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

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Hydro Smart 115 PLUS Installation Manual And Owner'S Manual Download Page 33

33

Gable vent

to outdoors

Install above

Outlet air to 

2 

per 

4,000 btu/h

Inlet air from 

Confined

Alternate

Air Inlet

2 

per

4,000 btu/h

Direct to outdoors openings

 duct openings

Outlet air to 

2 

per 

4,000 btu/h

2 

per 

Confined

4,000 btu/h

SIngle opening

Confined

1 in

2 

3,000 btu/h

Two permanent openings

Two permanent

Openings

1 in

2 

per 

12” maximum

1,000 btu/h

12” maximum

Confined

Space

Horizontal duct openings

1 in

2 

per 

Confined

Space

2,000 btu/h

Outlet

Inlet

Air Ducts

1 in

2 

per 

2,000 btu/h

Direct to outdoors openings

Two permanent openings

Two permanent

Openings

1 in

2 

per 

4,000 btu/h

12” maximum

12” maximum

Confined

Space

Summary of Contents for Smart 115 PLUS

Page 1: ... 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 If you have any questions please call or write to 10725 165th Ave NW Elk River MN 55331 Featuring Flow Activated 75 GPM Wall Hung Copper Heat Exchanger Temperature Range 99 140 F Freeze Protection Power Vent CAT III St...

Page 2: ...ERAL 11 GAS SUPPLY PIPE SIZE 13 PRESSURE RELIEF VALVE ELECTRICAL CONNECTIONS 15 APPLICATIONS 16 INITIAL OPERATION 18 OPERATING SAFETY 19 NORMAL OPERATION 21 TEMPERATURE SETTINGS 22 FLOW FREEZE PROTECTION 24 MAINTENANCE AND SERVICE 25 ADDITIONAL FEATURES 26 VENTING AND CLEARANCES 27 ERROR CODES 37 TROUBLESHOOTING 40 COMPONENTS DIAGRAM 42 PARTS LIST 46 OUTPUT TEMPERATURE CHART 48 NOTES 49 ...

Page 3: ... use we recommend that you read through this installation manual carefully Keep this manual for future reference If you need an additional manual contact the manufacturer or your local distributor When you call please tell us the product name and the serial number of your unit written on the rating plate of the boiler ...

Page 4: ...higher on your domestic water side Your space heating side should still reflect the recommended 18 25 PSI for system pressure Model HS115PLUS BTU h Natural Gas Input Operating Range Min 15 000 Max 140 000 Gas Connection 3 4 NPT Supply Return Connections 3 4 NPT Water Pressure psi Mpa 18 25 PSI For Radiant Only Systems Up to 150 with DHW W C Natural gas Inlet Pressure kPa Min 4 0 1 00 Max 10 5 2 61...

Page 5: ...s easy This diagram illustrates micro boiler design concepts only and does not accurately represent the boilers physical description 1 Your thermostat indicates a need for heat and turns on the circulator pump s 2 Water flows through the boiler 3 The 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 ign...

Page 6: ...e with all local codes or in the absence of local codes with the current edition of the National Electrical Code ANSI NFPA 70 in the USA or CSA standard C22 1 Canadian Electrical Code Part 1 in Canada 3 Carefully plan where you intend to install the boiler Please ensure Your boiler will have enough combustion air and proper ventilation Locate your boiler where water leakage will not damage surroun...

Page 7: ...urb your neighbors Ensure that the vent termination meets the minimum distance requirements set by code including minimum clearances from doorways or openings 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 water heater Regularly ensure that the area around the...

Page 8: ...t cover damage caused by water quality Only potable water can be used with this boiler Do not introduce pool or spa water or any chemically treated water into the boiler 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 all other types of applications Water hardness leads to scale formation and may ...

Page 9: ... Front Model Top Bottom Front Back Sides 12 in 305 mm 12 in HS115 PLUS NG LP 305 mm 4 in 102 mm 1 0 in 25 mm 3 in 76 mm 24 inches recommended for maintenance Installation Manual Qty 1 LP Conversion Kit Manifold gasket 1 Spare Screw 2 ...

Page 10: ...5 000 ft 915 to 1 524 m 5 001 to 7 500 ft 1 525 to 2 286 m 7 501 to 10 100 ft 2 287 to 3 078 m HS115 PLUS ON 1 2 3 4 5 6 7 8 9 10 OFF No 3 OFF No 4 OFF No 5 OFF ON 1 2 3 4 5 6 7 8 9 10 OFF No 3 OFF No 4 ON No 5 OFF ON 1 2 3 4 5 6 7 8 9 10 OFF No 3 OFF No 4 OFF No 5 ON ON 1 2 3 4 5 6 7 8 9 10 OFF No 3 OFF No 4 ON No 5 ON ON 1 2 3 4 5 6 7 8 9 10 OFF No 3 ON No 4 ON No 5 ON Altitude DIP switches HIGH...

Page 11: ...ited Covering non metallic vent pipe and fittings with thermal insulation is prohibited Ensure that the installation location has sufficient clean combustion air If unsure direct vent the boiler or refer to the Combustion Air Supply section below Combustion air from the room Install a 3 elbow into the air intake collar General rules for venting water heaters are The maximum length of intake air pipin...

Page 12: ...ng abnormal amounts of carbon monoxide can result in seri ous injury or death Avoid locating the boiler vent termination near any air intake devices These fans can pick up the exhaust flue products from the boiler and return them to the building This can create a health hazard Locate the vent termination so that it cannot be blocked by any debris at any time Most codes require that the termination ...

Page 13: ...ollow the requirements listed in the current edition of ANSI Z223 1 NFPA 54 USA B149 1 Canada or local codes Otherwise flow capabilities and output temperatures will be limited Min 8 0 W C 1 99 kPa Max 14 0 W C 3 48 kPa 1 Install a full port manual gas shutoff valve between the boiler and the gas supply line 2 When the gas connections are completed it is necessary to perform a gas leak test either b...

Page 14: ...a G Natural Gas Pipe Size Length ft m Diameter in 10 3 0 20 6 1 30 9 1 40 12 2 50 15 2 60 18 3 70 21 3 80 24 4 90 27 4 100 30 5 125 38 1 150 45 7 200 61 0 1 2 172 118 95 81 72 65 60 56 52 50 44 40 34 3 4 360 247 199 170 151 137 126 117 110 104 92 83 71 1 678 466 374 320 284 257 237 220 207 195 173 157 134 1 1 4 1 309 957 768 657 583 528 486 452 424 400 355 322 275 1 1 2 2 090 1 430 1 150 985 873 7...

Page 15: ...ective pressure relief valve The pressure relief valve must be manually operated periodically to check for correct operation WARNING Hot water will be released The contact of discharge may cause property damage and or bodily harm Before operating the pressure relief valve manually check that it will discharge in a safe place If water does not flow freely from the end of the discharge pipe turn the ...

Page 16: ...tain between 25 and 55 of Glycol Be aware that in a closed loop system low pressure in the heat exchanger can cause low temperature boiling resulting in excessive noise and damage to the micro boiler Consult with the glycol maker for specifications prior to use Hydro Smart Pre Built Space Heating Panels Hydro Smart pre plumbed panels help make space heating easy and reliable These panels are profe...

Page 17: ...e variety of boilers and delivers Priority potable heated water with no storage tank and hydronic space heating in a small reliable package Follow all local codes or in the absence of local codes follow the most recent edition of the National Standard Code ANSI Z21 10 3 For more information on Hydro Smart Combi panels and integrating space heating and domestic water for this boiler please visit ww...

Page 18: ...ks before firing the unit for the first time Open the main gas supply valve to the unit 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 qualified 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 unit because some gases are ...

Page 19: ...t be replaced 1 Turn off all electric power to the appliance if service is to be performed 2 Turn the gas shutoff valve located on the outside of the unit to the closed position FOR YOUR SAFETY READ BEFORE OPERATING OPERATING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE 1 STOP Read the safety information above on this label 2 Turn off all electric power to the appliance 3 Do not attempt to light the ...

Page 20: ...ause no damage Also there See Installation Manual heading PRESSURE RELIEF VALVES for installation and maintenance of relief valve discharge line and other safety precautions used will reduce but not eliminate the risk of vapors being ignited by the main burner Flammable Vapors Read and follow water heater warnings and instructions If the owner s manual is missing contact the retailer or manufactur...

Page 21: ...on per minute 1 5 L min BUILT IN CONTROLLER and REMOTE CONTROLLER from examples STANDBYLED Orange HOT Button COLD Button Press the HOT button or the COLD button to set the hot water temperature IN USE LED Green The indicator is ON to show that power is ON The indicator lights during combustion INFO Button Inlet water Each time the button is pressed the operation mode is selected in the sequence of...

Page 22: ...Increasing temperature from 120 F 50 C to 125 F 52 C 1 The boiler must be in Stand By to increase the temperature 2 Press the HOT button to set 120 F 50 C 3 Press and hold the INFO button and the HOT button for at least 3 seconds The remote will emit a beep and change to 125 F 52 C 4 To increase the set temperature further press the HOT button You can increase the temperature setting up to 140 F 6...

Page 23: ...y over the set temperature of the DIP switch settings NOTE The table above shows the correct DIP switch position for each temperature setting Each black square represents a switch Only adjust DIP switch No 9 Do not adjust the other DIP switches for temperature adjustment settings The temperature has been preset at the factory to 120 F 50 C Turn off the power supply to the boiler before changing the...

Page 24: ...aller s responsibility to be aware of freezing issues and take all preventative measures The manufacturer will not be responsible for any damage to the heat exchanger as a result of freezing If you will not be using your heater for a long period of time 1 Completely drain the water out of the unit 2 Disconnect power to your heater This will keep your unit from freezing and being damaged The flow ra...

Page 25: ...ed water supply system Contact the water supplier or local plumbing inspector on how 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 6 7 1 Close the manual gas shutoff valve 2 Turn off power to the unit and wait a couple of seconds Turn on again 3 Wait 30 seconds and then turn off power to the ...

Page 26: ... pressing the INFO button 3rd press Outlet water temperature will be displayed on the remote controller by pressing the INFO button 4th press Water flow will be displayed on the remote controller by pressing the INFO button Press the INFO button to finish information mode Inlet water temperature Outlet water temperature Water flow Operation Screen on the controller Built in controller 1 Remote contro...

Page 27: ...egulator assembly 3 feet 91 cm Clearance to service regulator vent outlet J 3 feet 91 cm 1 foot 30 cm Clearance to non mechanical air supply inlet to build ing or the combustion air inlet to any other applica tion K Clearance to mechanical air supply inlet 4 feet 122 cm from below or side opening 1 foot 30 cm from above opening 6 feet 1 83 m 3 feet 91 cm 91 cm 3 feet L 2 13 m 7 feet 2 13 m 7 feet ...

Page 28: ...exhaust terminations at least 3 ft 915 mm away from each other no matter the orientation unless they follow case 1 and 2 on p 23 For multiple unit rooftop terminations whether for standard or direct vent installations space all exhaust and intake terminations in accordance with local codes An exhaust termination must be spaced from a wall or surface in accordance with local codes as well In the ab...

Page 29: ...ed for the air intake Anticipated 3 ft 914 mm min snow level 1 ft 305 mm min 1 ft 305 mm min Intake air Exhaust gas Anticipated snow level Case 2 1 ft 305 mm min Exhaust Intake 0 4 ft 130 mm min Exhaust Intake 0 4 ft 130 mm min 1 ft 305 mm min 0 4 ft 130 mm min 0 4 ft 130 mm min Exhaust Intake Exhaust Intake Case 1 Clearances for sidewall terminations For direct vent sidewall terminations that use...

Page 30: ...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 DIP switch settings for direct vent installation Backflow preventer Recommended for freezing weather conditions 36 F 2 C and below Vertical condensation drain must be installed in accordance with local codes It is required to be installed in the venting system when there is more than 5 ft 1 5 m of equivalent vent lengt...

Page 31: ...ter Rain cap Improper venting of this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death Improper installation can cause nausea or asphyxiation severe injury or death from carbon monoxide and flue gases poisoning Improper installation will void product warranty DANGER Specific DIP switch settings are required depending on the length of you...

Page 32: ... length of exhaust vent piping must not exceed 60 ft 18 3 m Deduct 5 ft 1 5 m for each 90 elbow used in the venting system Do not use more than 6 elbows A 45 elbow is equivalent to 2 5 ft of vent length Vent type Diameter For each 90 elbow added deduct 5 ft 1 5m from max vent length For Intake vent refer to the above table of the installation of 6 elbows and 60 ft Max No of Elbows Intake 3 in 76 m...

Page 33: ...2 per Confined 4 000 btu h SIngle opening Confined 1 in2 3 000 btu h Two permanent openings Two permanent Openings 1 in2 per 12 maximum 1 000 btu h 12 maximum Confined Space Horizontal duct openings 1 in2 per Confined Space 2 000 btu h Outlet Inlet Air Ducts 1 in2 per 2 000 btu h Direct to outdoors openings Two permanent openings Two permanent Openings 1 in2 per 4 000 btu h 12 maximum 12 maximum Confin...

Page 34: ... same area Do not include appliances that are direct vented Refer to the following example Your boilers s BTU h rating is on the rating plate The BTU h ratings should be on the other appliances rating plates If you have trouble determining the BTU h ratings contact the manufacturer or have a qualified person determine the ventilation requirements NOTICE Beauty salons s b a l g n i s s e c o r p o t...

Page 35: ... 1 000 BTU h of the total input for all gas burning appliances in the same area 3 3 1000 btu h Example 235 000 1000 x 50 11 750 If the air volume of the room is less than the required air volume you must direct vent the water heater If the air volume of the room is greater than the required air volume it may be possible to install the as furnaces whole house fans and clothes dryers draw air out of...

Page 36: ...use the following values Each vent opening must be no smaller than 100 square inches Rectangular ducts must have a minimum dimension of no less than three inches All screens must have mesh or larger See graphics on pg 33 Opening Source Check that air source is clean and free of chemicals Minimum Free Area Direct to outdoors Table 1 indoor spaces 1 sq in per 4 000 BTU hr see Figure 1 2 Horizontal d...

Page 37: ... remote controller 321 will be displayed on the screen in its entirety Error code Green LED Green LED on the computer board The green LED on the computer board will indicate this code with two flashes every 1 2 second The pattern will repeat with a three second delay between patterns on on on on on on off off off off off 321 Error Indication Error code indicator on the built in controller Error code ind...

Page 38: ...d on If your boiler has been properly converted to use propane ensure that the tank is not empty Check if there is a buzzing spark ignition sound coming from the burner Part 101 when boiler prepares for combustion Listen for the double clunk sound coming from the gas valve assembly Part 102 when the boiler goes into combustion Check if there is leaking from heat exchanger Part 401 311 Two Flashes ...

Page 39: ...ction 741 N A Check if condensate drain is installed on the vent collar of the water heater Check if there is leaking from heat exchanger Part 401 Miscommunication between boiler and remote controller 751 N A Inspect the connections between the boiler and remote controller Check the power supply of the water heater Miscommunication betweenboiler and built in controller Inspect the connections betw...

Page 40: ...as supply pressure within specified limits Is the set temperature set too low The hot water turns cold and stays cold Make sure the unit has 120 VAC 60 Hz power supply Is the power button on the controller or inside the boiler turned on Is the gas supply valve fully open Is the water supply valve fully open Is the filter on the system clean Is the hot water fixture sufficiently open to draw at least 0 ...

Page 41: ...on and cross connection If you use the remote controller is the power button turned on Check if the inlet water temperature is too high If it is too close to the set temperature the boiler won t work Shorty Cycling Is the gas supply turned on Is power available to the unit If so is the power button on the controller or inside the water heater turned on Built in and remote controller do not display...

Page 42: ...42 Case Assembly 004 052 052 003 001 007 715 002 052 050 050 704 710 008 Built inTemperatureController 722 721 065 Components Diagram ...

Page 43: ... 401 To Water D To Water C 458 462 414 451 451 414 402 404 407 406 405 460 456 458 461 052 415 058 454 457 052 D Water inlet section 408 410 409 415 058 454 455 052 C Water outlet section WaterWayAssembly ...

Page 44: ...44 705 103 709 402 402 711 707 714 407 408 708 701 064 712 721 120 705 053 062 706 703 068 704 705 716 Computer board Assembly Surge box Assembly ...

Page 45: ... 053 105 106 112 708 150 117 116 121 062 114 701 102 119 101 107 151 062 062 067 062 055 056 052 055 111 113 061 110 711 711 714 053 053 057 060 109 115 053 108 104 122 052 709 Manifold assembly Burner assembly LP Conversion Kit 130 131 ...

Page 46: ...0X 064 065 Tapping screw M4x6 SUS3 Truss head Tapping screw M3x6 SUS3 Pan head Screw M3x6 SUS3 Binding head Pan screw M4x8 MFZN Tapping screw M4x14 SUS410 Truss head Screw M3x12 BSNI Raised counter sunk head 066 067 068 319143 439 N A N A 319143 201 319143 372 EW016 EW018 EW02A Screw M3x6 BSNI Binding head Pan screw M4x20 SUS410 Truss screw M4x8 SUS3 Tap tight screw M4x12 FEZN Truss screw M4x10 MF...

Page 47: ...nsor Water inlet Inlet drain plug Inlet water filter 319143 214 EKK4J 408 Inlet thermistor 319143 529 EK207 409 410 Outlet thermistor 319143 466 319143 079 EK104 EK239 412 Water outlet Outlet drain plug 319143 228 EM212 413 414 415 Hi Limit switch for 416 417 319143 067 319143 531 319143 468 100270581 319143 576 EX02A EK209 Overheat cut off fuse for heat exchanger Pipe heater Inlet heater Pipe inlet...

Page 48: ...niter assembly 319143 479 EK586 EW022 EK153 712 714 715 716 319143 274 319143 481 319143 426 N A EM329 EK112 EK184 EK615 Computer board cover Proportional gas valve wire Rubber grommet for Indoor models Surge box cover 721 722 319143 502 N A EK173 Temperature controller Controller fixing plate EK588 N A 320273 585 Communication cable for linking EKK0J OUTPUT TEMPERATURE CHART Chart is based on prop...

Page 49: ...49 Boiler Notes ...

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