Hydro Flame Furnace 8525 Manual

The Hydro Flame Furnace 8525 is a high-efficiency heating system designed for residential and light commercial applications. This forced-air furnace features electronic ignition, variable-speed blower motor, multiple heat stages, energy-saving operation, digital thermostat compatibility, safety shut-off systems, and easy maintenance access. Rated for natural gas or propane operation with AFUE ratings up to 95%. Below are key sections for safety, features, installation, setup, operation, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Thermostat 7. Operating Procedures 8. Maintenance Schedule 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Heat exchanger, blower assembly, gas valve, ignition system, pressure switches, flame sensor, control board, air filter compartment.

Feature	Description
Heat Exchanger	Stainless steel primary and secondary heat exchangers
Blower Motor	Variable-speed ECM motor for quiet operation
Ignition System	Hot surface ignition with flame verification
Gas Valve	Modulating gas valve for precise temperature control
Control Board	Microprocessor-based with diagnostic LED
Air Filter	Standard 1-inch or 4-inch media filter compatible
Pressure Switches	Dual pressure switches for combustion safety
Flame Sensor	Rod-type flame sensor for safety shut-off
Vent Connections	PVC venting compatible (2-inch diameter)
Electrical	120V AC, 60Hz operation

Installation

Unpack and inspect contents. Ensure proper clearances and venting.

Position furnace: Place on level surface with minimum clearances as specified.
Connect gas supply: Use approved gas piping; pressure test for leaks.
Connect electrical: Follow local codes; include disconnect switch.
Install venting: Use approved PVC materials; maintain proper slope.
Connect ductwork: Ensure proper airflow; seal all connections.

WARNING! Gas appliances can be dangerous; installation by qualified professional required. Ensure proper ventilation.

First-Time Setup

Power on furnace; follow startup sequence.

Gas pressure adjustment: Set manifold pressure per specifications.
Blower speed settings: Adjust for heating and continuous fan operation.
Thermostat configuration: Connect compatible digital thermostat.
System check: Verify proper ignition sequence and flame operation.
Airflow verification: Check static pressure and temperature rise.

CAUTION! Carbon monoxide hazard - ensure proper combustion and venting before operation.

Specifications

Heating Capacity: 60,000-100,000 BTU/h (multiple models).
AFUE Rating: Up to 95% efficiency.
Fuel Type: Natural gas or propane (conversion kit required).
Electrical: 120V AC, 60Hz, 5-8 amps.
Blower Motor: Variable-speed ECM, 1/3 to 3/4 HP.
Heat Stages: Single or two-stage operation.
Venting: PVC Category IV (2-inch diameter).
Dimensions: Varies by model (typically 21"W x 26"D x 40"H).
Warranty: 20-year heat exchanger, 5-year parts.

Controls and Settings

Access control board via front panel. LED diagnostic display shows error codes.

Control Board: POWER switch, FUSE, diagnostic LED, dip switch settings.

Operating Modes: HEAT, COOL (with AC), FAN ONLY. Temperature Settings: Via compatible thermostat. Blower Settings: Heating speed, continuous fan speed. Safety Controls: Limit switches, pressure switches, flame rollout protection. Diagnostic Codes: LED flash patterns indicate specific faults.

Connecting Thermostat

Compatible with most 24V digital thermostats. Standard terminal designations.

Turn off power to furnace before wiring.
Connect thermostat wires to control board terminals (R, W, Y, G, C).
Configure thermostat for furnace type (gas, forced air).
Test operation in heating mode.

Tip: Use 18-gauge thermostat wire; follow color coding standards.

Operating Procedures

Normal heating operation with safety monitoring.

Startup: Thermostat calls for heat; inducer motor starts.
Pressure check: Pressure switches verify venting.
Ignition: Hot surface igniter glows; gas valve opens.
Flame verification: Flame sensor confirms ignition.
Blower operation: Blower starts after heat exchanger warms.
Shutdown: Thermostat satisfied; gas valve closes; blower continues.

WARNING! Never bypass safety controls. Regular professional inspection recommended.

Maintenance Schedule

Annual professional service recommended. Regular homeowner maintenance.

Frequency	Task
Monthly	Check/replace air filter
Seasonal	Inspect vent system
Annual	Professional cleaning and inspection
Annual	Check heat exchanger
Annual	Verify gas pressure and combustion

Care & Cleaning

Turn off power before cleaning. Use soft brush and vacuum for dust removal.

CAUTION! Do not use water or chemical cleaners on electrical components. Keep combustion area clear of debris.

Regulatory Information

ANSI Z21.47: Certified for natural gas and propane operation. CSA 4.9: Approved for venting with PVC. UL listed components. For support, visit www.hydroflame.com or contact 1-800-555-8525. Installation must comply with local building codes and utility requirements.

Troubleshooting

Symptom	Possible Cause	Corrective Action
No heat	Thermostat/Power/Gas	Check thermostat setting; verify power; check gas supply.
Blower not working	Motor/Control board	Check blower door switch; verify motor operation.
Furnace cycles off	Overheating/Limit switch	Check air filter; verify airflow; inspect heat exchanger.
Ignition failure	Igniter/Gas valve	Inspect igniter; verify gas pressure; check flame sensor.
Error codes displayed	Various faults	Refer to diagnostic chart in service manual.

Reset: Power cycle furnace; check diagnostic LED for codes.

Service: 1-800-555-8525; www.hydroflame.com