HydroStat User Guide

ManualsBrandsPeerless ManualsBoilersMI-05-e - 100,000 BTU Output Intermittent Ignition Packaged Residential Water Boiler (Nat Gas)

126 Bailey Road, North Haven, CT 06473 • Phone (203) 776-0473 • FAX (203) 764-1711 • www.hydrolevel.com

4200 SERIES

Multi-Function

Gas Boiler Control

120 VAC Input / 24 VAC Burner Circuit

PATENT NO. 8,931,708; 8,844,834;

7,891,572; others pending

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 sustained below-freezing temperatures.

INSTALLATION INSTRUCTIONS

and OPERATING MANUAL

Five Function Control

• Ignition – Intermittent Spark Ignition with single rod flame sensing

• Temperature Limit Control

• Low Water Cut-Off

• Boiler Temperature Reset

• Two Zone – Circulator outputs for DHW or second heating zone

Optional primary/secondary operation

Available for atmospheric or induced draft boilers.

See model designations below.

MODEL NUMBERS

MODEL 4200a

Series

Vent Option

a = Atmospheric

i = induced

Mounting

Blank = Internal

X = External

PART NUMBERS

48-4200

Series

Vent Option

0 = Atmospheric

1 = Induced

Sensor

0 = 12" Sensor

1 = 24" Sensor

2 = 48" Sensor

Mounting

Blank = Internal

X = External

Read these instructions completely before proceeding with the installation and retain instructions for future reference.

Summary of content (16 pages)

PAGE 1
INSTALLATION INSTRUCTIONS and OPERATING MANUAL 4200 SERIES Multi-Function Gas Boiler Control 120 VAC Input / 24 VAC Burner Circuit PATENT NO. 8,931,708; 8,844,834; 7,891,572; others pending Five Function Control • Ignition – Intermittent Spark Ignition with single rod flame sensing • Temperature Limit Control • Low Water Cut-Off • Boiler Temperature Reset • Two Zone – Circulator outputs for DHW or second heating zone Optional primary/secondary operation Available for atmospheric or induced draft boilers.
PAGE 2
IMMERSION WELLS HydroStat-IC can be installed with an existing immersion well already in the boiler or with a Hydrolevel Electro-Well™ (sold separately). The low water cut-off function is automatically activated when installed with an Electro-Well™. IMPORTANT: The control will not provide low water cut-off protection when installed with a standard immersion well. NOTE: Do not use heat-conducting grease.
PAGE 3
WIRING shock hazard. To prevent electrical shock, death or equipment damage, disconnect power supply before WARNING Electrical installing or servicing this control. All wiring must comply with the National Electric Code or any other state or local codes or regulations.
PAGE 4
SETTING THE CONTROL Diagnostic LEDs Dynamic Display Water Temperature and Real Time Verification of Setting Adjustments.
PAGE 5
IGNITION SEQUENCING AND FLAME SAFETY Lights come on in sequence. The HydroStat-IC proves the safety limit devices on the boiler before igniting the pilot. As each limit is checked, the corresponding light will turn on indicating the limit is satisfied. If any limits are not satisfied, the corresponding light will blink and the ignition sequence will stop. After ignition, the HydroStat-IC continues to monitor the limit devices, vent damper or air pressure switch, and pilot flame.
PAGE 6
INITIATING BOILER IGNITION continued 3. Pilot Ignition: Once the control receives confirmation from the vent damper or inducer fan, the control will initiate the spark ignitor and turn on the pilot valve to light the pilot. The control will spark the pilot intermittently (approximately one second on followed by one second off) until it verifies that the pilot is lit. Prior to each one-second spark, the display will show the number corresponding to the ignition attempt (01, 02, 03, etc.).
PAGE 7
2-ZONE CIRCULATOR OPTIONS The HydroStat IC is equipped with a second zone for use with a 120 volt circulator. Unless the control is factory installed on a boiler designed for primary/secondary heating loops, the zone will be set to function with an indirect water heater for domestic hot water (DHW). The T-T input for this zone is the small screw terminals labeled "DHW or Zone2". The zone output is located in the LINE VOLTAGE plug receptacle (see page 3).
PAGE 8
LED LEGEND and TEST/SETTINGS BUTTON TEMP ACTIVE will continue to circulate and heat the house as long as the thermostat call continues. The LED will stay lit until the boiler temperature drops below the differential set point at which point the boiler will be allowed to fire again. See Differential explanation on page 12. NOTE: This LED illuminates regularly during normal boiler operation.
PAGE 9
IGNITION LED LEGEND and OPERATION IGNITION LIMITS V-PWR V-SW FLAME LIMITS Illuminates on a call for heat to indicate the V-SW Illuminates when the vent damper switch (on an external limits are satisfied. (External limits may include flame rollout, spill switch, secondary low water cut-off etc.). If the external limits are open, the LIMITS light will blink. atmospheric boiler) or the air pressure switch (on an induced draft boiler) has made.
PAGE 10
OPTIONAL FEATURES NOTE: The Program Mode – Pro – is accessed by turning the LO TEMP dial to a position just above OFF. Thermal Pre-Purge Thermal Pre-Purge is designed to maximize boiler efficiency. When activated, the control will supply latent heat that may remain in the boiler from a previous run cycle to the next heating zone that calls.
PAGE 11
OPTIONAL FEATURES continued 2-Zone Circulator Settings: The HydroStat-IC is equipped with a second zone designed for a 120-volt circulator that can be set to operate in one of three ways: • Domestic Hot Water (DHW) for use with an indirect water heater • A Second Heating Zone • Primary/Secondary Circulator Operation (Important: For use with primary/secondary piping systems only) See page 7 for details on the operation of each setting as well as the input and output connections for the second circulator.
PAGE 12
OPTIONAL FEATURES continued Low Limit Setting The HydroStat IC control can provide Low Limit functionality for boilers equipped with tankless coils. When activated, the control will operate the burner to maintain the selected temperature in the boiler at all times. To activate the Low Limit feature 1. Turn the PROGRAM / LO TEMP dial clockwise to enter the Program Mode – The display will read Pro 2. Turn the HI TEMP dial to select feature 7 3. Push the Test/Settings Button once.
PAGE 13
OPTIONAL FEATURES continued Restore Factory Default Settings To restore all features to the factory default settings (see chart on page 13 for default settings) 1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as Pro 2. Turn the HI TEMP dial to select feature dEf 3. Push the Test/Settings Button to Y to reset all features to the default settings. 4.
PAGE 14
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. TROUBLESHOOTING Temperature Display Exceeds High Limit Setting Under normal operation, boiler temperature will continue to rise after the control shuts off the burner.
PAGE 15
ELECTRO-WELLS HydroStat-IC installed with Electro-Well™ When installed with the Hydrolevel Electro-Well, HydroStat-IC 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. The Electro-Well is available separately for field installations.
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 HydroStat-IC control. This low cost, easy to install kit is available separately at Hydrolevel distributors. Part No.