Hydro-Smart HS120CON-LP, Installation Manual And Owner'S Manual

Page 1: ...iately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Hydro Smart 120 Condensing Gas Micro Boiler Installation Manual and Owner s Guide ANSI Z21 10 3 and CSA 4 3 If the information in these instruc...

Page 2: ...built Panels 27 APPLICATIONS 27 INITIAL OPERATION 29 OPTIONAL ITEMS 30 Owner s Guide OPERATING SAFETY 22 NORMAL OPERATION 34 Display of controller 34 General 34 Temperature table of controller 34 Temperature settings 35 Additional features 36 Flow 37 Freeze protection system 37 Maintenance and service 38 Unit draining and filter cleaning 38 TROUBLESHOOTING 39 General 39 Error codes 41 COMPONENTS DI...

Page 3: ...ad through this safety manual carefully Please refer to the back of the manual for details about the warranty Keep this manual for future reference If you lose the manual contact the manufacturer or your local distributor When you call please tell us the model number and the serial number of your unit written on the rating plate of the micro boiler ...

Page 4: ... Gas Input Operating Range BTU h Min 15 000 Max 120 000 Propane Input Operating Range BTU h Min 15 000 Max 120 000 Gas Connection 1 2 NPT Water Connection 3 4 NPT Water Pressure psi MPa 15 150 0 1 1 0 Natural gas Inlet Pressure inch W C kPa Min 5 0 1 2 Max 10 5 2 6 Propane Inlet Pressure inch W C kPa Min 8 0 2 0 Max 14 0 3 5 Manifold Pressure Natural Gas inch W C Pa 3 30 820 2 00 500 Propane inch ...

Page 5: ...lustrates condensing micro boiler design concepts only and does not accurately represent the micro boiler s physical description 1 Your thermostat indicates a need for heat and turns on a circulator pump 2 Fluid enters the heater 3 The flow sensor detects the fluid flow 4 The computer initiates the fan motor and sends a signal to the igniter to create an ignition spark 5 The gas ignites and flames app...

Page 6: ...er to p 8 4 Check the rating plate for the correct GAS TYPE GAS PRESSURE FLUIDPRESSUREand ELECTRIC RATING If this micro boiler does not match your requirements do not install and consult with the manufac turer 5 If any problem should occur turn off all thermostats and turn off the gas Then call a trained technician or the Gas Company or the manufacturer WARNING Do not store or use gasoline or other ...

Page 7: ...r to p 17 to 19 8 Particles from flour aerosols clothes dryers and other airborne contaminants may clog the air vent build up and reduce the functions of the rotating fan cause improper burning of the gas or cause damage to the micro boiler Regularly ensure that the area around the micro boiler is dust or debris free Regular maintenance is recommended for these types of environments Sealed combusti...

Page 8: ...be installed under the micro boiler in case of leaks It is recommended to direct vent the heater WARNING Damage caused by water quality is not covered by the warranty Only potable water or potable water glycol mixtures can be used with this micro boiler Do not introduce pool or spa water or any chemically treated water into the micro boiler Water hardness levels must not exceed 7 grains per gallon...

Page 9: ...information on optional items please refer to p 32 to 33 CLEARANCES Maintain all clearances around the micro boiler Model Top Bottom Front Back Sides HS120Con LP Liquid propane 12 in 305 mm 12 in 305 mm 4 in 102 mm 1 in 25 mm 3 in 76 mm HS120Con NG Natural Gas 24 inches recommended for maintenance Top Back Side Side Front 12 in 305 mm 12 in 305 mm 4 in 102 mm 1 in 25 mm 3 in 76 mm ...

Page 10: ...se venting that complies with ULC S636 General rules for venting micro boiler are Place the micro boiler as close as possible to the vent termination The vent collar of the micro boiler must be fastened directly to an unobstructed vent pipe Do not weld the vent pipe to the micro boiler s vent collar Do not cut or alter the vent collar of the micro boiler The vent must be easily removable from the ...

Page 11: ...chedule 40 PVC ANSI ASTM D1785 ULC S636 Certified Materials Only PVC DWV ANSI ASTM D2665 Schedule 40 CPVC ANSI ASTM F441 Schedule 40 ABS DWV ANSI ASTM D2661 Polypropylene UL 1738 Pipe Cement Primer PVC ANSI ASTM D2564 CPVC ANSI ASTM F493 ABS ANSI ASTM D2235 NOTE Do NOT Use Cellular Foam Core Pipe For each elbow added deduct 5 ft 1 5 m from max vent length For details on the vent connection refer to...

Page 12: ...N OFF ON 1 2 3 4 5 6 7 8 9 10 OFF ON 1 2 3 4 5 6 7 8 9 10 OFF ON 1 2 3 4 5 6 7 8 9 10 Set DIPswitches shown in the tables below depending on the vent length Only adjust switches with a black square Black squares indicate the position of the switch Vent length Single pipe 5 to 45 ft DEFAULT No 6 ON No 7 OFF 46 to 70 ft No 6 OFF No 7 OFF OFF ON 1 2 3 4 5 6 7 8 9 10 OFF ON 1 2 3 4 5 6 7 8 9 10 Vent l...

Page 13: ...er 2 Connect a 3 x 2 reducer directly on the exhaust vent collar of the micro boiler Make sure the couplings engage the o rings installed in the intake and exhaust vent collars 3 Connect a 2 straight pipe to the reducer Vent connections for single pipe The micro boiler came with a metal screen that will fit into a 3 inch elbow 3 elbow with bird screen Intake vent collar Female 3 x2 reducer 2 straig...

Page 14: ...ent collar Female The micro boiler came with a metal screen that will fit into a 3 inch elbow For details of the optional items refer to the Installation manual for each optional item 1 Connect 3 x 4 increasers directly on the exhaust and intake vent collar of the micro boiler Make sure the couplings engage the o rings installed in the intake and exhaust vent collars 2 Connect 4 straight pipes to t...

Page 15: ... Single pipe with room air intake Terminations Wall Hanger Hanger Roof Roof flashing Fire stop Termination Wall Hanger Roof flashing Fire stop Roof Refer to pages 17 and 19 for clearance information Examples of of 3 inch 4 inch vent ...

Page 16: ...0 F For best results a vent system should be as short and straight as possible The micro boiler is a Category IV appliance and must be vented accordingly with any 4 inch vent approved for use with Category III IV or Special BH type gas vent The manufacturer recommends the NovaVent Z Vent line However the following are also UL listed manufacturers ProTech Systems Inc FasNSeal Metal Fab Inc and Heat...

Page 17: ...tor assembly 3 feet I Clearance to service regulator vent outlet 3 feet J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other application 3 feet 1 foot 4 feet from below or side opening 1 foot from above opening K Clearance to mechanical air supply inlet 6 feet 3 feet 3 feet L Clearance above paved sidewalk or paved driveway located on public property ...

Page 18: ...least 1 ft 305 mm away from each other no matter the orientation A direct vent termination must also be at least 2 ft 610 mm away from an inside corner If the adjacent wall is less than 2 ft 610 mm of length the minimum required distance away from the inside corner will be equal to the length of that adjacent wall Combined intake and exhaust termination Inside corner 1 ft 305 mm min 2 ft 610 mm mi...

Page 19: ...A Intake air B B A Exhaust Gas A Exhaust terminations must be at least 1 ft 305 mm away from any obstructions B Intake terminations must be at least 1 ft 305 mm away from any obstructions Exhaust termination 2ft 610mm min Please follow all local and national codes in regards to proper termination clearances In the absence of such codes the clearances above can be used as guidelines Local codes sup...

Page 20: ...sure testing of that system at test pressures in excess of 1 2 psi 3 5 kPa The micro boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psi 3 5 kPa 3 Always purge the gas line of any debris and or water before connecting to the gas inlet Size ...

Page 21: ...re than one appliance Ex Point A to Point B add up the cubic ft requirements of the appliances that are being supplied by that section and size to the farthest appliance For Example The section from A to B supplies gas to the furnace range and dryer Adding up the BTU requirements and dividing by 1 000 yields a cubic ft requirement of 220 cubic ft of gas The farthest appliance is the range which is...

Page 22: ...ff position Do not use this micro boiler if any part has been submersed under water Immediately call a licensed professional to inspect the micro boiler to replace any damaged parts Do not reverse the hot outlet and cold inlet connections to the micro boiler This will not properly activate the micro boiler CAUTION 1 Shut off the manual gas valve on the gas supply line 2 Remove the screw for the pres...

Page 23: ...ressure relief valve and run the end of the tube to within 6 inches 152 mm from the floor This discharge tube must allow free and complete drainage without any restrictions If the pressure relief valve installed on the micro boiler discharges periodically this may be due to a defective thermal expansion tank defective pressure relief valve or it could be signs of internal scale build up The pressur...

Page 24: ...nect a 1 2 FPT X 3 8 or 1 2 HB Adaptor to the condensate drain port at the bottom of the micro boiler 2 Connect a condensate drain tube to the 1 2 FPT X 3 8 or 1 2 HB Adaptor The manufacturer recommends the material of the condensate tube be either EPDM or PVC 3 Leave an adequate amount of space between the end of the drain tube and the actual drain to facilitate proper drainage Case B If a neutra...

Page 25: ... than the micro boiler to prevent condensate water from building up inside the heat exchanger Condensate cannot be effectively neutralized if the neutralizer elements inside the Neutralizer accessory have been completely consumed If this happens condensate will remain acidic and can possibly cause damage to items such as pipes concrete etc if drained improperly The Neutralizer cartridge is designed...

Page 26: ...djust the necessary switches Bank of DIPswitches Computer board Altitude 0 to 2 000 ft DEFAULT 2 000 to 3 000 ft 3 000 to 5 000 ft 5 000 to 7 500 ft 7 500 to 10 100 ft DIPswitches No 3 OFF No 4 OFF No 5 OFF No 3 OFF No 4 ON No 5 OFF No 3 OFF No 4 OFF No 5 ON No 3 OFF No 4 ON No 5 ON No 3 ON No 4 ON No 5 ON OFF ON 1 2 3 4 5 6 7 8 9 10 OFF ON 1 2 3 4 5 6 7 8 9 10 OFF ON 1 2 3 4 5 6 7 8 9 10 OFF ON 1...

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Page 28: ...Call tech support 1 763 331 3066 for sizing assistance The Hydro Smart Dual Purpose Panel integrates with a wide variety of boilers and delivers priority potable heated water with no storage tank and hydronic space heating in a small reliable package To Domestic Potable Water System Hot Water Out Cold Water In Space Heating Return Space Heating Supply To Space Heating Panel System ater Out Cold Wa...

Page 29: ...ER CONNECTIONS for leaks before firing unit for the first time Open the main gas supply valve to the micro boiler using only your hand to avoid any spark Never use tools If the knob will not turn by hand do not try to force it call a quali fied service technician Forced repair may result in a fire or explosion due to gas leaks Be sure to check for the presence of leaking gas toward the bottom of the m...

Page 30: ...pump zone valve and telestats 1 Hydro Smart pre built space heating panels Call tech support 1 763 331 3066 for order assistance type L copper pipe and a powder coated panel Used when terminating direct vent sealed combustion systems with boilers that require a 3 in 76mm intake and a 3 in 76 mm This concentric termination provides the convenience of only having to make one penetration through a si...

Page 31: ...h this safety manual carefully Please refer to the back of the manual for details about the warranty Keep this manual for future reference If you lose the manual contact the manufacturer or your local distributor When you call please tell us the model number and the serial number of your unit written on the rating plate of the micro boiler Owner s Guide ...

Page 32: ...technician Forced or attempted repair may result in a fire or explosion D Do not use this micro boiler if any part has been under water Immediately call a qualified service technician to inspect the micro boiler and to replace any damaged parts OPERATING INSTRUCTIONS 1 STOP Read the safety information above or in the Owner s Manual 2 Turn off all electric power to the micro boiler 3 Do not attempt to...

Page 33: ...to the state to cause cancer birth defects death serious illness or other reproductive harm This product may contain such substances be their origin from fuel combustion gas oil or components of the product itself Vapors 1 Cannot be seen 2 Vapors are heavier than air 3 Go a long way on the floor 4 Can be carried from other rooms to the main burner by air currents Keep flammable products 1 Far away f...

Page 34: ...boiler begins firing again GENERAL COLD Button HOT Button Pressthe HOT buttonorthe COLD buttontosetthehotwatertemperature ON OFF Button Press this button to start or stop operation STANDBYLED Orange The indicator turns on when the boiler is ready for operation IN USE LED Green This lights during combustion When the STAND BY LED is ON the hot water set temperature will be displayed Display for Tempe...

Page 35: ...preset temperatures 120 F 49 C and 140 F 60 C that you can select from by changing the DIPswitch settings on the computer board See the table below When the controller is in normal operation the set temperature of the controller is given priority over the set temperature of the DIPswitch settings The temperature has been preset at the factory to 120 F 49 C Computer board Bank of DIPswitches NOTE O...

Page 36: ...sion mode Operation Screen on the controller 1 Press the ON OFF button on the controller in order to turn the controller on 2 When ON the orange LED is lit 3 The previous set temperature will be displayed on the screen 4 Press the INFO buttons for at least 3 seconds 5 The set temperature should now be displayed in the alternate unit of measurement EX 100 F EX 38 C ADDTIONAL FEATURES You can get so...

Page 37: ...through the venting into the heat exchanger by either negative pressures within the installation location or by strong outside wind The manufacturer highly recommends the use of a backflow preventer sold separately to minimize the amount of cold air entering through the exhaust venting when the micro boiler is off If you will not be using your boiler for a long period of time 1 Completely drain the ...

Page 38: ...ugh the burner window in the burner assembly located at the middle of the micro boiler The manufacturer recommends having the micro boiler checked once a year or as necessary by a licensed technician If repairs are needed any repairs should be done by a licensed technician UNIT DRAINING Turn off the electrical power supply and close the manual gas shutoff valve and the manual water control valve bef...

Page 39: ... is not available when a there is a call for heat Make sure the unit has 120 VAC 60 Hz power supply Is the temperature controllerpower button turned on Is the gas supply valve fully open p 29 Is the system Y strainer clean Can the emitters sufficiently draw at least 0 5 GPM 1 9 L min through the water heater p 34 Is the unit frozen p 37 Is there enough gas in the tank cylinder For Propane model Is i...

Page 40: ...ut of the flue Abnormal sounds from the micro boiler Is the correct gas type of a micro boiler installed p 6 Are the DIPswitch settings for your altitude set correctly p 26 Check the flame quality p 38 Is the intake or exhaust vent blocked p 10 Is the vent length and diameter correct p 11 to 16 Is the manifold pressure set correctly p 4 Unit sounds abnormal while in operation Contact the manufacture...

Page 41: ...nstallation of the unit the error code will be displayed on the temperature controller Consult with the table on the following pages for the description of each error code Example If your unit has the 321 error code which signifies an inlet thermistor failure Indicator on the controller 321 will be displayed on the screen in its entirety Green LED on the computer board The green LED on the computer...

Page 42: ...unctioning Check for connection breakage of wires Part 412 707 708 709 710 burn marks on the computer board Part 701 and or soot on the flame rod Part 108 Check if there is a buzzing spark ignition sound coming from the burner Part 101 when micro boiler prepares for combustion Listen for the double clunk sound coming from gas valve assembly Part 102 when the micro boiler goes into combustion Checki...

Page 43: ...721 Six Times False flame detection Checkifthereisleakingfromheatexchanger Part 401 751 N A Miscommunication betweenmicro boiler and temperature controller Inspect the connections between the micro boiler and temperature controller Check the power supply of the micro boiler 941 Five Times Abnormal exhaust temperature Check to see of the exhaust temperature is higher than 149 F 65 C 991 Five Times I...

Page 44: ...44 Page Caseassembly 702 704 052 052 052 004 004 001 007 003 050 002 714 Temperature controller COMPONENTS DIAGRAM Components Diagram Owner s Guide 722 721 056 721 724 ...

Page 45: ...45 Page Computer board assembly Surge box assembly 709 710 103 708 402 707 701 711 716 402 407 408 060 713 706 701 710 703 120 053 705 712 712 Components Diagram Owner s Guide ...

Page 46: ...1 116 053 117 103 105 064 054 104 115 053 053 106 107 108 708 110 061 109 111 709 112 053 114 113 707 102 053 120 709 150 057 055 062 053 711 117 055 119 151 118 051 Manifold assembly Burner assembly Components Diagram Owner s Guide ...

Page 47: ...053 415 403 052 467 463 063 455 458 462 413 451 451 413 451 414 414 451 052 409 457 460 453 408 059 454 410 416 455 458 402 459 457 404 406 456 405 052 453 407 059 416 A B A B 401 154 E E 467 463 063 455 458 455 455 468 418 419 465 715 464 053 Components Diagram Owner s Guide ...

Page 48: ...x6 Screw M3x6 EW00A EW009 EK191 061 062 063 064 Pan screw M4x8 Wire clamp 60 Screw M4x10 Screw M3x6 SUS3 EW00D EM167 EW00P EW00B 101 102 Burner assembly Manifold with gas valve assembly LP Manifold with gas valve assembly NA EK458 EK459 EK460 103 Fan motor EK109 104 105 106 107 Burner gasket Fan damper for Burner window Rod holder gasket EKK2X EK491 EKK2V EKK2W 108 109 110 111 Flame rod Igniter ro...

Page 49: ...K469 415 416 Drain tube Inlet heater EK470 EK105 417 Secondary heat exchanger EK471 418 419 Secondary heat exchanger heater Heater fixing plate EK473 EK474 450 451 452 Pipe heater fixing plate Heater fixing plate 16 Fuse fixing plate EK475 EK031 EK476 453 454 455 456 457 O ring P4 FKM O ring P6 FKM O ring P14 FKM O ring P15 FKM O ring P16 FKM EZF04 EZF06 EZF14 EZF15 EZF16 458 459 Fastener 14 22 Fasten...

Page 50: ...X004 EKK1M EX13C 715 716 Exhaust thermistor Exhaust Hi limit switch wire EKH6E EK180 721 722 Temperature controller Fixing plate EK487 EK490 OUTPUT TEMPERATURE CHART Chart is based on properly sized gas line 100 105 110 115 120 125 130 135 140 40 3 8 3 5 3 2 3 0 2 8 2 7 2 5 2 4 2 3 50 4 6 4 1 3 8 3 5 3 3 3 0 2 9 2 7 2 5 60 5 7 5 1 4 6 4 1 3 8 3 5 3 3 3 0 2 9 70 7 0 6 4 5 6 5 0 4 5 4 1 3 8 3 5 3 2 ...

Page 51: ...mited warranty This limited warranty gives you specific legal rights and you may also have other rights which vary from State to State The manufacturer will honor the warranty to the original retail buyer at the original location only within the United States or Canada and it is not transferable THIS WARRANTY COVERS ONLY FAILED MECHANICAL AND ELECTRICAL PARTS DUE TO FACTORY DEFECTS UNDER NORMAL USA...

Page 52: ...orrect gas type and or gas pressures that fall outside the product s specified range Water incorrect water pipe sizing water pressures that fall outside the product s specified range recirculation flow rates that fall outside the product s specified range air removal and or lack of proper methods of air removal in a closed loop circulation system See installation manual for details Electric supply pow...