Hydro-Smart 199, Installation Manual And Owner'S Manual

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Page 2: ...stem 28 Multi Unit System 32 Hydro Smart Pre built Panels 33 Hydro Smart Dual Purpose Panel 34 INITIAL OPERATION 35 Owner s Guide OPERATING SAFETY 37 NORMAL OPERATION 39 General 39 Temperaturesettings 40 Temperature table of controller 40 Additionalfeatures 41 Temperature settings on the PCB Without remote controller 42 Flow 43 Freezeprotectionsystem 43 Maintenanceandservice 44 Unit draining 44 TR...

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: ...199 Gas Condensing Micro Boiler Natural Gas Input Operating Range BTU h Min 15 000 Max 199 000 Propane Input Operating Range BTU h Min 13 000 Max 199 000 Gas Connection 3 4 NPT Water Connections 3 4 NPT Water Pressure psi MPa 15 150 0 1 1 Natural gas Inlet Pressure inch W C kPa Min 5 0 1 24 Max 10 5 2 61 Propane Inlet Pressure inch W C kPa Min 8 0 1 99 Max 14 0 3 48 Manifold Pressure Natural Gas i...

Page 5: ... the micro boiler s physical description 1 Your thermostat indicates a need for heat and turns on a circulator pump 2 Water enters the boiler 3 The water flow sensor detects the water 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 appear within the burner chamber 6 Water circulates through the heat exchanger and t...

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: ...any doorway or opening to prevent exhaust from entering a building Refer to p 19 8 Particles from flour aerosols and other 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 unit is dust or debris free Regular maintenance is recommended for these type...

Page 8: ...damage is required to be installed under the micro boiler in case of leaks WARNING The warranty will not cover damage caused by water quality Only distilled water or distilled 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 120 ppm for single f...

Page 9: ...mm 12 in 305 mm 24 in 610 mm 0 5 in 13 mm 2 in 51 mm 24 inches recommended for maintenance Back Side Front Side Top Check that these items below are included with the micro boiler Installation manual and owner s guide Bird screen Communication cable Qty 1 Qty 1 Qty 2 HS199Con LP Liquid propane 36 in 914 mm 12 in 305 mm 24 in 610 mm 0 5 in 13 mm 2 in 51 mm ...

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Page 11: ...e the direction the DIPswitches should be set to Computer board Lower bank of DIPswitches 0 DEFAULT Up to 2 500 ft Up to 5 000 ft Up to 7 500 ft Up to 10 100 ft HS199Con Boiler Lower bank of DIPswitches No 2 OFF No 3 OFF No 4 OFF No 2 OFF No 3 ON No 4 OFF No 2 OFF No 3 OFF No 4 ON No 2 OFF No 3 ON No 4 ON No 2 ON No 3 ON No 4 ON OFF ON 1 2 3 4 5 6 OFF ON 1 2 3 4 5 6 OFF ON 1 2 3 4 5 6 OFF ON 1 2 3...

Page 12: ...or other form of termination that prevents rain water from entering into the micro boiler must be installed Do not terminate vent into a chimney If the vent must go through the chimney the vent must run all the way through the chimney with approved vent pipe General rules for vent terminations Avoid locating the micro boiler vent termination near any air intake devices These fans can pick up the e...

Page 13: ...o 4 OFF 41 to 70 ft No 3 ON No 4 ON OFF ON 1 2 3 4 5 6 7 8 OFF ON 1 2 3 4 5 6 7 8 OFF ON 1 2 3 4 5 6 7 8 Set DIPswitches shown in the tables below depending on the vent length 3 venting Vent length Upper bank of DIPswitches 5 to 45 ft DEFAULT No 3 ON No 4 OFF 46 to 70 ft No 3 OFF No 4 OFF OFF ON 1 2 3 4 5 6 7 8 OFF ON 1 2 3 4 5 6 7 8 Set DIPswitches shown in the table below depending on the vent l...

Page 14: ...ipe and Fittings Schedule 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 Diameter Max No of Elbows Max Vertical and Horizontal Total Vent Length 3 in 76 mm 5 ...

Page 15: ...lings directly on the exhaust and intake vent collar of the micro boiler 2 Connect 3 straight pipes to the couplings 1 Connect 3 x4 increasers directly on the exhaust and intake vent collar of the micro boiler 2 Connect 4 straight pipes to the increasers 4 straight pipe 3 x4 increaser Exhaust vent collar Female Intake vent collar Female 4 straight pipe 3 x4 increaser Horizontal Roof Roof Fire stop...

Page 16: ...ing PVC ABS or polypropylene vent 1 Connect a 3 elbow directly on the intake vent collar of the micro boiler 2 Connect a 3 x4 increaser directly on the exhaust vent collar of the micro boiler 3 Connect a 4 straight pipe to the increaser 3 coupling 3 straight pipe Exhaust vent collar Female 3 elbow with bird screen Intake vent collar Female 4 straight pipe 3 x4 increaser Exhaust vent collar Female ...

Page 17: ...the following are also UL listed manufacturers ProTech Systems Inc FasNSeal Metal Fab Inc and Heat Fab Inc Saf T Vent Follow the vent pipe manufacturer s instructions when installing the vent pipe The maximum length of exhaust vent piping must not exceed 100 ft 30 5 m deducting 5 ft 1 5 m for each elbow used in the venting system Do not use more than 5 elbows When the horizontal vent run exceeds 5...

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Page 19: ...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 20: ... 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 Exhaust termination Inside corner 1 ft 305 mm min 2 ft 610 mm min 1 ft 305 mm min Combined intake and exhaust termination Inside corner 1 ft 305 mm min 2 ft 610 mm min 1 ft 305 mm min For direct vent sidewall terminati...

Page 21: ... 610 mm away from an opposite surface wall Do not place the termination directly in front of an opening into a building Please follow all local and national codes in regards to proper termination clearances In the absence of such codes the clearances below can be used as guidelines Local codes supersede these guidelines CAUTION Exhaust terminations must be at least 1 ft 305 mm away from any obstru...

Page 22: ...essures 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 the gas pipe appropriately to supply t...

Page 23: ...ppliance 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 50 ft away f...

Page 24: ...he micro boiler to replace any damaged parts micro boiler e h t o t s n o i t c e n n o c t e l n i d l o c d n a t e l t u o t o h e h t e s r e v e r t o n o D 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 pressure port located on the gas inlet of the micro boiler shown in the diagram on the right 3 Conne...

Page 25: ...ut any restrictions If the pressure relief valve installed on the micro boiler discharges periodically this may be due to a defective thermal expansion tank or defective pressure relief valve The pressure relief valve must be manually operated periodically to check for correct operation No valve must be placed between the relief valve and the micro boiler CONDENSATE DRAIN The micro boiler does not...

Page 26: ...r 2 Connect the Neutralizer to the 3 8 MPT connection of the adaptors There is a flow direction indicator on the neutralizer Please orient the neutralizer in the proper direction 3 Connect a 1 2 drain tube to the other end of neutralizer 4 Leave an adequate amount of space between the end of the drain tube and the actual drain to facilitate proper drainage WARNING Discharge condensate acidic water ...

Page 27: ...ain neutralizer and drain tube must be at a lower elevation 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 ...

Page 28: ... 4 units without the need for a multi unit controller A 4 unit system has full automatic modulation between 13 000 BTU h Propane or 15 000 BTU h Natural gas to 796 000 BTU h 1 Verify the set temperatures of all units within the system Every single micro boiler must be set to the same set temperature General Hot Out Gas In Cold In The Easy Link System is limited up to 4 units If you connect more th...

Page 29: ...oller display the unit The numbering system automatically allocates the unit to each micro boiler in the Easy Link System in accordance with the table below Computer board B Basic diagram of connections between the Easy Link System units NOTE The dark squares indicate the direction the DIPswitches should be set to Type of unit Unit of easy link Parent 1 Child 2 3 or 4 To change the DIPswitch setti...

Page 30: ...ors Connectors OFF ON 1 2 3 4 5 6 Lower bank of DIPswitches Lower bank of DIPswitches 1 2 3 4 5 6 OFF ON PARENT 1 2 PARENT 1 2 Unless you change DIPswitch No 1 of the PARENT unit to the ON position the system will not work as an Easy Link System The units will operate as individual units PARENT unit CHILD 1 unit Wrong Connectors Connectors OFF ON 1 2 3 4 5 6 Lower bank of DIPswitches OFF ON 1 2 3 ...

Page 31: ...ectors together from two separate units may damage the computer board The communication cable has a female end and a male end so it s impossible to have a PARENT to PARENT connection with the communication cable Do not splice or modify connectors WARNING PARENT unit CHILD 1 unit CHILD 2 unit Wrong Connectors Connectors Connectors Lower bank of DIPswitches 1 2 3 4 5 6 OFF ON OFF ON 1 2 3 4 5 6 Lowe...

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Page 35: ...WATER 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 th...

Page 36: ...is 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 37: ...tely 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 light the burner by hand 4 Turn the manual gas valve located on the outside of the unit clockwise to the OFF position 5 Wait five 5 minutes to...

Page 38: ...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 from boiler 2 In approved containers 3 Tightly closed 4 Out of children s reach WARNING Do no...

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Page 41: ...isplayed 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 Operation Screen on the controller Temperature controller Remote controller 1 First of all inlet water temperature will be displayed on the controller by pressing the INFO button 2 Outlet water temperature will be displayed on th...

Page 42: ...over the set temperature of the DIPswitch settings Owner s Guide NOTE Only change the switches with dark squares The dark squares indicate the direction the DIPswitches should be set to WARNING DO NOT adjust the upper bank of DIPswitches Turn off the power supply to the micro boiler before changing the DIPswitch settings The temperature has been preset at the factory to 120 F 49 C Lower bank of DIP...

Page 43: ...ing and being damaged Owner s Guide The flow rate through the micro boiler is limited to a maximum of 10 0 GPM 38 L min The temperature setting along with the supply temperature of the water will determine the flow rate output of the unit Only pipes within the micro boiler are protected by the freeze protection system Any water pipes hot or cold located outside the unit will not be protected Properl...

Page 44: ...on Visual check of burner flames see below through the burner window in the burner assembly located at the middle of the micro boiler The manufacturer recommends having the unit 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 and FILTER CLEANING Owner s Guide Turn off the electrical power supply and ...

Page 45: ...the unit has 120 VAC 60 Hz power supply If you are using the remote controller and or temperature controller is the power button turned on Is the gas supply valve fully open p 35 Is the water supply valve fully open p 35 Is the unit frozen p 43 Is there enough gas in the tank cylinder For Propane models The hot water turns cold and stays cold Is the flow rate enough to keep the micro boiler running...

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Page 48: ...n installed in a contaminated area 111 Three Times Ignition failure Check if the Hi limit switch Part 412 is properly functioning Check for connection breakage of wires Part 413 708 709 710 712 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 List...

Page 49: ...drive circuit failure Refer to the 111 and 121 error codes 721 Six Times False flame detection Check if condensate drain is installed on the vent collar of the micro boiler Check ifthereis leakingfromheatexchanger Part 401 741 N A Miscommunication between micro boiler and remote controller Check the model type of the remote controller Inspect the connections between the micro boiler and remote cont...

Page 50: ...age COMPONENTS DIAGRAM Case assembly Temperature remote controller 724 723 722 056 052 052 003 007 002 050 702 704 008 052 050 052 717 713 004 001 004 Temperature controller Components Diagram Owner s Guide ...

Page 51: ...51 Page Computer board assembly Surge box assembly 121 713 703 706 063 709 053 703 701 714 403 715 721 707 722 715 402 402 103 713 708 711 709 716 Components Diagram Owner s Guide ...

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Page 54: ...screw M4x12 FEZN EW004 EW005 EW018 EKK31 058 059 060 061 Screw M3x6 Screw M4x6 Screw M4x12 Screw M3x6 EW00A EW009 EKK37 EK191 062 063 064 065 Pan screw M4x8 Wire clamp 60 Screw M4x10 Screw M3x6 SUS3 EW00D EM167 EK230 EW00B 101 102 Burner assembly Manifold with gas valve assembly LP Manifold with gas valve assembly NA EK192 EK181 EK182 103 Fan motor EK109 104 105 106 107 Burner gasket Fan damper Bu...

Page 55: ...137 408 Outlet thermistor EKK1A 409 410 411 Water outlet Outlet drain plug Heat exchanger thermistor EK208 EKK2E EKK2T 412 Hi Limit switch EKN34 413 414 Overheat cut off fuse Pipe heater EK333 EK209 415 Inlet heater EK210 416 417 Drain tube Inlet heater EK231 EK105 418 Secondary heat exchanger EK251 450 451 452 453 Pipe heater fixing plate Heater fixing plate 16 Fuse fixing plate 18 Fuse fixing plate 1...

Page 56: ...6 706 707 708 120 VAC Power ON OFF switch Remote controller wire Gas valve wire EKK4V EK165 EK168 709 711 Flame rod wire Igniter assembly EK166 EK153 713 Switch wire with thermostat EK184 714 715 716 717 Proportional gas valve wire 24V cables Computer board cover Cable clamp EM167 EK179 EKK1M EX13C 718 719 721 722 723 Exhaust thermistor Remote fixing plate Exhaust Hi limit switch wire Temperature c...

Page 57: ...ty 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 USAGE FOR THE P...

Page 58: ...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...