8-1 Daily Maintenance ..................................................... 26
8-2 Weekly Maintenance.................................................. 27
8-3 Extended Period Shut Down and Start Up................ 28
SECTION IX: Appendix
9-1 Modes of Operation Flow Diagram ............................ 29
9-2 General Trouble Shooting Guide .............................. 30
9-3 Module Specific Trouble Shooting Guide .................. 31
9-4 Maintenance Instructions ......................................32-40

HARDY MANUFACTURING CO., INC (MODEL KBP270) PAGE 1
SECTION I
GENERAL INFORMATION
1 –1 Specifications
Type of fuel –Wood pellets
For outdoor use only
Electrical Rating 115 VAC/ 60 HZ / 1PH
MFS-20 AMP, MCA-20 AMP
Clearance to Combustibles
Top, Rear, Sides 18”
Chimney Connector 18”
Front 48”
Flooring Non Combustible
Water Capacity
KBP270 –Holds Approximately 40 Gallons of Water
Heater Dimensions
Description Width Depth Height Weight
KBP270 31” 75” 48” 636 lbs.

HARDY MANUFACTURING CO., INC (MODEL KBP270) PAGE 2
1-2 Heater Component Parts (Model KBP270)
Standard Components
Legend Part No. Description
1 2007.30 Complete Feed Auger Assembly
2 2007.40 Process Control Module
3 2007.45 System Control Switch
4 2004.96 Control Switch Cover
5 2007.10 Firebox Door and Frame Assembly
6 3107.37 Outside Weather Resistant Insulated
Cover
F
o
Water
2
3
4
5
6
1

HARDY MANUFACTURING CO., INC (MODEL KBP270) PAGE 3
1-2 Heater Component Parts (Model KBP270)continued
Legend Part No. Description
7 3100.58 Tank Assembly
8 607.42 3/4” Boiler Drain Valve
9 2007.19 Combustion Blower Assembly
10 502.00 Taco 009 Bronze Circulator
11 607.12 3/4” Brass Ball Valve
12 1100.28 Low Water Switch
13 1100.27 Automatic Water Fill Solenoid
14 2006.21 Stir Motor Assembly
15 2000.53 Process Control Relay
16 2000.55 Process Control Relay Socket
17 810.30 3/4” x 11.75” Raupex Pex A Pipe
18 810.32 3/4” x 2.5” Raupex Pex A Pipe
19 2007.13 Air/Power Transmission Assy
20 2004.00 GFCI
7
9
10
11
11
12
13
14
15
16
17
18 19
20
8

HARDY MANUFACTURING CO., INC (MODEL KBP270) PAGE 4
1-2 Heater Component Parts (Model KBP270)continued
Standard Components
Legend Part No. Description
21 2007.11 Firebox Burn Chamber Assembly
22 2007.24 Stir Rod/Combustion Air Distribution Assy
23 2007.20 Front Bearing assembly
24 2007.70 Front Bearing Hi-Temp Assy
25 2007.12 Heat/Particulate Recovery Module.
26 2007.50 Firebrick Assy.
27 608.36 1” Brass Union Fitting.
25
21
24
23
22
26
27

HARDY MANUFACTURING CO., INC (MODEL KBP270) PAGE 5
Legend Part No. Description
30 2007.36 Feed Auger Motor Cover Assy
31 2007.39 Feed Auger Hopper Top
32 2006.22 Feed Auger Motor Assy (6 rpm)
33 2007.35 Feed Auger Motor Mount Assy
34 2007.37 Feed Auger Drive Assy.
35 2007.34 Feed Auger Hopper Tube Assy.
36 660.10 2” Union Fitting
37 2007.33 Feed Auger Tube.
38 2007.38 Feed Auger Flighting.
39 2007.49 Feed Auger Conduit Assy.
1-2 Heater Component Parts (Model KBP270)
Feed Auger Components
30
31
32 33 34 35 36 37 38
39

HARDY MANUFACTURING CO., INC (MODEL KBP270) PAGE 6
F
o
Water
1-2 Heater Component Parts (Model KBP270)continued
Optional Component Parts
Legend Part No. Description
40 2007.85 Optional Day Hopper Assy
41 2007.86 Optional Tank Frame Assy
40
41

HARDY MANUFACTURING CO., INC (MODEL KBP270) PAGE 7
SECTION II
INSTALLATION OF HEATER
2-1 Location of Heater
The Hardy heater is designed to operate outside the structure to be heated. The unit
must be located a minimum of 10 feet from the structure.
The heating unit should be installed on a concrete pad with a recommended minimum
dimension of 30”W x 75”L x 4”D . This dimension is the minimum size for installation of
the furnace with the optional Hardy Day Hopper Assembly and/or Hardy Tank Frame
Assembly. If you will be using an alternate Fuel hopper then you will need to adjust the
dimensions accordingly. On the plumbing end of the heater you will need to bring up
through the pad a 4” water tight chase pipe to route your water lines and electrical lines
from the structure to be heated to the furnace.
75.000
30.000 12.000
3.500
5.000
9.125
Concrete Pad
Top View
Day Hopper on this
end
Heater on this
end
4" pipe should be located
within shaded area.
3.000
24.500
Hardy or other suitable

HARDY MANUFACTURING CO., INC (MODEL KBP270) PAGE 8
2-2 Location of Plumbing and Electrical Lines
To locate the connection points for plumbing and electrical lines you will need to
remove the rear access panel of the heater. The plumbing and electrical lines for your
unit must be installed underground in a water tight pipe or other suitable insulation
means. The water lines must be buried below the frost line to prevent freezing. Verify
the correct depth according to local building codes prior to installation.
The installation will require a trench wide enough to accommodate a 4” watertight pipe
or other insulation means. All plumbing and electrical lines should be installed inside
the 4” water tight pipe or other insulation means for a standard installation. An
additional pipe may be required if more than 1 zone or location is to be heated. If more
than one location is to be heated, a second 4” or single 6” watertight pipe or other
insulation means will need to be installed underground for the water lines and
thermostat wires of the second location.
This pipe will run from the rear of the unit to the location to be heated. Contained Inside
the 4” watertight pipe is a minimum of two water lines and electrical supply wire. The
listing below describes each line and related function.
1. One water supply line to heating system
2. One water return line from heating system
(Note: The supply and return lines must be at least 3/4” pipe. 1” pipe may be
required for longer distances. Some hydronic applications also require 1” pipe.)
3. One #12/2 W/Gnd NM type UF underground wire

HARDY MANUFACTURING CO., INC (MODEL KBP270) PAGE 9
2-3 Connection of Power to Heater
This unit must be wired by a qualified electrician
in accordance with the National Electrical Code.
Verify that all electrical power is turned off. Install a 20 amp circuit with #12/2 W/Gnd
NM Type UF wire from the power source through the 4” watertight pipe or other
means to the heater. This wire will connect to the “LINE” Terminals on the GFCI
Receptacle located on the rear of the furnace. The breaker installed at the power
source should be a 20 amp GFCI.
2-4 Wiring Diagram
11
109
8
7
6
5
43
2
1
4
1
5
12 8
9
14
13
MAIN HOT BK MAIN NEUTRAL W EARTH GROUND G
100/BK
101/W
101/W
101/W
100/BK
200/BK
201/R
202/O
203/BL WATER LEVEL SENSOR
204/BK Auto Water Fill
205/BL Combustion Blower
206/R Main Feed Auger
207/O Stir Motor
WHITE
RED
ORANGE
GREEN
BLUE
BLACK BK
BL
G
O
R
W
W
WIRE COLOR CODE
PROCESS CONTROL MODULE
MAIN POWER SWITCH
PUMP RECEPTACLE
PROCESS CONTROL
MODULE RELAY
203/BL WATER LEVEL SENSOR

HARDY MANUFACTURING CO., INC (MODEL KBP270) PAGE 10
2-5 Plumbing Connections
Connection to Heating System
1. The pipe that will supply the heating system is connected on the lower side of the
pump, ( Item 1).
2. The pipe that will carry the return water from the heating system is connected to the
3/4” Tee fitting as shown in diagram below. ( Item 2 ).
Water pipes must be designed for hot water service (ex. copper,
cpvc, or Pex A). Pipes should be installed in a 4” watertight pipe or
some other type of insulating means to prevent heat loss from heater
to heating system. Use only copper, brass, or stainless steel fittings.
Do not use galvanized or black iron.
2
Supply to
Heating
System
Heating
System
Return
1

HARDY MANUFACTURING CO., INC (MODEL KBP270) PAGE 11
2-6 Installation of Smoke Stacks and Condenser Stack
The space between the smoke stack opening and outside cover will need a bead of
silicone applied to fill any openings. The silicone is applied to prevent any water from
entering the outside cover. The condenser tank will also need to be sealed in this
manner. The application of silicon to these openings is illustrated by the diagram
below.
After the silicone is applied, you can install the two three foot sections of smoke stack.
The trim collar should be slid down the smoke stack until it rests on the outside cover.
The condenser stack must also be installed in the condenser stack opening. The trim
collar should be slid down the condenser stack until it rests on the outside cover.
DO NOT SEAL THE CONDENSER STACK TO THE WATER TANK
CONDENSER STACK OPENING. THIS IS THE WATER TANK VENT.
F
Water
Condenser Stack And
Collar
Do not seal Condenser
Stack to the Water Tank
Condenser Stack Opening.
Seal perimeter of Condenser
Stack Ring to Heater Hull using
Silicone Sealant.
6x8 Smoke Stack Cap
6x8 Smoke Stack
Extension.
6x8 Smoke Stack & Collar
Seal perimeter of Smoke Stack
to Heater Hull using
Silicone Sealant.

HARDY MANUFACTURING CO., INC (MODEL KBP270) PAGE 12
2-7 Filling the Heater with Water
THE FURNACE MUST BE FILLED WITH WATER BEFORE OPERATION.
There is a low water switch located in a fitting on the rear of the heater. This low water switch
signals a low water condition in the process control module. The process control module will
enable the automatic water fill valve assembly until the condition no longer exists. The
Furnace will not operate while in a Low Water Condition.
There are certain parts of the country that have high enough levels of chloride in the water to
be harmful to stainless steel tanks. Even though the USDA allows up to 250 parts per million
of chloride (salt) in the water as acceptable for drinking, experience has shown that chloride
levels as low as 45 parts per million will eventually cause stress corrosion cracking in stainless
steel tanks when water is heated. It is therefore required to use rain water or bottled water with
chloride content of less than 15 parts per million or test the water supply for chloride to assure
that the water supply does not exceed 45 parts per million. Call your Hardy dealer to obtain a
chloride test on your water supply. If the chloride content of your local water supply exceeds
the specifications mentioned above and necessitates the use of bottled or rain water, please
do so to maintain the warranty of your heater.
Fill your heater with water through the condenser stack opening until the water level is
approximately 1” from top of tank.