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Table of Contents
Related Manuals for Hydro-Smart HS199CON-LP
Summary of Contents for Hydro-Smart HS199CON-LP
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Page 2: Table Of Contents
Gas supply and gas pipe sizing .......................22 Water connections....................24 Condensate drain........................25 Electrical connections......................27 Easy-Link System..................28 Multi-Unit System ....................32 Hydro Smart Pre-built Panels....................33 Hydro Smart Dual Purpose Panel..................34 INITIAL OPERATION........................35 Owner's Guide OPERATING SAFETY ........................37 NORMAL OPERATION ....................... 39 General...........................39 Temperature settings......................40 Temperature table of controller.....................40... -
Page 3: Installation Manual
Installation Manual CONGRATULATIONS Congratulations and thank you for choosing our condensing micro- boiler. Before use, we recommend that you read through this safety manual carefully. Please refer to the back of the manual for details about the warranty. Keep this manual for future reference. If you lose the manual, contact the manufacturer or your local distributor. -
Page 4: Specifications
SPECIFICATIONS Hydro Smart 199 Gas Condensing Micro-Boiler Natural Gas Input Min.: 15,000 BTU/h (Operating Range) Max.: 199,000 Propane Input Min.: 13,000 BTU/h (Operating Range) Max.: 199,000 Gas Connection 3/4" NPT Water Connections 3/4" NPT Water Pressure* 15 - 150 (0.1 - 1) -
Page 5: Introduction
INTRODUCTION • 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. •... -
Page 6: Safety Guidelines
Installation Manual Safety Guidelines 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. -
Page 7: Installation
Regularly ensure that the area around the unit is dust- or debris-free. Regular maintenance is recommended for these types of environment. 9. The Hydro Smart 199 Gas Condensing Micro-Boiler is to be installed indoors only. This unit is equipped with a thermistor and hi-limit switch for the exhaust gas, detecting excess temperatures within the flue and enabling the unit to safely stop operations if needed. -
Page 8: Optional Items
• Installation and service must be performed by a qualified installer (for example, a licensed plumber or gas fitter), otherwise the warranty will be void. WARNING • 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. -
Page 9: Clearances
CLEARANCES Maintain all clearances around Back Side the micro-boiler. Front Side Model Bottom Front Back Sides HS199Con-LP 36 in. 12 in. 24 in. 0.5 in. 2 in. (Liquid propane) (914 mm) (305 mm) (610 mm) (13 mm) (51 mm) HS199Con-NG 36 in. -
Page 11: High-Altitude Installations
HIGH-ALTITUDE INSTALLATIONS Check the elevation where your micro-boiler is installed. Set DIPswitches shown in the table below depending on the altitude. Altitude 0 (DEFAULT) Up to 2,500 ft Up to 5,000 ft Up to 7,500 ft Up to 10,100 ft DIPswitches ON 1 2 3 4 5 6 ON 1 2 3 4 5 6... -
Page 12: Venting Instructions
VENTING INSTRUCTIONS -General- • Improper venting of this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death. • Improper installation can cause nausea or asphyxiation, severe injury or death DANGER from carbon monoxide and flue gases poisoning. Improper installation will void product warranty. - Page 13 -DIPswitch settings for Vent length- <Two-pipe, direct-vent Refer to p. 15 for details. Set DIPswitches shown in the tables below depending on the vent length. 3" venting Vent length (Upper bank of DIPswitches) ON 1 2 3 4 5 6 7 8 5 to 20 ft (DEFAULT) No.
- Page 14 -Exhaust vent (ABS, PVC, CPVC, or polypropylene vent)- This appliance 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, plastic venting must be certified to ULC S636 standards.
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Page 15: Optional Items
PVC, ABS, or polypropylene vent Typical using Horizontal Wall Roof Roof Fire stop Connect between exhaust vent collar and piping. See the below. For details of the optional items, refer to the Installation manual for each optional item. <How to install intake and exhaust venting (two-pipe, direct-vent) 3"... - Page 16 Typical using PVC, ABS, or polypropylene vent Horizontal Wall Roof Roof Elbow Fire stop Elbow Connect between exhaust vent collar and piping. See the below. For details of the optional items, refer to the Installation manual for each Optional item. <How to install single vent>...
- Page 17 -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.
- Page 19 INSIDE CORNER DETAIL Vent terminal Air supply inlet Area where is not permitted Gas meter / regulator Canada U.S.A Direct-vent and other Direct- Other than than Direct-vent vent Direct-vent Clearance above grade, veranda, porch, deck, or 1 foot 1 foot 1 foot balcony 4 feet from below or...
- Page 20 Please follow all local and national codes in regards to proper termination clearances. In the absence of such codes, the clearances below can be used as guidelines. Local codes supersede these guidelines. CAUTION For multiple sidewall exhaust terminations (e.g. Multi- 2 ft.
- Page 21 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 Exhaust termination 2 ft. (610 mm) Please follow all local and national codes in regards to proper termination clearances.
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Page 22: Gas Supply And Gas Pipe Sizing
GAS SUPPLY AND GAS PIPE SIZING -General- • Check that the type of gas matches the rating plate first. • Ensure that any and all gas regulators used are operating properly and providing gas pressures within the specified range shown below. Excess gas inlet pressure may cause serious accidents. - Page 23 -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 199 Cubic ft./hr. Unit: Cubic feet per hour Pipe Size Length...
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Page 24: Water Connections
-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 unit 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. -
Page 25: Condensate Drain
-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 unit does not come with an approved pressure relief valve. •... - Page 26 Discharge condensate (acidic water) in accordance with all local codes and common safety practices. WARNING The micro-boiler is a high efficiency condensing unit that produces condensate (acidic water). The acidic condensate generated in the secondary heat exchanger can be neutralized by the Neutralizer accessory.
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Page 27: Electrical Connections
• 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. -
Page 28: Easy-Link System
EASY-LINK SYSTEM -General- The Hydro Smart 199 micro-boiler can be connected with communication cables to work as a multiple-unit manifold system. • The Easy-Link System allows up to 4 units to manifold together. • A communication cable (gray color) comes with each unit. - Page 29 2. Select one unit to be the “PARENT” unit. 3. “PARENT” unit : Locate the two banks of DIPswitches at the bottom left of the computer board of the unit that you select to be the “PARENT” unit. Change DIPswitch No. 1 on the lower bank of DIPswitches to the ON position.
- Page 30 (C) Examples of incorrect settings and /or connections CASE 1: Wrong DIPswitch setting on the "PARENT" unit • Unless you change DIPswitch No. 1 PARENT unit CHILD-1 unit of the “PARENT” unit to the “ON” Connectors Connectors position, the system will not work as an Easy-Link System.
- Page 31 CASE 3: Wrong connections between the "CHILD-1" unit and the "CHILD-2" unit • If you connect the “PARENT” connector of the “CHILD-1” unit to the “1” connector of the “CHILD-2” unit, the “CHILD-2” unit will operate as an individual unit, and will not be part of the Easy-Link System.
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Page 35: Initial Operation
INITIAL OPERATION FOR YOUR SAFETY, READ BEFORE OPERATING • Check the GAS and WATER CONNECTIONS for leaks before firing unit for the first time. • Open the main gas supply valve to the micro-boiler using only your hand to avoid any spark. -
Page 36: Owner's Guide
Owner's Guide Owner's Guide CONGRATULATIONS Congratulations and thank you for choosing our gas micro-boiler. Before use, we recommend that you read through this safety manual carefully. Please refer to the back of the manual for details about the warranty. Keep this manual for future reference. If you lose the manual, contact the manufacturer or your local distributor. -
Page 37: Operating Safety
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. - Page 38 Owner's Guide DANGER 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.
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Page 41: Additional Features
Owner's Guide ADDITIONAL FEATURES You can get some information about the micro-boiler condition by pressing the "INFO" button. For more information, follow the procedures below: Screen on the controller Operation Temperature controller Remote controller Inlet water temperature First of all, inlet water temperature will be displayed on the controller by pressing the "INFO"... -
Page 42: Temperature Settings On The Pcb (Without Remote Controller)
Owner's Guide TEMPERATURE SETTINGS ON THE PCB (WITHOUT REMOTE CONTROLLER) There are 2 preset temperatures (120 °F (49 °C) and 140 °F (60 °C)) that you can select from by changing the DIPswitch settings on the computer board without the remote controller. See the table below. When the remote controller is in normal operation, the set temperature of the remote controller is given priority over the set temperature of the DIPswitch settings. -
Page 43: Flow
Owner's Guide FLOW • The flow rate through the micro-boiler is limited to a maximum of 10.0 GPM (38 L/min). • The temperature setting, along with the supply temperature of the water will determine the flow rate output of the unit. FREEZE PROTECTION SYSTEM •... -
Page 44: Maintenance And Service
Owner's Guide MAINTENANCE AND SERVICE Turn off the electrical power supply and close the manual gas shutoff valve before servicing. WARNING • Be sure that all openings for combustion and ventilation air are not blocked. • The venting system should be checked annually for any leaks, corrosion, blockages or damage. •... -
Page 45: Troubleshooting
Owner's Guide TROUBLESHOOTING GENERAL PROBLEM SOLUTIONS The water is not hot • Compare the flow and temperature. See the charts on p. 56. enough. • Check cross plumbing between cold water lines and hot water lines. • Is the gas supply valve fully open? (p. 35) •... -
Page 48: Error Codes
Owner's Guide -Fault Analysis of Error Codes- If the error code is displayed on the computer board of the micro-boiler or remote controller and/or temperature controller, please check the following. After checking, consult with the manufacturer. Green Malfunction Remote Diagnosis description One Time Incorrect DIPswitch... - Page 49 Owner's Guide Green Malfunction Remote Diagnosis description Two Times Air-fuel ratio rod • Check for connection/breakage of wires (Part #709) failure and/or soot on the AFR rod (Part #108). Two Times Flow sensor failure • Check for connection/breakage of wires and/or debris on the flow sensor impeller (Part #402).
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Page 50: Components Diagram
Owner's Guide Components Diagram COMPONENTS DIAGRAM Case assembly Temperature controller Temperature remote controller Page... - Page 51 Owner's Guide Components Diagram Computer board assembly 707 722 Surge box assembly Page...
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Page 54: Parts List
Owner's Guide Parts List PARTS LIST Part # Item # Description Case assembly EK159 Front cover EK158 Intake air port assembly EK170 Bracket EK162 Junction box EK190 Power supply cord assembly EK171 Back guard panel EK161 Chamber fixing plate EK160 Condensate drain port EKH23 Screw M4×12 (W/Washer) - Page 55 Owner's Guide Parts List Part # Item # Description Pressure port EKK2D Combustion chamber tube EX019 Gas inlet EK117 Gas inlet ring EX00D Surge box plate EK163 O-ring P18 NBR (Black) EZP18 O-ring P20 NBR (Black) EK042 Primary heat exchanger EK250 Flow adjustment valve / Flow sensor EK129...
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Page 56: Output Temperature Chart
Owner's Guide Parts List Item # Description Part # Fastener “16-25A” EKK39 Fastener “6-15” EX12K Flat heater EK217 Drain tube EK218 Cold pipe EK220 Stainless heat exchanger out pipe EK222 Header connection EK226 Drain port EK228 Thermistor fixing plate EK13H Exhaust thermistor gasket EK13L Hi-limit switch for exhaust... -
Page 57: Limited Warranty
Owner's Guide Warranty LIMITED WARRANTY 1. 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. - Page 58 • 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 & provincial codes, ordinances, and good trade practices.
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Questions and answers
My zone pumps work but water is not flowing through the boiler enough to turn it on. What is the problem?
Insufficient water flow through the Hydro-Smart HS199CON-LP boiler could be caused by:
1. The flow rate being below 0.5 GPM (1.9 L/min).
2. A dirty system Y-strainer.
3. Reverse or cross connection in the plumbing.
4. Incorrect water pipe sizing.
5. Water pressures outside the specified range.
6. Recirculation flow rates outside the specified range.
7. Lack of proper air removal in a closed-loop circulation system.
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What fuse can be used for the computer board?
The compatible fuse for the Hydro-Smart HS199CON-LP computer board is not specified in the provided context.
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