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 marked installation clearances. - inspect and clean entire venting system including all flues and chimney regularly.
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 Outside Air Knockout (either side) Power Cord Circuit Breaker Side Access Panel Boiler Drain (Either Side) Firebox Door Firebox Draft Test Port Levelling Feet 3 1- Controlled & 1-Un-controlled 120VAC Outlets
Table of Contents Options 5 Installation Venting Plumbing Electrical 6 9 14 20 Operation 26 Maintenance 33 Troubleshooting 38 Specifications 39 Wiring Diagram 40 Warranty 41 Testing Label 42 Service Parts 43 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.
Options Outside Air Components Flex pipe part# 1-00-08543 (25') Inlet Cover part# 1-10-08542 Direct Vent Wall Passthrough 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- 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.
Installation Boiler Kit Materials: (Refer to page 3) List of items shipped with the unit. 1 - 3/4” Boiler Drain 1 - 3/4” Safety Relief Valve 1 - 1/2” Dual Temperature/Pressure Gauge 1 - Outdoor Air Sensor 2 - Piping Support Brackets 1 - Scraper Tool 4 - 1½” Levelling Feet. (page 7) Preparation For Installation: 1. Install 3/4” MPT boiler drain in the fitting as shown. Either side can be utilized.
Installation 29 1/8” [739.78mm] Minimum non-combustible floor protection area NON-COMBUSTIBLE FLOOR PROTECTION 46 7/8” [1190.63mm]US 48 7/8” [1241.43mm]CAN 29 1/8” [739.78mm] 6” [152.4mm] 16” [406.4mm]US 18”[457.2mm]CAN 46 7/8” [1190.63mm]US 48 7/8” [1241.43mm]CAN Floor Protection: The striped area indicates the minimum required floor protection area if the boiler is going to be placed on a combustible floor.
Installation C B A D Minimum Clearances To Combustible Materials Sidewall To Appliance A 6” (152 mm) Mur Latéral à l’Appareil Backwall To Appliance B 6” (152 mm) Mur Arrière à l’Appareil Stove Top To Ceiling 16” (406 mm) Haut du Poêle au Plafond 48” (1219 mm) Des Combustibles au Devant du Poêle C Stove Front To Combustibles D Combustibles To Pellet Vent 3” (76 mm) Matériaux Combustibles au Conduit de Fumée Minimum Alcove Height 72” (1829 mm) Hauteur de l’Alcôve Minimum Alcove Width 48
Venting 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 combustible 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.
Venting Venting Use only 3” pellet vent pipe to vent your pellet boiler. 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.
Venting Venting The minimum vent configuration is a 90o or Tee on a starter collar and a 24” length horizontal through an exterior wall. A cap on the end should direct the flue gases down and away from the structure. See Fig. 5. 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*.
Venting Installation To reduce probability of reverse drafting during a power failure, Hearth & Home Technologies strongly recommends: •Installing the pellet vent with a minimum vertical rise of five feet. Preferably terminating above the roof line. •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: •Maintain specified clearances to windows, doors and air inlets, including air conditioners.
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. Fig. 6 Outside Air Pipe Knockout Per national building codes, consideration must be given to combustion air supply for all appliances in the vicinity of the pellet boiler.
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.
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.
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.
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.
Installation-Plumbing EXAMPLES OF TYPICAL DOMESTIC HOT WATER STORAGE PIPING EXAMPLE #2 EXAMPLE #1 CAUTION: No domestic water temperature regulation shown HIGHER TEMPERATURE WATER (IF NEEDED) CAUTION: No domestic water temperature regulation shown FROM BOILER FROM BOILER COLD TEMPERED HOT WATER FOR SHOWERS AND FAUCETS HOT COLD MIXING VALVE MIXING VALVE SET TO DESIRED WATER TEMPERATURE. NORMALLY NOT MORE THAN 120 DEGREES.
Installation-Plumbing EXAMPLE OF A COMBINATION HIGH/LOW MULTI-ZONE HEATING SYSTEM WITH INDIVIDUAL ZONE CIRCULATORS 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”.
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.
Installation With A Hot Air System Existing T'stat New T'stat set 3° below new t'stat set 3° above existing t'stat L W1 O/B L Y G R C W1 O/B Y G R C SPLICE ( by installer ) Existing T'stat Wiring New T'stat Wire ( by installer ) SPLICE ( by installer ) 24 VAC com.
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 24 VAC com.
3 4 1 5 6 7 3 4 1 5 6 7 Grainger#2XC02 Omron LY2F 120V R1 RELAY 8 Grainger#2XC01 Omron LY2F 24V R2 RELAY 8 ( by installer ) L N INSIDE the CONTROL SPLICE HIGH VOLTAGE ( ORANGE) from the control HIGH VOLTAGE ( N ) ( by installer ) ( by installer ) HIGH VOLTAGE ( L1 ) ( by installer ) LOW VOLTAGE 24 VAC COIL will power the fan on temperature rise. not the fan relay.
Connection with a wireless thermostat WIRELESS THERMOSTAT WIRING BROWN BROWN to control board L LT.BLUE N LT.BLUE to control board Installer Supplied Wireless T’stat Receiver GREEN/YELLOW LT. BLUE BROWN GREEN/YELLOW ORANGE from control 8 5 4 3 GREEN/YELLOW T 7 6 VIOLET from control LT. BL VIO UE LE WHITE RED GREEN 1 R1 RELAY Grainger#2XC02 Omron LY2F 120V LOW VOLTAGE LT.BLUE BROWN BROWN 1.5 AMP AUX.
Installation Draft Testing Port 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”.
Operation Power Light Indicates power to the control board. (Ready) Feed adjuster Sets the maximum feed rate Status Light Will be lit anytime the unit is in operation. Test Combustion blower, feed motor and safety dump zone are fully energized for the first minute. Then, the combustion blower will stay on low. Overheat Saftey Zone Light Indicates that the boiler water temperature has reached 210 Degrees F. Lighting Mode Selector Switched between Auto and Manual lighting.
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.
OAT 65o 60o 55o 50o 45o 40o 35o 30o 25o 20o 15o 10o 5o 0o Example 2 Max set at 180o Min set at 150o Water Temp 150o 150o 150o 150o 155o 160o 165o 170o 175o 180o 180o 180o 180o 180o Water Temp 140o 145o 150o 155o 160o 165o 170o 175o 180o 185o 185o 185o 185o 185o Degree Change * * * -30o -25o -20o -15o -10o -5o 0o 0o 0o 0o 0o Degree Change -45° -40° -35° -30° -25o -20o -15o -10o -5o 0o 0o 0o 0° * No change in boiler temperature after reaching minimum setpoint temperature.
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.
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.
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. 9. Fill hopper with pellets and remove ashes as required. 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.
Operation 11. Apply starting gel as shown in Fig.15 12. Light The Starting Gel With A Match. Fig. 15 NOTE: Stirring the starting gel into the pellets usually allows the fire to become established quicker. CAUTION: A vapor flash could occur if too much time is allowed to pass before lighting the starting gel. CAUTION: Care must be taken not to get starting gel on your hands or clothing. Serious burns could occur during the lighting process.
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.
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.
Maintenance Firebox Baffle Removal Spirals can be used to scrape the heat exchange tubes. Se ali Ta b ng s( 2) Ar Slo ea ts (2) Silicone sealing gasket La tch 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.
Maintenance The boiler MUST be OFF at the circuit breaker, and COOL before you attempt to clean the combustion blower. Blower Cover The wire to the combustion blower doesn’t need to be disconnected during the cleaning process. Latch Fig. 22 Theexhaust sensing probe (ESP) is located here. Three Thumb Screws Fig. 23 5” Double Bladed Fan (standard) #3-21-502221 Fig. 24 Remove the combustion blower cover.There are two latches that hold the shield in place (Fig. 22).
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.
Troubleshooting FEEDER DOES NOT FEED 1. No pellets in hopper. 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. 5.
.7 AMP 2.3 AMP .05 AMP .2 KWH Auger motor Igniter element Control board Approximate operating wattage 525 Lbs. Shipping Weight (Includes Packaging) Duty Cycle 80% - Although this model is rated for 60,000 BTU on high burn, it is not intended to remain on high burn continuously. 1.4 AMP 120 VAC 60 Hz Combustion blower Electrical * 8500 BTU per pound figures Max. Burn = 7 pounds per hour Min. Burn = 1.1 pound per hour 0 BTU if system is satisfied.
LOW PRESSURE SWITCH N.O.CONTACTS FEEDER MOTOR GREEN/YELLOW BONDED TO STOVE BODY GREEN WIRE IS GROUND LT. BLUE IGNITER PUMP LT.BLUE GREEN/YELLOW BONDED TO STOVE BODY GREEN WIRE IS GROUND BLACK POWER CORD BLACK LT.BLUE RD BLACK T WAT 450 VAC 120 IGNITER ELEMENT LT. BLUE YELLOW BROWN BLACK GREEN/YELLOW GREEN/YELLOW WHITE 10 AMP CIRCUIT BREAKER YELLOW 18/3 RUBBER CO BROWN 120 VOLTS A.C. 60 HZ. 635 WATTS- 5.3 AMPS ( ignition mode ) 200 WATTS- 1.
Warranty ECO-CHOICE™ LIMITED WARRANTY Hearth & Home Technologies Inc., on behalf of its Heatilator® brand (”HHT”), extends the following warranty for all ECOCHOICE™ furnace and boiler products (“Products”) that are purchased from an HHT authorized dealer.
Testing Label BH60 8 BH60 A L T Wood Pellets I N U O T . R N E IO F E AT R , RM L E FO B A IN L E TY L P FE M A A S S WARNING: Risk of fire ATTENTION: Risque de feu R O F Flooring must be non-combustible material extending 6” to the sides, and 16” (US) or 18”(CAN) in front of the ash removal door. Do not operate with the flue draft exceeding -.9 in Water Column / -224Pa.
bh105 Service Parts beginning manufacturing date: july 2009 Ending manufacturing date: Active bioflow hydronic 105k Pellet boiler 1 2 28 3 27 26 4 5 25 6 7 8 24 23 22 21 20 9 10 19 11 12 18 13 14 15 16 17 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.
bh60 Service Parts 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. ITEm description COmmENTS Stocked at depot PArT NumbEr 1 Plumbing Support Kit - Qty. 2 req.
bh60 Service Parts 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. ITEm description COmmENTS PArT NumbEr Stocked at depot 32 3/8" Flex Connector Qty. 2 req.
bh60 Service Parts 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. ITEm description COmmENTS Stocked at depot PArT NumbEr 61 Spring Latch Qty. 4 req.
Notes
**See the section on Maintenance for more details about cleaning. *See the section on Operation for information about Manual Lighting and Emergency Power. The boiler will ignite if the temperature of the boiler water is less than the temperature set on MAX TEMP dial.. 9 Flip the igniter switch to Auto.* 8 Turn MIN TEMP dial to the desired settings.* 7 Turn the MAX TEMP dial to the desired temperature. 6 Turn Feed Adjuster back to the #4, or previously known setting.
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.
