Hydro Flame Furnace 8535 Manual

The Hydro Flame Furnace 8535 is a high-efficiency heating system designed for residential and light commercial applications. This forced-air furnace features advanced combustion technology, multiple heating stages, digital thermostat compatibility, energy-saving modes, safety shutoff 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, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Multi-speed blower motor, electronic ignition system, heat exchanger, gas valve, pressure switches, flame sensor, control board, and safety limit switches.

Installation Requirements

Unpack and inspect all components. Verify proper clearances and location requirements.

1. Location: Install in approved areas with proper combustion air and clearances.
2. Gas connection: Use approved pipe and fittings; pressure test for leaks.
3. Electrical: 120V AC power supply with proper grounding.
4. Venting: Install approved PVC or metal venting per local codes.
5. Ductwork: Size appropriately for CFM requirements; seal all connections.

WARNING! Installation must be performed by qualified technician. Gas leaks can cause explosion or fire.

First-Time Setup

Complete installation verification before initial startup.

1. Gas pressure adjustment: Set manifold pressure per specifications.
2. Venting verification: Confirm proper draft and vent termination.
3. Electrical connections: Verify thermostat wiring and power supply.
4. System checkout: Run through complete startup sequence.
5. Combustion analysis: Verify proper CO levels and efficiency.

CAUTION! Never bypass safety controls. Test all safety functions before regular operation.

Technical Specifications

• Heating Capacity: 35,000 - 135,000 BTU/hr (multiple models)
• Fuel Type: Natural gas or propane (field convertible)
• Efficiency: Up to 95% AFUE
• Electrical: 120V AC, 60Hz, 3.5 amps maximum
• Blower Motor: Multi-speed ECM or PSC
• Venting: Category IV PVC or approved metal
• Gas Connection: 1/2" NPT
• Dimensions: Varies by model (check specific model data)
• Weight: 85-150 lbs depending on model
• Operating Temp Range: -30°F to 120°F ambient

Controls and Settings

Integrated control board with diagnostic capabilities. Thermostat connections for conventional and heat pump systems.

Control Board: LED status indicator, dip switch settings, terminal strip connections.

Operating Modes: Heat, Fan Only, Emergency Heat (heat pump). Blower Settings: Continuous fan, auto fan, variable speed adjustments. Temperature Control: Single-stage or two-stage thermostat compatibility. Diagnostic Codes: Flash patterns indicate specific fault conditions.

Venting and Ductwork

Category IV sealed combustion system. Requires proper vent sizing and installation.

1. Vent materials: Schedule 40 PVC, CPVC, or approved ABS.
2. Vent sizing: Follow manufacturer specifications for length and elbows.
3. Termination: Proper clearances from windows, doors, and air intakes.
4. Duct sizing: Calculate CFM requirements for heating capacity.
5. Airflow: Verify static pressure and adjust blower speed accordingly.

Tip: Always install carbon monoxide detectors when installing gas appliances.

Operating Instructions

Normal operation through connected thermostat.

1. Thermostat setting: Set to desired temperature and HEAT mode.
2. Startup sequence: Control board initiates pre-purge, ignition, and verification.
3. Normal operation: Burner operates at selected stage; blower activates after delay.
4. Shutdown: Thermostat satisfied; gas valve closes; blower continues for post-purge.
5. Fan operation: Continuous or automatic modes available.

WARNING! Never operate without proper venting. Monitor for unusual sounds or odors.

Maintenance Procedures

Regular maintenance ensures efficiency and longevity.

1. Monthly: Check and replace air filter as needed.
2. Annual: Professional inspection and cleaning.
3. Burner inspection: Clean and verify proper flame pattern.
4. Heat exchanger: Visual inspection for cracks or damage.
5. Blower assembly: Clean wheel and housing; lubricate if required.
6. Venting: Inspect for obstructions or deterioration.

CAUTION! Turn off power and gas supply before performing maintenance.

Safety Features

Multiple safety systems protect against hazardous conditions.

• Flame rollout switches: Detect improper burner combustion
• High limit switches: Prevent heat exchanger overheating
• Pressure switches: Verify proper venting operation
• Flame sensor: Confirms burner ignition
• Gas valve: Automatic shutoff on power loss
• Ignition control: Limited trial for ignition attempts

Regulatory Compliance

ANSI Z21.47: Certified for gas-fired central furnaces. UL 795: Commercial-industrial gas heating equipment. Meets applicable ASHRAE standards. For support, contact Hydro Flame Technical Services at 1-800-555-HEAT or visit www.hydroflame.com.

Troubleshooting Guide

Reset Procedure: Turn power off for 30 seconds, then restore.

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