Hydro-Smart 115 User manual

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‐Donotstoreorusegasolineorother
flammablevaporsandliquidsinthevicinityof
thisoranyotherappliance.
‐WHATTODOIFYOUSMELLGAS
Donottrytolightanyappliance.
Donottouchanyelectricswitch,donot
useanyphoneinyourbuilding.
Immediatelycallyourgassupplierfroma
neighbor'sphone.Followthegas
supplier'sinstructions.
Ifyoucannotreachyourgassupplier,call
thefiredepartment.
‐Installationandservicemustbeperformed
byaqualifiedinstaller,serviceagencyorthe
gassupplier.
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Hydro‐Smart115
“MicroBoiler”forRadiantHeating
InstallationManualandOwner’sGuide
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H
y
dro‐Smart115
Ifyouhaveanyquestions,please
callorwriteto:
Hydro‐SmartInc.
10725165thAveNW,
Elk River, MN 55330
WARNING
Iftheinformationinthese
instructionsisnotfollowed
exactly,afireorexplosion
mayresultcausing
propertydamage,personalinjuryordeath.
PleasemakesurethepropergaspressureguidelinesandrecommendationfromHydro‐
Smartfailuretodosocancauseafireorexplosionandmayresult,causingproperty
damage,personalinjury,ordeath.
ANSI Z21.10.3 andCSA4.3

Contents
2│Page
CONTENTS
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SPECIFICATIONS…………………………………………………………………………………………..………………………...
INTRODUCTION…………………………………………………………………………………………………..………………….
SAFETYGUIDELINES…………….………………………………………………………………………………………..………..
INSTALLATION………………………………………………………………………………………………..…………………..….
General………………………………………………………………………………………………………………………..…..…
Clearances…………………………………………………………………………………………………………………………..
IncludedAccessories…………….………………………………………………………………………………………..…..
OptionalItems…………………………………………………………………………………………………………………….
WarningforInstallations…………………………………………………………………………………………………….
High‐AltitudeInstallations…………………………………………………………………………………………………..
VentingInstructions…………………………………………………………………………………………………………...
GasSupplyandGasPipeSizing………........................................................................................
WaterConnections……………..………………………………………………………………………………………………
ElectricalConnections……………………………………………………………………..…………………………….......
RemoteControllerConnections……..……………………………………………………………………….………..…
APPLICATIONS...………………………………………………………………………………………………………………..……
INITIALOPERATION..………………………………………………………………………………………………………….……
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OPERATINGSAFETY…………………………………………………………………………………………………………………
NORMALOPERATION…………………………………………………………………………………………………………..…
General………..……….………….…………………………………………………………………………………………………
Operation……………………………………………………………………………………………………………………….....
TemperatureSettings.…….……..……………………………………………………………………………………………
Flow…………………………………………………………………………………………………………………………………….
FreezeProtectionSystem…….…………………………………………………………………………………………..…
MaintenanceandService………………………………………………………………………………………………….…
UnitDraining…………………………………………….…………………………………………………………………………
TROUBLESHOOTING……..……………………………………………………………………………………………………..…
General………..……….………….…………………………………………………………………………………………………
ErrorCodes.…………………….…..………………………………………………………………………………………………
COMPONENTSDIAGRAM……………………………………………………………………………………………………..…
PARTSLIST………………….………………………………………………………………………………………………..…………
OUTPUTTEMPERATURECHART…………………………………………………………………………………………...…
LIMITEDWARRANTY…………………………………………………………....…………………………………………….….
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InstallationManual
Owner’sGuide

Specifications
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SPECIFICATIONS
ModelHydro‐Smart115
NaturalGasInput
(OperatingRange)
Min:19,500Btu/h
Max:140,000Btu/h
PropaneInput
(OperatingRange)
Min:19,500Btu/h
Max:140,000Btu/h
GasConnection¾”NPT
WaterConnections¾”NPT
WaterPressure15‐150psi*
NaturalGas
InletPressure
Min.5.0”WC
Max.10.5”WC
Propane
InletPressure
Min.8.0”WC
Max.14.0”WC
Manifold
Pressure**
Natural2.0”WC
Propane2.5”WC
Weight33lbs.
DimensionsH20.5”xW13.8”xD6.7”
IgnitionElectricIgnition
Electric
Supply120VAC/60Hz
Consumption
Operation73.1W/0.61A
Standby6.2W/0.05A
Freeze‐
Protection111W/0.93A
*40psioraboveisrecommendedformaximumflow.
**TheManifoldPressureisthefactorysettingandgenerallyshouldnotneedadjustment.
NOTE:
Checktheratingplatetoensurethisproductmatchesyourspecifications.
InaccordancewithANSIZ21.10.3,COemissiondoesnotexceed400PPMfor
normalinput.
Hydro‐Smartreservestherighttodiscontinue,orchangeatanytime,
specificationsordesignswithoutnoticeandwithoutincurringobligations.
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Introduction
4│Page
INTRODUCTION
Thismanualprovidesinformationnecessaryfortheinstallation,operation,and
maintenanceofthewaterheater.
Themodeldescriptionislistedontheratingplatewhichisattachedtothefrontpanel
ofthewaterheater.
Pleasereadallinstallationinstructionscompletelybeforeinstallingthisproduct.
Ifyouhaveanyproblemsorquestionsregardingthisequipment,consultwithHydro‐
Smart.
Hydro‐Smart115isawaterheaterdesignedtobeusedwithradiantheatingina
combinationHydroPanel.
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1. Ahotwatertapisturnedon.
2. Waterenterstheheater.
3. Thewaterflowsensordetectsthewaterflow.
4. Thecomputerinitiatesthefanmotorandsendsasignaltotheignitertocreateanignition
spark.
5. Thegasignitesandflamesappearwithintheburnerchamber.
6. Watercirculatesthroughtheheatexchangerandthengetshot.
7. Usingthermistorstomeasuretemperaturesthroughoutthewaterheater,thecomputer
modulatesthegasandwatervalvestoensureproperoutputwatertemperature.
8. Whentheta
p
isturnedoff
,
theunitshutsdown.
Theprinciplebehindtanklesswaterheatersissimple:
Pleasereadallinstallationinstructionscompletelybeforeinstallingthisproduct.
ThisproductisonlytobeusedwithHydro‐SmartHeatingPanels,“Integrator”.
*Thisdiagram
illustratestankless
waterheaterdesign
conceptsonlyand
doesnotaccurately
representtothewater
heater’sphysical
description.
Watersupply
Heatingpanel“Integrator” Strainer
Gasvalve
Thermistor
Burner
Hydro‐Smart115
GAS
Airvent
Expansiontank
Flowsensor
Watercontrolvalve
Pumpcontroller
Primarypump
Secondarypump
Radiantheating
Checkvalve

SafetyGuidelines
5│Page
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Watertemperaturesover125°F (52
°
C) cancausesevereburnsinstantlyordeath
fromscalding.Thewatertemperatureissetat122°F(50°C)fromthefactoryto
minimizeanyscaldingrisk.Beforebathingorshoweringalwayscheckthewater
temperature.
Donotstoreorusegasolineorotherflammables,vapors,orliquidsinthevicinity
ofthisappliance.
Donotreversethewaterand/orgasconnectionsasthiswilldamagethegas
valvesandcancausesevereinjuryordeath.Followthediagramonp.20when
installingyourwaterheater.
Donotusethisapplianceifanyparthasbeenincontactwithorbeenimmersed
inwater.Immediatelycallalicensedplumber,alicensedgasfitter,ora
professionalservicetechniciantoinspectand/orservicetheunitifnecessary.
Donotdisconnecttheelectricalsupplyiftheambienttemperaturewilldrop
belowfreezing.TheFreezePreventionSystemonlyworksiftheunithaselectrical
power.Thewarrantywillnotbecoverediftheheatexchangerisdamageddueto
freezing.RefertothesectionontheFreezePreventionSystemonp.30formore
information.
SAFETYGUIDELINES
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SAFETYDEFINITIONS
Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,willresultin
deathorseriousinjury.
Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,couldresult
indeathorseriousinjury.
Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,couldresult
inminorormoderateinjury.
GENERAL
1. Followalllocalcodes,orintheabsenceoflocalcodes,followthemostrecenteditionofthe
NationalFuelGasCode:ANSIZ223.1/NFPA54intheUSAorCAN/CSAB149.1NaturalGas,Propane
InstallationCodeinCanada.
2. Properlygroundtheunitinaccordancewithalllocalcodesorintheabsenceoflocalcodes,with
theNationalElectricalCodes:ANSI/NFPA70intheUSAorCSAstandardC22.1CanadaElectrical
CodePart1inCanada.
3. Carefullyplanwhereyouintendtoinstallthewaterheater.Pleaseensure:
Yourwaterheaterwillhaveenoughcombustibleairandproperventilation.
Locateyourheaterwherewaterleakagewillnotdamagesurroundingareas(pleaserefer
top.7).
4. ChecktheratingplateforthecorrectGASTYPE,GASPRESSURE,WATERPRESSUREandELECTRIC
RATING.
*Ifthisunitdoesnotmatchyourrequirements,donotinstallandconsultwithHydro‐Smart.
5. Ifanyproblemshouldoccur,turnoffallhotwatertapsandturnoffthegas.Thencallatrained
technicianortheGasCompanyorHydro‐Smart.
WARNING
CAUTION
DANGER
WARNING

Installation
6│Page
INSTALLATION
GENERAL
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1. Followalllocalcodes,orintheabsenceoflocalcodes,followthemostrecenteditionofthe
NationalFuelGasCode:ANSIZ223.1/NFPA54intheUSAorCAN/CSAB149.1NaturalGas,
PropaneInstallationCodeinCanada.
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2. Allgaswaterheatersrequirecarefulandcorrectinstallationtoensuresafeandefficient
operation.Thismanualmustbefollowedexactly.Readthe“SafetyGuidelines”section.

3. Themanifoldgaspressureispresetatthefactory.Itiscomputercontrolledandshouldnot
needadjustment.

4. Maintainproperspaceforservicing.Installtheunitsothatitcanbeconnectedorremoved
easily.RefertotheClearancesSectiononp.8forproperclearances.
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5. Thewaterheatermustbeinstalledinalocationwheretheproperamountofcombustibleair
willbeavailabletoitatalltimeswithoutobstructions.
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6. Theelectricalconnectionrequiresameansofdisconnection,toterminatepowertothewater
heaterforservicingandsafetypurposes.
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7. Donotinstalltheunitwheretheexhaustventispointingintoanyopeninginabuildingorwhere
thenoisemaydisturbyourneighbors.Makesuretheventterminationmeetstherequired
distancebylocalcodefromanydoorwayoropeningtopreventexhaustfromenteringabuilding
(refertop.15).
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8. Particlesfromflour,aerosols,andothercontaminantsmayclogtheairventorreducethe
functionsoftherotatingfanandcauseimproperburningofthegas.Regularlyensurethatthe
areaaroundtheunitisdust‐ordebris‐free;regularmaintenanceisrecommendedforthese
typesofenvironment.
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9. Ifyouwillbeinstallingthewaterheaterinacontaminatedareawithahighlevelofdust,sand,
flour,aerosolsorothercontaminants/chemicals,theycanbecomeairborneandenterandbuild
upwithinthefanandburnercausingdamagetothewaterheater.
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10. FortheHydro‐Smart115:
Theseunitsmaybeconvertedtoadirect‐vent(sealedcombustion)appliancebyinstallinga
direct‐ventconversionkitPartNo.9007667005(TK‐TV10)whichwillbringinallrequired
combustibleairfromoutsidethebuilding.Wheninstallingthedirect‐ventconversionkit,
pleasefollowallinstructionsincludedwiththekit.
Ifthewaterheaterisusedasadirect‐ventappliance,theunitrequiresa3”combustibleair
supplypipe.Theintakepipemustbesealedairtight.AirsupplypipecanbemadeofABS,
PVC,galvanizedsteel,corrugatedaluminum,corrugatedstainlesssteelorCategoryIII
stainlesssteel.
Terminatingtheventingthroughasidewallisrecommendedforthedirect‐ventsystem.
Runningtheexhaustventandtheintakepipeparallelisrecommended.
Terminatingtheexhaustandintakeonthesamewall/surfaceisrecommended.
Terminatinginthesamepressurezoneallowsforpressurebalancing,whichprevents
nuisanceshutdowns.


Installation
7│Page
Installationandservicemustbeperformedbyaqualifiedinstaller(for
example,alicensedplumberorgasfitter),otherwisethewarrantybyHydro‐
Smartwillbevoid.
Theinstaller(licensedprofessional)isresponsibleforthecorrectinstallation
ofthewaterheaterandforcompliancewithallnational,state/provincial,
andlocalcodes.
Hydro‐Smartdoesnotrecommendinstallingthewaterheaterinapitor
locationwheregasandwatercanaccumulate.
Donothavetheventterminalpointingtowardanyoperatingwindow,door,or
openingintoabuilding.
Donotinstallnexttoanysourceofairbornedebris,suchasaclothesdryer,
thatcancausedebristobetrappedinsidethecombustionchamber,unless
thesystemisdirect‐vented.
Hydro‐Smartdoesnotrecommendinstallingthewaterheaterinanatticdue
tosafetyissues.Ifyouinstallthewaterheaterinanattic:
Makesuretheunitwillhaveenoughcombustionairandproperventilation.
Keeptheareaaroundthewaterheaterclean.Whendustcollectsonthe
flamesensor,thewaterheaterwillshutdownonanerrorcode.
Iftheaboveconditionscannotbemet,usethedirectventconversionkit
PartNo.9007667005(TK‐TV10).
Placetheunitforeasyaccessforserviceandmaintenance.
Adrainpan,orothermeansofprotectionagainstwaterdamage,is
re
q
uiredtobeinstalledunderthewaterheaterincaseofleaks.
Thewarrantywillnotcoverdamagecausedbywaterquality.
Onlypotablewaterorpotablewater/glycolmixturescanbeusedwiththis
waterheater.Donotintroducepoolorspawater,oranychemically
treatedwaterintothewaterheater.
Waterhardnesslevelsmustnotexceed7grainspergallon(120ppm)for
singlefamilydomesticapplicationsormorethan4grainspergallon(70
ppm)forallothertypesofapplications.Waterhardnessleadstoscale
formationandmayaffect/damagethewaterheater.Hardwaterscaling
mustbeavoidedorcontrolledbyproperwatertreatment.
WaterpHlevelsmustbebetween6.5and8.5
Wellwatermustbetreated.
Donotinstalltheunitwherewater,debris,orflammablevaporsmaygetinto
theflueterminal.
Hydro‐Smartrecommendsusingthedirectventkitwhenthewaterheateris
installedinabeautysalon.Somechemicalsusedinabeautysalonmayaffect
theflamesensor.Waterheatermaynotworkproperly.
Althoughthewaterheaterisdesignedtooperatewithminimalsound,Hydro‐
Smartdoesnotrecommendinstallingtheunitonawalladjacenttoa
bedroom,oraroomthatisintendedforquietstudyormeditation,etc.
Locateyourheaterclosetoadrainwherewaterleakagewillnotdodamageto
surroundingareas.Aswithanywaterheatingappliance,thepotentialfor
leakageatsometimeinthelifeoftheproductdoesexist.Hydro‐Smartwill
notberesponsibleforanywaterdamagethatmayoccur.Ifyouinstalladrain
panundertheunit,ensurethatitwillnotrestrictthecombustionairflow.




CAUTION
WARNING

Installation
8│Page


CLEARANCES













ModelTopBottomFrontBackSides
Hydro‐Smart115*12”12”24”1”2“
*Standardindoorinstallationsanddirect‐ventindoorinstallationshavethesameclearances.





INCLUDEDACCESSORIES

Checkthattheseitemsbelowareincludedwiththewaterheater.

1.InstallationManualand
Owner’sGuide

2. ProductRegistrationCard 3.Remotecontroller
900766605(TK‐RE02)





OPTIONALITEMS
ModelHydro‐Smart115
9007678005(TK‐BF01) ✔
9007667005(TK‐TV10) ✔
9007671005(TK‐PCJr2) ✔
9007608005(TK‐KPWL4)
9007609005(TK‐KPWH4) ✔
9007680005(TK‐KPCT43) ✔


Bottom
Side
Top
Side
Front
Back
Maintainallclearancesaround
thewaterheater.
Qty:1Qty:1Qty:1

Installation
9│Page


1.BackflowPreventer:9007678005(TK‐BF01)
TheBackflowpreventerprevents
thebackflowofairthroughthe
exhaustvent.Thishelpsprevent
harmfulexhaustgasesfrom
enteringthehome,aswellas
helpingtopreventtheunitfrom
freezinginareaswherecoldaircanbeblown
ordrawnintotheexhaustsystem.Installthis
ventdamperinaccordancewiththe
installationinstructionsandanyapplicable
codes.
2.Direct‐VentConversionKit:9007667005
(TK‐TV10)
Thiskitcanbeusedto
convertthewater
heaterfromastandard
ventsystemtoa
direct‐vent(orsealed
combustion)system.
Installthisconversionkitinaccordancewith
theinstallationinstructionsandanyapplicable
codes.
3.PipeCovers:9007671005(TK‐PCJr2)
Thepipecoverprotectstheplumbingpipestothewaterheaterfromunexpected
adjustments.Thispipecoverisfixedtothebottomofthewaterheater,whichhides
theplumbingandimprovesthevisualaspectsofthewholeinstallationforthewater
heater.
4.T‐VentWallThimblewithTermination:9007608005(TK‐KPWL4)and9007609005(TK‐KPWH4)

Theseterminationsareusedwhenventingoutthroughthewall
andarecompatiblewiththeT‐Ventpipesystem.
Theseterminationsarespecialstainlesssteelventsforgas
appliancesandareULlistedasCategoryII,IIIandIV.Thereare
twotypesofterminations:theLouverterminationandtheHood
termination.Fordifferentwallthicknesses,therearetworanges
oflengthsavailable(refertotheventingbrochurefordetails).
Installtheseventterminationsinaccordancewiththeir
installationinstructionsandanyapplicablelocalcodes.

5.Direct‐VentConcentricTermination:9007680005(TK‐KPCT43)

Usedwhenterminatingdirect‐vent(sealed‐combustion)systems,
withdirect‐ventmodelsthatrequirea3”intakeanda4”exhaust.
Thisconcentricterminationprovidestheconvenienceofonly
havingtomakeonepenetrationthroughasidewallinsteadoftwo
separatepenetrationsfortheintakeandexhaustpiping.The
terminationincludesabirdscreen,restrictingsmallanimals,
pests,andforeignobjectsfromenteringintotheventsystem.
Thissidewallterminationisavailableinthreedifferentsizes,to
coverallrangesofwallthicknesses.
Direct‐ventConcentricTermination
Part#Coveringwallthickness
9007680005(TK‐KPCT43‐1)3.9”–7.1”
9007772005(TK‐KPCT43‐2)6.9”–10.1”
9007773005(TK‐KPCT43‐3)9.8”–13.0”
Louver
Termination
9007608005
(TK‐KPWL4)
Hood
Termination
9007609005
(TK‐KPWH4)

Installation
10│Page

WARNINGFORINSTALLATIONS
FORYOURSAFETY,READBEFOREINSTALLATION:
DonotinstalltheHydro‐Smart115wherewater,
debrisorflammablevaporsmaygetintotheflue
terminal.ThismaycausedamagetotheHydro‐
Smart115andvoidthewarranty.


Donotinstallnexttoadryeroranysourceof
airbornedebristhatcanbetrappedinsidethe
combustionchamber,unlessthesystemisdirect
vented.
Hydro‐Smart115isprohibitedandnot
recommendstobeinstalledinanatticdueto
safetyissues.


FORYOURSAFETY,READBEFOREINSTALLATION:
Prohibited
Prohibited