Hydrolevel Fuel Smart 3200-Plus boiler temperature and low water cut-off control, OS-100 outdoor sensor kit INSTALLATION INSTRUCTIONS and OPERATING MANUAL

Page 1
MODEL 3200-Plus
Temp Limit / LWCO Control
with Thermal Targeting™
for Water Boilers
120 VAC Input / 24 VAC Burner Circuit
PATENT NO. 8,931,708; 8,844,834;
7,891,572; others pending
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.
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.
Electrical shock hazard. To prevent electrical shock, death or
WARNING
equipment damage, disconnect power supply before
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,
WARNING
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.
126 Bailey Road, North Haven, CT 06473 • Phone (203) 776-0473 • FAX (203) 764-1711 • www.hydrolevel.com
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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. Heat transfer
grease should not be used. NOTE: For proper operation, there must
be 1/2" clearance between the copper well tube and any furnace
within the boiler.
See Electro-Well™ models on page 15.
Installing HydroStat
with Standard Immersion Well
When installing on a standard immersion well, the LWCO function should be turned off (see page 9 for instructions). A buildup of
heat transfer grease or other coatings in older wells can interfere
with continuity between the sensor and the well causing a false low
water shutdown. Turning off the LWCO function will prevent this
from occurring.
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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.
STEP 1 Two mounting positions
are available on the back of the control
(Fig. 1). Select which of the two positions
(2 knockouts) is best for the location of
the control. Remove the knockout.
STEP 2 Place control on the well.
While holding box against well nut,
tighten well clamp screw. (Fig. 2)
STEP 3
Insert sensor ALL THE
WAY into well through the knockout (A
or B) you have chosen. (Fig. 3)
BACK OF
FUEL SMART HYDROSTAT BOX
FIG. 1
FIG. 2
FIG. 3
IMPORTANT – Sensor must be inserted all the way into the well for proper operation.
CORRECT
INCORRECT
NOTE: In the case of space restrictions, the Fuel Smart HydroStat control may be mounted in a horizontal orientation without any
loss of function. Hydrolevel recommends vertical mounting, when possible, for proper orientation of LED display.
REMOTE MOUNTING KITS
Remote Mounting Kits are available separately for mounting the Fuel Smart HydroStat control box in a remote location. Each kit
includes mounting hardware and a remote sensor.
Part No.
Description
48-101
48-102
48-103
48-104
48-121
HydroStat
HydroStat
HydroStat
HydroStat
HydroStat
Remote Mount Kit with 24" sensor
Remote Mount Kit with 48" sensor
Remote Mount Kit with 10' sensor
Remote Mount Kit with 20' sensor
Pipe Mounting Kit with 48" sensor
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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
STEP 2
Connect 120 VAC Hot to terminal L1. Connect 120 VAC
Common to terminal L2. Disconnect means and overload
protection as required (provided by others).
Connect the burner circuit to B1-B2. (B2 is common.)
STEP 3
STEP 4
Connect the circulator to C1-C2. (C2 is common.)
Connect the thermostat to T/TV.
STEP 5
If the boiler is equipped with a plug-in style vent damper,
unplug the factory installed jumper from the receptacle on the
circuit board and replace it with the vent damper plug.
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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.
STEP 6 For Systems with Indirect Water Heaters
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. Calls to I1 and I2 will bypass the Thermal Targeting or Outdoor Reset feature and allow the
boiler to fire to the high limit setting to heat the indirect tank.
NOTE: 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 6).
ZONE VALVE WIRING
IMPORTANT: Use a separate transformer to power zone valves. Connecting zone valves to Z-TV may overload the
HydroStat and cause a lock-out condition (see Troubleshooting on page 12 for more information). The total load, including
the burner circuit, vent damper, and Z-TV connections must not exceed 1.2 amps (30 VA). Connect zone valve end-switch
to T/TV as shown below.
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Page 6
SETTING THE CONTROL
Diagnostic LEDs
Dynamic
Display
Test/Settings Button
Water Temperature
and Real Time
Verification of Setting
Adjustments.


High Temperature
Limit Setting
(100°-220°F)

Economy Dial
(OFF or LO, 1, 2, 3,
4, 5, HI)
Factory 1
Indicator Light
(announces heat call)
Factory 190°F
Low Temperature
Limit Setting
(OFF or 110°-220°F)
Jumper
Spade Connectors
for OS-100 Outdoor
Sensor Kit

Factory OFF
Differentials are automatic
and will vary based on
control settings and boiler
temperature.
Vent Damper
Receptacle
Note: The high limit differential
can be adjusted when the economy feature is turned off. See
Optional Features on page 9.
er temperature (see “How Thermal Targeting Works” on page
7). 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, the
Economy Feature should be turned OFF to ensure the boiler
supplies adequate temperature to heat the indirect tank.
NOTE: Settings can be checked using the
TEST/SETTINGS Button. See page 11 for details.
Setting the High Limit
The high limit is factory set at 190°F. To adjust, turn the HI
TEMP Dial  until the desired setting is displayed. (Setting
range: 100°-220°F)
Setting the Low Limit
The low limit is designed to maintain temperature in boilers
equipped with tankless coils used for domestic hot water. The
low limit is factory set to OFF. Prior to adjusting, remove the
jumper (not equipped on all units) . Then turn the LO
TEMP Dial  clockwise until the desired temperature is displayed. For proper operation, the low temperature limit setting
should be at least 10° below the high limit setting. NOTE: For
cold start operation, the low limit must be turned OFF. IMPORTANT: If low limit temperature cannot be set above 140°F,
remove jumper . (Setting range: OFF or 110°-220°F).
SETTING
Disables economy function. Will allow boiler to fire until hilimit temp is reached and re-fire with a 10° subtractive
differential.
Provides lowest level of fuel savings. Use this setting only if
the house does not stay warm at higher settings.
Recommended setting for single zone systems
Recommended setting for Two zone systems
Recommended setting for Three zone systems
Recommended setting for Four zone systems
Recommended setting for Five zone systems
Provides highest level of fuel savings
Setting the Economy Feature
The Economy Feature is factory set for a 1 zone heating system. To adjust, turn the ECONOMY Dial  until the number
displayed equals the number of heating zones. Do not
include indirect water heaters in the number of heating
zones. The Economy Feature conserves fuel by reducing boil-
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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.
NOTE:
• Smart DHW Priority: During a call from an indirect water heater, the control will de-energize the circulator contacts (C1/C2) to
heat only the indirect tank ensuring an adequate supply of domestic hot water. The control will re-energize the circulator when
the indirect tank is satisfied or if the boiler temperature reaches 170°F. If the indirect call continues for 45 minutes, the control
will override the priority function energizing the circulator to provide space heating.
HOW THERMAL TARGETING WORKS
Thermal Targeting technology analyzes thermostat activity and continually evaluates 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 boiler’s 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 boiler’s Target temperature – saving fuel – while continuing to provide comfort to the house.
RECORD YOUR SETTINGS
DATE INSTALLED
__________________
HIGH LIMIT SETTING
__________________
LOW LIMIT SETTING
__________________
ECONOMY SETTING
__________________
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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. The control monitors how quickly the boiler temperature is declining and activates the burner only when it determines that the latent heat is insufficient to satisfy the call. During
the purge cycle, the display will indicate Pur. This feature works with single-zone and multi-zone heating systems utilizing circulators or zone valves. No change in wiring is needed.
To activate Thermal Pre-Purge
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 1
3. Push the Test/Settings Button to turn Thermal Pre-Purge on or OFF
4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 6)
Degrees Fahrenheit or Celsius
The control has the ability to operate in degrees Fahrenheit or Celsius. When operating in Celsius, a
next to the temperature whenever the temperature is below 100 degrees.
Pro
c will appear in the display
To change between degrees Fahrenheit and degrees Celsius
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 2
3. Push the Test/Settings Button to c for Celsius or F for Fahrenheit
4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 6)
Manual Reset Low Water Cut-Off
The low water cut-off operation on the HydroStat can be set to operate in automatic (default) or manual reset mode. When in
manual reset mode, the control will shut-down the burner immediately when a low water condition is detected. If the low water
condition is sustained for 30 seconds, the low water light will blink, indicating that the control has locked out the burner. The
control can only be reset by pushing the Test Settings button on the top of the control. The manual reset feature meets CSD-1
code requirements.
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.
To activate Manual Reset LWCO mode
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 3
3. Push the Test/Settings Button to A for Automatic Reset Mode or b for Manual Reset Mode
4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 6)
To Test the Manual Reset Feature: Press and hold the Test/Settings button located on the top of
the control for 30 seconds to simulate a low water condition. After 30 seconds, the Low Water light
will blink indicating that the control is locked out. To reset the lock-out condition, press the
Test/Settings button momentarily.
MORE OPTIONAL FEATURES ON NEXT PAGE
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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. Turn the HI TEMP dial to select feature 4
3. Push the Test/Settings Button to select between the following options:
- Circulator on T/TV call only
- Circulator on I1/I2 call only
- Circulator on both T/TV & I1/I2 calls
4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 6)
Pro
Circulator Hold Off (Enhanced Condensing Protection)
To reduce the potential for condensing, on a call for heat the control will allow the boiler to heat to 125°F prior to energizing the
circulator. Once energized, the circulator will remain on for the duration of the heating call unless the boiler temperature drops
below 115°F. If this occurs, the circulator will re-energize when the boiler returns to 125°F. Circulator Hold Off will expire after 15
minutes.
To activate Circulator Hold Off
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 5
3. Push the Test/Settings Button to turn Circulator Hold Off on or OFF
4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 6)
Pro
Low Water Cut-Off Function
To turn off Low Water Cut-Off
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 8
3. Push the Test/Settings Button to turn Low Water Cut-Off on or OFF
4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 6)
Pro
High Limit Differential
When the Economy feature is on, the control’s Thermal Targeting feature actively sets varying differentials based on system
conditions. This option allows for selecting a 10, 20 or 30 degree fixed differential when the Economy feature is turned OFF.
These optional differential settings are subtractive from the HIGH LIMIT setting. Note: If the Economy feature is on, this setting
will be overridden by the control's Thermal Targeting function.
To change the high limit differential
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 9
3. Push the Test/Settings Button to select a high limit differential of 10, 20, or 30
4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 7)
9
Pro
Page 10
OPTIONAL FEATURES continued
RESTORING FACTORY DEFAULT SETTINGS ON NEXT PAGE
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 Pro
2. Turn the HI TEMP dial to select feature dEf
Dial
Setting
Feature
Options
1
Thermal Pre-Purge
2
OFF
on
Fahrenheit or Celsius
3
LWCO Manual or
Automatic Reset
4
Circulator Options
5
Circulator Hold Off
6
7
F
c
A
b
A
b
c
on
OFF
Description
Purge Inactive
Purge Active
Default
Setting
OFF
Degrees Fahrenheit
Degrees Celsius
F
Automatic Reset
Manual Reset
A
Circulator operation on TT call only
Circulator operation on ZC/ZR call only
Circulator operation on call from either
A
Circulator Hold Off – Active
Circulator Hold Off – Inactive
on
Low Water Cut-Off ON
Low Water Cut-Off OFF
on
10° Differential
20° Differential
30° Differential
10
Restore Defaults
Do Not Restore Defaults
n
Not available
on this control
Not available
on this control
8
Low Water Cut-Off
Function
9
High Limit
Differential
dEF
Restore Factory
Defaults
on
OFF
10
20
30
Y
n
NOTE: If the HydroStat is factory-equipped on a boiler, some options may be set differently from the default settings.
SEE PAGE 6 FOR ADDITIONAL SETTINGS
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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. 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 6.
NOTE: This LED illuminates regularly during normal boiler
operation.
Indicates that the Fuel Smart
HydroStat control is powered and that the temperature
function is active.
TEMP HI TEMP
Illuminates when the boiler water
temperature reaches the high limit setting. It will remain lit
until the water temperature falls 10°. The Fuel Smart
HydroStat prevents burner operation while this LED is on.
See Differential explanation on page 6.
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.
TEST/SETTINGS Button
To Test Low Water Cut-Off: Press and hold the Test/
Settings button for 5 seconds. The display will read LCO.
LWCO TEST
00
The red Low Water light should illuminate and the burner
circuit (B1 and B2) 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).
LWCO LOW WATER
Indicates that the boiler is in a
low water condition. The HydroStat control will prevent burner
operation during this condition. If the LOW WATER light is
blinking, the control has been programmed to provide lockout protection in the event a low water condition is detected
(see Manual Reset Low Water Cut-Off on page 8). Pressing
the TEST/SETTINGS button will reset the control.
To View Current Settings: Press and release the
Test/Settings Button in short intervals to sequentially display
the following settings:
IMPORTANT: The system must be checked by a qualified
heating professional prior to resuming operation.
HIGH LIMIT SETTING
00
WARNING: ALLOW THE BOILER TO FULLY COOL
BEFORE ADDING WATER.
LOW LIMIT SETTING
00
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 7 for more information).
ECONOMY SETTING
000
CURRENT TARGET TEMPERATURE
The display will return to boiler temperature (default) if
Test/Settings Button in not pressed for 5 seconds.
ECONOMY TARGET When the Economy feature is
active, the Fuel Smart HydroStat continually sets target
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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.
TROUBLESHOOTING
Burner Will Not Fire
See Flow Chart 1, page 13
Burner Will Not Shut Down
See Flow Chart 2, page 14
Temperature Display Exceeds
High Limit Setting
Under normal operation, boiler temperature will continue to rise after the control shuts off
the burner. This condition, known as “thermal stacking”, results from hot boiler surfaces
continuing to release heat into the boiler water.
No or Insufficient
Domestic Hot Water
For boilers equipped with a tankless coil, make sure the low limit setting on the HydroStat
is set properly. NOTE: If the low limit setting is dialed fully counter clockwise, it will shut off
the low temperature maintenance feature and will function as a cold start control. If
installed with an indirect water heater, verify that the end switch in the relay box controlling
the indirect water heater is connected to the I1-I2 terminals. This will ensure that the
domestic water calls are prioritized. (see “Heating and Indirect Water Heater” on page 6).
Low Water Light
(Red LED) is On
or Blinking
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.
When Installed on an Electro-Well™
When the LOW WATER light is on, this indicates that the control is not detecting water in
the boiler. When the LOW WATER light is blinking, this indicates that the control has been
programmed to provide low water lock-out protection and is currently locked out (see
Manual Reset Low Water Cut-Off on page 8). Pressing the TEST/SETTINGS button after
the low water condition is resolved will reset the lock-out condition.
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 is protruding enough to come in
contact with the inside of the well tube. Check that the well does not have excessive
build-up of heat transfer grease that may interfere with the clip contacting the well.
2. Remove well and examine for excessive residue build-up. Clean and re-install.
When Installed on a Standard Immersion Well
If either LWCO LED lights are illuminated and the control is installed on a standard
immersion well, this is a false reading caused by a loss of continuity between the sensor
and the inside of the well tube. It is recommended when the control is installed on a
standard immersion well, the LWCO Function be turned off (see page 9 for details).
Boiler Will Not Maintain
Low Limit Temperature
Check for overlapping high temperature setting. If the high limit setting is set below the
low limit setting, the control will default to the high limit setting and the corresponding
high limit differential setting.
House Will Not Get
or Stay Warm
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, in some cases, prevent the house
from coming up to temperature. Move to a lower setting (see “Setting the Economy
Feature” on page 6).
Circulator Contacts
C1 and C2 Not Energized
on Call for Heat
If the Circulator Hold Off is active (see page 9), check to see that boiler water is at or
above 125°F. On a call for heat, the control will not permit the circulator to operate if the
boiler water temperature is below 125°F.
If the LED lights and the temp display are blinking alternately, this indicates the control
has sensed a boiler temperature of 250°F. When this occurs, the control pulses the burner relay and then shuts down and locks out the burner until the temperature falls below
All LED Lights and Temp Display 210°F. The system should be analyzed to determine the cause of the overheating condition. Check that the sensor is inserted all the way into the well so it can accurately sense
are Blinking
the temperature of the boiler water. Check system wiring and operation as well as the
control’s high limit setting. If the cause of the overheating condition cannot be determined, the control should be replaced.
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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.
NO
Is the
Green LED
(TEMP ACTIVE)
On?
The Temp Active LED will be on at all times when the control is
powered.
Check for 120 VAC on terminals L1 and L2.
YES
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.
Check that the system is filled with water.
Check that the sensor is inserted fully into the well and contact
between its spring clip and the copper well tube is made.
Check that the control is tightly clamped to the well.
Also see page 12 for additional troubleshooting information.
NO
Is the
Yellow LED
(HI TEMP)
On?
YES
The Control is
Sensing High
Temperature.
The burner will not fire until the boiler water has dropped to the
high limit differential set-point (10° below high limit setting).
Check that the high temperature setting is correct.
NO
Is the
Yellow LED
(TARGET)
On?
YES
The Boiler has
Reached the
Target
Temperature.
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 7). The burner will not fire until the boiler temperature
drops to the automatically calculated Target Temp Differential.
NO
Is the
Thermostat
(T/TV) Calling
for Heat?
NO
YES
Is There
24 VAC
Between B1
and B2?
Is the
Indirect
(I1-I2) Calling
for Heat?
NO
Is the
Low Limit Dial
Set to OFF?
YES
YES
The Control
is Operating
Properly.
NO
HydroStat is supplying 24 VAC to the burner circuit.
Recheck wiring and operation of burner and other limit controls.
NO
Replace
Control
YES
When the low temperature
setting is set to OFF, the
HydroStat will act as a cold
start control. The burner
will not fire unless there is
a call from the thermostat
(T/TV) or an external zone
(I1/I2).
Set thermostat to call
for heat. Burner should
fire.
If the boiler has a tankless coil, set the Low
Temperature Limit to
maintain temperature.
If both the red and yellow LEDs are off and
there is a call to fire the burner, there will be 24
VAC on terminals B1 and B2.
If 24 VAC is not present, the control should
be replaced.
13
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!
CAUTION – ALWAYS ALLOW A BOILER TO FULLY COOL
BEFORE ADDING WATER.
NO
Is either
Yellow LED
On?
YES
The Control has
Reached Target
or High Limit
Temperature.
YES
The Control is
Operating
Normally.
Recheck wiring. Make sure that burner is wired to
B1. Burner should never fire when red or yellow
LED is lit.
NO
Is the
Thermostat
(T/TV) Calling
for Heat?
NO
Is the
Indirect
(I1/I2) Calling
for Heat?
The burner will continue to fire when there is a call
from the thermostat or external zone.
YES
The Control is
Operating
Normally.
NO
Check temperature display. When the Low Limit is
set, the HydroStat will fire the burner until the
temperature reaches the Low Limit Setting.
NO
Is the
Low Limit Dial
Set to OFF?
YES
Is there
24 VAC between
B1 and B2?
NO
When there is no call to fire the burner, the voltage
should be 0 volts between B1 and B2.
Recheck
Wiring.
Make sure the burner is wired to B1.
YES
Replace
Control.
If there is no call for heat (from T/TV, I1/I2 or Low
Limit), there should be 0 VAC between B1-B2.
If there is voltage between B1-B2, the control
should be replaced.
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Page 15
ELECTRO-WELLS
Fuel Smart HydroStat
installed with Electro-Well™
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. The Electro-Well is available separately
for field installations.
1/2" CLEARANCE
1/2" CLEARANCE
1/2" CLEARANCE
Electro-Well™ Models
15
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.
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.
Description
48-140
Model OS-100 Outdoor Sensor Kit
DIMENSIONS
SPECIFICATIONS
FUEL SMART HYDROSTAT MODEL 3200-Plus
Input voltage
Burner contacts
Circulator contacts
Operating range – low limit
Operating range – high limit
Operating range – differentials
Thermostat heat anticipator setting
120 VAC, 60 HZ
30 VA @ 24 VAC
5.8 FLA, 34.8 LRA@120 VAC
Off or 110°F (43°C) - 200°F (93°C)
100°F (38°C) - 220°F (104°C)
Automatic
0.2A
LIMITED MANUFACTURER’S 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.
126 Bailey Road, North Haven, CT 06473 • Phone (203) 776-0473 • FAX (203) 764-1711 • www.hydrolevel.com
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3200P-0416
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