Hydro Flame Furnace Manual

The Hydro Flame Furnace is a high-efficiency heating system designed for residential and commercial use, featuring advanced hydro-thermal technology, digital temperature controls, energy-saving modes, safety shut-off systems, and compatibility with various fuel sources. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Hydro-thermal heat exchanger, Digital Control Panel, Fuel Input Port, Exhaust Vent, Water Circulation Ports, Safety Sensors.

Installation

Unpack and inspect all components. Ensure proper ventilation and clearance.

1. Position unit: Place on level surface with minimum 12-inch clearance on all sides.
2. Connect fuel source: Attach appropriate fuel line to input port using approved fittings.
3. Connect water circulation: Install input and output water lines with proper seals.
4. Install exhaust vent: Route vent pipe to exterior with proper slope.
5. Connect electrical: Plug into dedicated 120V AC outlet.

WARNING! Installation must be performed by qualified technician. Ensure all connections are leak-free and secure.

First-Time Setup

Power on furnace; follow initialization sequence.

1. System purge: Press PURGE button to remove air from water lines.
2. Set operating parameters: Use digital panel to set desired temperature ranges.
3. Calibrate sensors: Run auto-calibration sequence from settings menu.
4. Test operation: Verify proper ignition and heat output.

CAUTION! Do not operate without proper water flow. Ensure ventilation system is unobstructed.

Specifications

• Heating Capacity: 80,000-120,000 BTU/hr
• Efficiency Rating: 95% AFUE
• Fuel Types: Natural gas, Propane, Oil
• Water Temperature Range: 100°F - 180°F
• Electrical Requirements: 120V AC, 60Hz, 15A
• Dimensions: 36" H x 24" W x 18" D
• Weight: 185 lbs
• Operating Pressure: 12-30 PSI
• Vent Requirements: 4-inch diameter, Category III

Controls and Settings

Access control panel for all system adjustments. Front Panel: POWER, MODE, TEMP UP/DOWN, DISPLAY, RESET.

Digital Interface: Temperature display, Mode selection, Schedule programming, System status, Error codes.

Operating Modes: AUTO (thermostat controlled), MANUAL (continuous operation), ECONOMY (reduced output). Temperature Settings: Set point adjustment, Differential settings, Maximum temperature limit. System Settings: Pump control, Vent damper, Ignition sequence, Safety timeout.

Connecting to Systems

Compatible with standard hydronic heating systems, radiant floor systems, and baseboard radiators.

1. Turn off power and fuel supply before making connections.
2. Connect water lines: Use 3/4-inch copper or PEX piping.
3. Install circulation pump: Ensure proper flow rate and head pressure.
4. Connect thermostat: Use compatible 24V thermostat system.
5. Test system: Check for leaks and proper operation.

Tip: Install isolation valves for easy maintenance and service.

Operation Modes

Multiple operating modes for different heating requirements.

1. AUTO Mode: Responds to thermostat calls for heat automatically.
2. MANUAL Mode: Continuous operation at set temperature.
3. ECONOMY Mode: Reduced output for energy savings.
4. VACATION Mode: Maintains minimum temperature during absence.
5. BOOST Mode: Temporary high-output for rapid heating.

WARNING! Do not operate in manual mode for extended periods without monitoring.

Safety Features

High-limit switch: Shuts off burner if temperature exceeds safe limits. Pressure relief valve: Releases excess pressure from water system. Flame failure detection: Monitors burner operation and shuts down if flame is lost. Vent safety switch: Ensures proper venting before operation.

Maintenance & Cleaning

Annual maintenance required for optimal performance and safety.

1. Clean heat exchanger: Remove and clean annually.
2. Inspect burners: Check for proper flame pattern and cleanliness.
3. Check water quality: Test and treat as needed to prevent scaling.
4. Clean vents: Remove any obstructions from exhaust system.
5. Lubricate pump: Apply approved lubricant to circulation pump.

CAUTION! Always disconnect power and fuel before performing maintenance.

Regulatory Information

UL Certified: Meets UL 795 standards for commercial-industrial gas heaters. ANSI Z21.13: Complies with gas-fired low pressure steam and hot water boilers. EPA Compliant: Meets emissions standards for residential heating equipment. For technical support, visit www.hydroflame.com or contact 1-800-555-HEAT.

Troubleshooting

Reset Procedure: Hold RESET button for 5 seconds to clear error codes.

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