MODEL 3200
Temp Limit / LWCO Control with Thermal Targeting
™
for Water Boilers
120 VAC Input / 24 VAC Burner Circuit
PATENT PENDING
INSTALLATION INSTRUCTIONS and OPERATING MANUAL
• Saves Fuel – Features Thermal Targeting™ technology and
Thermal Pre-Purge capability
• Universal Design – Replaces common cold-start and triple-action
Aquastats*
• Easy to Install – Industry standard wiring, dial-type settings, no external sensors
• Operating Indicators – LEDs, Dynamic Display and Test Button provide continual and on-demand status checks
• Prioritizes Hot Water – Gives priority to low limit setting or to calls from indirect water heater
•
*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
Utilizes Thermal Targeting™ technology to conserve fuel by monitoring heating demand and establishing target boiler temperatures below the high limit setting (see page 4 for details).
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.
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.
See Electro-Well models on page 8.
NOTE: When installed on a standard immersion well, the “LWCO Active”
LED will not illuminate.
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.
N OT 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.
BACK OF
FUEL SMART HYDROSTAT BOX
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)
FIG. 1 FIG. 2 FIG. 3
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 are available separately for mounting the Fuel Smart HydroStat control box in a remote location.
Each kit includes mounting hardware and a remote sensor. See page 8 for kit options.
2
WIRING
WARNING
Electrical shock hazard.
To prevent electrical shock, death or equipment damage, disconnect power supply before installing or servicing this control.
STEP 1
Connect 120 VAC Hot to terminal L1.
Connect 120 VAC Neutral to terminal L2.
Disconnect means and overload protection as required (provided by others).
STEP 2
Connect the burner circuit to B1-B2. (B2 is neutral.)
STEP 3
Connect the circulator to C1-C2. (C2 is neutral.)
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 6 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.
STEP 4
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.
NOTE: Once a vent damper plug is connected to the HydroStat, the control is permanently altered and will no longer function when the vent damper plug is disconnected.
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 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 the turned OFF to insure that the boiler supplies adequate temperature to heat the indirect tank (see page 4).
3
SETTING THE CONTROL
NOTE: Settings can be checked using the TEST/SETTINGS
Button. See page 5 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)
Dynamic
Display
Water Temperature and Real Time
Verification of
Setting Adjustments.
Diagnostic LEDs and Test Button
Jumper
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°-200°F).
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 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, the
Economy
Feature should be
SETTING
Disables economy function. Will allow boiler to fire until hilimit temp is reached and re-fire with a 10° subtractive turned OFF to insure the boiler supplies adequate temperature to heat the indirect tank.
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
Low Temperature
Limit Setting
(OFF or 110°-200°F)
Factory OFF
Economy Dial
(OFF or LO, 1, 2, 3,
4, 5, HI)
Indicator Light
(announces heat call)
High Temperature
Limit Setting
(100°-220°F)
Factory 190°F
Differentials are automatic and will vary based on control settings and boiler temperature.
Activating Thermal Pre-Purge (optional)
NOTE: Activation of this feature is not recommended for boilers with tankless coils.
Fuel Smart HydroStat has a Thermal Pre-Purge feature to maximize efficiency. When activated, 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 display will indicate Pur.
If the heat is not sufficient to satisfy the thermostat, the control will energize the burner. This feature works with single- and multi-zone heating systems utilizing circulators or zone valves. No change in wiring is needed.
To Activate Thermal Pre-Purge
Push and hold the TEST/SETTINGS button for 20 seconds.
The display will read Pur On.
To deactivate the feature, push and hold the button a second time for 20 seconds. The display will read Pur OFF.
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
.
4
LED LEGEND and TEST/SETTINGS BUTTON
TEMP ACTIVE
Indicates that the
Fuel Smart HydroStat control is powered and that the temperature function is active.
TEMP HIGH TEMP
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 4). 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.
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.
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 4 for more information).
ECONOMY TARGET
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 to the differential set point (see Target Temp Differential on page 4) at which point the boiler will be allowed to fire again. NOTE: This LED illuminates regularly during normal boiler operation.
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).
To View Current Settings: Press and release the
Test/Settings Button in short intervals to sequentially display the following settings:
HIGH LIMIT SETTING
00
LOW LIMIT SETTING
00
ECONOMY SETTING
000
CURRENT TARGET TEMPERATURE
PRE-PURGE SETTING
000
The display will return to boiler temperature (default) if
Test/Settings Button in not pressed for 5 seconds.
5
TROUBLESHOOTING
Burner Will Not Fire
Burner Will Not Shut Down
Temperature Display Exceeds
High Limit Setting
No or Insufficient
Domestic Hot Water
Boiler Will Not Maintain
Low Limit Temperature
House Will Not Get or Stay Warm
All LED Lights and Temp
Display are Blinking
See Flow Chart 1, page 7
See Flow Chart 2, page 8
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.
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, insure that the end switch in the relay box controlling the indirect water heater is connected to the I1-I2 terminals. This will insure that the domestic water calls are prioritized. (see “Heating-With Indirect Water Heater” on page 3).
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.
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 4).
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
210°F. The system should be analyzed to determine the cause of the overheating condition. Check system wiring and operation as well as the controlʼs high limit setting. If the cause of the overheating condition cannot be determined, the control should be replaced.
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.
During a call from the indirect, the economy feature will be disabled allowing the boiler run to the high limit setting. That operation is not subject to override after 45 minutes.
6
Troubleshooting Flow Chart 1 – Burner Will Not Fire
Is the
Green LED
(TEMP ACTIVE)
On?
NO
The Control is
Not Powered.
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
Is the
Red LED
(LOW WATER)
On?
YES
NO
The Control is
Sensing
Low Water.
CAUTION – ALWAYS ALLOW A BOILER TO COOL BEFORE ADDING WATER
The burner will not fire until the low water condition is satisfied.
Check that the system is filled with water.
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.
Check that the control is tightly clamped to the well.
Is the
Yellow LED
(HI TEMP)
On?
NO
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.
Is the
Yellow LED
(TARGET)
On?
NO
YES
Is the
Thermostat
(T-T) Calling for Heat?
YES
Is There
24 VAC
Between B1 and B2?
NO
NO
YES
The Boiler has
Reached the
Target
Temperature.
Is the
Domestic Water
(I1-I2) Calling for
Heat?
NO
YES
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 4). The burner will not fire until the boiler temperature drops to the Target Temp Differential (see “Differentials” on page 4).
Is the
Low Limit Dial
Set to OFF?
NO
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-T) or the indirect water heater (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.
The Control is Operating
Properly.
HydroStat is supplying 24 VAC to the burner circuit.
Recheck wiring and operation of burner and other limit controls.
Replace
Control
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.
7 0
Troubleshooting Flow Chart 2 – Burner Will Not Shut Down
Is the
Red LED
(LOW WATER)
On?
YES
NO
The Control is
Sensing
Low Water.
Is either
Yellow LED
On?
YES
The Control has
Reached Target or High Limit
Temperature.
NO
Is the
Thermostat
(T-T) Calling for Heat?
YES
NO
The Control is
Operating
Normally.
Is the
Domestic Water
(I1-I2) Calling for
Heat?
YES
NO
The Control is
Operating
Normally.
WARNING!
TURN OFF POWER TO BURNER IMMEDIATELY!
CAUTION – ALWAYS ALLOW A BOILER TO FULLY COOL
BEFORE ADDING WATER.
Recheck wiring. Make sure that burner is wired to
B1. Burner should never fire when red or yellow
LED is lit.
The burner will continue to fire when there is a call from the thermostat or external zone.
Is the
Low Limit Dial
Set to OFF?
NO
Check temperature display. When the Low Limit is set, the HydroStat will fire the burner until the temperature reaches the Low Limit Setting.
YES
Is there
24 VAC between
B1 and B2?
NO
YES
Recheck
Wiring.
Replace
Control.
When there is no call to fire the burner, the voltage should be 0 volts between B1 and B2.
Make sure the burner is wired to B1.
If there is no call for heat (from T-T, 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.
8
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.
REMOTE MOUNTING KITS
Part No.
Description
48-101 HydroStat Remote Mount Kit with 24" sensor
48-102 HydroStat Remote Mount Kit with 48" sensor
ELECTRO-WELLS
Part No.
Description
48-103 HydroStat Remote Mount Kit with 10' sensor
48-104 HydroStat Remote Mount Kit with 20' sensor
DIMENSIONS
SPECIFICATIONS
FUEL SMART HYDROSTAT MODEL 3200
Input voltage
Burner contacts
Circulator contacts
Operating range – low limit
120 VAC, 60 HZ
30 VA@24 VAC
5.8 FLA, 34.8 LRA@120 VAC
Off or 110°F - 200°F
Operating range – high limit 100°F - 220°F
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
9
3200-0513
