Fuel Smart HydroStat 3250-Plus
Contents
1. INDIRECT WATER CIRCULATOR HEATER ZONE VALVE NOTE If a Zone Valve Control Panel has no priority zone To ensure adequate boiler tempera ture to satisfy the domestic hot water tank it may be necessary to turn the Economy Feature off MULTIPLE CIRCULATORS Typical Three Zone Switch Relay ZONE INDIRECT SWITCH EMP POSITION CONTROL REMOVE JUMPER FOR ZONE 1 ZONE 1 ZONE 2 ZONE 3 PRIORITY PRIORITY 2 C2 C1 B1 B2 ZC ZR ZONE aisles ebekkel ZONE 1 ZONE 2 ZONE 3 JUMPER CIRCULATOR FOR NOTE The wire from ZR to the hot terminal of the indirect circulator will ensure that indirect calls will fire to limit and receive priority over heating calls Taco s SR503 combines ZR amd X2 SETTING THE CONTROL Diagnostic LEDs Test Settings Button Dynamic DT EY S Water Temperature and Real Time Verification of Setting Adjustments Low Temperature Limit Setting OFF or 110 200 F Factory OFF NOTE Settings can be checked using the TEST SETTINGS Button See page 11 for details Setting the High Limit The high limit is factory set at 190 F To adjust turn the HI TEMP Dial y until the desired setting is displayed Setting range 100 220 F Setting the Low Limit The low limit is designed to maintain temperature in boilers equipped with tankless coils used for domestic hot water The low limit is factory set to OFF Prior to adjusting remove2. down The boiler water will continue to circulate and heat the house as long as the thermostat call continues The LED will stay lit until the boiler temperature drops below the differential set point at which point the boiler will be allowed to fire again See Differential explanation on page 7 NOTE This LED illuminates regularly during normal boiler operation TEST SETTINGS Button To Test Low Water Cut Off Press and hold the Test Settings button for 5 seconds The display will read LCO LWCO TEST LLU The red Low Water light should illuminate and the burner circuit B1 and B2 should de energize NOTE The control must be installed with a Hydrolevel Electro Well for low water cut off functionality see page 2 for more details To View Current Settings Press and release the Test Settings Button in short intervals to sequentially display the following settings HIGH LIMIT SETTING HL v so LOW LIMIT SETTING LL v ECONOMY SETTING ELO v CURRENT TARGET TEMPERATURE OOo The display will return to boiler temperature default if Test Settings Button in not pressed for 5 seconds Remove the Electro Well from the heating system every five years and clean any scale or sediment deposits from all parts that are exposed to the boiler water After cleaning reinstall the well using pipe sealing compound Teflon tape is not recommended TROUBLESHOOTING Burner Will Not Fire See Flow Chart 1 page 13 Burner Will Not Shut Down
3. the jumper not equipped on all units Then turn the LO TEMP Dial clockwise until the desired temperature is dis played For proper operation the low temperature limit set ting should be at least 10 below the high limit setting NOTE For cold start operation the low limit must be turned OFF IMPORTANT If low limit temperature cannot be set above 140 F remove jumper Setting range OFF or 110 200 F Setting the Economy Feature The Economy Feature is factory set for a 1 zone heating sys tem To adjust turn the ECONOMY Dial until the number displayed equals the number of heating zones Do not include indirect water heaters in the number of heating zones The Economy Feature conserves fuel by reducing E ELI Indicator Light announces heat call High Temperature Limit Setting 100 220 F Factory 190 F Spade Connectors for OS 100 Outdoor Sensor Kit Differentials are automatic and will vary based on control settings and boiler tem perature boiler temperature see How Thermal Targeting Works on page 8 If the heating system is unable to supply needed heat to the house the ECONOMY Dial should be turned to a lower setting example In a three zone house turn the dial to 2 or 1 Conversely if the boiler provides adequate heat added fuel savings can be achieved by selecting a higher set ting example 4 or 5 If the heating and indirect water heater signals were not separated wh
4. FUEL SMART EEVA e STAT INSTALLATION INSTRUCTIONS MODEL 3250 Plus and OPERATING MANUAL Temp Limit LWCO Control Saves Fuel Features Thermal Targeting technology and with Thermal Targeting Thermal Pre Purge capability for Water Boilers Outdoor Reset Ready Provides Outdoor Reset and Warm Weather Shut Down capability with the addition of Hydrolevel OS 100 Outdoor 120 VAC Operating Voltage Sensor Kit sold separately Universal Design Replaces common cold start and triple action PATENT NO 7 891 572 Aquastats Operating Indicators LEDs Dynamic Display and Test Button provide continual and on demand status checks Prioritizes Domestic Hot Water Gives priority to low limit setting or to calls from indirect water heater Reduces Condensation Holds circulator off until boiler reaches 125 F Aquastatis a registered trademark of Honeywell International Inc Three Function Design Temperature Limit Control Designed for cold start and tankless coil boilers Low Water Cut Off Provides protection against potentially dangerous low water conditions when installed with the Hydrolevel Electro Well see page 2 for details Boiler Reset Control e Thermal Targeting On board micro processor adjusts boiler temperature based on heating demand e Outdoor Reset Ready Compatible with Hydrolevel OS 100 Outdoor Sensor Kit sold separately for outdoor reset and warm weather shut down functio
5. See Flow Chart 2 page 14 Temperature Display Exceeds High Limit Setting No or Insufficient Domestic Hot Water Low Water Light Red LED is On or Blinking Boiler Will Not Maintain Low Limit Temperature House Will Not Get or Stay Warm Circulator Contacts C1 and C2 Not Energized on Call for Heat All LED Lights and Temp Display are Blinking Under normal operation boiler temperature will continue to rise after the control shuts off the burner This condition known as thermal stacking results from hot boiler surfaces continuing to release heat into the boiler water For boilers equipped with a tankless coil make sure the low limit setting on the HydroStat is set properly NOTE If the low limit setting is dialed fully counter clockwise it will shut off the low temperature maintenance feature and will function as a cold start control If installed with an indirect water heater check that the Zone Indirect Switch is set in the Indirect I position Verify that the end switch in the relay box controlling the indirect water heater is connected to the ZC ZR terminals This will ensure that the domestic water calls are prioritized see Heating and Indirect Water Heater on page 4 6 dangerous condition Do not attempt to add water to a hot boiler Allow the boiler to fully cool before adding water When Installed on an Electro Well When the LOW WATER light is on this indicates that the control is not detectin
6. 8 140 Model OS 100 Outdoor Sensor Kit REMOTE MOUNTING KITS Part No Description Part No Description 48 101 HydroStat Remote Mount Kit with 24 sensor 48 103 HydroStat Remote Mount Kit with 10 sensor 48 102 HydroStat Remote Mount Kit with 48 sensor 48 104 HydroStat Remote Mount Kit with 20 sensor 48 121 HydroStat Pipe Mounting Kit with 48 sensor 1 29 gt e COO OO alt nig ca ca i 4 375 48 201 3 4 NPT Standard 5 75 48 202 3 4 NPT Extended 4 5 48 221 1 2 NPT Standard 6 0 48 222 1 2 NPT Extended a SPECIFICATIONS FUEL SMART HYDROSTAT MODEL 3250 Plus Input voltage Burner contacts Circulator contacts Operating range low limit Operating range high limit Operating range differentials 120 VAC 60 HZ 7 4 FLA 44 4 LRA 120 VAC 5 8 FLA 34 8 LRA 120 VAC Off or 110 F 43 C 200 F 93 C 100 F 38 C 220 F 104 C Automatic Thermostat heat anticipator setting 0 2A Gi LISTED MADE IN LIMITED MANUFACTURER S WARRANTY We warrant products manufactured by Hydrolevel Company to be free from defects in material and workmanship for a period of two years from the date of manufacture or one year from the date of installation whichever occurs first In the event of any claim under this warranty or otherwise with respect to our products which is made within such period we will at our option repair or replace such products or r
7. THERMOSTAT INDIRECT INDIRECT END SWITCH O SWITCH END SWITCH O SWITCH FROM ZONE RELAY O POSITION CIRCULATOR o POSITION OR MULTI ZONE NEL EE 1 L2 C2 C1 B1 B2 ZC ZR ZR lal slelgis beke eeel END SWITCH END SWITCH CIRCULATOR FROM INDIRECT FROM INDIRECT ZONE RELAY ZONE RELAY Connect thermostat or end switch from zone relay or multi zone Connect end switch from heating circulator relays or multi zone panel to T T Connect circulator to C2 C1 Connect end switch panel to T T Connect end switch from indirect circulator relay to from indirect zone relay to ZC ZR Move Zone Indirect Switch ZC ZR Move Zone Indirect Switch to I down to I WARNIN Electrical shock hazard To prevent electrical shock death or equipment damage disconnect power supply before Z g installing or servicing this control NOTE For proper operation of the boiler reset function all heating thermostats must input to T T or ZC ZR terminals as indicated below Jumping the T T terminals and wiring the thermostat to the primary will override the economy feature STEP 3B HEATING and Indirect Water Heater continued MULTIPLE CIRCULATORS Typical Zone Panel with Priority Zone QO ZONE INDIRECT SWITCH POSITION ZONE 4 PRIORITY ON ZONE 1 ZONE 2 ZONE 3 ZONE 4 H pe Bi B2 bekke sieisle ZONE 2 ZONE 3 ZONE 4 eo CIRCULATOR FOR INDIRECT NOTE The w
8. as Pro 2 Turn the HI TEMP dial to select feature 3 Push the Test Settings Button to turn Thermal Pre Purge an or DEF 4 Reset LO TEMP and HI TEMP settings to desired temperatures see page 7 Degrees Fahrenheit or Celsius The control has the ability to operate in degrees Fahrenheit or Celsius When operating in Celsius a i will appear in the dis play next to the temperature whenever the temperature is below 100 degrees To change between degrees Fahrenheit and degrees Celsius 1 Turn the LO TEMP dial to access the Program Mode indicated in the display as Fra 2 Turn the HI TEMP dial to select feature c amp 3 Push the Test Settings Button to c for Celsius or F for Fahrenheit 4 Reset LO TEMP and HI TEMP settings to desired temperatures see page 7 MORE OPTIONAL FEATURES ON NEXT PAGE OPTIONAL FEATURES continued Manual Reset Low Water Cut Off The low water cut off operation on the HydroStat can be set to operate in automatic default or manual reset mode When in manual reset mode the control will shut down the burner immediately when a low water condition is detected If the low water condition is sustained for 30 seconds the low water light will blink indicating that the control has locked out the burner The control can only be reset by pushing the Test Settings button on the top of the control The manual reset feature meets CSD 1 code requirements IMPORTANT The system must be checked by a qualified heating pr
9. ed Condensing Protection To reduce the potential for condensing on a call for heat the control will allow the boiler to heat to 125 F prior to energizing the circulator Once energized the circulator will remain on for the duration of the heating call unless the boiler temperature drops below 115 F If this occurs the circulator will re energize when the boiler returns to 125 F To activate Circulator Hold Off 1 Turn the LO TEMP dial to access the Program Mode indicated in the display as Pra 2 Turn the HI TEMP dial to select feature 5 3 Push the Test Settings Button to turn Circulator Hold Off an or OFF 4 Reset LO TEMP and HI TEMP settings to desired temperatures See page 7 MORE OPTIONAL FEATURES ON NEXT PAGE OPTIONAL FEATURES continued Low Water Cut Off Function To turn off Low Water Cut Off 1 Turn the LO TEMP dial to access the Program Mode indicated in the display as Pro 2 Turn the HI TEMP dial to select feature E 3 Push the Test Settings Button to turn Low Water Cut Off an or DEF 4 Reset LO TEMP and HI TEMP settings to desired temperatures see page 7 Restore Factory Default Settings To restore all features to the factory default settings see following chart for default settings 1 Turn the LO TEMP dial to access the oran Mode indicated in the display as Pro 2 Turn the HI TEMP dial to select feature dEF 3 Push the Test Settings Button to 4 to reset all features to the default settings 4 Re
10. ed below Jumping the T T terminals and wiring the thermostat to the primary will override the economy feature STEP 3A HEATING ONLY No Indirect Water Heater CHOOSE Q OR BELOW SINGLE CIRCULATOR MULTIPLE CIRCULATORS ZONE ZONE THERMOSTAT INDIRECT INDIRECT END SWITCH SWITCH SWITCH ZONE RELAY POSITION POSITION MULTI ZONE PANEL C2 C1 B1 B2 ZC ZR beke sisists O END SWITCH FROM CIRCULATOR RELAY OR MULTI ZONE PANEL CIRCULATOR 120VAC Connect thermostat or end switch from zone relay or multi Connect end switch from circulator relay or multi zone panel to zone panel to T T Connect circulator to C2 C1 Move ZC ZR Move Zone Indirect Switch up to Z Zone Indirect Switch up to Z STEP 3B HEATING and Indirect Water Heater IMPORTANT When installing with an indirect water heater the Zone Indirect Switch must be set in the I position When set in the I position calls to ZC ZR will bypass the Thermal Targeting feature and allow the boiler to fire to the high limit setting to heat the indirect tank The indirect signal must be separate from all heating zone signals If you choose not to separate the indirect signal from the heating zones the Economy Feature should be turned OFF to ensure that the boiler supplies adequate temperature to heat the indirect tank see page 7 CHOOSE FROM THROUGH BELOW OR ON PAGE 5 OR 6 SINGLE CIRCULATOR MULTIPLE CIRCULATORS T T ZONE ZONE
11. efund the pur chase price paid to us by you for such products In no event shall Hydrolevel Company be liable for any other loss or damage whether direct indirect incidental or conse quential This warranty is your EXCLUSIVE remedy and shall be IN PLACE OF any other warranty or guarantee express or implied including without limitation any warranty of MERCHANTABILITY or fitness for a particular purpose This warranty may not be assigned or transferred and any unauthorized transfer or assignment thereof shall be void and of no force or effect HYDROLEVEL COMPANY 16 83 Water Street e New Haven CT 06511 Phone 203 776 0473 FAX 203 773 1019 e www hydrolevel com 3250 1113
12. en wiring the control the Economy Feature should be turned OFF to ensure the boiler supplies adequate temperature to heat the indirect tank Setting the Zone Indirect Switch See WIRING on page 4 6 SETTING GFF Disables economy function Will allow boiler to fire until hi limit temp is reached and re fire with a 10 subtractive differential LUG Provides lowest level of fuel savings Use this setting only if the house does not stay warm at higher settings Recommended setting for single zone systems Z Recommended setting for Two zone systems J Recommended setting for Three zone systems H Recommended setting for Four zone systems S Recommended setting for Five zone systems HI Provides highest level of fuel savings SYSTEM START UP At initial start up with the Economy Feature active the control establishes a 145 F target temperature To test the high limit shut off function the Economy Dial must be turned to OFF Once tested restore the Economy setting If the heating demand is high the target will increase over time to satisfy the heat load NOTE e Smart DHW Priority During a call from an indirect water heater the control will de energize the circulator contacts C1 C2 to heat only the indirect tank ensuring an adequate supply of domestic hot water The control will re energize the circulator when the indirect tank is satisfied or if the boiler temperature reaches 170 F If the indirect call continues for 45 minute
13. g power from the control and then repowering while simultaneously pressing the Test Settings button on the top of the control If the cause of the overheating condition is not determined the control should be replaced Troubleshooting Flow Chart 1 Burner Will Not Fire Does the Display Read Pur YES NO Is the Green LED TEMP ACTIVE On NO Is the Red LED LOW WATER On NO Is the Yellow LED HI TEMP On NO Is the Yellow LED TARGET On YES NO Is the Thermostat T T Calling for Heat NO YES Between B1 and B2 NO Replace Control The Control is Purging Latent Heat from the Boiler The Control is Not Powered The Control is Sensing Low Water The Control is Sensing High Temperature The Boiler has Reached the Target Temperature YES The Control is Operating Properly The Thermal Pre Purge feature holds off the burner until the control determines if the latent heat in the boiler can satisfy the heat call The Temp Active LED will be on at all times when the control is powered gt Check for 120 VAC on terminals L1 and L2 CAUTION ALWAYS ALLOW A BOILER TO COOL BEFORE ADDING WATER The burner will not fire until the low water condition is satisfied gt Check that the system is filled with water gt Check that the sensor is inserted fully into the we
14. g water in the boiler When the LOW WATER light is blinking this indicates that the control has been programmed to provide low water lock out protection and is currently locked out see Manual Reset Low Water Cut Off on page 9 Pressing the TEST SETTINGS button after the low water condition is resolved will reset the lock out condition 1 If the light is on and the heating system is filled with water pull the sensor out of the well and inspect it Make sure that the metal clip is protruding enough to come in contact with the inside of the well tube Check that the well does not have excessive build up of heat transfer grease that may interfere with the clip contacting the well 2 Remove well and examine for excessive residue build up Clean and re install When Installed on a Standard Immersion Well If either LWCO LED lights are illuminated and the control is installed on a standard immersion well this is a false reading caused by a loss of continuity between the sensor and the inside of the well tube It is recommended when the control is installed on a standard immersion well the LWCO Function be turned off see page 10 for details 3 WARNING A low water condition is a serious and potentially Check for overlapping high temperature setting If the high limit setting is set below the low limit setting the control will default to the high limit setting and the corresponding high limit differential setting Check for air bound radiator
15. hen installed with the Hydrolevel Electro Well Ls Insulator PROVIDES Fuel Smart HydroStat will provide both temperature TEMPERATURE and low water cut off functionality If the control was ECONOMY AND supplied by the boiler manufacturer it was installed tii ep A ONA with an Electro Well The Electro Well is available separately for field installations Sensor Connects to HydroStat control Electrical Insulator Temperature Sensor IMPORTANT For proper opera tion of the low water cut off func tion there must be a minimum of Ye clearance between the cop per well tube and any surface within the boiler Copper Well Tube Low Water Detection Sensor IMPORTANT DO NOT remove Brass Nut this part Electro Well Models T F 3 4 1 7 E Y Y ii F ZJ T2 l 1 75 3 0 B 48 205 48 225 48 204 Standard c 48 224 Standard 48 201 48 202 Extended 3 4 NPT 48 221 48 222 Extended 1 2 NPT Standard Extended 3 4 NPT Extra Short Standard Extended 1 2 NPT Extra Short 3 4 NPT 3 4 NPT Short Insertion Insertion 1 2 NPT 1 2 NPT Short Insertion Insertion 15 OUTDOOR SENSOR KIT Hydrolevel s optional Outdoor Sensor Kit automatically activates outdoor reset functionality and warm weather shutdown capa bility when plugged in to the Fuel Smart HydroStat control This low cost easy to install kit is available separately at Hydrolevel distributors Part No Description 4
16. ire from ZR to the hot terminal of the indirect circulator will ensure that indirect calls will fire to limit and receive priority over heating calls SINGLE CIRCULATOR Multiple Zone Valves including Indirect No Zone Control Panel ZONE INDIRECT SWITCH POSITION DPDT RELAY ee by others L1 L2 C2 C1 B1 B2 ZC ZR ZONE VALVE TRANSFORMER ZONE VALVE ZONE VALVE HEAT INDIRECT CIRCULATOR NOTE When using zone valves for both heat and indirect the calls must be separated in order to prioritize indirect calls This can be accomplished by using a general purpose relay as shown above However for ease of installation a zone control panel is rec ommended see wiring diagram 7 on next page MORE WARNIN Electrical shock hazard To prevent electrical shock death or equipment damage disconnect power supply before L N installing or servicing this control NOTE For proper operation of the boiler reset function all heating thermostats must input to T T or ZC ZR terminals as indicated below Jumping the T T terminals and wiring the thermostat to the primary will override the economy feature STEP 3B HEATING and Indirect Water Heater continued SINGLE CIRCULATOR Typical Multiple Zone Valve Panel with Indirect Tm POSITION NORMAL RESET ZONE4 PRIORITY SMTH ZONE 1 ZONE 2 ZONE 3 ZONE 4 L1 L2 C2 C1 B1 B2 ZC ZR ale BBS MEME END END SWITCH SWITCH N O COM N C ZONE 1 ZONE 2 ZONE 3 ZONE 4
17. laced 13 Troubleshooting Flow Chart 2 Burner Will Not Shut Down Is the Red LED LOW WATER On The Control is Sensing Low Water Z WARNING TURN OFF POWER TO BURNER IMMEDIATELY CAUTION ALWAYS ALLOW A BOILER TO FULLY COOL BEFORE ADDING WATER gt Recheck wiring Make sure that burner is wired to B1 Burner should never fire when red or yellow The Control has LED is lit Reached Target or High Limit Temperature Is either Yellow LED On Is the Thermostat T T Calling for Heat The Control is Operating Normally The burner will continue to fire when there is a call from the thermostat or external zone Is the External Zone ZC ZR Calling for Heat The Control is Operating Normally Is the gt Check temperature display When the Low Limit is Low Limit Dial set the HydroStat will fire the burner until the Set to OFF temperature reaches the Low Limit Setting When there is no call to fire the burner the voltage Recheck should be 0 volts between B1 and B2 wiring gt Make sure the burner is wired to B1 If there is no call for heat from T T ZC ZR or Low Replace Limit there should be 0 VAC between B1 B2 Control gt If there is voltage between B1 B2 the control should be replaced 14 ELECTRO WELLS Fuel Smart Fuel Smart HydroStat ie et raien installed with Electro Well Control Ereto wel W
18. ll and contact between its spring clip and the copper well tube is made gt Check that the control is tightly clamped to the well Also see page 12 for additional troubleshooting information The burner will not fire until the boiler water has dropped to the high limit differential set point 10 below high limit setting gt Check that the high temperature setting is correct When the ECONOMY function is active the control monitors heating demand and establishes Target boiler temperatures below the high limit setting to conserve fuel see How Thermal Targeting Works on page 8 The burner will not fire until the boiler temperature drops to the automatically calculated Target Temp Differential When the low temperature setting is set to OFF the HydroStat will act as a cold start control The burner will not fire unless there is a call from the thermostat T T or an external zone ZC ZR gt Set thermostat to call for heat Burner should fire gt If the boiler has a tank less coil set the Low Temperature Limit to maintain temperature Is the Low Limit Dial Set to OFF NO HydroStat is supplying 120 VAC to the burner circuit gt Recheck wiring and operation of burner and other limit controls If both the red and yellow LEDs are off and there is a call to fire the burner there will be 120 VAC on terminals B1 and B2 gt If 120 VAC is not present the control should be rep
19. nality NWARNIN Electrical shock hazard To prevent electrical shock death or NCAUTIO To prevent serious equipment damage disconnect power supply before burns boiler installing or servicing control Only qualified personnel may install or service this control in should be thoroughly cooled before installing or accordance with local codes and ordinances Read instructions completely before proceeding servicing control NWARNIN Frozen pipes water damage Central heating systems are prone to shut down as a result of power or fuel outages safety related fault conditions or equipment failure Installation of freeze protection monitoring or other precautions is recommended for unattended dwellings in climates subject to sustain below freezing temperatures ipt as 83 Water Street e New Haven CT 06511 Phone 203 776 0473 FAX 203 773 1019 e www hydrolevel com 1 Fuel Smart HydroStat can be installed on a Hydrolevel Electro Well or on an existing immersion well already in the boiler IMPORTANT The control will only provide low water cut off protection when installed on an Electro Well Installing HydroStat with Hydrolevel Electro Well Fuel Smart HydroStat Hydrolevel Control Electro Well Electrical E Insulator Los PROVIDES 7 TEMPERATURE ECONOMY AND mmm LOW WATER CUT OFF ey FUNCTIONALITY When installed on an Electro Well sold separately the Low Water Cut Off function is automatically ac
20. ofessional prior to resuming operation WARNING DO NOT ADD WATER UNTIL THE BOILER HAS FULLY COOLED To activate Manual Reset LWCO mode 1 Turn the LO TEMP dial to access the Program Mode indicated in the display as Pro 2 Turn the HI TEMP dial to select feature 4 3 Push the Test Settings Button to H for Automatic Reset Mode or b for Manual Reset Mode 4 Reset LO TEMP and HI TEMP settings to desired temperatures see page 7 To Test the Manual Reset Feature Press and hold the Test Settings button located on the top of the control for 30 seconds to simulate a low water condition After 30 seconds the Low Water light will blink indicating that the control is locked out To reset the lock out condition press the Test Settings button momentarily Circulator Activation Options When in the default mode the HydroStat activates the circulator C1 C2 contacts on calls to TT The control can be pro grammed to activate the circulator on calls to ZC ZR in place of or in addition to calls to TT To change how the Circulator is activated 1 Turn the LO TEMP dial to access the Program Mode indicated in the display as Pro 2 Turn the HI TEMP dial to select feature 4 3 Push the Test Settings Button to select between the following options H Circulator on TT call only b Circulator on ZC ZR call only L Circulator on both TT amp ZC ZR calls 4 Reset LO TEMP and HI TEMP settings to desired temperatures see page 7 Circulator Hold Off Enhanc
21. s Check thermostat settings including heat anticipator settings common on non digital thermostats Check the Economy setting The Economy feature much like outdoor reset controls lowers average boiler temperature and can slow or in some cases prevent the house from coming up to temperature Move to a lower setting see Setting the Economy Feature on page 7 Check to see that boiler water is at or above 125 F On a call for heat the control will not permit the circulator to operate if the boiler water temperature is below 125 F see Circulator Hold Off on page 9 If the LED lights and the temp display are blinking alternately this indicates the control has sensed a boiler temperature of 250 F When this occurs the control pulses the burner relay and then shuts down and locks out the burner The system should be analyzed to determine the cause of the overheating condition Check that the sensor is inserted all the way into the well so it can accurately sense the temperature of the boiler water Check the load on the burner contacts If the load exceeds the 7 4 Amp rating the contacts may have welded Correct the overloading condition and replace the control before reenergizing the system If the load on the contacts is below the rating check system wiring and operation as well as the control s high limit setting If the cause of the overheating is found and the system is deemed safe the control can be reset by removin
22. s the control will override the priority function energizing the circulator to provide space heating HOW THERMAL TARGETING WORKS Thermal Targeting technology analyzes thermostat activity and continually evaluates how much heat the house requires When it is very cold outside the heat demand is high and the Fuel Smart HydroStat will raise the boiler s Target temperature to provide needed heat to the home When the outside temperature is milder the heat demand is lower During these periods the Fuel Smart HydroStat will lower the boiler s Target temperature saving fuel while continuing to provide comfort to the house OPTIONAL FEATURES NOTE The Program Mode f o is accessed by turning the LO TEMP dial to a position just above OFF Thermal Pre Purge Thermal Pre Purge is designed to maximize boiler efficiency When activated the control will supply latent heat that may remain in the boiler from a previous run cycle to the heating zone that is now calling The control monitors how quickly the boil er temperature is declining and activates the burner only when it determines that the latent heat is insufficient to satisfy the call During the purge cycle the display will indicate Pur This feature works with single zone and multi zone heating systems uti lizing circulators or zone valves No change in wiring is needed To activate Thermal Pre Purge 1 Turn the LO TEMP dial to access the Program Mode indicated in the display
23. sert sensor ALL THE WAY into well through the knockout A or B you have chosen Fig 3 KNOCKOUT A KNOCKOUT B FIG 3 NOTE In the case of space restrictions the Fuel Smart HydroStat control may be mounted in a horizontal orientation without any loss of function Hydrolevel recommends vertical mounting when possible for proper orientation of LED display ata ey Le ub egg are available separately for mounting the Fuel Smart HydroStat control box in a remote location Each kit includes mounting hardware and a remote sensor See page 16 for kit options WARNIN Electrical shock hazard To prevent electrical shock death or equipment damage disconnect power supply before Z installing or servicing this control L1 L2 C2 C1 B1 B2 ZC ZR L1 L2 C2 C1 B1 B2 ZC ZR ES E E C eese eo SERVICE SWITCH 120VAC OIL BURNER 120VAC NEUTRAL STEP 1 Connect 120 VAC Hot to terminal L1 Connect STEP 2 Connect the burner circuit to B1 B2 120 VAC Neutral to terminal L2 Disconnect means and B2 is neutral overload protection as required provided by others Select the Diagram that Matches your System Configuration on Pages 4 5 or 6 WARNIN Electrical shock hazard To prevent electrical shock death or equipment damage disconnect power supply before L N installing or servicing this control NOTE For proper operation of the boiler reset function all heating thermostats must input to T T or ZC ZR terminals as indicat
24. set LO TEMP and HI TEMP settings to desired temperatures see page 7 Dial Default Setting Feature Options Description Setting Thermal Pre Purge EE Purge Inactive Hee an Purge Active uud Fahrenheit or Celsius Degrees Fahrenheit Degrees Celsius LWCO Manual or Automatic Reset Circulator Options Circulator operation on TT call only Circulator operation on ZC ZR call only Circulator operation on call from either Circulator Hold Off n Circulator Hold Off Active YE Circulator Hold Off Inactive Not available E on this control Not available on this control B Low Water Cut Off on Low Water Cut Off ON Function GFF Low Water Cut Off OFF dEF Restore Factory Jj Restore Defaults Defaults n Do Not Restore Defaults NOTE If the HydroStat is factory equipped on a boiler some options may be set differently from the default settings SEE PAGE 7 FOR ADDITIONAL SETTINGS 10 LED LEGEND and TEST SETTINGS BUTTON TEMP ACTIVE Indicates that the Fuel Smart HydroStat control is powered and that the temperature function is active TEMP HI TEMP llluminates when the boiler water temperature reaches the high limit setting It will remain lit until the water temperature falls 10 The Fuel Smart HydroStat prevents burner operation while this LED is on See Differential explanation on page 7 wcoJAcrivE Indicates that the low water cut off LWCO function of the Fuel Smart HydroStat is active When the control is installed with a H
25. tivated Heat transfer grease should not be used NOTE For proper operation there must be 1 2 clearance between the cop per well tube and any furnace within the boiler See Electro Well models on page 15 MOUNTING THE CONTROL Installing HydroStat with Standard Immersion Well Fuel Smart HydroStat Control MUS Standard Immersion Well PROVIDES TEMPERATURE AND ECONOMY FUNCTIONALITY ONLY When installing on a standard immersion well the LWCO function should be turned off see page 10 for instructions A buildup of heat transfer grease or other coatings in older wells can interfere with continuity between the sensor and the well causing a false low water shutdown Turning off the LWCO function will prevent this from occurring IMPORTANT Make sure that the immersion well or Electro Well is installed in the boiler manufacturer s designated temperature limit control tapping NOTE If installing an Electro Well pipe sealing compound should be used Teflon tape is not recommended STEP 1 Two mounting positions are available on the back of the control Fig 1 Select which of the two positions 2 knockouts is best for the location of the control Remove the knockout BACK OF FUEL SMART HYDROSTAT BOX WELL CLAMP KNOCKOUT A KNOCKOUT B N WELL CLAMP SCREW STEP 2 Place control on the well While holding box against well nut tighten well clamp screw Fig 2 STEP 3 in
26. ydrolevel Electro Well this LED will be on at all times when the control is powered IMPORTANT If the control is installed with a well other than the Electro Well this LED will not illuminate indicating that the control is not providing low water cut off functionality O wcojLow WATER Indicates that the boiler is in a low water condition The HydroStat control will prevent burner operation during this condition If the LOW WATER light is blinking the control has been programmed to provide lock out protection in the event a low water condition is detected see Manual Reset Low Water Cut Off on page 9 Pressing the TEST SETTINGS button will reset the control IMPORTANT The system must be checked by a qualified heating professional prior to resuming operation WARNING ALLOW THE BOILER TO FULLY COOL BEFORE ADDING WATER O ECONOMY JACTIVE Indicates that the Thermal Targeting function is active and the Fuel Smart HydroStat will reduce boiler temperature to conserve fuel The Economy feature is activated using the ECONOMY dial See How Thermal Targeting Works on page 8 for more information Q ECONOMY TARGET When the Economy feature is active the Fuel Smart HydroStat continually sets target Low water 11 e eS z Lii e e LLI temperatures below the high limit setting to maximize fuel efficiency When the boiler water reaches the target temperature the LED illuminates and the burner will shut
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