Hardy KB165 User manual

INSTALLATION AND
OPERATING INSTRUCTIONS
FOR
THE HARDY
OUTSIDE WOOD
BURNING HEATER
Model –KB165
HARDY MANUFACTURING
COMPANY, INC.
12345 ROAD 505
PHILADELPHIA, MS 39350
PHONE: [phone]
FAX: [phone]
www.hardyheater.com
INSTALLATION AND
OPERATING INSTRUCTIONS
FOR
THE HARDY
OUTSIDE WOOD
BURNING HEATER
Model –KB165
HARDY MANUFACTURING
COMPANY, INC.
12345 ROAD 505
PHILADELPHIA, MS 39350
PHONE: [phone]
FAX: [phone]
www.hardyheater.com
Rev. 5/7/2015

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(MODEL KB165)
i
INTRODUCTION
Thank you for purchasing the KB165 which is certified to the EPA 2015 Emission
Standards. The KB165 is an all stainless steel Hardy Outside Wood Fired Hydronic
Heater. It represents the result of many years of Hardy experience and the input of
Hardy customers in the production of a top quality heater. 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 Wood Fired Hydronic 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 shovel
(7) 1.75” flue brush with handle
(8) Panel and insulation to put between fire box door & ash door
(9) Fire poker
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 Hydronic Heater.
Sincerely,
Frank L. Moore
President
Hardy Manufacturing Co., Inc.

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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 KB165)
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: Clean seasoned oak hardwood. Clean wood means wood that has no paint,
stains, or other types of coatings, and wood that has not been treated with
preservatives, including but not limited to, copper chromium arsenate, creosote, or
pentachlorophenol.
 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, any additional warnings on the unit, or instructions
contained in this manual may result in an accident causing personal injury and/or loss
of warranty.

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iv
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v
3. FUEL USED: Only those listed fuels recommended by the manufacturer of your unit.
OUTDOOR WOOD HEATER BEST BURN PRACTICES
1.1. Read and follow all operating instructions supplied by the manufacturer.
2. This heater is designed to burn natural wood only. Higher efficiencies and lower
emissions generally result when burning air dried seasoned hardwoods, as compared
to softwoods or to green or freshly cut hardwoods.
4. LOADING FUEL: For a more efficient burn, pay careful attention to loading times and
amounts. Follow the manufacturer’s written instructions for recommended loading
times and amounts.
5. STARTERS: Do not use lighter fluids, gasoline, or chemicals.
6. LOCATION: It is recommended that the unit be located with due consideration to the
prevailing wind direction.
7. Always remember to comply with all applicable state and local codes.
Outdoor Furnace Manufacturers Caucus
• Furnace should be located no less than 100 feet from any residence not served by
the furnace.
• If located within 100 feet to 300 feet to any residence not served by the furnace, it
is recommended that the stack be at least 2 feet higher than the peak of that
residence.
Chimney Height Installation Scenario
Residence
served by furnace
Residence not
served by furnace
Chimney height
should be 2 feet above roof line.
2 feet
Minimum of 100 feet

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vi
THE HARDY OUTSIDE WOOD FIRED HYDRONIC HEATER
How does an outside heater heat my home?
The Hardy outside wood fired hydronic heater is designed to save the most energy and
provide the most comfortable heating available. It heats your home by heating a
stainless steel tank filled with water, which surrounds the firebox of the outside heater.
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 wood 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 the Hardy Heater be located?
The outside unit should be located at least 10 feet from your home, other structures or
any other combustible materials so that all fire danger is removed. The unit may be
installed as much as 100 feet away. 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 wood 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. Additionally refer to the Best Burn Practices section in this manual.

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Additional Installation and Operational Considerations
Installation
Person(s) operating a Hardy hydronic heater must comply with all applicable
laws or other requirements, such as state laws or regulations and local
ordinances. Person(s) is/are also responsible for operation in a manner that
does not create a public or private nuisance condition. The distance and stack
height Hardy Mfg. recommends and the requirements in any applicable laws or
other requirements may not always be adequate to prevent nuisance
conditions due to terrain or other factors. This wood heater has a manufacturer-
set minimum low burn rate that must not be altered. This wood heater needs
periodic inspection and repair for proper operation. It is against federal
regulations to alter this setting or otherwise operate this wood heater in a
manner inconsistent with operating instructions in this manual.
Operation in a manner inconsistent with the owner’s manual will void the
warranty.
EPA’s Burnwise Program
http://www.epa.gov/burnwise
How to Use a Moisture Meter Video
http://www.youtube.com/watch?v=jM2WGgRcnm0
EPA offers tips on how to properly use a moisture meter to test firewood
before using in a wood-burning stove or fireplace. Wet wood can create
excessive smoke which is wasted fuel.
Split, Stack, Cover and Store Video
http://www.youtube.com/watch?v=yo1--Zrh11s
EPA offers four simple steps to properly dry firewood before using in a
wood-burning stove or fireplace. Wet wood can create excessive smoke
which is wasted fuel. Burning dry, seasoned firewood with a moisture
content of 20% or less can save money and help reduce harmful air
pollution.
Wet Wood is a Waste brochure
http://www.epa.gov/burnwise/pdfs/wetwoodwastebrochure.pdf
This tri-fold brochure provides colorful illustrations of the four easy steps
to dry firewood.

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TABLE OF CONTENTS
SECTION I: General Information
1-1 Specifications............................................................1-2
1-2 Heater Component Parts ..........................................3-5
SECTION II: Installation of Heater
2-1 Location of Heater........................................................6
2-2 Chimney Connection....................................................7
2-3 Location of Plumbing & Electrical Lines .......................7
2-4 Connection of Power to Heater ....................................8
2-5 Wiring Diagram .........................................................8-9
2-6 Plumbing Connections ...............................................10
2-7 Installation of Smoke Stacks and Condenser Stack 11
2-8 Filling the Heater with Water……………………………12
2-9 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 Hot Water .........19
SECTION VI: Heater Operation
6-1 Firing the KB165 ........................................................20
6-2 Loading the KB165 ....................................................21

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ix
TABLE OF CONTENTS continued
SECTION VII: Service Information
7-1 Water Temperature.................................................... 22
7-2 Fuel Usage ................................................................ 22
7-3 Moisture in the Firebox .............................................. 22
7-4 Improper Burning ....................................................... 22
7-5 Ash Removal ............................................................. 22
7-6 Water Circulation System .......................................... 22
7-7 Combustion Air Blower Assembly…………………… . 22
7-8 Air Volume Box .......................................................... 23
7-9 Low Water Float......................................................... 23
7-10 Temperature Logic Controller .................................. 23
7-11 Low Water Lockout Relay ........................................ 23
7-12 Timer........................................................................ 23
7-13 Time Delay Relay..................................................... 23
7-14 Moisture Content of Wood……………………........... 24
7-15 Fuel Usage .............................................................. 24
SECTION VIII: Heater Maintenance
8-1 Weekly Maintenance.................................................. 25
8-2 Monthly Maintenance................................................. 26
8-3 Extended Period Shut Down and Start Up................ 27
SECTION IX: Appendix
9-1 General Trouble Shooting Guide .........................28-30
SECTION X: Component Service / Replacement Procedure
10-1 Water Solenoid Valve ........................................31-32
10-2 Low Water Float Switch ......................................33-34
10-3 Pump ..................................................................35-36
10-4 Damper Solenoid ................................................37-38
10-5 Damper Solenoid Bracket ........................................ 39
10-6 Air Volume Box Seal ................................................ 40
10-7 Lockout Relay / Time Delay Relay ........................... 41
10-8 Temperature Logic Controller .............................42-43
10-9 Blower...................................................................... 44
10-10 Bypass Damper ................................................45-46
10-11 Door Seals ........................................................47-49
10-12 Fire Box Door Latch Adjustment .......................50-51
SECTION Xl: Heater Repair Parts
11-1 Heater Repair Parts ................................................ 53
Warranty Card Copy ........................................................ 55

HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 1
1 –1 Specifications
KB165 Hardy Wood Fired Hydronic Heater
For Outdoor Use Only
Type of fuel –Clean seasoned oak hardwood
Never use the following: Garbage; Lawn clippings or yard waste; Materials containing
rubber, including tires; Materials containing plastic; Waste petroleum products, paints
or paint thinners, or asphalt products; Materials containing asbestos; Construction or
demolition debris; Railroad ties or pressure-treated wood; Manure or animal remains;
Salt water driftwood or other previously salt water saturated materials; Unseasoned
wood; or Paper products, cardboard, plywood, or particleboard. The prohibition against
burning these materials does not prohibit the use of fire starters made from paper,
cardboard, saw dust, wax and similar substances for the purpose of starting a fire in an
affected wood heater. Burning these materials may result in release of toxic fumes or
render the heater ineffective and cause smoke.
Wood Dimension & Condition -
22” to 24” in Length, 30% Moisture or less, Cured between 6 to 9 months.
Any round wood over 7” in diameter must be split at least once.
Wood Load Capacity -
10 to 15 pounds / cubic ft.
Firebox is approximately 13 Cubic Feet
Wood weight is approximately 130 to 195 pounds.
SECTION I
GENERAL INFORMATION
This manual describes the installation and operation of The Hardy, Model KB165
Wood Fired Hydronic Heater, certified to the EPA 2015 Emission Standards.
This heater meets the 2015 U.S. Environmental Protection Agency's crib wood
emission limits for wood heaters sold between May 15, 2015 and May 15, 2020.
Under specific test conditions this heater has been shown to deliver heat at rates
ranging from 18,475 to 139,629 Btu/hr with efficiencies ranging from 53.4% to 68.5%.
This wood heater has a manufacturer-set minimum low burn rate that must not be
altered. It is against federal regulations to alter this setting or otherwise operate this
wood heater in a manner inconsistent with operating instructions in this manual.
Operation in a manner inconsistent with the owner’s manual will void the warranty.

HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 2
1 –1 Specifications (continued)
Clearance to Combustibles
Top, Rear, Sides 18”
Chimney Connector 18”
Front 48”
Flooring Non Combustible
Electrical Rating 115 VAC/ 60 HZ / 1PH
MFS-20 AMP, MCA-20 AMP
Water Capacity
KB165 –Holds Approximately 130 Gallons of Water
Heater Outside Dimensions
Model Width Depth Height Weight
KB165 - 150,000 BTU 34” 60” 61” 1092 lbs.
This model wood fired hydronic heater has a preset forced air draft fan that requires
no draft adjustments.
Draft is the force of air drawn from outside the heater and pushed throughout the
various chambers before finally exiting through the smoke/flue stack. Excess ash or
creosote buildup can hinder this process causing the heater to under perform and
produce excess emissions. Normal maintenance at scheduled intervals keeping all
air passages clean will insure optimal performance.
DO NOT OVERFIRE THIS HEATER. Attempts to over fire this heater to achieve
more than rated outputs will void your warranty.

HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 3
1-2 Heater Component Parts Model KB165
Standard Components
Legend Part No. Description
1 1100.00 Water Solenoid Valve Assembly
2 1100.28 SMD 1/2” Float Switch
3 2004.00 Ground Fault Interrupter Receptacle
4 2004.30 Terminal Block Assy.
5 508.50 Taco 008 SS pump
6 502.50 Taco 009 SS Pump
7 2002.69 1TDR6 Blower
8 7165.45 Air Volume Box
9 2065.10 Temperature Logic Controller
7 6
5
4
3
2
1
9
8

HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 4
1-2 Heater Component Parts Model KB165
Standard Components (continued)
Legend Part No. Description
10 2065.50 Turbulators
11 7165.99 Bypass Damper
12 2001.05 Damper Solenoid
13 7165.40 Air Tube Damper Assy.
12
11
10
Inside of Air Volume Box
13

HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 5
1-2 Heater Component Parts Model KB165
Standard Components (continued)
Legend Part No. Description
14 3105.18 Secondary Air Distribution Plenum
15 3105.17 Fire Grates
16 2165.27 Back wall brick
17 2165.28 Side Brick
18 2165.31 Bottom Front & Back Bricks
19 7165.20 Primary Air Distribution Plenum
17
14
16
15
17
19
18

HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 6
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 any structure.
The heating unit should be installed on a concrete pad with a recommended minimum
dimension of 34”W x 61”L x 4”D. 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.
Reference the illustration below for pad layout and ideal placement of 4” pipe.
Concrete Pad
Top View
4" pipe should be located
within shaded area.
3.0000
3.0000
12.0000
9.125 38.000
60.000

HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 7
2-3 Location of Plumbing & 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” water tight 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 one zone or location is to be heated. If
more than one location is to be heated, a second 4” or single 6” water tight 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
2-2 Chimney Connection
Do not connect this unit to a chimney flue servicing another appliance

HARDY MANUFACTURING CO., INC (MODEL KB165) PAGE 8
2-4 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 Heater. The breaker installed at the power
source should be a 20 amp GFCI.
2-5 Wiring Diagram
This equipment must be installed in accordance
with the National Electrical Code.
( See wiring diagram next page )