Manual

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83 Water Street • New Haven, CT 06511 • Phone (203) 776-0473 • FAX (203) 773-1019 • www.hydrolevel.com

MODEL 3200-Plus

Temp Limit / LWCO Control

with Thermal Targeting

™

for Water Boilers

120 VAC Input / 24 VAC Burner Circuit

PATENT NO. 7,891,572

WARNING

Electrical shock hazard. To prevent electrical shock, death or

equipment damage, disconnect power supply before

installing or servicing control. Only qualified personnel may install or service this control in

accordance with local codes and ordinances. Read instructions completely before proceeding.

CAUTION

To prevent serious

burns, boiler

should be thoroughly cooled before installing or

servicing control.

WARNING

Frozen pipes/water damage. Central heating systems are prone to shut down as a result of power or fuel outages,

safety related fault conditions or equipment failure. Installation of freeze protection monitoring or other precautions

is recommended for unattended dwellings in climates subject to sustain below-freezing temperatures.

Three Function

Design

Temperature Limit Control

Designed for cold start and tankless

coil boilers.

Low Water Cut-Off

Provides protection against potentially

dangerous low water conditions

when installed with the Hydrolevel

Electro-Well™ (see page 2 for details).

Boiler Reset Control

•

Thermal Targeting – On-board micro-

processor adjusts boiler temperature

based on heating demand.

•

Outdoor Reset Ready – Compatible with

Hydrolevel OS-100 Outdoor Sensor Kit

(sold separately) for outdoor reset and

warm weather shut-down functionality.

INSTALLATION INSTRUCTIONS

and OPERATING MANUAL

• Saves Fuel – Features Thermal Targeting™ technology and

Thermal Pre-Purge capability

• Outdoor Reset Ready – Provides Outdoor Reset and Warm Weather

Shut-Down capability with the addition of Hydrolevel OS-100 Outdoor

Sensor Kit (sold separately)

• Universal Design – Replaces common cold-start and triple-action

Aquastats*

• Operating Indicators – LEDs, Dynamic Display and Test Button provide

continual and on-demand status checks

• Prioritizes Domestic Hot Water – Gives priority to low limit setting or to

calls from indirect water heater

• Reduces Condensation – Holds circulator off until boiler reaches 125°F

•

*Aquastat is a registered trademark of Honeywell International, Inc.

HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 1

Summary of content (16 pages)

PAGE 1
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg MODEL 3200-Plus Temp Limit / LWCO Control with Thermal Targeting™ for Water Boilers 120 VAC Input / 24 VAC Burner Circuit PATENT NO.
PAGE 2
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 2 IMMERSION WELLS Fuel Smart HydroStat can be installed on a Hydrolevel Electro-Well™ or on an existing immersion well already in the boiler. IMPORTANT: The control will only provide low water cut-off protection when installed on an Electro-Well™. Installing HydroStat with Hydrolevel Electro-Well™ When installed on an Electro-Well™ (sold separately), the Low Water Cut-Off function is automatically activated.
PAGE 3
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 3 MOUNTING THE CONTROL IMPORTANT Make sure that the immersion well or Electro-Well™ is installed in the boiler manufacturer’s designated temperature limit control tapping. NOTE: If installing an Electro-Well, pipe sealing compound should be used. Teflon tape is not recommended. Two mounting positions are available on the back of the control (Fig. 1).
PAGE 4
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 4 WIRING shock hazard. To prevent electrical shock, death or equipment damage, disconnect power supply before WARNING Electrical installing or servicing this control. STEP 1 Connect 120 VAC Hot to terminal L1. Connect 120 VAC Common to terminal L2. Disconnect means and overload protection as required (provided by others). STEP 2 STEP 3 STEP 4 Connect the burner circuit to B1-B2. (B2 is common.
PAGE 5
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 5 WIRING continued shock hazard. To prevent electrical shock, death or equipment damage, disconnect power supply before WARNING Electrical installing or servicing this control. When installing with an indirect water heater, the signal from the indirect must be separated from the heating zone signals and wired to I1 and I2 as shown above.
PAGE 6
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 6 SETTING THE CONTROL Diagnostic LEDs Dynamic Display Test/Settings Button Water Temperature and Real Time Verification of Setting Adjustments.
PAGE 7
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 7 SYSTEM START-UP At initial start up, with the Economy Feature active, the control establishes a 145°F target temperature. To test the high limit shut-off function, the Economy Dial must be turned to OFF. Once tested, restore the Economy setting. If the heating demand is high, the target will increase over time to satisfy the heat load.
PAGE 8
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 8 OPTIONAL FEATURES NOTE: The Program Mode – Thermal Pre-Purge – is accessed by turning the LO TEMP dial to a position just above OFF. Thermal Pre-Purge is designed to maximize boiler efficiency. When activated, the control will supply latent heat that may remain in the boiler from a previous run cycle to the next heating zone that calls.
PAGE 9
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 9 OPTIONAL FEATURES continued Circulator Activation Options When in the default mode, the HydroStat activates the circulator (C1/C2 contacts) on calls to T/TV. The control can be programmed to activate the circulator on calls to I1/I2 in place of, or in addition to, calls to T/TV. To change how the Circulator is activated 1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as 2.
PAGE 10
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 10 OPTIONAL FEATURES continued Restore Factory Default Settings To restore all features to the factory default settings (see following chart for default settings) 1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as 2. Turn the HI TEMP dial to select feature 3. Push the Test/Settings Button to to reset all features to the default settings. 4.
PAGE 11
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 11 LED LEGEND and TEST/SETTINGS BUTTON TEMP ACTIVE temperatures below the high limit setting to maximize fuel efficiency. When the boiler water reaches the target temperature, the LED illuminates and the burner will shut down. The boiler water will continue to circulate and heat the house as long as the thermostat call continues.
PAGE 12
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 12 MAINTENANCE Remove the Electro-Well from the heating system every five years and clean any scale or sediment deposits from all parts that are exposed to the boiler water. After cleaning, reinstall the well using pipe sealing compound. Teflon tape is not recommended.
PAGE 13
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 13 Troubleshooting Flow Chart 1 – Burner Will Not Fire Does the Display Read YES The Control is Purging Latent Heat from the Boiler. NO The Control is Not Powered. ? The Thermal Pre-Purge feature holds off the burner until the control determines if the latent heat in the boiler can satisfy the heat call.
PAGE 14
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 14 Troubleshooting Flow Chart 2 – Burner Will Not Shut Down Is the Red LED (LOW WATER) On? YES The Control is Sensing Low Water. WARNING! TURN OFF POWER TO BURNER IMMEDIATELY! NO Is either Yellow LED On? CAUTION – ALWAYS ALLOW A BOILER TO FULLY COOL BEFORE ADDING WATER. YES The Control has Reached Target or High Limit Temperature. YES The Control is Operating Normally. Recheck wiring.
PAGE 15
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 15 ELECTRO-WELLS Fuel Smart HydroStat installed with Electro-Well™ 1/2" CLEARANCE 1/2" CLEARANCE Electro-Well™ Models 15 1/2" CLEARANCE When installed with the Hydrolevel Electro-Well, Fuel Smart HydroStat will provide both temperature and low water cut-off functionality. If the control was supplied by the boiler manufacturer, it was installed with an Electro-Well.
PAGE 16
HydroStat 3200-Plus Instructions: HydroStat Instructions.8pg 11/14/13 3:34 PM Page 16 OUTDOOR SENSOR KIT Hydrolevel's optional Outdoor Sensor Kit automatically activates outdoor reset functionality and warm weather shutdown capability when plugged into the Fuel Smart HydroStat control. This low cost, easy to install kit is available separately at Hydrolevel distributors. Part No.