Hydro Smart 120 Condensing Gas Micro Boiler
Contents
1. TEMPERATURE and AMOUNT OF HOT WATER Fluctuation in hot e ls the gas line sized properly p 21 water temperature e Is the supply gas pressure sufficient p 20 and 22 e Check for cross connection between cold water lines and hot water lines UJ Owner s Guide Troubleshooting paw PROBLEM SOLUTIONS Unit does not ignite e s the power on the micro boiler when water goes e Is the gas on through the unit e Is the flow rate over 0 5 GPM 1 9 L min p 34 e Is the system Y strainer clean e Check for reverse connection and cross connection p 22 e isthe temperature controller power button turned on p 34 and 35 e Check if the system return temperature is too high The fan motor is e This is normal After operation has stopped the fan motor keeps still spinning after running from 15 to 70 seconds in order to re ignite quickly as well operation has stopped as purge all the exhaust gas out of the flue Abnormal sounds from Is the correct gas type of a micro boiler installed p 6 the micro boiler e Are the DIPswitch settings for your altitude set correctly p 26 e Check the flame quality p 38 e ls the intake or exhaust vent blocked p 10 e Is the vent length and diameter correct p 11 to 16 e Is the manifold pressure set correctly p 4 Unit sounds abnormal Contact the manufacturer at 1 763 331 3066 while in operation Controller does not e Make sure the micro boiler is supplied with power dis2. Exhaust Secondary heat exchanger Exhaust Thermistor Primary heat exchanger Igniter Water control 8 valve Gas valve Computer IE DM Fan motor board Dom l KOR Flow sensor Thermistor 22 EE Condensate drain port Gas inlet Hot water outlet Cold water inlet Thermistor This diagram illustrates condensing micro boiler design concepts only and does not accurately represent the micro boiler s physical description Your thermostat indicates a need for heat and turns on a circulator pump Fluid enters the heater The flow sensor detects the fluid flow The computer initiates the fan motor and sends a signal to the igniter to create an ignition Spark The gas ignites and flames appear within the burner chamber Fluid circulates through the heat exchanger and then gets hot Using thermistors to measure temperatures throughout the micro boiler the computer modulates the gas and water valves to ensure proper output fluid temperature Your room reaches desired temperature and the micro boiler shuts off Installation Manual SAFETY GUIDELINES SAFETY DEFINITION Indicates an imminently hazardous situation which if not avoided will result in death or serious injury DANGER Indicates an imminently hazardous situation which if not avoided could result in death or serious injury WARNING Indicates an imminently hazardous situation which if not avoided could result in minor or moderate injury CAUTI
3. button to set the hot water temperature ON OFF Button STAND BY LED Orange Press this button to start The indicator turns on when the or stop operation boiler is ready for operation GENERAL e Flow rate to activate the micro boiler 0 5 gallon per minute at the default set temperature 1 9 L min e Flow rate to keep the micro boiler running 0 4 gallon per minute 1 5 L min e The controllers have an energy saving mode Five minutes after the micro boiler stops operating the backlight of the controller turns off e The backlight of the controller will turn back on once the micro boiler begins firing again TEMPERATURE TABLE OF THE CONTROLLER ra 100 105 110 115 120 125 130 135 140 EY gt 40 43 15 BON gt 551 571760 Factory setting Default Owner s Guide Normal Operation TEMPERATURE SETTINGS Ne Sereen on the controller 1 Turn on the 120 VAC power supply to the micro boiler 2 Press the ON OFF button on the controller in ue order to turn the controller on Oo 3 When ON the STAND BY LED is lit 4 It shows the set temperature on its display as shown a Bd EX 120 F jn the picture on the right EX 120 F now ULI 5 Press the HOT button or the COLD button to set fe oww H of A the temperature setting of the unit Temperature setting on the PCB There are 2 preset temperatures 120 F 49 C and 140 F 60 C that you can select from by changing the DIPswitch setting
4. GPM Max 7 0 GPM with Various Inlet Water Temperature o9 o O O utput Hot Water GPM Incoming Temp F 50 Page Owner s Guide a TED WARRANTY The manufacturer warrants this product against defects in materials or workmanship as described in this document if installed within the United States or Canada The manufacturer or its authorized Service Representative will at its sole discretion repair or replace any failed or defective mechanical or electrical parts or components thereof or if the manufacturer or its authorized Service Representative cannot replace said parts and repair is not commercially practicable the manufacturer or its authorized Service Representative will refund the purchase price The manufacturer or its authorized Service Representative may at its sole discretion use new refurbished or reconditioned parts 2 Warranty for all models Unit Year Application Type PTE TN Single Family Residential Heating 150218 Commercial or Multi Family Residential Heating 106 5 1 1 Limited Labor Coverage e The manufacturer will provide for reasonable labor charges associated with warranty repairs or replacements within one 1 year from the date of purchase The manufacturer will only pay directly to the service provider e Warranty service must be performed by an authorized Service Representative A list of authorized Service Representatives is available upon request e All warranty claims and warranty
5. Installation Manual INITIAL OPERATION FOR YOUR SAFETY READ BEFORE OPERATING e Check the GAS and WATER CONNECTIONS for leaks before firing unit for the first time e 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 e Be sure to check for the presence of leaking gas toward the bottom of the micro boiler because some gases are heavier than air and may settle towards the floor e Check the GAS PRESSURE Refer to p 20 and 22 e Do not try to light the burner manually It is equipped with an electronic ignition device which automatically lights the burner e Check for PROPER VENTING and COMBUSTION AIR to the micro boiler e Purge the GAS and WATER LINES to remove any air pockets e Do not use this micro boiler if any part has been submersed under water Immediately call a qualified service technician to inspect the micro boiler and to replace any damaged parts IF YOU SMELL GAS e Do not try to start the micro boiler e Do not touch any electric switches do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas WARNING supplier s instructions e If you cannot reach your gas supplier call the fire department Once the above checks have been completed
6. please clean L filter of any debris Refer to p 38 for instructions 3 Fully open the manual water control valve on the water supply line Turn on the thermostat and verify that fluid flows T 3 through your radiant system Then turn off your thermostat 4 Fully open the manual gas control valve installed Turn on the 120 VAC 60 Hz power supply to the water heater Now turn on the thermostat You are ready to enjoy hours of endless comfort OPTIONAL ITEMS le Hydro Smart Pre built panels Single zone pump zone valve and telestats 2 4 inch Backflow Preventer a em OOOO O caei Installation Manual In sta II E a IOTIO nN IU CIUT I Call for order assistance HS 2ZVB04 4 inch Exhaust Sidewall Vent Terminator Hood and 4 inch Wall Thimble 4 3 inch Concentric PVC Termination 1 Hydro Smart pre built space heating panels Call tech support 1 763 331 3066 for order assistance Features e Constructed with with top quality materials including heavy duty type L copper pipe and a powder coated panel e Engineered and proven panel design uses professional hydronic practices e With nothing extra and nothing spared on each panel every component is there to help ensure your system provides years of trouble free operation There are two functions available for this adaptor which can be connected with the micro boiler and category Ill venting and p
7. 16 For each elbow added deduct 5 ft 1 5 m from max vent length 11 Page Installation Manual Installation DIPswitch settings for Vent length Set DIPswitches shown in the tables below depending on the vent length Only adjust switches with a black square Black squares indicate the position of the switch 2 inch venting Vent length Single pipe ON sa 3 me 6 7 210 5 to 6 5 ft lulmlalnln 3 inch venting Vent length Vent length Single pipe Mesa elns ER 5 to 20 ft CCD A eo 5 to 45 ft g nmee sae DEFAULT No 6 ON DEFAULT No 6 ON No 7 OFF ON MRENE 6 7 8 210 21 to 40 ft orr Omm 46 to 70 ft JG No 6 OFF No 6 OFF No 7 OFF No 7 OFF 41 to 70 ft No 6 ON No 7 ON 4 inch venting Vent length Two pipe and Single pipe on 223 avs 6 7 5 to 50 ft Bi l DEFAULT No 6 ON ON an 567 51 to 100 ft orp i No 6 OFF No 7 OFF 12 Page Installation Manual Intake and Exhaust Venting Illustrations Typical installations using ABS PVC CPVC or polypropylene vent 2 inch vent installation Vent connections for single pipe ye straight pipe 3 elbow with bird SS aia Sree x2 reducer Exhaust vent collar Female Intake vent collar Female The micro boiler came with a metal screen that will fit into a 3 inch elbow 1 Connect a 3 elbow directly o
8. 820 500 3 00 1 60 750 400 58 22 5 58 22 5 H 21 3 4 x W 14 x D 9 1 4 H 552 x W 352 x D 236 Electric Ignition 120 60 53 9 0 7 3 2 0 05 223 9 1 94 40 psi 0 27 MPa or above is recommended for maximum flow The Manifold Pressure is the factory setting and should not need adjustment NOTE e Check the rating plate to ensure this product matches your specifications e In accordance with ANSI Z21 10 3 CO emission does not exceed 400 PPM for normal input e The manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligation Installation Manual INTRODUCTION RWN FP HD UT This manual provides information necessary for the installation operation and maintenance of the micro boiler The model description is listed on the rating plate which is attached to the side panel of the micro boiler Please read all installation instructions completely before installing this product If you have any problems or questions regarding this equipment consult the manufacturer or its local representative These high efficiency models have a built in secondary heat exchanger that absorbs latent heat from the exhaust gas The 140 Indoor T H3M DV model is only to be installed indoors The 140 Outdoor T H3M OS model is only to be installed outdoors The principle behind condensing micro boiler is simple Intake port i
9. a licensed professional to inspect the micro boiler to replace any damaged parts e Do not reverse the hot outlet and cold inlet connections to the micro boiler CAUTION This will not properly activate the micro boiler All pipes pipe fittings valves and other components including soldering materials must be suitable for space heating systems 1 A manual shutoff valve must be installed on the cold water inlet to the micro boiler between the main water supply line and the micro boiler 2 In addition a manual shutoff valve is also recommended on the hot water outlet of the micro boiler If the micro boiler is installed within or subjected to a closed loop water system a thermal expansion tank or code approved device to handle thermal expansion must be installed We recommend isolation valve sets with hose bibs for serviceability such as flushing See maintenance and service section 3 Before installing the micro boiler flush the system to remove all debris and after installation is complete purge the air from the line Failure to do so may cause damage to the boiler As Close as Possible Hot Cold l outlet inlet Pressure relief valve Installation Manual Pressure relief valve The micro boiler has a high temperature shutoff switch built in as a standard safety feature called a Hi Limit switch therefore a pressure only relief valve is required This micro boiler does not come with an approved pressure relie
10. intake and exhaust piping The termination includes a bird screen restricting small animals pests and foreign objects from entering into the vent system Owner s Guide Owner s Guide CONGRATULATIONS Congratulations and thank you for choosing our condensing Before use we recommend that you read through this safe carefully Please refer to the back of the manual for details warranty Keep this manual for future reference If you lose the manual contact the manufacturer or distributor When you call please tell us the model numb serial number of your unit written on the rating plate of boiler 3 1 Page Owner s Guide OPERATING SAFETY FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This micro boiler does not have a pilot It is equipped with an ignition device that automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the micro boiler area for evidence of leaking gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas
11. service must be authorized and approved by the manufacturer 2 Includes recirculation and storage tank applications with proper circulation pump control eg aquastat and or timer Lack of a proper pump control will reduce the heat exchanger and parts warranty to 3 years 3 In all applications the total of length of operation time must be less than 3 000 hours for the 140 T H3M model 4 Includes dual purpose applications combination heating and domestic 3 General terms of limited warranty This limited warranty gives you specific legal rights and you may also have other rights which vary from State to State The manufacturer will honor the warranty to the original retail buyer at the original location only within the United States or Canada and it is not transferable THIS WARRANTY COVERS ONLY FAILED MECHANICAL AND ELECTRICAL PARTS DUE TO FACTORY DEFECTS UNDER NORMAL USAGE FOR THE PRODUCT S INTENDED PURPOSES AND WITHIN THE APPLICABLE PERIOD SPECIFIED IN THE TABLES ABOVE ONLY DIRECT DAMAGES SHALL BE RECOVERABLE BY A CLAIMANT UNDER THIS LIMITED WARRANTY AND IN NO EVENT WHETHER AS A RESULT OF BREACH OF CONTRACT BREACH OF WARRANTY TORT LIABILITY INCLUDING NEGLIGENCE STRICT LIABILITY INDEMNITY OR OTHERWISE WILL BE LIABLE FOR ANY SPECIAL INCIDENTAL OR INDIRECT CONSEQUENTIAL DAMAGES INCLUDING PROPERTY DAMAGE PERSONAL DAMAGES LOSS OF USE OR INCONVENIENCE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CON
12. states and the District of Columbia of the United States of America and Canada Any product installed in applications that cause the micro boiler to activate more than 300 times per day This averages to an activation every 5 minutes in a 24 hour period Any failures that are not due to defects in materials or workmanship mechanical and or electrical parts Damages due to improper installation e Gas incorrect gas pipe sizing incorrect gas meter sizing incorrect gas type and or gas pressures that fall outside the product s specified range e 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 e Electric supply power voltages that fall outside the product s specified range Damages due to water quality e Introduction of liquids other than water or water glycol mixtures into the product e Introduction of pool water spa water or any chemically treated water into the product e Introduction of hard water 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 e Introduction of untreated or poorly treated well water into the product e Intr
13. 01 when micro boiler prepares for combustion Listen for the double clunk sound coming from gas valve assembly Part 102 when the micro boiler goes into combustion Check if there is leaking from heat exchanger Part 401 Check that the gas is turned on Check gas supply Check if the Hi limit switch Part 411 is properly functioning Check for connection breakage of wires Part 412 707 708 710 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 Check gas supply Check for connection breakage of wires and or debris on thermistor Part 407 408 715 Check the resistance Owner s Guide Displa i Malfunction Diagnosis i description 6 Two Times Air fuel ratio rod e Check for connection breakage of wires Part 708 failure and or soot on the AFR rod Part 108 510 Six Times Abnormal main gas Check for connection breakage of wires Part 707 solenoid valve and or burn marks on the computer board Part 701 e Check for signs of vent corrosion e Check gas valve contacts and gas valve wire harness connections for signs of rust or corrosion 551 Six Times Abnormal gas e Check for connection breakage of wires Part 707 solenoid valve and or burn marks on the computer board Part 701 e Check gas valve contacts and gas valve wire harness connections for signs of rust or corrosion 611 Four Times Fan motor faul
14. 11 121 311 321 341 One Time Five Times description Incorrect DIPswitch setting Warning for the 991 error code Three Times Ignition failure Three Times Loss of flame Two Times Two Times Two Times Outlet thermistor failure Inlet thermistor failure Exhaust thermistor failure Check the DIPswitch settings on the PCB Part 701 Check if the gas type of the micro boiler matches the gas supplied to it Check if there is any blockage in the intake air and or exhaust If the micro boiler 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 micro boiler is installed and match the appropriate DIPswitches Check if there is grease and or dirt in the burner Part 101 and the fan motor Part 103 especially if the micro boiler has been installed in a contaminated area Check if the DIPswitches match gas type of the micro boiler Check the manifold pressure at Max and Min Check combustion chamber tube Part 4117 to make sure it is clear and securely installed Check if the Hi limit switch Part H411 is properly functioning Check for connection breakage of wires Part 412 707 708 709 710 burn marks on the computer board Part 701 and or soot on the flame rod Part 4108 Check if there is a buzzing spark ignition sound coming from the burner Part 1
15. 148 126 112 3 4 567 393 315 267 237 217 196 185 173 162 146 132 112 i Tee 1 071 732 590 504 448 409 378 346 322 307 275 252 213 ices 2 205 1 496 1 212 1 039 913 834 771 724 677 630 567 511 440 aA 3 307 2 299 1 858 1 559 1417 1275 NN ME 10231976 11866 1 787 675 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 Gas sizing example HS120 Natural Gas Micro boiler 120 000 BTU h Dryer 35 000 BTU h 10 Length 10 Length 1 2 Pipe size 15 Length 10 Length 1 1 4 Pipe size A 1 Pipe size 1 2 Pipe size 10 Length 1 Pipe size 10 Length 15 Length 3 4 Pipe size C 1 2 Pipe size Furnace 120 000 BTU h Range 65 000 BTU h Based on Energy Content of 1 000 BTU Cubic ft Divide each appliance s BTU requirement by 1 000 BTU h 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 For sections of the gas line supplying gas to more than one appliance Ex Point A to Point B add up the cubic ft requirements of the appliances that are being supplied by that section and size to the farthest appliance For Example The section from A to B supplies gas to the furnace range and dryer Adding up the BTU requirements and dividing by 1 000 yields a cubic ft requirement of 220 cubic ft of gas The farthest appliance is the range which is 50 f
16. HART tiscntse a2 04 wate eee lakkert servanter dekan 50 LUMITED WARRANTY rv esce en bens eet wee ENNA 51 NOTICE This installation manual is approved for installation in the United States Installation Manual O o Installation Manual O O CONGRATULATIONS Congratulations and thank you for choosing our condensing boiler Before use we recommend that you read through t manual carefully Please refer to the back of the manual for detail warranty Keep this manual for future reference If you lose the manual contact the manufacturer or distributor When you call please tell us the model numbe serial number of your unit written on the rating plate of boiler 3 Page SPECIFICATIONS Hydro Smart Gas Condensing Micro Boiler Installation Manual Natural Gas Input Operating Range Propane Input Operating Range Gas Connection Water Connection Water Pressure Natural gas Inlet Pressure Propane Inlet Pressure Natural Manifold Gas Pressure Propane Weight Dimension Ignition Supply S Operation D E u Oo Wi E Standby Eg 8 reeze Protection BTU h BTU h psi MPa inch W C kPa inch W C kPa inch W C Pa inch W C Pa Ibs kg inch mm VAC Hz W A W A W A Min 15 000 Max 120 000 Min 15 000 Max 120 000 1 2 NPT 3 4 NPT 15 150 0 1 1 0 Min 5 0 1 2 Max 10 5 2 6 Min 8 0 2 0 Max 14 0 3 5 3 30 2 00
17. Hydro Smart 120 Condensing Gas Micro Boiler Installation Manual and Owner s Guide ANSI Z21 10 3 and CSA 4 3 LOW LEAD Models x e HS120CON LP Liquid propane Ss e HS120CON NG Natural gas ENERGY STAR If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death WARNING Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the Please refer to local codes for space heating compliance gas supplier The Hydro Smart 120 condensing Gas Micro Boiler is a compact and powerful residential unit with a versatile BTU modulating range FEATURING e EFFICENCY 93 e TEMP RANGE 99 140 F e COMPACT SPACE SAVING e FLOW ACTIVATED 75 GPM e COMPUTERIZED SAFETY If you have any questions please call or write to e NO PILOT LIGHT 10725 165th Ave NW e Satisfies the 2012 SCAQMD Rule Elk River MN 55330 1146 2 for Ultra Low NOx 1 763 331 3066 Emissions Installation Manual CONTENTS
18. Installation Manual SPECIFICATIONS 2 eg 4 IN TRODUWUCHION 222 denna 5 SAFETY GUIDELINES Lengden Tr 6 INSTALLATION 2 SLT 7 GEN MG 7 Included accessories vuuuunuuvnnnvr ec eee eee eee ee eee ee r rer even 9 CICA ONGC arr 9 Venting NST NN TE 10 Gas supply and gas pipe SANG suse es ves oe wad 544 54 Hea eo ao dad 20 Water cONNeCHO NS NLD 22 Condensate EE aAa EN 23 Electrical connectionS 4 a4 4 i40 44454606 man mnawsdanawslva as oe av eee Uw eae ed 25 High altitude installations lt lt 2 lt s00nncndcdeaed dae www eae each tates dee ee re 26 Hydro Smart Pre built PanelS ee Fedden BE 27 APPLUC AION 2 NN 27 INITIAL OPERATION 2226208264246 50ememe a d deweseee neues eee ee PERERA ENA NE 29 OPTIONALITEMS 2222 LTS NL 30 Owner s Guide OPERATING SAFE and 22 NORMAL OPERATION aar 34 Display OF controler ae enteataohers e2cbenteesssbouwesaanheeesessues ee ween ens 34 GENT gee sien nen arn ae ee oes oe oe oe ee ae Ge eee E EE 34 Temperature table of controller 0 0 eee ee eee rn rer ees 34 Temperature settings once tte so 6eee aun eeeeee donee teehee epee eee aa eas 35 Additional TOAtULES EE EE NE 36 POW re 37 Freeze NNN NN 37 Maintenance and servce siatvantndseedeeeear peer bever e dan 38 Unit draining and filter cleaning 16466264 d ddesesunss Sed eskere see 38 TROPENE 39 GEN TNS 39 ENO OOO Lupen 41 COMPONENTS DIAGRAM csssirrcscsesesessssresesesssonnsisoserusoresudssorrsri 44 PARTS LOT 2 re 48 OUTPUT TEMPERATURE C
19. K2E 411 Hi Limit switch EM212 412 Overheat cut off fuse EX02A 413 Pipe heater EK468 414 Inlet heater EK469 415 Drain tube EK470 416 Inlet heater EK105 417 Secondary heat exchanger EK471 418 Secondary heat exchanger heater EK473 419 Heater fixing plate EK474 450 Pipe heater fixing plate EK475 451 Heater fixing plate 16 EK031 452 Fuse fixing plate EK476 453 O ring P4 FKM EZF04 454 O ring P6 FKM EZFO6 455 O ring P14 FKM EZF14 456 O ring P15 FKM EZF15 457 O ring P16 FKM EZE16 458 Fastener 14 22 EKK24 459 Fastener 16A EM192 460 Fastener 16 25A EKK39 461 Flat heater EK217 462 Cold pipe for 140 model EK477 463 Header connection EK478 464 Thermistor fixing plate EX13H 465 Exhaust thermistor gasket EX13L 466 Hi limit switch for exhaust EKH6G 467 Gasket EK229 468 Inlet pipe packing EK479 49 Page Description Owner s Guide Parts List 701 Computer board EK480 702 Rubber grommet EX148 703 Surge box EK280 704 120 VAC wire EK146 705 120 VAC Power ON OFF switch EKK4V 707 Gas valve wire EK482 708 Flame rod wire EK483 709 Igniter assembly EK484 710 Freeze protection thermostat EKJ59 711 Proportional gas valve wire EK112 712 Nylon clamp FC6 EX004 713 Computer board cover EKK1M 714 Cable clamp EX13C 715 Exhaust thermistor EKH6E 716 Exhaust Hi limit switch wire EK180 721 Temperature controller EK487 722 Fixing plate EK490 OUTPUT TEMPERATURE CHART Chart is based on properly sized gas line Output Temperature vs
20. Mr LL UP UP E NI 3inch and 4 inch vent installations onl The clearance of A is recommended on the basis of the structure of the micro boiler Installation Manual Exhaust and or direct vent sidewall terminations should be at least 2 ft 610 mm away from an opposite surface wall Do not place the termination directly in front of an opening into a building 2 4 Exhaust min lt For rooftop terminations gt 2 ft 610 mm min 3 ft 914 mm min Intake air Intake air Exhaust gas oe T A Exhaust terminations must be at least 1 ft 305 mm away from any obstructions B Intake terminations must be at least 1 ft 305 mm away from any obstructions Please follow all local and national codes in regards to proper termination clearances In the absence of such codes the clearances above can be used as CAUTION guidelines Local codes supersede these guidelines Installation Manual GAS SUPPLY AND GAS PIPE SIZING General e Check that the type of gas matches the rating plate first e Ensure that any and all gas regulators used are operating properly and providing gas pressures within the specified range shown below Excess gas CAUTION inlet pressure may cause serious accidents e Conversion of this micro boiler from natural gas to propane or vice versa will void all warranty Contact your local distributor to get the correct unit for your gas type The manufactur
21. NN SND D D lt N GN Ne SP b Fire stop TJ DV UD Ve D ag P 5 y wa Single pipe with room air intake pp emner Roof S l l N 7 l x Ay ae NW Rv N Roof flashing NE p Fire sto DEE P Trz llr Li a TA g _ Refer to pages 17 and 19 for clearance information Installation Manual Exhaust vent Stainless steel vent This is a Category IV appliance and must be vented accordingly The vent system must be sealed airtight All seams and joints without gaskets must be sealed with high heat resistant silicone sealant or UL listed aluminum adhesive tape having a minimum temperature rating of 160 F For best results a vent system should be as short and straight as possible e The micro boiler is a Category IV appliance and must be vented accordingly with any 4 inch vent approved for use with Category III IV or Special BH type gas vent e The manufacturer recommends the NovaVent Z Vent line However the following are also UL listed manufacturers ProTech Systems Inc FasNSeal Metal Fab Inc and Heat Fab Inc Saf T Vent e Follow the vent pipe manufacturer s instructions when installing the vent pipe e 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 e Wh
22. ON GENERAL 1 Follow all local codes or in the absence of local codes follow the most recent edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 in the USA or CAN CSA B149 1 Natural Gas Propane Installation Code in Canada 2 Properly ground the micro boiler in accordance with all local codes or in the absence of local codes with the National Electrical Codes ANSI NFPA 70 in the USA or CSA standard C22 1 Canada Electrical Code Part 1 in Canada 3 Carefully plan where you intend to install the micro boiler Please ensure e Your micro boiler will have enough combustible air and proper ventilation e Locate your boiler where fluid leakage will not damage surrounding areas please refer to p 8 4 Check the rating plate for the correct GAS TYPE GAS PRESSURE FLUID PRESSURE and 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 e Do not store or use gasoline or other flammables vapors or liquids in the vicinity of this appliance e Do not reverse the fluid and or gas connections as this will damage the gas WARNING valves and can cause severe injury or death Follow the diagram on p 22 when installing your micro boiler e Do not use this micro boiler if any part has been in contact with or been immersed i
23. SEQUENTIAL DAMAGES SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU 4 Limitation on Duration of Implied Warranties ANY IMPLIED WARRANTIES ARISING UNDER STATE LAW INCLUDING 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 product that is not installed by a licensed plumber gas installer or contractor Damages due to accidents abuse misuse improper installation misapplication or incorrect sizing Damages due to fires flooding freezing electrical surges or any Acts of God Damages due to unauthorized alterations attachments and or repairs Damages due to a lack of maintenance e g Y strainer water treatment system vent blockage etc Any product installed in an improper environment e g corrosive dusty chemically contaminated excessive lint etc Freeze damage that occurs without taking proper preventive measures as described in the installation manual Condensate damage due to improperly installed or lack of a condensate trap drain Any product not installed in compliance with all applicable local amp provincial codes ordinances and good trade practices Any product sold to or installed in areas outside of the fifty
24. SIDE CORNER DETAIL Vent terminal Xi Air supply inlet L EE EE eter ZA age e Area where is not permitted 2 ak RE Gas meter regulator Clearance above grade veranda porch deck or 1 foot 1 foot balcony Clearance to window or door that may be opened 3 feet 1 foot Clearance to permanently closed window Vertical clearance to ventilated soffit located above the vent terminator within a horizontal distance a P of 2 feet 61cm from the center line of the terminator Clearance to unventilated soffit i Clearance to outside corner a Clearance to inside corner i Clearance to each side of center line extended P 3 feet above meter regulator assembly Clearance to service regulator vent outlet 3 feet i Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other 3 feet 1 foot application Clearance to mechanical air supply inlet 6 feet 3 feet Clearance above paved sidewalk or paved driveway E 7 feet located on public property Clearance under veranda porch deck or balcony 1 foot Direct vent and other Other than than Direct vent vent Direct vent 1 foot 4 feet from below or side opening 1 foot from above opening 4 feet from below or side opening 1 foot from above opening 3 feet 7 feet For clearances not specified in ANSI Z223 1 NFPA 54 or CAN CSA B149 1 please use clearances in accordance with local inst
25. ack guard panel Screw M4x12 W Washer Screw M4x10 W Washer Screw M4x10 Coated Screw M4x10 Hex head screw M4x12 W Washer Hex head screw M4x8 Pan screw M4X20 Tap tight screw M4x12 FEZN Screw M3x6 SUS Screw M4x6 Screw M3x6 Pan screw M4x8 Wire clamp 60 Screw M4x10 Screw M3x6 SUS3 Burner assembly Manifold with gas valve assembly LP Manifold with gas valve assembly NA Fan motor Burner gasket Fan damper for Burner window Rod holder gasket Flame rod Igniter rod Rod holder Rod cap Burner damper Manifold gasket A Manifold gasket B Burner holder gasket Pressure port Combustion chamber tube Gas inlet Gas inlet ring Surge box plate 4 Q bi A O on Owner s Guide EK450 EK452 EK454 EK455 EK190 EK456 EK457 EW000 EWOO1 EW002 EW003 EW004 EW005 EW018 EKK31 EWOOA EW009 EK191 EWOOD EM167 EWOOP EWOOB EK458 EK459 EK460 EK109 EKK2X EK491 EKK2V EKK2W EK193 EK461 EKK32 EK462 EK463 EKK2Y EKK2K EKKOG EKK2D EX019 EK465 EKK2Z EK466 Owner s Guide Parts List Description O ring P18 NBR Black EZP18 O ring P20 NBR Black EK042 154 Silicon ring EKN50 401 Heat exchanger assembly EK467 402 Flow adjustment valve Flow sensor EK129 403 Condensate drain port EKH23 404 Water inlet EKK1U 405 Inlet drain plug EKK2B 406 Inlet water filter EKK2C 407 Inlet thermistor EKK4J 408 Outlet thermistor EK207 409 Water outlet EK104 410 Outlet drain plug EK
26. allation codes and the requirements of the gas supplier SOO BESS AKSER G p Exhaust termination ji p G Combined j intake and exhaust Inside termination Z lt corner lt Case 1 gt Exhaust For direct vent sidewall terminations that use two 1ft 305 mm separate penetrations for min the intake and exhaust keep the termination clearances shown in the diagrams on the right lt Case 2 gt A 0 5 ft 159mm Intake Exhaust Intake Exhaust Installation Manual For multiple sidewall exhaust terminations an exhaust termination must be at least 1 ft 305mm away from another exhaust termination must also be at least 2 ft 610 mm away from an inside corner If the adjacent wall is less than 2 ft 610 mm of length the minimum required distance away from the inside corner will be equal to the length of that adjacent wall An exhaust termination For multiple direct vent sidewall terminations that combine the intake and exhaust into a single penetration space each direct vent termination at least 1 ft 305 mm away from each other no matter the orientation A direct vent termination must also be at least 2 ft 610 mm away from an inside corner If the adjacent wall is less than 2 ft 610 mm of length the minimum required distance away from the inside corner will be equal to the length of that adjacent wall
27. anufacturer recommends that condensate be disposed of into a standard drain Connect a drain tube from the condensate drain port shown below located on the bottom of the micro boiler to a standard drain Follow all code requirements of the local authority on condensate neutralizers and whether or not they are required for the installation Condensate drain port Installation Manual Condensate Drain Connections Discharge condensate acidic water in accordance with all local codes and common safety practices WARNING The micro boiler is a high efficiency condensing model that produces condensate acidic water The acidic condensate generated in the secondary heat exchanger can be neutralized by the Neutralizer acces SOry Case A If a neutralizer is not required L Connect a 1 2 FPT X 3 8 or 1 2 HB Adaptor to the condensate drain port at the bottom of the micro boiler Connect a condensate drain tube to the 1 2 FPT X 3 8 or 1 2 HB Adaptor The manufacturer recommends the material of the condensate tube be either EPDM or PVC Leave an adequate amount of space between the end of the drain tube and the actual drain to facilitate proper drainage Case B If a neutralizer is required installing the Neutralizer assembly dh UJ Condensate Condensate drain port drain port T 1 2 FPT x 3 8 Connect the 1 2 FPT X 3 8 MPT Adaptor to the condensate drain port at the botto
28. ated 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 Always purge the gas line of any debris and or water before connecting to the gas inlet Size the gas pipe appropriately to supply the necessary volume of gas required for the micro boiler using ANSI Z223 1 NFPA 54 in the USA or CAN CSA B149 1 in Canada or local codes Otherwise flow capabilities and output temperatures will be limited Installation Manual Installation Natural Gas Supply Piping Maximum delivery Capacity of Cubic Feet of Gas per Hour of IPS Pipe carrying Natural Gas with 0 60 Specific Gravity Based on Pressure Drop of 0 5 W C Based on Energy Content of 1 000 BTU Cubic ft The micro boiler requires 120 Cubic ft hr Unit Cubic feet per hour Length Diameter 10 20 30 40 so 60 70 go 90 100 125 150 200 1 2 172 118 3 4 363 249 200 171 152 138 127 118 Je 684 470 377 323 286 259 239 222 208 197 174 158 135 JE 1 404 965 775 663 588 532 490 456 428 404 358 324 278 12 2 103 1 445 1 161 993 880 798 734 683 641 605 536 486 416 2 4 050 2 784 2 235 1 913 1 696 1 536 1 413 1 315 1 234 1 165 1 033 936 801 Propane LP Supply Piping Unit kBTU per hour Diameter 10 20 30 40 so 60 70 go 90 100 125 150 200 1 2 268 184
29. ater heater Consult with the glycol maker for specifications prior to use Hydro Smart Pre Built Space Heating Panels Hydro Smart pre built panels help make space heating easy and reliable These panels are professionally engineered and use proven primary secondary hydronic practices Call tech support 1 763 331 3066 for sizing assistance One zone interator panel Zoning by Pump multi zones Low temperature Low temperature Zoning by Zone Valve multi zones Zoning by Telestat multi zones Low temperature i Low temperature Installation Manual Installation Dual purpose hot water heating Domestic and Space Heating Insert a Hydro Smart Dual Purpose Panel to provide potable heated water and Hydonic Heating with one heat source Call tech support 1 763 331 3066 for sizing assistance Hot Water Cold Water Out In Hydre Smart me Space Heating EEG Supply fem male NE s i Space Heating l nns Return sae me k ie Boiler Supply Ja P Boiler Return The Hydro Smart Dual Purpose Panel integrates with a wide variety of boilers and delivers priority potable heated water with no storage tank and hydronic space heating in a small reliable package NOTICE e 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 28 Page
30. e enough combustion air and proper ventilation e Keep the area around the micro boiler clean When dust collects on the flame sensor the micro boiler will shut down on an error code e Place the micro boiler in a location that provides easy access for service and maintenance e A drain pan or other means of protection against water damage is required to be installed under the micro boiler in case of leaks e It is recommended to direct vent the heater Damage caused by water quality is not covered by the warranty Only potable water or potable water glycol mixtures can be used with this micro boiler Do not introduce pool or spa water or any chemically treated water into the micro boiler Water hardness levels must not exceed 7 grains per gallon 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 affect damage the micro boiler Hard water scaling must be avoided or controlled by proper water treatment Water pH levels must be between 6 5 and 8 5 Well water must be treated Do not install the micro boiler where water debris or flammable vapors may get into the flue terminal Although the micro boiler is designed to operate with minimal sound the manufacturer does not recommend installing the micro boiler on a wall adjacent to a bedroom or a room that is intended for quiet study or meditation etc Loca
31. ection to terminate power to the micro boiler for servicing and safety purposes 7 Do not install the micro boiler where the exhaust vent is pointing into any opening in a building or where the noise may disturb your neighbors Make sure the vent termination meets the required distance by local code from any doorway or opening to prevent exhaust from entering a building refer to p 17 to 19 8 Particles from flour aerosols clothes dryers and other airborne contaminants may clog the air vent build up and reduce the functions of the rotating fan cause improper burning of the gas or cause damage to the micro boiler Regularly ensure that the area around the micro boiler is dust or debris free Regular maintenance is recommended for these types of environments Sealed combustion is recommended too 9 The Hydro Smart 120 micro boiler is to be installed indoors only The model is equipped with a thermistor and hi limit switch for the exhaust gas detecting excess temperatures within the flue and enabling the micro boiler to safely stop operation if needed These components are always monitoring exhaust gas conditions in order to prevent heat damage to ABS PVC CPVC or Polypropylene Plastic venting if ABS PVC CPVC or Polypropylene is used If the exhaust gas temperature exceeds 140 F 60 C these components will enable the micro boiler to safely stop operation e The micro boiler requires 3 inch or 4 inch diameter intake air supply p
32. en the horizontal vent run exceeds 5 ft 1 5 m support the vent run at 3 ft 0 9 m intervals with overhead hangers Diameter Max No of Elbows Max Vertical and Horizontal Total Vent Length 4 in 102 mm 5 100 ft 30 5 m For each elbow added deduct 5 ft 1 5 m from max vent length No of Elbows Max Vertical or Horizontal Vent Length 0 100 ft 30 5 m 1 95 ft 29 0 m 2 90 ft 27 4 m 3 85 ft 25 9 m 4 80 ft 24 4 m 5 75 ft 22 9 m Excludes vent terminators termination elbows or rain caps Vent connections for two pipe Vent connections for single pipe 4 stainless i steel vent 4 elbow straight pipe with bird 4 stainless 4 stainless steel vent ae Hike screen straight pipe straight pipe OC 3 amp 5 Se Exhaust vent Tra Exhaust vent Intake vent collar SSS collar Female Ss collar Female Female j Intake vent collar Female 1 Connect 4 stainless steel vent straight pipes directly on the exhaust intake vent collar of the micro boiler 1 Connect a 4 stainless steel vent straight pipes directly on the exhaust vent collar of the micro boiler 2 Connect a 4 elbow directly on the intake vent collar of the micro boiler For details of the optional items refer to the Installation manual for each Optional item hs A gJ O E G Tmn m K L M Installation Manual Vent termination clearances IN
33. er is not liable for any property and or personal damage resulting from gas conversions The minimum and maximum inlet gas pressures are Gas type Inlet gas pressure Natural Gas Min 5 0 W C 1 24 kPa Max 10 5 W C 2 61 kPa Propane Min 8 0 W C 1 99 kPa Max 14 0 W C 3 48 kPa Inlet gas pressures that fall outside the range of values listed above may adversely affect the performance of the micro boiler These pressures are measured when the micro boiler 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 micro boiler Until testing of the main gas line supply pressure is completed ensure the gas line to the micro boiler is disconnected to avoid any damage to the micro boiler Gas connections Install a manual gas shutoff valve between the micro boiler and the gas supply line The gas supply line shall be checked for leaks using code approved methods When the gas connections are completed it is necessary to perform a gas leak test either by applying soapy water to all gas fittings and observing for bubbles or by using a gas leak detection device e The micro boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psi 3 5 kPa e The micro boiler must be isol
34. f valve An approved pressure relief valve must be installed on the hot water outlet The pressure relief valve must conform to ANSI Z21 22 or CAN 1 4 4 and installation must follow local codes The discharge capacity must be at least 120 000 BTU h The pressure relief valve needs to be rated for a maximum of 150 psi 1 MPa The discharge piping for the pressure relief valve must be directed so that the hot water cannot splash on anyone or on nearby equipment Follow local codes Attach the discharge tube to the pressure relief valve and run the end of the tube to within 6 inches 152 mm from the floor This discharge tube must allow free and complete drainage without any restrictions If the pressure relief valve installed on the micro boiler discharges periodically this may be due to a defective thermal expansion tank defective pressure relief valve or it could be signs of internal scale build up The pressure relief valve must be manually operated periodically to check for correct operation No valves may be placed between the relief valve and the micro boiler CONDENSATE DRAIN The micro boiler does not include a built in condensate neutralizer cartridge for reducing the pH level of condensate water If local codes dictate that condensate must be neutralized prior to drainage a condensate neutralizer must be installed An accessory Neutralizer assembly is sold separately In the absence of applicable local codes and regulations the m
35. freezing In any area subject to freezing temperatures freezing issues can occur if cold air enters through the venting into the heat exchanger by either negative pressures within the installation location or by strong outside wind The manufacturer highly recommends the use of a backflow preventer sold separately to minimize the amount of cold air entering through the exhaust venting when the micro boiler is off If you will not be using your boiler for a long period of time 1 Completely drain the water out of the micro boiler Refer to p 38 2 Disconnect power to your boiler This will keep your micro boiler from freezing and being damaged Only pipes within the micro boiler are protected by the freeze protection system Any water pipes hot or cold located outside the micro boiler will not CAUTION be protected Properly protect and insulate these pipes from freezing Owner s Guide MAINTENANCE AND SERVICE Turn off the electrical power supply and close the manual gas shutoff valve and the manual water control valve before servicing WARNING e Be sure that all openings for combustion and ventilation air are not blocked e The venting system should be checked annually for any leaks corrosion blockages or damage e The burner should be checked annually for dust lint grease or dirt e Keep the area around the micro boiler clear Remove any combustible materials gasoline or any flammable vapors and liquids e In accordance
36. ic venting must be certified to ULC S636 standards Item AELTIE United States Schedule 40 PVC ANSI ASTM D1785 l PVC DWV ANSI ASTM D2665 e Te ANSI ASTM F441 Schedule 40 ABS DWV ANSI ASTM D2661 ULC 5636 Certified Polypropylene UL 1738 Materials Only PVC ANSI ASTM D2564 Pipe Cement Primer CPVC ANSI ASTM F493 ABS ANSI ASTM D2235 NOTE Do NOT Use Cellular Foam Core Pipe e The maximum length of exhaust vent piping must not exceed 70 ft 21 3 m for 3 venting which depends on the elevation where the micro boiler is installed and 100 ft 30 5 m for 4 venting deducting 5 ft 1 5 m for each elbow used in the venting system Do not use more than 5 elbows See the table below e When the horizontal vent run exceeds 5 ft 1 5 m support the vent run at 3 ft 0 9 m intervals with overhead hangers Max Vertical or Horizontal Total Vent Lengh TE a Elbow Up to 3 000 ft Up to 3 000 ft Up to 6 000 ft Up to 10 100 ft Up to 10 100 ft O 65ft 2 0m 70ft 21 3m 40ft 12 2m 25 ft 7 6m 100 ft 30 5 m 1 15ft 0 5m 65ft 19 8m 35ft 10 7m 20 ft 6 1m 95 ft 29 0 m 2 N A 60 ft 18 3m 30ft 9 1m 15 ft 4 6m 90 ft 27 4 m 3 N A 55 ft 16 8 m 25ft 7 6m 10ft 3 0m 85 ft 25 9 m 4 N A 50 ft 15 2 m 20ft 6 1m 5ft 1 5m 80 ft 24 4 m 5 N A 45 ft 13 7 m N A N A 75 ft 22 9 m Excludes vent terminators termination elbows or rain caps For details on the vent connection refer to p 13 to
37. icro boiler for normal service and inspection of the unit Avoid using an oversized vent pipe or using extremely long runs of the pipe For rooftop venting a rain cap or other form of termination that prevents rain water from entering into the micro boiler must be installed Do not terminate the 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 exhaust flue products from the micro 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 be at least 12 inches 305 mm above grade but the installer may determine if it should be higher depending on the job site condition and applicable codes A proper sidewall termination is recommended when the micro boiler is vented through a sidewall Regarding the clearances from the exhaust termination to the air inlet or opening refer to p 17 to 19 Installation Manual Installation Exhaust vent ABS PVC CPVC or polypropylene vent The micro boiler can be vented with ABS PVC CPVC or polypropylene temperature rated up to at least 149 F Vent material certified to ULC S636 standards is recommended in the USA In Canada plast
38. installation will void product warranty When installing the vent system all applicable national and local codes must be followed If you install thimbles fire stops or other protective devices and they penetrate any combustible or noncombustible construction be sure to follow all CAUTION applicable national and local codes The micro boiler must be vented in accordance with the section Venting of Equipment of the latest edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 in the United States and or Section 7 of the CAN CSA B149 1 Natural Gas and Propane Installation Code in Canada as well as applicable local building codes The use of venting materials approved for Category III IV appliances is recommended whenever possible However the micro boiler may also be vented with plastic pipe materials such as ABS PVC CPVC or Polypropylene For details please refer to the Exhaust Vent ABS PVC CPVC or Polypropylene Vent section on p 11 Vent installations in Canada which utilize plastic vent systems must use venting that complies with ULC S636 General rules for venting micro boiler are Place the micro boiler as close as possible to the vent termination The vent collar of the micro boiler must be fastened directly to an unobstructed vent pipe Do not weld the vent pipe to the micro boiler s vent collar Do not cut or alter the vent collar of the micro boiler The vent must be easily removable from the top of the m
39. ipe The intake pipe must be sealed airtight e Air supply pipe can be made of aluminum flexible tube ABS PVC CPVC Polypropylene corrugated stainless steel or Category Ill IV stainless steel Regarding exhaust pipe please refer to p 11 for detailed information e Sidewall venting is recommended for this boiler Vertical venting roof termination is acceptable e The manufacturer recommends running the exhaust vent and the intake pipe as parallel as possible WARNING CAUTION Installation Manual Installation and service must be performed by a qualified installer for example a licensed plumber or gas fitter otherwise the warranty will be void The installer licensed professional is responsible for the correct installation of the micro boiler and for compliance with all national state provincial and local codes The manufacturer does not recommend installing the micro boiler in a pit or location where gas and water can accumulate Do not have the vent terminal pointing toward any operating window door or opening into a building Do not install the micro boiler next to any source of airborne debris such as a clothes dryer and a vent that can cause debris to be trapped inside the combustion chamber unless the system is direct vented The manufacturer does not recommend installing the micro boiler in an attic due to safety issues If you install the micro boiler in an attic e Make sure the micro boiler will hav
40. m of the micro boiler 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 Connect a 1 2 drain tube to the other end of neutralizer Leave an adequate amount of space between the end of the drain tube and the actual drain to facilitate proper drainage 2 1 2 FPT x 3 8 MPT or 1 2 HB Included with Neutralizer accessory 3 8 or 1 2 Neutralizer cartrid lt ___ lt ___ Be Condensate Included with drain tube Neutralizer accessory 3 8 MPT x 1 2 HB Included with Neutralizer accessory A a 1 2 Condensate Drain Drain _ drain tube j Adequate space _ Adequate space Installation Manual e The condensate drain is at atmospheric pressure non pressurized and therefore must be allowed to drain freely with gravity only Please ensure that there are no blockages along the condensate drain tube All portions of the WARNING condensate drain 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 e Condensate cannot be effectively neutralized if the neutralizer elements inside the Neutralizer accessory have been completely consumed If this happens condensate will remain acidic and can possibly cause damage to items such as pipes concrete etc if drained improperly e The Neutrali
41. n Owner s Guide DANGER FLAMMABLES Vapors from flammable liquids will explode and catch fire causing death or severe burns Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the micro boiler Keep flammable products Vapors 1 Far away from boiler 1 Cannot be seen 2 In approved containers 2 Vapors are heavier than air 3 Tightly closed 3 Go a long way on the floor 4 Out of children s reach 4 Can be carried from other rooms to the main burner by air currents WARNING California Proposition 65 lists chemical substances known to the state to cause cancer birth defects death serious illness or other reproductive harm This product may contain such substances be their origin from fuel combustion gas oil or components of the product itself Owner s Guide NORMAL OPERATION DISPLAY OF THE CONTROLLER The illustration below shows an example of the display of the controllers The exact display may differ from examples INFO Button Display for Temperature Each time the button is pressed a s IIC When the STAND BY LED is ON the the operation mode is selected now LILI fun hot water set temperature will be in the following sequence displayed Inlet water Outlet water Water Lp ai nm temperature temperature gt fwJ Kor omr HOT Button COLD Button IN USE LED Green p Press the HOT button or the COLD This lights during combustion vene
42. n the intake vent collar of the micro boiler 2 Connect a3 x 2 reducer directly on the exhaust vent collar of the micro boiler Make sure the couplings engage the o rings installed in the intake and exhaust vent collars 3 Connect a 2 straight pipe to the reducer For details of the optional items refer to the Installation manual for each optional item Single pipe with room air intake Refer to pages 17 and 19 for clearance information 3 inch vent installation Vent connections for two pipe straight pipe T 3 straight pipe 3 coupling Exhaust Intake vent vent collar collar Female Female 1 Connect 3 couplings directly on the exhaust and intake vent collar of the micro boiler Make sure the couplings engage the o rings installed in the intake and exhaust vent collars 2 Connect 3 straight pipes to the couplings Installation Manual Vent connections for single pipe FR ia straight pipe 3 elbow with bird screen m 3 coupling LO ers ee Exhaust colla Female Female The micro boiler came with a metal screen that will fit into a 3 inch elbow 1 Connect a 3 elbow directly on the intake vent collar of the micro boiler 2 Connect a 3 coupling directly on the exhaust vent collar of the micro boiler Make sure the couplings engage the o rings installed in the intake and exhaust vent collars 3 Connect a 3 straight pipe t
43. n water Immediately call a licensed plumber a licensed gas fitter or a professional service technician to inspect and or service the micro boiler if necessary e Do not disconnect the electrical supply if the ambient temperature will drop below freezing The Freeze Protection System only works if the micro boiler has electrical power The heat exchanger will not be covered under warranty if it is damaged due to freezing Refer to the section on the Freeze Protection System on p 40 for more information Installation Manual INSTALLATION GENERAL 1 Follow all local codes or in the absence of local codes follow the most recent edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 in the USA or CAN CSA B149 1 Natural Gas Propane Installation Code in Canada 2 All gas micro boilers require careful and correct installation to ensure safe and efficient operation This manual must be followed exactly Read the Safety Guidelines section 3 The manifold gas pressure is preset at the factory It is computer controlled and should not need adjustment 4 Maintain proper space for servicing Install the micro boiler so that it can be connected or removed easily Refer to the Clearances section on p 9 for proper clearances 5 The micro boiler must be installed in a location where the proper amount of combustible air will be available to it at all times without obstructions 6 The electrical connection requires a means of disconn
44. o the coupling For details of the optional items refer to the Installation manual for each optional item 4 inch vent installation Vent connections for two pipe 4 straight APER PE c gt pipe md ME a 3 yg Lo i ae 3 YA in creaser increaser Exhaust Intake vent DE vr collar collar Female Female 1 Connect 3 x 4 increasers directly on the exhaust and intake vent collar of the micro boiler Make sure the couplings engage the o rings installed in the intake and exhaust vent collars 2 Connect 4 straight pipes to the increasers Vent connections for single pipe La a straight pipe 3 elbow with I 3 x4 increaser bird screen PT J Exhaust vent collar Female The micro boiler came with a metal screen that will fit into a 3 inch elbow 1 Connect a 3 elbow directly on the intake vent collar of the micro boiler 2 Connect a 3 x 4 increaser directly on the exhaust vent collar of the micro boiler Make sure the couplings engage the o rings installed in the intake and exhaust vent collars 3 Connect a 4 straight pipe to the increaser For details of the optional items refer to the Installation manual for each optional item Installation Manual Examples of installation of 3 inch amp 4 inch vent Two pipe direct vent Hanger pF 0 i Tna N
45. o boiler has been installed in a contaminated area e Check the DiPswitches match gas type of the micro boiler e Check the manifold pressure at Max and Min e Check combustion chamber tube part 117 to see if it is clear and securely installed Owner s Guide Components Diagram COMPONENTS DIAGRAM Case assembly 44 Page Owner s Guide Components Diagram Computer board assembly R y S a eng EN S gt A EG p E SA D A BR a Sk ya BO A A SN Me NE ASS SN OG t hrm LIS F E we Vg VB N a p Za 2 T AN N x lt O 2 u T 5 An Owner s Guide Manifold assembly AV SOU ay TOMO N E Ni X SN ANY ORA TTT eee ee ee AT Owner s Guide Components Diagram Ke aD 05 AN MO pr MO Som ap jd MO 47 Page PARTS LIST 001 002 003 004 005 006 007 050 051 052 053 054 055 056 057 058 059 060 061 062 063 064 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 Description Case assembly Front cover Intake air port assembly Bracket Junction box Power supply cord assembly B
46. oduction of water with pH levels less than 6 5 and greater than 8 5 into the product
47. peration Sereen on the controller 1 order to turn the controller on When ON the orange LED is lit The previous set temperature will be displayed on the screen Press the ON OFF button on the controller in EX 100 F Press the INFO buttons for at least 3 seconds The set temperature should now be displayed in the UT i wine EX 38 C alternate unit of measurement H EX st gaa 2 G D SAA JD H d g e Owner s Guide FLOW The flow rate through the micro boiler is limited to a maximum of 7 0 GPM 26 5 L min The temperature setting along with the return temperature of the water in the system will determine the flow rate output of the micro boiler FREEZE PROTECTION SYSTEM This micro boiler comes equipped with heating blocks to protect it against damage associated with freezing For this freeze protection system to operate there has to be electrical power to the micro boiler 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 freeze protection thermostat senses temperatures at 36 5 F 2 5 C or lower It is the installer 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
48. play anything when Make sure the connection to the micro boiler is correct the power button is turned on WATER HEATER NOTICE When the micro boiler has not operated for five minutes or more the display of the controllers turns off to conserve energy nnn Se 2 Sms j 5 oD _ _ dd O u c An ERROR code is e Please see p 41 to 43 displayed 40 Page Owner s Guide ERROR CODES General e The micro boiler has self diagnostics for safety and convenience when troubleshooting e If there is a problem with the micro boiler itself or the installation of the unit the error code will be displayed on the temperature controller e Consult with the table on the following pages for the description of each error code aes g J Green LED Error code indicator on the temperature controller Example If your unit has the 321 error code which signifies an inlet thermistor failure e Indicator on the controller 321 will be displayed on the screen in its entirety ms ttf GE Error code e Green LED on the computer board The green LED on the computer board will be blinking two times Owner s Guide Fault Analysis of Error Codes If the error code is displayed on the computer board of the micro boiler and or on the temperature controller please check the following After checking consult with the manufacturer Malfunction DIE Fale 031 101 1
49. revents the backflow of air through the exhaust vent This helps prevent harmful exhaust gases from entering the home as well as helping to prevent the micro boiler from freezing in areas where cold air can be blown or drawn into the exhaust system Install this adaptor in accordance with the installation instructions that are packaged with the adaptor and any applicable codes 5 4 inch Exhaust Sidewall Vent Terminator Hood and 4 inch Wall Thimble 4 inch Exhaust Sidewall Vent Terminator 4 Wall Kit 4 inch Wall Thimble 4 Chimney Flat Roof Flashing O mm mm 4 Wall Vent Kit w Thimble 4 7 amp BF preventer HS 2ZVWBO4 4 Wall Thimble 5 10 HS 2SVSWTEFO4 HS ZSVSRCFO4 HS 2SVSSCSF04 4 Rain Cap They are used when venting out through the wall These terminations are special stainless steel vents for gas appliances and are UL listed as Category Ill For different wall thicknesses there are two ranges of lengths available Install these vent terminations in accordance with their installation instructions and any applicable local codes 6 3 inch Concentric PVC Termination HS CVent 3 Used when terminating direct vent sealed combustion systems with boilers that require a 3 in 76mm intake gt and a 3 in 76 mm This concentric termination provides en the convenience of only having to make one penetration T m through a sidewall instead of two separate penetrations for the
50. s on the computer board See the table below When the controller is in normal operation the set temperature of the controller is given priority over the set temperature of the DIPswitch settings e The temperature has been preset at the factory to 120 F 49 C 120 F 49 C DEFAULT 140 F 60 C Mt Ta de Computer board sed Bank of DIPswitches No 9 OFF NOTE Only change the switches with dark squares The dark squares indicate the direction the DIPswitches should be set to 35 Page I e Owner s Guide Normal Operation ADDTIONAL FEATURES Information mode You can get some information about the micro boiler condition by pressing the INFO button For more information follow the procedures below NSL operation ___Screen on the controller 1 Inlet water temperature cx 60 F Inlet water temperature will be displayed on the controller by pressing the INFO button Outlet water temperature EX 120 F Outlet water temperature will be displayed on the controller by pressing the INFO button Water flow T EX 3 5 GPM Water flow rate in gpm will be displayed on the controller by pressing the INFO button Press the INFO button to finish information mode Unit conversion mode The controller display information can be changed from English Units to S I metric units Please follow the procedures below o
51. supplier s instructions e If you cannot reach your gas supplier call the fire department C Use only your hand to turn the gas valve knob Never use tools If the knob will not turn by hand don t try to repair it Call a qualified service technician Forced or attempted repair may result in a fire or explosion D Do not use this micro boiler if any part has been under water Immediately call a qualified service technician to inspect the micro boiler and to replace any damaged parts OPERATING INSTRUCTIONS STOP Read the safety information above or in the Owner s Manual Turn off all electric power to the micro boiler Do not attempt to light the burner by hand Turn the manual gas valve located on the outside of the unit clockwise to the OFF position Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to next step Turn the manual gas valve located on the outside of the unit counterclockwise to the ON position Turn on all electrical power to the micro boiler If the micro boiler will not operate follow the instructions to Turn Off Gas to Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE Turn off all electric power to the micro boiler if service is to be performed Turn the manual gas valve located on the outside of the unit clockwise to the OFF positio
52. t away from the meter Looking at the above chart and under the column of 50 ft Section A to B needs to be 1 in order to supply 220 cubic ft 2 1 Page Installation Manual Measuring inlet gas pressure 1 Turn off all electric power to the micro boiler if service is to be performed 2 Turn the manual gas valve located on the outside of the micro boiler clockwise to the off position The micro boiler cannot perform properly without sufficient inlet gas pressure Below are instructions on how to check the inlet gas pressure THIS IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL 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 Connect the manometer to the pressure port 4 Re open the manual gas valve Check to see that there are no gas leaks Take a reading of the gas pressure Open some of the fixtures that use the highest flow rate to turn on the micro boiler 5 Check the inlet gas pressure Take another reading When the micro boiler is on maximum and minimum burn the manometer should read from 5 0 to 10 5 W C 1 24 to 2 61 kPa for Natural gas or from 8 0 to 14 0 W C 1 99 to 3 48 kPa for Propane Verify that the pressure drop is acceptable Pressure port WATER CONNECTIONS e Do not use this micro boiler if any part has been submersed under water Immediately call
53. t e Check for connection breakage of wires dust buildup in the fan motor Part 103 and or burn marks on the computer board Part 701 e Check for frozen corrosion of connectors Part 103 701 One Time Computer board fault e Check for connection breakage of wires Part 711 711 One Time Gas solenoid valve Refer to the 111 and 121 error codes drive circuit failure 721 Six Times False flame e Check if there is leaking from heat exchanger Part 401 detection 751 N A Miscommunication Inspect the connections between the micro boiler between micro boiler and temperature controller and temperature e Check the power supply of the micro boiler controller 941 Five Times Abnormal exhaust Check to see of the exhaust temperature is higher temperature than 149 F 65 C 991 Five Times Imperfect e Check if the gas type of the micro boiler matches combustion the gas supplied to it e Inspect the environment around the micro boiler Determine how long the micro boiler has been installed and match DIPswitches e Check the altitude elevation of the area of where the micro boiler is installed e Check if there is any blockage in the intake air and or exhaust e If the micro boiler is installed as a direct vent system check whether there is enough distance between the intake air terminal and the exhaust terminal e Check if there is grease and or dirt in the burner Part 101 and the fan motor Part 103 especially if the micr
54. te your boiler close to a drain where water leakage will not do damage to surrounding areas As with any fluid heating appliance the potential for leakage at some time in the life of the product does exist The manufacturer will not be responsible for any water damage that may occur If you install a drain pan under the micro boiler ensure that it will not restrict the combustion air flow Installation Manual Installation INCLUDED ACCESSORIES Check that these items below are included with the micro boiler Installation Manual Bird Screen and Owner s Guide Indoor model only Qty 1 For more information on optional items please refer to p 32 to 33 CLEARANCES Top Maintain all clearances around Back the micro boiler a Side tp Model Top Bottom Front Back Sides HS120Con LP 12 in 12 in 4 in lin 3 in Liquid propane 305mm 305mm 102mm 25mm 76mm HS120Con NG 12 in 12 in A in 1 in 3 in Natural Gas 305mm 305mm 102mm 25mm 76mm 24 inches recommended for maintenance 9 Page Installation Manual VENTING INSTRUCTIONS For the 140 Indoor T H3M DV model General e Improper venting of this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death e Improper installation can cause nausea or asphyxiation severe injury or death DANGER from carbon monoxide and flue gases poisoning Improper
55. ter valve Owner s Guide Troubleshooting TROUBLESHOOTING GENERAL NN PROBLEM SOLUTIONS It takes a long time to amp If you would like to receive hot water to your fixtures quicker you may get hot water at the want to consider a hot water recirculation system p 27 emitters The water is not hot Compare the flow and temperature See the charts on p 50 enough e Check cross plumbing between cold water lines and hot water lines e Is the gas supply valve fully open p 29 e ls the gas line sized properly p 21 e Is the gas supply pressure sufficient p 20 and 22 e Is the set temperature set too low p 34 to 36 The water is too hot Is the set temperature set too high p 34 to 36 The hot water is not Make sure the unit has 120 VAC 60 Hz power supply available when a e isthe temperature controller power button turned on there is a call for e Is the gas supply valve fully open p 29 heat e Is the system Y strainer clean e Can the emitters sufficiently draw at least 0 5 GPM 1 9 L min through the water heater p 34 e Is the unit frozen p 37 e Is there enough gas in the tank cylinder For Propane model e s it plumbed backwards with reverse plumbing The hot water turns Is the flow rate enough to keep the micro boiler running p 34 cold and stays cold Is the gas supply valve fully open p 29 e Is the system Y strainer clean e Is the system clean of debris and obstructions
56. to 5 000 to 7 500 to 3 000 ft 5 000 ft 7 500 ft 10 100 ft ON ON ON ON eet oA EEEEE HEGRE a GERABEHEEE or HEARR DIPswitches No 3 OFF No 3 OFF No 3 OFF No 3 OFF No 3 ON No 4 OFF No 4 ON No 4 OFF No 4 ON No 4 ON No 5 OFF No 5 OFF No 5 ON No 5 ON No 5 ON NOTE The dark squares indicate the direction the DIPswitches should be set to Only adjust the necessary switches Computer board I I i N Y WWY AN S Bank of DIPswitches 26 Page Installation Manual Installation APPLICATIONS Space Heating Applications FG 000005 1 EEE JE JE NE Mr EEE s e In order to purge air in water pipes within a closed loop system an air vent _ air seperator and expansion tank should be installed in the system Optional Hydro Smart pre built space heating panels incorporate all these WARNING features e Water temperature over 125 F 52 C can cause severe burns instantly or death from scalding e Chemicals such as diluted Glycol can be used for radiant floor Hydro fan coil air or Baseboard heating only The diluted solution of glycol must contain between 25 and 55 of Glycol Be aware that in closed loop glycol systems low pressure in the heat exchanger can cause low temperature boiling resulting in excessive noise and damage to the w
57. with all local codes and common safety practices water discharged from the pressure relief valve can cause severe burns instantly from scalding DO NOT touch the pressure relief valve e If the relief valve discharges periodically it may be due to thermal expansion in a closed water supply system Contact the water supplier or local plumbing inspector on how to correct this situation e 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 micro boiler checked once a year or as necessary by a licensed technician If repairs are needed any repairs should be done by a licensed technician RNOAFNONN j N AD NY blowing up Red or Yellow Blue flame AAMAAAAA flame Satisfactory Unsatisfactory Unsatisfactory UNIT DRAINING Drain plug Large 1 Close the manual gas shutoff valve Large 2 Turn off power to the micro boiler and wait a couple of seconds Turn on again i 3 Wait 30 seconds and then turn off power to the micro boiler yet again 4 Close the water shutoff valve 5 Have a bucket or pan to catch the water from the micro boiler s drain plugs Unscrew the Small drain plug first and unscrew the Large drain plug next to drain all the water out of the micro boiler 6 Wait a few minutes to ensure all water has completely drained from the micro boiler Drain plug valve Small Wa
58. zer cartridge is designed to last for 3 years before replacement However the actual life of the neutralizer may vary depending on the application and usage Please ensure that the cartridge is properly replaced before the neutralizer elements have been completely consumed e All preventative measures and safety practices must be adhered to when draining condensate The manufacturer will not be responsible for any damage caused by condensate e Adrain pan or other means of protection against water damage is required to be installed under the micro boiler in case of leaks ELECTRICAL CONNECTIONS Follow the electrical code requirements of the local authority having jurisdiction In the absence of such requirements follow the latest edition of the National Electrical Code ANSI NFPA 70 in the U S or the latest edition of CSA C22 1 WARNING Canadian Electrical Code Part 1 in Canada When servicing or replacing parts within the micro boiler label all wires prior to disconnection to facilitate an easy and error free reconnection Wiring errors can CAUTION Cause improper and dangerous operation Verify proper operation after servicing All micro boilers come with a power plug instead of a junction box Installation Manual Installation HIGH ALTITUDE INSTALLATIONS Check the elevation where your micro boiler is installed Set DIPswitches shown in the tables below depending on the altitude 0 to 2 000 ft DEFAULT 2 000 to 3 000
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