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Hydro-Smart 115, Installation Manual And Owner'S Manual

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Hydro-Smart 115 Installation Manual And Owner'S Manual Download Page 35

 

Troubleshooting

 

35

│

Page

 

 

‐

FAULT

 

ANALYSIS

 

OF

 

ERROR

 

CODES

‐ 

 
 

 

Red

 

LED

 

Remote

 

Malfunction

 

description

 

Diagnosis

 

One

 

Time

 

03

 

Incorrect

 

dipswitch

 

setting

 

 

Check

 

the

 

dipswitch

 

settings

 

on

 

the

 

PCB.

 

(Part

 

#701)

 

Five

 

Times

 

10

 

Warning

 

for

 

the

 

“991”

 

error

 

code

 

Check

 

the

 

gas

 

type

 

of

 

the

 

water

 

heater.

  

 

Check

 

if

 

there

 

is

 

any

 

blockage

 

in

 

the

 

intake

 

air

 

and/or

 

exhaust.

 

 

If

 

the

 

water

 

heater

 

is

 

installed

 

as

 

a

 

direct

‐

vent

 

system,

 

check

 

whether

 

there

 

is

 

enough

 

distance

 

between

 

the

 

intake

 

air

 

terminal

 

and

 

the

 

exhaust

 

terminal.

 

 

Check

 

the

 

altitude/elevation

 

of

 

area

 

of

 

where

 

the

 

water

 

heater

 

installed.

 

 

Check

 

if

 

there

 

is

 

grease

 

and/or

 

dirt

 

in

 

the

 

burner

 

(Part

 

#101)

 

and

 

the

 

fan

 

motor

 

(Part

 

#103),

 

especially

 

if

 

the

 

water

 

heater

 

has

 

been

 

installed

 

in

 

a

 

contaminated

 

area.

Three

 

Times

 

11

 

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

 

water

 

heater

 

prepares

 

for

 

combustion.

 

 

Listen

 

for

 

the

 

double

 

“clunk”

 

sound

 

coming

 

from

 

gas

 

valve

 

assembly

 

(Part

 

#102)

 

when

 

water

 

heater

 

goes

 

into

 

combustion.

 

 

Check

 

if

 

there

 

is

 

leaking

 

from

 

heat

 

exchanger.

 

(Part

 

#401)

Three

 

Times

 

12

 

Loss

 

of

 

flame

 

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

 

leaking

 

from

 

heat

 

exchanger.

 

(Part

 

#401)

Two

 

Times

 

31

 

Outlet

 

thermistor

 

failure

 

 

Check

 

for

 

connection/breakage

 

of

 

wires

 

and/or

 

debris

 

on

 

thermistor.

 

(Part

 

#407,

 

408)

 

32

 

Inlet

 

thermistor

 

failure

 

Two

 

Times

 

39

 

Air

 

–fuel

 

Ratio

 

Rod

 

failure

 

 

Check

 

for

 

connection/breakage

 

of

 

wires

 

(Part

 

#709)

 

and/or

 

soot

 

on

 

the

 

AFR

 

rod.

 

(Part

 

#108)

 

 

If

 

the

 

error

 

code

 

displayed

 

on

 

the

 

computer

 

board

 

of

 

the

 

Water

 

heater

 

or

 

remote

 

controller,

 

please

 

check

 

the

 

following.

  

After

 

checking,

 

Consult

 

with

 

the

 

manufacturer

.

 

Summary of Contents for 115

Page 1: ...rmed by a qualified installer service agency or the gas supplier Hydro Smart 115 Micro Boiler for Radiant Heating Installation Manual and Owner s Guide Hydro Smart 115 If you have any questions please call or write to Hydro Smart Inc 10725 165th Ave NW Elk River MN 55330 WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage ...

Page 2: ...ons Electrical Connections Remote Controller Connections APPLICATIONS INITIAL OPERATION OPERATING SAFETY NORMAL OPERATION General Operation Temperature Settings Flow Freeze Protection System Maintenance and Service Unit Draining TROUBLESHOOTING General Error Codes COMPONENTS DIAGRAM PARTS LIST OUTPUT TEMPERATURE CHART LIMITED WARRANTY 3 4 5 6 6 8 8 9 10 11 12 17 20 21 22 23 25 26 28 28 28 29 30 30...

Page 3: ...tric Ignition Electric Supply 120 VAC 60 Hz Consumption Operation 73 1 W 0 61 A Standby 6 2 W 0 05 A Freeze Protection 111 W 0 93 A 40 psi or above is recommended for maximum flow The Manifold Pressure is the factory setting and generally should not need adjustment NOTE Check the rating plate to ensure this product matches your specifications In accordance with ANSI Z21 10 3 CO emission does not e...

Page 4: ...on spark 5 The gas ignites and flames appear within the burner chamber 6 Water circulates through the heat exchanger and then gets hot 7 Using thermistors to measure temperatures throughout the water heater the computer modulates the gas and water valves to ensure proper output water temperature 8 When the tap is turned off the unit shuts down The principle behind tankless water heaters is simple ...

Page 5: ...ates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates an imminently hazardous situation which if not avoided could result in death or serious injury Indicates an imminently hazardous situation which if not avoided could result in minor or moderate injury GENERAL 1 Follow all local codes or in the absence of local codes follow the most recent e...

Page 6: ...les from flour aerosols and other contaminants may clog the air vent or reduce the functions of the rotating fan and cause improper burning of the gas Regularly ensure that the area around the unit is dust or debris free regular maintenance is recommended for these types of environment 9 If you will be installing the water heater in a contaminated area with a high level of dust sand flour aerosols...

Page 7: ...n case of leaks The warranty will not cover damage caused by water quality Only potable water or potable water glycol mixtures can be used with this water heater Do not introduce pool or spa water or any chemically treated water into the water heater Water hardness levels must not exceed 7 grains per gallon 120 ppm for single family domestic applications or more than 4 grains per gallon 70 ppm for...

Page 8: ...hat these items below are included with the water heater 1 Installation Manual and Owner s Guide 2 Product Registration Card 3 Remote controller 900766605 TK RE02 OPTIONAL ITEMS Model Hydro Smart 115 9007678005 TK BF01 9007667005 TK TV10 9007671005 TK PCJr2 9007608005 TK KPWL4 9007609005 TK KPWH4 9007680005 TK KPCT43 Bottom Side Top Side Front Back Maintain all clearances around the water heater Q...

Page 9: ...ugh the wall and are compatible with the T Vent pipe system These terminations are special stainless steel vents for gas appliances and are UL listed as Category II III and IV There are two types of terminations the Louver termination and the Hood termination For different wall thicknesses there are two ranges of lengths available refer to the venting brochure for details Install these vent termin...

Page 10: ...terminal This may cause damage to the Hydro Smart 115 and void the warranty Do not install next to a dryer or any source of airborne debris that can be trapped inside the combustion chamber unless the system is direct vented Hydro Smart 115 is prohibited and not recommends to be installed in an attic due to safety issues FOR YOUR SAFETY READ BEFORE INSTALLATION Prohibited Prohibited ...

Page 11: ...epending on the altitude Altitude 0 to 2 000 ft DEFAULT 2 000 to 4 000 ft 4 000 to 6 000 ft Over 6 000 ft Switch No 3 OFF ON OFF Consult Hydro Smart at 763 331 3066 Switch No 4 OFF OFF 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 WARNING The dark squares indicate the direction the dipswitches should be set to Dipswitches ...

Page 12: ...ter as close as possible to the vent terminator The vent collar of the water heater must be fastened directly to an unobstructed vent pipe Do not weld the vent pipe to the water heater s vent collar Do not cut the vent collar of the unit The vent must be easily removable from the top of the water heater for normal service and inspection of the unit The water heater vent must not be connected to an...

Page 13: ...f the vent must go through the chimney the vent must run all the way through the chimney with Category III approved or Special BH vent pipe When the horizontal vent run exceeds 5 ft support the vent run at 3 ft intervals with overhead hangars The maximum length of exhaust vent piping must not exceed 50 ft deducting 5 ft for each elbow used in the venting system Do not use more than 5 elbows Diamet...

Page 14: ...cal Installation Diagram With direct venting The water heater Intake port of Direct Vent Conversion Kit Installation Diagram of Direct Vent Conversion Kit with water heater Wall Direct vent Concentric Termination Plate of Direct Vent Conversion Kit See the picture below for detailed connection instructions to the Direct Vent Conversion Kit Vertical Condensation Drain Backflow Preventer Wall Sidewa...

Page 15: ...F Clearance to outside corner G Clearance to inside corner H Clearance to each side of center line extended above meter regulator 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 m...

Page 16: ... a single penetration space each direct vent termination at least 1 ft away from each other no matter the orientation A direct vent termination must also be at least 2 ft away from an inside corner if the adjacent wall is less than 2 ft of length the minimum required distance away from the inside corner will be equal to the length of that adjacent wall For multiple unit rooftop terminations whethe...

Page 17: ...ely affect performance These pressures are measured when the water heater is in full operation Inlet gas pressure must not exceed the above maximum values gas pressure above the specified range will cause dangerous operating conditions and damage to the unit Until testing of the main gas line supply pressure is completed ensure the gas line to the water heater is disconnected to avoid any damage t...

Page 18: ...76 866 787 675 2 6 221 4 331 3 465 2 992 2 646 2 394 2 205 2 047 1 921 1 811 1 606 1 496 1 260 For more information please see the below Based on Energy Content of 1 000BTU Cubic Ft Divide each appliance s BTU requirement by 1 000BTU to get the appliances Cubic Ft requirement Take into account the distance the appliance is from the gas meter look in the above gas chart to properly size the line Fo...

Page 19: ...NE BY A LICENSED PROFESSIONAL 1 Shut off the manual gas valve on the supply gas line 2 Remove the screw for the pressure port located on the gas inlet of the water heater shown in the diagram to the right 3 Connect the manometer to the pressure port 4 Re open the manual gas valve Check to see that there are no gas leaks Open some of the fixtures that use the highest flow rate to turn on the water ...

Page 20: ... to maintain optimum flow Pressure relief valve The water heater has a high temperature shut off switch built in as a standard safety feature called a Hi Limit switch therefore a pressure only relief valve is required This unit does not come with an approved pressure relief valve An approved pressure relief valve must be installed on the hot water outlet The pressure relief valve must conform to A...

Page 21: ...utdoor models only 1 The water heater must be electrically grounded Do not attach the ground wire to either the gas or the water piping 2 The water heater requires 120 VAC 60 Hz electrical power supply that is properly grounded A proper disconnect i e on off switch power plug etc controlling the main power to the water heater must be provided for service reasons Must comply with local codes Connec...

Page 22: ...are firmly fixed 5 Pull the remote s wires through the hole at the bottom of the water heater s casing 6 Properly attach the remote s wires to the remote controller terminal on the computer board No polarity Do NOT jump or short circuit the wires or computer will be damaged 7 Replace Front Cover securely 8 Wires used for the remote controller connection must be Minimum 18AWG wire No polarity Maxim...

Page 23: ... any chemicals were added to the water heating appliances When the system requires water for space heating at temperatures higher than required for other uses a means such as a mixing valve shall be installed to temper the water for those other uses in order to reduce scald hazard potential Water temperature over 125 F 52 C can cause severe burns instantly or death from scalds Chemicals such as di...

Page 24: ...ust Be Sized Properly With Each Application Pump Shall Run 60 Seconds Every 6 Hours Pressure Gauge Apply Correct Thermal Expansion Tank Size Per Application Tempered Water To House Cold Inlet Shut Off Valve Check Valve Will Have 1 8 Hole in Check As Per Mass Code Thermometer Thermostatic Mixing Valve Shut Off Valves Check Valve Hot Water Outlet Cold Water Inlet T Handle Gas Shut Off Valve Maximum ...

Page 25: ...ge the GAS and WATER LINES to remove any air pockets Do not use this water heater if any part has been submersed under water Immediately call a qualified service technician to inspect the water heater and to replace any damaged parts INITIAL OPERATION 1 Refer to p 31 for instructions 2 Fully open the manual water control valve on the water supply line 3 Open a hot water tap to verify that water is...

Page 26: ...e or attempted repair may result in a fire of explosion D Do not use this water heater if any part has been under water Immediately call a qualified service technician to inspect the water heater and to replace any damaged parts OPERATING INSTRUCTIONS 1 STOP Read the safety information above or in the Owners Manual 2 Turn off all electric power to the water heater 3 Do not attempt to light the bur...

Page 27: ...t WARNING The outlet hot water temperature of the water heater is factory set at 122 F 50 C Use this heater at your own risk The set outlet water temperature can cause severe burns instantly or death from scalds Test the water before bathing or showering Do not leave children or an infirm person in the bath unsupervised DANGER Hot Water temperature over 125 F 52 C can cause severe burns instantly ...

Page 28: ... the below 3 Press the HOT button or the COLD button to set the temperature setting of the unit 4 You can set the temperature from 99 F 38 C to 167 F 75 C Exterior view of the remote controller The temperature options 99 100 102 104 106 108 110 111 113 115 117 122 131 140 158 167 Flow rate to activate the water heater 0 5 gallons per minute at the default set temperature Flow rate to keep the wate...

Page 29: ...e several more temperature options Refer to p 9 for a list of available temperatures on the remote controller This water heater is an on demand tankless water heater designed to efficiently supply endless hot water without reference to temperature settings Dipswitches Dipswitch settings for each temperature on the computer board 45 OFF ON C 113 F 1 2 3 4 5 6 7 8 OFF ON 1 2 3 4 5 6 7 8 50 C 122 F D...

Page 30: ...tection system to operate there has to be electrical power to the unit Damage to the heat exchanger caused by freezing temperatures due to power loss is not covered under the warranty In cases where power losses can occur consider the use of a backup power supply The freeze protection system will activate when the surrounding and or outside temperatures drop below 36 5 F 2 5 C For the Hydro Smart ...

Page 31: ...to correct this situation Visual check of burner flames see below through the burner window in the burner assembly located at the middle of the water heater Hydro Smart 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 1 Close the manual gas shut off valve 2 Turn off power ...

Page 32: ...high p 28 29 The hot water is not available when a fixture is opened Make sure the unit has 120 VAC 60 Hz power supply If you are using the remote controller is the power button turned on Is the gas supply valve fully open p 25 Is the water supply valve fully open p 25 Is the hot water fixture sufficiently open to draw at least 0 5 GPM through the water heater p 28 Is the unit frozen p 30 Is there...

Page 33: ...ll spinning after operation has stopped This is normal After operation has stopped the fan motor keeps running from 15 to 70 seconds in order to re ignite quickly as well as purge all the exhaust gas out of the flue Unit sounds abnormal while in operation Contact Hydro Smart Remote controller OPTIONAL Remote controller does not display anything when the power button is turned on Make sure the unit...

Page 34: ...n the remote controller if it is installed Consult with the table on the following page for the cause of each error code Single unit installations Example If your unit displays the 321 error code which signifies an inlet thermistor failure Hydro Smart 115 The red LED on the computer board will be blinking two times If the remote controller 9007666005 TK RE02 is installed 32 will display on the scr...

Page 35: ... 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 water heater prepares for combustion Listen for the double clunk sound coming from gas valve assembly Part 102 when water heater goes into combustion Check if there is leaking from heat exchanger Part 401 Three Times 12 Loss of flame Chec...

Page 36: ... if condensate drain is installed on the vent collar of the water heater Check if there is leaking from heat exchanger Part 401 N A 74 Miscommunication between Water heater and remote controller Check the model type of the remote controller Inspect the connections between the water heater and remote controller Check the power supply of the water heater Five Times 99 Imperfect combustion Check the ...

Page 37: ...ay assembly Computer board Assembly 456 460 409 455 410 454 408 064 C 402 461 458 052 415 064 460 456 404 405 454 407 457 B 463 413 453 414 412 063 451 B C 401 414 452 450 Water inlet section Water outlet section 002 050 702 052 007 052 052 003 052 001 004 051 720 704 721 Temperature remote controller 722 ...

Page 38: ...mbly 106 107 108 109 110 065 712 701 053 120 053 712 711 053 714 062 055 119 151 118 052 121 703 053 704 705 401 104 105 101 709 111 052 053 112 113 114 708 053 067 055 053 706 053 059 103 115 058 713 150 061 059 101 709 111 102 Manifold assembly ...

Page 39: ...6 067 Screw M3x6 Screw M4x6 Pan screw M4x8 Nylon clamp Wire clamp 60 319143 087 319143 328 319143 059 319143 143 319143 048 101 102 103 104 105 Burner assembly Manifold with gas valve assembly LP Manifold with gas valve assembly NA Fan motor Burner holder gasket Burner gasket 319143 161 319143 169 319143 165 319143 347 319143 341 319143 031 106 107 108 109 110 Burner window Rod holder gasket Flame...

Page 40: ...19143 082 455 456 457 458 460 O ring P6 FKM O ring P14 FKM O ring P15 FKM O ring P16 FKM Fastener 14 22 319143 080 319143 100 319143 091 319143 083 319143 105 461 463 Fastener 16A Silicon ring 319143 226 319143 065 701 702 703 704 705 Computer board Transformer Surge box AC120V wire Transformer wire 319143 164 319143 182 319143 168 319143 427 319143 155 706 707 708 709 710 AC120V Power ON OFF swit...

Page 41: ...7 0 Out Put Hot Water GPM 40 F 50 F 60 F 70 F 40 F 3 8 3 5 3 3 3 1 2 9 2 7 2 5 2 4 2 3 2 1 1 9 1 8 50 F 4 6 4 2 3 8 3 5 3 3 3 1 2 9 2 7 2 5 2 3 2 1 2 0 60 F 5 7 5 1 4 6 4 2 3 8 3 5 3 3 3 1 2 9 2 5 2 3 2 2 70 F 6 6 6 6 5 7 5 1 4 6 4 2 3 8 3 5 3 3 2 9 2 5 2 4 100 105 110 115 120 125 130 135 140 150 160 165 Chart is based on properly sizes gas line ...

Page 42: ...CLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY SHALL IN NO EVENT EXTEND PAST THE EXPIRATION OF ANY WARRANTY PERIOD HEREUNDER SOME STATES DO NO ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU 5 THIS WARRANTY WILL NOT COVER THE FOLLOWING Any Hydro Smart unit that is not installed by a licensed plumber gas in...

Page 43: ... measuring more than 7 grains per gallon 120 ppm for single family domestic applications or more than 4 grains per gallon 70 ppm for all other types of applications into the product Introduction of untreated or poorly treated well water into the product Introduction of water with pH levels less than 6 5 and greater than 8 5 into the product Failure of Hydro Smart due to use other than micro boiler...

Page 44: ...Warranty 44 Page 75E012 1 HS115 ...

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