Hydro Smart 115 PLUS User manual

Hydro Smart 115 PLUS Gas Micro Boiler
Installation Manual and Owner’s Guide
If the information in these instructions is not
followed exactly, a re or explosion may result
causing property damage, personal injury or
death.
-Do not store or use gasoline or other ammable
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
re department.
-Installation and service must be performed by
a qualied installer, service agency or the gas
supplier.
If you have any questions,
please call or write to:
10725 165th Ave. NW
Elk River, MN 55331
Featuring
• Flow Activated: .75 GPM
• Wall Hung
• Copper Heat Exchanger
• Temperature Range: 99°-140° F
• Freeze Protection
• Power Vent
• CAT III Stainless Steel Venting
• Built in Boiler Remote
• Includes LP Conversion Kit
The Hydro Smart 115 PLUS Gas
Micro Boiler is a compact and powerful
residential unit with a versatile BTU
modulating range.
Do not return to stores. Damages or
repairs call Hydro Smart 763-331-3066
M-F 8 AM - 5 PM Sat 8 AM - Noon
NG/LP
Boiler is set up for
NG, includes LP
Conversion Kit

2
CONTENTS
Installation Manual/Owners Guide
SPECIFICATIONS..............................................................................................4
INTRODUCTION................................................................................................5
SAFETY GUIDELINES.......................................................................................6
INSTALLATION (GENERAL)..............................................................................7
CLEARANCES...................................................................................................9
HIGH ALTITUDE INSTALLATIONS...................................................................10
VENTING INSTRUCTIONS (GENERAL)..........................................................11
GAS SUPPLY & PIPE SIZE..............................................................................13
PRESSURE RELIEF VALVE/ELECTRICAL CONNECTIONS..........................15
APPLICATIONS................................................................................................16
INITIAL OPERATION........................................................................................18
OPERATING SAFETY.......................................................................................19
NORMAL OPERATION.....................................................................................21
TEMPERATURE SETTINGS............................................................................22
FLOW/FREEZE PROTECTION........................................................................24
MAINTENANCE AND SERVICE.......................................................................25
ADDITIONAL FEATURES.................................................................................26
VENTING AND CLEARANCES........................................................................27
ERROR CODES...............................................................................................37
TROUBLESHOOTING.....................................................................................40
COMPONENTS DIAGRAM..............................................................................42
PARTS LIST......................................................................................................46
OUTPUT TEMPERATURE CHART..................................................................48
NOTES.............................................................................................................49

3
Installation Manual
& Owners Guide
CONGRATULATIONS
Congratulations and thank you for choosing our micro boiler. Before use, we
recommend that you read through this installation manual carefully. Keep
this manual for future reference.
If you need an additional manual, contact the manufacturer or your local
distributor. When you call, please tell us the product name and the serial
number of your unit written on the rating plate of the boiler.

4
SPECIFICATIONS
*18-25 PSI is recommended for maximum ow (Space Heating)
**The Manifold Pressure is the factory setting and generally should not need adjustment.
NOTE:
• Check the rating plate to ensure this product matches your specications.
• The manufacture reserves the right to discontinue, or change at any time, specications, or
designs without notice and without incurring obligation.
*When using boiler in-conjunction with Hydro Smart Combi panel, system pressure may be much higher on your domestic
water side. Your space heating side should still reect the recommended 18-25 PSI for system pressure.
Model HS115 PLUS
BTU/h
Natural Gas Input
(Operang Range)
Min.: 15,000
Max.: 140,000
Gas Connecon 3/4" NPT
Supply/Return Connecons 3/4" NPT
Water Pressure* psi
(Mpa) 18-25 PSI (For Radiant Only Systems), Up to 150 with DHW
" W.C.
Natural gas
Inlet Pressure (kPa)
Min. 4.0 (1.00)
Max. 10.5 (2.61)
Weight lbs. (kg) 37.5 (17.0)
Dimensions H20.5 x W13.8 x D9.1 (Inch)
H520 x W351 x D231 (mm)
Ignion Electric Ignion
Electric
Supply VAC / Hz 120 / 60
Consumpon
Operaon W / A 54 / 0.64 79 / 0.99 82 / 1.02
Standby W / A 2 / 0.06 2 / 0.06 3 / 0.07
Freeze-
Protecon W/ A 96 / 0.82 96 / 0.82 97 / 0.82

5
INTRODUCTION
• This manual provides information necessary for the installation, operation, and maintenance of the
boiler.
• The model description is listed on the rating plate which is attached to the side panel of the boiler.
• Please read all instructions completely before installing this product.
• If you have any problems or questions regarding this equipment, consult the manufacturer or its
local representative.
• This equipment is a micro boiler designed to e󰀩ciently supply endless hot water for your needs.
(Radiant Heating, or Domestic Water used in-conjunction with Radiant Heating) See Combi panel
for more information on integrating domestic water with your radiant heating system.
• These boilers are only to be installed indoors.
• The principle behind micro boilers is easy:
*This diagram illustrates micro boiler design concepts only and does not accurately represent the
boilers physical description.
1. Your thermostat indicates a need for heat and turns on the circulator pump(s).
2. Water ows through the boiler.
3. The ow sensor detects the water ow.
4. The computer initiates the fan motor and sends a signal to the igniter to create an ignition spark.
5. The gas ignites and ames appear within the burner chamber.
6. Water circulates through the heat exchanger and then gets hot.
7. Using thermistors to measure temperatures throughout the micro-boiler, the computer modulates
the gas and water valves to ensure proper output water temperature.
8. When your room reaches desired temperature the pumps turn o󰀨 and the boiler shuts down.
Burners
Exhaust vent
Heat exchanger
Gas valves
Fan motor
Flow adjustment valve
Thermistor
Return From Panel Gas inlet
Supply to Panel
Thermistor
Burners
Computer board
Flow sensor
Igniter
Intake vent

6
SAFETY GUIDELINES
SAFETY DEFINITION
Indicates informaon considered important but not hazard related.
GENERAL
WARNING
CAUTION
Indicates an imminently hazardous situaon which, if not avoided, could result
in death or serious injury.
Indicates an imminently hazardous situaon which, if not avoided, could result
in minor or moderate injury.
DANGER
Indicates an imminently hazardous situaon which, if not avoided, will result in
death or serious injury.
WARNING cause severe injury or death.
NOTICE
• The conversion to propane must be done by a qualified service agent or a gas ulity
serviceman in accordance with the gas conversion instrucons and all codes and
requirements of the authority having jurisdicon. Failure to follow instrucons could
result in serious injury or property damage. The qualified agent performing this work
assumes responsibility for this conversion.
• Do not use this appliance if any part has been under water. Immediately contact a
qualified installer or service agency to replace a flooded boiler. Do not aempt
to repair the unit! It must be replaced!
• Do not disconnect the electrical supply if the ambient temperature will drop below
freezing. The Freeze Protecon System only works if the unit has electrical power. The
warranty will not be covered if the heat exchanger is damaged due to freezing.
1. Follow all local codes, or in the absence of local codes, follow the current edion of the Naonal Fuel Gas Code:
ANSI Z223.1/NFPA 54 in the USA or B149.1 Natural Gas and Propane Installaon code in Canada.
2. Properly ground the unit in accordance with all local codes, or in the absence of local codes, with the current
edion of the Naonal Electrical Code: ANSI/NFPA 70 in the USA or CSA standard C22.1 Canadian Electrical
Code Part 1 in Canada.
3. Carefully plan where you intend to install the boiler.Please ensure:
• Your boiler will have enough combuson air and proper venlaon.
• Locate your boiler where water leakage will not damage surrounding areas.
4. Check the rang 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 the manufacturer. The boiler is
configured only for use with Natural Gas at the factory. If the appliance is used with propane gas, conversion to
propane gas with an included conversion kit (LP Conversion Kit) is required. The conversion must
be done by a qualified service agent or a gas ulity serviceman in accordance with this instrucon and all codes
and requirements of the authority having jurisdicon. Failure to follow instrucons could result in serious injury
or property damage. The agent performing this work assumes responsibility for this conversion. (Refer to the
gas conversion leaflet.)
5. If any problem should occur, turn offall hot water fixtures and turn offthe gas. Then call a trained technician
or the Gas Company or the manufacturer.
• Water temperatures over 125 °F (52 °C) can cause severe burns instantly or death from
scalding. The water temperature is set at 120 °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 connecons as this will damage the gas valves and can
DHW Use

7
INSTALLATION
GENERAL
1. Follow all local codes, or in the absence of local codes, follow the current edion of the Naonal Fuel
Gas Code: ANSI Z223.1/NFPA 54 in the USA or B149.1 Natural Gas and Propane Installaon Code in
Canada.
2. All gas boilers require careful and correct installaon to ensure safe and efficient operaon.
This manual must be followed exactly. Read the “Safety Guidelines” secon.
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.
5. The boiler must be installed in a locaon where the proper amount of combusble air will be
available to it at all mes without obstrucons.
6. The electrical connecon requires a means of disconnecon, to terminate power to the water heater.
This is necessary for servicing and safety purposes.
7. Do not install the unit where the exhaust vent is poinng into any opening in a building or where the
noise may disturb your neighbors. Ensure that the vent terminaon meets the minimum distance
requirements set by code, including minimum clearances from doorways or openings.
8. Parcles from flour, aerosols, and other contaminants may clog the air vent, build up and reduce
the funcons of the rotang fan, cause improper burning of the gas, or cause damage to the water
heater. Regularly ensure that the area around the unit is dust- or debris-free. Regular maintenance is
recommended for these types of environments. Direct Venng is recommended.
9. Venng:
• If the boiler is used as a direct-vent appliance, the unit requires a 3 in. (76 mm)
combusble air supply pipe. The intake pipe must be sealed airght.
• Terminang the venng through a sidewall is recommended for the direct-vent system.
• Running the exhaust vent and the intake pipe parallel is recommended.
• Terminang the exhaust and intake on the same wall/surface is recommended. Terminang in
the same pressure zone allows for pressure balancing, which prevents nuisance shutdowns.
• Only install the boiler in a heated area where below freezing temperatures cannot occur.
The warranty does not cover damage caused by freezing.
• The boiler must be securely mounted to a wall or other suitable structure.

8
WARNING
•Installaon and service must be performed by a qualified installer (for example,
a licensed plumber or gas fier). Otherwise, the warranty will be void.
•The installer (licensed professional) is responsible for the correct installaon of
the boiler and for compliance with all naonal, state / provincial, and local
codes.
•The manufacturer does not recommend installing the boiler in a pit or
locaon where gas and water can accumulate.
• Do not have the vent terminal poinng toward any operang 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 combuson chamber, unless the system
is direct-vented.
•The manufacturer does not suggest installing the boiler in an ac due to
safety issues.If you install the water heater in an ac:
• Make sure the unit will have enough combuson air and proper venlaon.
• Keep the area around the boiler and its terminaon clean. When dust
collects on the flame sensor, the water heater will shut down and produce an
error code.
• Place the unit for easy access for service and maintenance.
• A drain pan, or other means of protecon against water damage, is
recommended to be installed under the boiler in case of leaks. The
manufacturer is not responsible for damage due to water leaks.
CAUTION
•The warranty will not cover damage caused by water quality.
• Only potable water can be used with this boiler.Do not introduce pool
or spa water, or any chemically treated water into the boiler.
• Water hardness levels must not exceed 7 grains per gallon (120 ppm) for
single family domesc applicaons or more than 4 grains per gallon (70 ppm)
for all other types of applicaons. Water hardness leads to scale formaon
and may affect / damage the boiler.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.
•The manufacturer recommends direct venng when the boiler is installed
in beauty salons, dry cleaners or any other locaons in which such chemicals
are present in the air.Some chemicals used in beauty salons or dry cleaners may
affect the flame sensor.In such cases, the boiler may not work properly.
•Although the boiler is designed to operate with minimal sound, the
manufacturer does not recommend installing the unit on a wall adjacent toa
bedroom, or a room that is intended for quiet study or meditaon, etc.
• Locate your boiler close to a drain where water leakage will not do damage to
surrounding areas. As with any water heang appliance, the potenal for leakage
at some me in the life of the product does exist. The manufacturer 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 combuson air flow.

9
CLEARANCES
Top
Back
Side
Side
Front
Model Top Boom Front Back Sides
12 in.
(305 mm)
12 in.
HS115 PLUS (NG/LP) (305 mm)
4 in.**
(102 mm)
1.0 in.
(25 mm)
3 in.
(76 mm)
**24 inches recommended for maintenance.
Installaon
Manual
Qty: 1
LP Conversion Kit
Manifold gasket: 1
Spare Screw : 2

10
Bank of DIP switches
HS115 PLUS Computer board
NOTE: The dark squares indicate the correct DIP switch posions.
Check the elevaon where your boiler is installed. Set your DIP switches according to altude as
shown below.
DIP Switch Sengs
0 to 2,000 .
(0 to 610 m)
(DEFAULT)
2,001 to
3,000 .
(611 to 914 m)
3,001 to
5,000 .
(915 to 1,524 m)
5,001 to
7,500 .
(1,525 to 2,286 m)
7,501 to
10,100 .
(2,287 to 3,078 m)
HS115 PLUS
ON 1 2 3 4 5 6 789 10
OFF
No. 3 : OFF
No. 4 : OFF
No. 5 : OFF
ON 1 2 3 4 5 6 789 10
OFF
No. 3 : OFF
No. 4 : ON
No. 5 : OFF
ON 123456789 10
OFF
No. 3 : OFF
No. 4 : OFF
No. 5 : ON
ON 123456789 10
OFF
No. 3 : OFF
No. 4 : ON
No. 5 : ON
ON 123456789 10
OFF
No. 3 : ON
No. 4 : ON
No. 5 : ON
Altude
DIP switches
HIGH-ALTITUDE INSTALLATIONS
Installaon altude
The maximum cerfied or
allowable installed altude
is 10,100 . (3,078 m)