220°F (104°C) Max High Limit
MODEL 3000
190°F (88°C) Max High Limit
MODEL 3000-190
High Temp Limit / LWCO Control
with Thermal Targeting™
for Gas Water Boilers
24 VAC Operating Voltage
PATENT NO. 7,891,572
INSTALLATION INSTRUCTIONS
and OPERATING MANUAL
• Saves Fuel – Features Thermal Targeting™ technology and
Thermal Pre-Purge capability
• Universal Design – Replaces common High Temp Aquastats*
• Easy to Install – Industry standard wiring, dial-type settings,
no external sensors necessary
• Operating Indicators – LEDs and Test Button provide continual and
on-demand status checks
• Prioritizes Hot Water – Gives priority to calls from indirect water heater
•
*Aquastat is a registered trademark of Honeywell International, Inc.
Three
Function
Design
Temperature Limit Control
Provides high limit functionality for
cold start 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
Utilizes Thermal Targeting™
technology to conserve fuel by
monitoring heating demand and
establishing target boiler temperatures
below the high limit setting
(see page 5 for details).
Model 3000
Electrical shock hazard. To prevent electrical shock, death or
equipment damage, disconnect power supply before
WARNING
installing or servicing control. Only qualified personnel may install or service this control in
To prevent serious
CAUTION
burns, boiler
should be thoroughly cooled before installing or
accordance with local codes and ordinances. Read instructions completely before proceeding.
servicing control.
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
WARNING
is recommended for unattended dwellings in climates subject to sustain below-freezing temperatures.
83 Water Street • New Haven, CT 06511 • Phone (203) 776-0473 • FAX (203) 773-1019 • www.hydrolevel.com
1
IMMERSION WELLS
Fuel Smart HydroStat can be installed on an existing immersion well already in the boiler or on a Hydrolevel Electro-Well™
(sold separately). The low water cut-off function is automatically activated when installed on an Electro-Well™.
IMPORTANT: The control will not provide low water cut-off protection when installed on a standard immersion well.
NOTE: Do not use heat-conducting grease.
Fuel Smart HydroStat installed
with Hydrolevel Electro-Well™
Fuel Smart HydroStat installed
with standard immersion well
IMPORTANT: For proper operation of the low water cut-off function, there
must be a minimum of ½" clearance between the copper well tube and any
surface within the boiler.
NOTE: When installed on a standard immersion well, the “LWCO Active”
LED will not illuminate.
See Electro-Well models on page 8.
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.
STEP 1
Place control on the well.
While holding box against well nut,
tighten well clamp screw. (Fig. 2)
STEP 2
Insert sensor ALL THE WAY into well. (Fig. 1)
FIG. 1
FIG. 2
NOTE: In the case of space restrictions,
the Fuel Smart HydroStat control may
be mounted in a horizontal orientation
without any loss of function.
2
shock hazard. To prevent electrical shock, death or equipment damage, disconnect power supply before
installing or servicing this control.
WARNING Electrical
WIRING TO CONTROL CENTER
USE CABLE 1 – For boilers equipped with a Honeywell R8285 Control Center or equivalent.
Step Step Y
G
C
W
R
Connect the WHITE wire to C and the RED wire to R
using the screw terminals on the control center.
Unplug the factory-wired quick connect from terminal Y and plug into YELLOW wire with male connector. Plug YELLOW wire from cable with female
connector into terminal Y.
USE CABLE 2 – For Thermal Targeting and is optional. If Cable 2 is not used, turn Economy OFF.
IMPORTANT: When installing with an indirect water heater, the indirect wiring cable will bypass the Thermal Targeting feature and allow the boiler to fire to the
high limit setting to heat the indirect tank. The indirect signal must be separate from all heating zone signals. If you choose not to separate the indirect signal from
the heating zones, the Economy Feature should be turned OFF to insure that the boiler supplies adequate temperature to heat the indirect tank (see page 5).
Step Step Y
G
C
Y
W
C
R
Connect the WHITE wire to G and the RED wire to R
using the screw terminals on the control center. The
RED and WHITE wires must be connected in parallel
with the heating thermostat.
G
3
W
R
Connect the two YELLOW wires to the end switch
from the indirect water heater relay. NOTE: If you are
not connecting to an indirect water heater, the bare
ends of the YELLOW wires must be capped off separately with wire nuts.
shock hazard. To prevent electrical shock, death or equipment damage, disconnect power supply before
installing or servicing this control.
WARNING Electrical
WIRING TO IGNITION CONTROL MODULE
For use on boilers equipped with Integrated Boiler Control Module
FROM
THERMOSTAT
INPUT ON
CONTROL
MODULE
TO
INDIRECT
WATER
HEATER
#45-531-56
Wire
Harness
CABLE 1 — Disconnect boiler wire Harness from the “SECONDARY” port on the Integrated Control Module
and plug into female plug adapter on #45-531-56 Wire Harness. Plug male adapter on #45-531-56 Wire
Harness into “SECONDARY” port on the Integrated Control Module. � Plug the other end of the Wire Harness
into the Model 3000 Low Water Cut-Off. � Connect the yellow wires in series with Limit Circuit.
CABLE 2 — Plug Wire Harness into the Model 3000 Low Water Cut-Off. Connect the two YELLOW wires
to the end switch from the indirect water heater relay. NOTE: If you are not connecting to an indirect water heater,
the bare ends of the YELLOW wires must be capped off separately with wire nuts. Connect the RED and WHITE
wires in parallel to wiring from the thermostat input on the control module and the existing thermostat wiring.
4
SETTING THE CONTROL
The high limit is factory set at 190°F. To adjust,
turn the HI TEMP Dial to the desired setting.
Setting range: Model 3000 – 100°-220°F
Model 3000-190 – 100°-190°F
1 30
145
16
0
Setting the High Limit
115
The Economy Feature is factory set for a 1 zone heating system. To adjust, turn the ECONOMY Dial to
the number of heating zones. Do not include indirect
water heaters in the number of heating zones. The
Economy Feature conserves fuel by reducing boiler
temperature (see “How Thermal Targeting Works”
below). If the heating system is unable to supply needed heat to the house, the ECONOMY Dial should be
turned to a lower setting (example: In a three zone
house, turn the dial to 2 or 1). Conversely, if the boiler provides adequate heat, added fuel savings can be achieved by
selecting a higher setting (example: 4 or 5). If the heating
and indirect water heater signals were not separated when
wiring the control or if you do not use optional Cable 2, the
Economy Feature must be turned OFF to insure the boiler
supplies adequate temperature to heat the indirect tank.
175
190
Setting the Economy Feature
Model 3000
Model 3000-190
Fuel Smart HydroStat has a Thermal Pre-Purge feature to
maximize efficiency. When active, the control will purge higher
boiler temperatures down to 135° at the start of any thermostat call and supply the latent energy in the boiler to the heating zone that is calling. During the purge cycle, the PURGE
LED will light. If the heat is not sufficient to satisfy the thermostat, the control will energize the burner. This feature works
with single-zone and multi-zone heating systems utilizing circulators or zone valves. No change in wiring is needed.
Activating Thermal Pre-Purge (optional)
SETTING
OFF Disables economy function. Will allow boiler to fire until hilimit temp is reached and re-fire with a 10° subtractive
differential.
LO Provides lowest level of fuel savings. Use this setting only if
the house does not stay warm at higher settings.
1 Recommended setting for single zone systems
2 Recommended setting for Two zone systems
3 Recommended setting for Three zone systems
4 Recommended setting for Four zone systems
5 Recommended setting for Five zone systems
HI Provides highest level of fuel savings
To Activate Thermal Pre-Purge
Push and hold the LWCO TEST button for 10 seconds. The
PURGE LED will blink twice and remain on as long as your
finger is on the button. To deactivate the feature, push and
hold the button a second time for 10 seconds. The PURGE
LED will blink twice and turn off.
Differentials are automatic and will vary based on
control settings and boiler temperature.
Differentials
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.
HOW THERMAL TARGETING WORKS
Thermal Targeting technology analyzes thermostat activity and continually evaluate how much heat the house requires. When it
is very cold outside, the heat demand is high and the Fuel Smart HydroStat will raise the boilerʼs Target temperature to provide
needed heat to the home. When the outside temperature is milder, the heat demand is lower. During these periods, the Fuel
Smart HydroStat will lower the boilerʼs Target temperature – saving fuel – while continuing to provide comfort to the house.
5
LED LEGEND and LWCO TEST BUTTON
HI TEMP
ECONOMY TARGET
Illuminates when the
boiler water temperature reaches the
high limit setting. It will remain lit until
the water temperature falls 10° (see
High Limit Differential on page 5). The
Fuel Smart HydroStat prevents burner
operation while this
LED is on.
LWCO ACTIVE Indicates that
the low water cut-off (LWCO) function
of the Fuel Smart HydroStat is active.
When the control is installed with a
Hydrolevel Electro-Well, this LED will
be on at all times when the control is
powered. IMPORTANT: If the control is
installed with a well other than the
Electro-Well, this LED will not illuminate
indicating that the control is not providing
low water cut-off functionality.
Model 3000 shown above.
Model 3000-190 has 190° max high limit.
PURGE
LWCO LOW WATER
Illuminates if the boiler is in a
low water condition. The Fuel Smart HydroStat will prevent
burner operation during this condition. IMPORTANT: The
system must be checked by a qualified heating professional
prior to resuming operation.
WARNING: DO NOT ADD WATER UNTIL THE
BOILER HAS FULLY COOLED.
When
the Economy feature is active, the
Fuel Smart HydroStat continually sets
target 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. The LED will stay lit until
the boiler temperature drops below
the differential (see Differentials on
page 5) at which point the boiler will
be allowed to fire again. NOTE: This
LED illuminates regularly during
normal boiler operation.
The control is purging latent heat from the boiler and will not
fire until the temperature drops to 135°F. See page 5 for
additional information on Thermal Pre-Purge.
LWCO TEST Button
To Test Low Water Cut-Off: Press and hold the LWCO
TEST button.
ECONOMY ACTIVE
Indicates that the Thermal
Targeting function is active and the Fuel Smart HydroStat will
reduce boiler temperature to conserve fuel. The Economy
feature is activated using the ECONOMY dial. (See “How
Thermal Targeting Works” on page 5 for more information).
The red Low Water light should illuminate and the burner
circuit should de-energize. NOTE: The control must be
installed with a Hydrolevel Electro-Well for low water cut-off
functionality (see page 2 for more details).
TROUBLESHOOTING
Burner Will Not Fire
No or Insufficient
Domestic Hot Water
House Will Not Get
or Stay Warm
Low Water Light
(Red LED) is On
See Flow Chart, page 7
If installed with an indirect water heater, insure that the end switch in the relay box
controlling the indirect water heater is properly connected to Cable 2 (see wiring steps 3
and 4 on page 3). This will insure that the domestic water calls are prioritized. If Cable 2
is not used, turn the Economy Feature OFF.
1. Check for air-bound radiators. 2. Check thermostat settings including heat anticipator
settings (common on non-digital thermostats). 3. Check the Economy setting. The
Economy feature, much like outdoor reset controls, lowers average boiler temperature
and can slow or the house from coming up to temperature. Move to a lower setting (see
“Setting the Economy Feature” on page 5).
WARNING: A low water condition is a serious and potentially dangerous condition. Do not
attempt to add water to a hot boiler. Allow the boiler to fully cool before adding water.
The LOW WATER light indicates that the control is not detecting water in the boiler.
1. If the light is on and the heating system is filled with water, pull the sensor out of the well and
inspect it. Make sure that the metal clip on the sensor is intact. This metal clip must be in contact
with the inside of the copper well in order for the control to sense the presence of water. Check
that the well does not have excessive build-up of heat transfer grease that may interfere with clip
contacting the well.
2. Remove well and examine for excessive residue build-up. Clean and re-install.
6
Troubleshooting Flow Chart – Burner Will Not Fire
Is the
PURGE
LED On?
YES
The Control is
Purging Latent
Heat from the
Boiler.
The Thermal Pre-Purge feature holds off the burner until the
circulator has purged the boiler temperature down to 135°F.
See Purge on page 5.
NO
CAUTION – ALWAYS ALLOW A BOILER TO COOL BEFORE ADDING WATER
The burner will not fire until the low water condition is satisfied.
Is the
Red LED
(LOW WATER)
On?
YES
The Control is
Sensing
Low Water.
NO
Is the
Yellow LED
(HI TEMP)
On?
왘 Check that the system is filled with water.
왘 Check that the sensor is inserted correctly into well.
Note: The use of heat-conductive grease may interfere with the
contact between the spring clip and the copper well tube.
왘 Check that the control is tightly clamped to the well.
YES
The Control is
Sensing High
Temperature.
YES
The Boiler has
Reached the
Target
Temperature.
NO
왘 Recheck Wiring
Yes
왘 Recheck Wiring
The burner will not fire until the boiler water has dropped to the
high limit differential set-point (10° below high limit setting).
왘 Check that the high temperature setting is correct.
NO
Is the
Yellow LED
(TARGET)
On?
When the ECONOMY function is active, the control monitors heating
demand and establishes Target boiler temperatures below the high
limit setting to conserve fuel (see “How Thermal Targeting Works”
on page 5). The burner will not fire until the boiler temperature
drops to the Target Temp Differential (see “Differentials” on page 5).
NO
Does the
Control Have
Power?
YES
Is the
Limit Circuit
Closed?
NO
Replace
Control
If both the red and yellow LEDs are off and
there is a call to fire the burner, the Limit
Contacts should be closed.
7
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.
ELECTRO-WELLS
DIMENSIONS
SPECIFICATIONS
Input voltage
FUEL SMART HYDROSTAT
MODEL 3000 and MODEL 3000-190
24 VAC, 60 HZ
Burner contacts
50 VA@24 VAC Pilot Duty
Operating range–high limit
Model 3000: 100°F (38°C) - 220°F (104°C)
Model 3000-190: 100°F (38°C) - 190°F (88°C)
Ambient temperature
Operating range–low limit
Room
Off or 110°F (43°C) - 200°F (93°C)
LIMITED MANUFACTURERʼS WARRANTY
We warrant products manufactured by Hydrolevel Company to be free from defects in
material and workmanship for a period of two years from the date of manufacture or
one year from the date of installation, whichever occurs first. In the event of any claim
under this warranty or otherwise with respect to our products which is made within
such period, we will, at our option, repair or replace such products or refund the purchase price paid to us by you for such products. In no event shall Hydrolevel Company
be liable for any other loss or damage, whether direct, indirect, incidental or consequential. This warranty is your EXCLUSIVE remedy and shall be IN PLACE OF any other
warranty or guarantee, express or implied, including, without limitation, any warranty
of MERCHANTABILITY or fitness for a particular purpose. This warranty may not be
assigned or transferred and any unauthorized transfer or assignment thereof shall be
void and of no force or effect.
83 Water Street • New Haven, CT 06511 • Phone (203) 776-0473 • FAX (203) 773-1019 • www.hydrolevel.com
8
3000-0312
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