Hydro Smart 199 Condensing Gas Micro Boiler Installation Manual and Owner’s Guide Models: HS199Con-NG HS199Con-LP Do not return to stores. Damages or repairs call Hydro Smart 763-331-3066 M-F 8 AM - 5 PM Sat 8 AM - Noon If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. The Hydro Smart 199 Condensing Gas Micro Boiler is a compact and powerful residential unit with a versatile BTU modulating range.
CONTENTS Installation Manual SPECIFICATIONS..........................................................................................................4 INTRODUCTIONS..........................................................................................................5 SAFETY GUIDELINES...................................................................................................6 INSTALLATION..............................................................................................................
Installation Manual CONGRATULATIONS Congratulations and thank you for choosing our condensing micro boiler. Before use, we recommend that you read through this installation manual carefully. Keep this manual for future reference. If you need an additional manual, contact the manufacturer or your local distributor. When you call, please tell us the product name and the serial number of your unit written on the rating plate of the boiler.
SPECIFICATIONS Hydro Smart 199 Gas Condensing Micro-Boiler Natural Gas Input (Opera Range) BTU/h Min.: 15,000 Max.: 199,000 Propane Input (Opera Range) BTU/h Min.: 13,000 Max.: 199,000 Gas 3/4" NPT Water 3/4" NPT Water Pressure* Natural gas Inlet Pressure Propane Inlet Pressure Manifold Pressure** Weight Dimensions Natural Gas Propane psi (MPa) inch W.C. (kPa) inch W.C. (kPa) inch W.C. (Pa) inch W.C. (Pa) 15 - 150 (0.1 - 1) Min. 5.0 (1.24) Max. 10.5 (2.61) Min. 8.0 (1.99) Max. 14.0 (3.48) 2.
INTRODUCTION • • • • • • • • This manual provides information necessary for the installation, operation, and maintenance of the boiler. The model description is listed on the rating plate which is attached to the side panel of the boiler. Please read all instructions completely before installing this product. If you have any problems or questions regarding this equipment, consult the manufacturer or its local representative.
SAFETY GUIDELINES SAFETY DEFINITION DANGER WARNING CAUTION Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury. Indicates an imminently hazardous situation which, if not avoided, could result in minor or moderate injury. GENERAL 1.
INSTALLATION GENERAL 1. Follow all local codes, or in the absence of local codes, follow the current edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or 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.
• WARNING • • • • • 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 for 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.
CLEARANCES Top Maintain all clearances around the micro-boiler. Model Back Side Front Side Top Bo om Front Back Sides HS199Con-LP (Liquid propane) 12 in. (914 mm) 12 in. (305 mm) 24 in. (610 mm) 0.5 in. (13 mm) 2 in. (51 mm) HS199Con-NG (Natural Gas) 12 in. (914 mm) 12 in. (305 mm) 24 in. (610 mm) 0.5 in. (13 mm) 2 in. (51 mm) *24 inches recommended for maintenance. INCLUDED ACCESSORIES Check that these items below are included with the micro boiler.
HIGH-ALTITUDE INSTALLATIONS Check the elevation where your micro boiler is installed. Set DIPswitches shown in the table below depending on the altitude. 0 (DEFAULT) Up to 2,500 DIPswitches HS199Con Boiler (Lower bank of DIPswitches) Up to 5,000 Up to 7,500 Up to 10,100 ON 1 2 3 4 5 6 ON 1 2 3 4 5 6 ON 1 2 3 4 5 6 ON 1 2 3 4 5 6 ON 1 2 3 4 5 6 OFF OFF OFF OFF OFF No. 2 : OFF No. 3 : OFF No. 4 : OFF No. 2 : OFF No. 3 : ON No. 4 : OFF No. 2 : OFF No. 3 : OFF No. 4 : ON No. 2 : OFF No.
VENTING INSTRUCTIONS GENERAL • DANGER CAUTION Improper venting of this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death. • Improper installation can cause nausea or asphyxiation, severe injury or death from carbon monoxide and flue gases poisoning. Improper installation will void product warranty. When installing the vent system, all applicable national and local codes must be followed.
DIPswitch settings for Vent length Set DIPswitches shown in the tables below depending on vent length. 3" (Upper bank of DIPswitches) Vent length ON 1 2 3 4 5 6 7 8 5 to 20 (DEFAULT) OFF No. 3 : ON No. 4 : OFF ON 1 2 3 4 5 6 7 8 OFF 21 to 40 No. 3 : OFF No. 4 : OFF ON 1 2 3 4 5 6 7 8 OFF 41 to 70 No. 3 : ON No. 4 : ON 4" (Upper bank of DIPswitches) Vent length ON 1 2 3 4 5 6 7 8 5 to 50 (DEFAULT) OFF No. 3 : ON No.
Exhaust vent (ABS, PVC, CPVC, or polypropylene vent) This appliance can be vented with ABS, PVC, CPVC, or polypropylene (temperature rated up to 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.
Two-pipe, direct vent illustrations Typical installation using PVC. ABS, or polypropylene vent Horizontal Installation Vertical Installation 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.
Single pipe with room-air intake illustrations Typical installation using PVC. ABS, or polypropylene vent Horizontal Installation Vertical Installation 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. 3” vent connection 1. Connect 3” elbow directly on the intake vent collar of the micro boiler. 2.
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.
Direct-vent and single vent illustrations Horizontal Installation Vertical Installation Rain cap Wall Roof Hanger Hanger Fire stop Sidewall vent • The diagram above shows direct-vent installations. For single vent installation, connect a 4” elbow directly on the intake vent collar instead of a straight pipe. See the instructions below for the detail. For details of the optional items, refer to the installation manual for each optional item.
Vent termination clearances INSIDE CORNER DETAIL V Vent terminal X Air supply inlet V Area where is not permi ed G H A D E V B B B C V F V FIXED ED CLOS E BL A R E OP V L V ED ABLE FIXLOSED C OPER V B B V I X M V X K J A Gas meter / regulator B Canada Direct-vent and other than Direct-vent Directvent 1 foot 1 foot 1 foot B Clearance to window or door that may be opened 3 feet 1 foot 4 feet from below or side opening.
For sidewall terminations 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. 1 For multiple sidewall exhaust terminations (e.g. Multi-unit Systems), an exhaust termination must be at least 1 ft. (305mm) away from another exhaust termination. An exhaust termination must also be at least 2 ft. (610mm) away from an inside corner.
2 Exhaust termina (610 mm) min Exhaust and/or direct-vent sidewall terminations should be at least 2 ft. (610mm) away from an opposite surface/wall. Do not place the termination directly in front of an opening into a building. For rooftop terminations 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.
GAS SUPPLY AND GAS PIPING SIZE • • CAUTION • • • • • Check that the type of gas matches the rating plate first. Ensure that any and all gas regulators are operating properly and providing gas pressures withing the specified range shown below. Excess gas inlet pressure may cause serious accidents. Conversion of this unit 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.
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.
Measuring inlet gas pressure WARNING 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. 3. Failure to follow these steps could lead to a fire or explosion, resulting in personal injury or death. The micro boiler cannot perform properly without sufficient inlet gas pressures. Below are instructions on how to check the inlet gas pressure.
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. • An approved pressure relief valve must be installed on the hot water outlet. • The pressure relieve vale must conform to ANSI Z21.22 or Can 1-4.4 and installation must follow local codes. • The discharge capacity must be at least 199,000 BTU/h.
Condensate Drain Connections WARNING Discharge condensate (acidic water) in accordance with all local codes and common safety practices. The micro boiler is a high efficiency condensing micro boiler that produces condensate (acidic water). The acidic condensate generated in the secondary heat exchanger can be neutralized by the Neutralizer accessory. Case A: If a neutralizer is not required 1. 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. 2.
• WARNING • • • • • WARNING 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 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.
APPLICATIONS • WARNING • • Space Heating Applications In order to purge air in water pipes within a closed loop system, an air vent, air separator, and expansion tank should be installed in the system. (Hydro Smart pre-built space heating panels incorporate all of these features). Water temperature over 125° F (52° C) can cause sever burns instantly of death from scalding. Chemicals such as diluted Glycol can be used for radiant floor, Hydro/fan coil air or Baseboard heating only.
Dual-purpose hot water heating (Domestic and Space Heating) Insert a Hydro Smart Combi Panel to provide potable heated water and Hydronic Heating (with space heating panel(s)) with one heat source. The Hydro Smart Combi 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.
INITIAL OPERATION • • • • • • • • Check the Gas and Water Connections for leaks before firing the unit for the first time. Open the main gas supply valve to the unit using only your had to avoid and spark. Never use tools. If the knob will not sure by had, do not try to force it; call a qualified service technician. Forced repair may result in a fire or explosion due to gas leaks.
Owner’s Guide CONGRATULATIONS Congratulations and thank you for choosing our condensing micro boiler. Before use, we recommend that you read through this owner’s guide carefully. Keep this manual for future reference. If you need an additional manual, contact the manufacturer or your local distributor. When you call, please tell us the product name and the serial number of your unit written on the rating plate of the boiler.
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. 1. The 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. 2. Before operating smell all around the micro boiler area for evidence of leaking gas.
DANGER Vapors from flammable liquids will explode and catch fire causing death or sever burns. Do not use or store flammable products such as gasoline, solvents or adhesives in the same room or area near the micro boiler. FlammableVapors Read and follow micro boiler warnings and instructions. if the owner’s manual is missing, contact the manufacturer. Keep flammable products: Vapors: 1. 2. 3. 4. 1. 2. 3. 4. Far away from boiler. In approved containers. Tightly closed and out of reach of children.
NORMAL OPERATION TEMPERATURE CONTROLLER AND REMOVE CONTROLLER The illustration below shows an example of the controllers. The exact display may differ from examples. Remote controller Temperature Built-in controller Controller Display for Temperature When the STAND BY LED is ON, the hot water temperature will be displayed. "INFO" Button Each time the button is pressed, the operation mode is selected in the sequence of the following.
TEMPERATURE SETTINGS Set Temperature Screen on the controller Operation Built-in controller 1. Turn on the 120 VAC power supply to the unit. 2. Press the "ON/OFF" button on the controller in order to turn the controller on. 3. When ON, the STAND BY LED is lit. 4. It shows the set temperature on its display as shown in the picture on the right. (EX.: 120 °F) Remote controller (EX.: 120 °F) Press the "HOT" button or the "COLD" button to set the temperature setting of the unit. 5.
ADDITIONAL FEATURES Information mode You can get some information about the micro boiler condition by pressing “Info” button. For more information, follow the procedures below: Screen on the controller Opera Temperature controller 1. First of all, inlet water temperature will be displayed on the controller by pressing the "INFO" bu on. 2. Outlet water temperature will be displayed on the controller by pressing the "INFO" bu on. 3.
TEMPERATURE SETTINGS ON THE PCB (WITHOUT REMOTE CONTROLLER) There are 2 preset DIPswitches (120° F (50° 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 th set temperature of the DIPswitch settings. • The temperature has been preset at the factory to 120° F (50° C).
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 • This unit comes equipped with heating blocks to protect it against damages associated with freezing. • For this freeze protection system to operate, there has to be electrical power to the unit.
MAINTENANCE AND SERVICE Turn off the electrical power supply and close the manual gas shutoff valve and the manual water control valve before servicing. • • • • • • • 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. The burner should be checked annually for dust, lint, grease or dirt. Keep the area around the micro boiler clear.
TROUBLESHOOTING General TEMPERATURE and AMOUNT OF HOT WATER PROBLEM SOLUTIONS The water is not hot • Compare the flow and temperature. enough. • Check cross plumbing between cold water lines and hot water lines. • Is the gas supply valve fully open? • Is the gas line sized properly? • Is the gas supply pressure sufficient? • Is the set temperature set too low? The water is too hot. • Is the set temperature set too high? The hot water is not • Make sure the unit has 120 VAC, 60 Hz power supply.
Troubleshooting (Cont’d) PROBLEM Is the flow rate over 0.5 GPM (1.9 L/min)? Check for the filter on the cold water inlet. Check for reverse connection and cross connection. If you use the remote controller and/or temperature controller, is the power button turned on? • Check if the inlet temperature is too high. If it is too close to the set temperature, the water heater will not activate. • This is normal.
ERROR CODES • • • The units are self-diagnostic for safety and convenience when troubleshooting. If there is a problem with the installation or the unit, the error code will be displayed on the temperature controller and remote controller. Consult with the table on the following pages for the description of each error code.
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. Remote 031 Green LED Diagnosis descrip 111 Incorrect DIPswitch • Check the DIPswitch se on the PCB (Part #701). se Five Times Warning for the • Check the gas type of the micro-boiler. • Check if there is any blockage in the intake air and/ “991” error code or exhaust.
Remote Green LED 391 Two Times 441 Two Times 510 Six Times 551 Six Times 611 Four Times 651 Four Times 661 Four Times 701 711 One Time One Time 721 Six Times 741 N/A 751 N/A 761 N/A 941 Five Times 991 Five Times Diagnosis descrip Air-fuel ra rod failure Flow sensor failure (Easy-Link System only) Abnormal main gas solenoid valve Abnormal gas solenoid valve Fan motor fault reakage of wires (Part #709) • Check for c and/or soot on the AFR rod (Part #108).
COMPONENTS DIAGRAM Case assembly 052 052 003 007 004 713 052 004 717 002 001 702 008 052 704 050 050 Temperature controller Temperature remote controller 723 724 056 722 44
Computer board assembly 709 711 701 708 714 713 403 103 402 402 715 707 722 721 715 716 Surge box assembly 121 703 713 703 706 45 053 709 063
Burner assembly Burner assembly 101 104 115 053 053 709 108 107 401 106 116 053 110 062 109 111 711 Manifold assembly 112 117 053 114 102 103 105 113 065 708 054 150 121 119 711 707 062 151 057 055 055 117 063 118 051 719 714 46
Water Way assembly 418 413 453 452 F 412 058 458 462 472 064 473 418 468 473 462 458 462 415 064 E 458 451 B A E D 414 466 466 470 540 model 053 F 459 454 411 401 451 D 451 415 718 458 458 152 471 468 467 153 455 414 416 414 463 C 450 240 and 340 models 464 465 009 052 455 463 469 456 460 052 458 456 460 462 B Bypass section D C 403 A 404 454 408 052 462 417 409 052 461 458 458 402 455 47 410 406 457 405 417 059 454 407
PARTS LIST Item # Part # Descrip 001 Case assembly EK159 002 003 004 005 006 007 008 009 050 051 052 053 054 055 056 057 058 059 060 061 062 063 064 065 101 102 Front cover Intake air port assembly Bracket box Power supply cord assembly Back guard panel Chamber fixing plate Condensate drain port Screw M4×12 (W/Washer) Screw M4×10 (W/Washer) Screw M4×10 (Coated) Screw M4x10 Hex head screw M4×12 (W/Washer) Hex head screw M4x8 Pan screw M4x20 Tap ht screw M4x12 FEZN Screw M3x6 Screw M4x6 Screw M4x12 Scre
Item # Part # Descrip 116 117 118 119 121 150 151 401 Pressure port Combus chamber tube Gas inlet Gas inlet ring Surge box plate O-ring P18 NBR (Black) O-ring P20 NBR (Black) Primary heat exchanger EKK2D EX019 EK117 EX00D EK163 EZP18 EK042 EK250 402 403 404 405 407 408 Flow adjustment valve / Flow sensor Bypass valve Water inlet Inlet drain plug Inlet thermistor Outlet thermistor EK129 EKD58 EKK1U EKK2B EK137 EKK1A 409 410 411 412 413 414 415 416 417 418 450 451 452 453 454 455 456 457 458 459 460
Item # Descrip Part # 462 463 464 465 466 467 468 469 470 471 472 473 701 702 703 704 706 707 708 709 711 713 714 715 716 717 718 719 721 722 723 Fastener “16-25A” Fastener “6-15” Flat heater Drain tube Cold pipe Stainless heat exchanger out pipe Header c Drain port Thermistor fixing plate Exhaust thermistor gasket Hi-limit switch for exhaust Gasket Computer board Rubber grommet Surge box 120 VAC wire 120 VAC Power ON-OFF switch Remote controller wire Gas valve wire Flame rod wire Igniter assembly Switch
NOTES: 51
