Hydrolevel Company HydroStat OS-100 User manual

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126 Bailey Road, North Haven, CT 06473 • Phone [phone] • FAX [phone] • www.hydrolevel.com
MODEL OS-100
Outdoor Sen or Kit
for Model 3200-Plus and
Model 3250-Plus
Fuel Smart HydroStat
manufactured after 0/0/11
WARNING Electrical shock hazard. To prevent electr cal shock, death or
equ pment damage, d sconnect power supply before
nstall ng or serv c ng control. Only qual f ed personnel may nstall or serv ce th s control n
accordance w th local codes and ord nances. Read nstruct ons completely before proceed ng.
CAUTION To prevent ser ous
burns, bo ler
should be thoroughly cooled before nstall ng or
serv c ng control.
Kit Includes
• Outdoor Reset Sensor w th 9-foot cable
• Sensor mount ng bracket w th 2 screws and 1 w re cl p
• Two spade connectors
• Knockout w re bush ng
This document provides instructions for connecting the Hydrolevel Outdoor Sensor Kit to an installed
Fuel Smart HydroStat control. For information on installing the HydroStat control, please refer to the
installation instructions provided with the control or log onto www.hydrolevel.com.
Before installation, determine the
proper location for the sensor
• Sensor should be mounted on the
northern outside wall of the house,
shielded from direct sunlight.
• Sensor should be installed high
enough off the ground to protect
it from accidental damage or
drifting snow.
• Sensor should be installed away
from potential heat sources
such as exhaust fans, windows,
or doors.
WARNING Frozen pipes/water damage. Central heat ng systems are prone to shut down as a result of power or fuel outages,
safety related fault cond t ons or equ pment fa lure. Installat on of freeze protect on mon tor ng or other precaut ons
s recommended for unattended dwell ngs n cl mates subject to susta ned below-freez ng temperatures.

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INSTALLING THE SENSOR
WIRING
STEP 2 Secure the
sensor on the bracket by
pressing it down into the
slotted hole as shown
above.
STEP 3 Using an extended wood
or masonry bit, drill a ¼" hole
through the side of the house at a
location giving the best access to
the boiler and the HydroStat control.
WARNING: Use caution to select
the hole location away from wires
or piping within the house wall.
STEP 4 Feed the sensor cable
through the hole and into the house.
Seal the hole with a bead of silicone
or other appropriate caulking
material.
STEP 5 Inside the house, route
the sensor cable to the HydroStat
control. Splice in an additional length
of wire, up to 500 feet, as needed.
Use 18 awg wire for distances up to
250 feet or 16 awg wire for distances
over 250 feet. Using a crimping tool,
terminate wires with the two spade
connectors provided.
NOTE: To avoid interference with
the sensor signal, do not run the
sensor cable close to any other
wiring such as telephone, cable,
power, etc.
Locate the three quick connect posts on the HydroStat
circuit board. The sensor cable will plug into two of
these terminals depending on the features to be used.
OU DOOR RESE AND
WARM WEA HER SHU DOWN
Attach the spade connectors to the right and
center spade posts (OR and C) for full outdoor reset
functionality including warm weather shutdown protec-
tion. Wiring this way overrides the Thermal Targeting
function of the Fuel Smart HydroStat control.
WARM WEA HER SHU DOWN ONLY
Connect the wire ends to the left and center spade
connectors (WWSD and C) to add warm weather shut-
down functionality only. When wired this way, the Fuel
Smart HydroStat control will utilize its internal Thermal
Targeting function to reset the boiler temperature.
STEP 1 Using the
two screws and wire
clip provided, attach
the sensor bracket to
the side of the house.

SETTING THE CONTROL
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IMPOR AN : he outdoor sensor must be plugged in prior to setting the control.
SE ING WARM WEA HER SHU DOWN
The warm weather shutdown feature prevents the boiler from providing space heating when the outside tempera-
ture reaches a level that you select. Available settings range from OFF or 40°- 70°F. The boiler will still operate to
satisfy a call for domestic hot water. The factory default setting for the warm weather shutdown is 70°F.
o set the desired warm weather shutdown temperature:
Press and hold the TEST/SETTING BUTTON and simultaneously adjust the ECONO Y dial to the desired setting.
To turn the feature off – which will allow space heating regardless of outdoor temperature – press and hold the
TEST/SETTING BUTTON and simultaneously turn the ECONO Y dial fully counter-clockwise. Release the
TEST/SETTING BUTTON. Be sure to reset the ECONO Y dial to the correct setting. Any time the outdoor temp
exceeds the WWSD setpoint, the display will toggle boiler temperature (8 seconds), outdoor temperature (2 sec-
onds), and OFF (2 seconds).
SE ING HE OU DOOR RESE
The outdoor reset will regulate the boiler’s temperature based on the temperature outside. On cold days, the boiler
will run at higher temperatures to meet the heating load in the house. On warmer days, the boiler will run cooler to
save energy while still meeting the heating needs of the house. The HydroStat control uses a Reset Ratio to calcu-
late and maintain the proper boiler temperature.
o set the desired outdoor Reset Ratio:
1. Determine the Reset Ratio using the table below:
a. Locate the Outdoor Design Temperature for the system on the bottom of the Reset Ratio Chart below.
Round down to the next lowest number.
b. Locate the Boiler Design Temperature (supply temperature needed to meet heating load at the Outdoor
Design Temperature) on the left of the Reset Ratio Chart below.
2. Adjust the ECONO Y dial on the Fuel Smart HydroStat control to the Reset Ratio determined by the intersec-
tion of a. and b. above.
Example: For a house located in Springfield A (Design Temperature of 0°F) with baseboard heat
(that was sized for the house based on the 180°F baseboard rating), the reset ratio is 1.50.
220 1.50 1.50 1.50 1.50 1.75 1.75 1.75 2.00 2.00 2.25 2.50 2.50 2.50 2.50 2.50 2.50 2.50 2.50
215 1.25 1.50 1.50 1.50 1.50 1.75 1.75 1.75 2.00 2.25 2.25 2.50 2.50 2.50 2.50 2.50 2.50 2.50
210 1.25 1.25 1.50 1.50 1.50 1.50 1.50 1.75 2.00 2.00 2.25 2.50 2.50 2.50 2.50 2.50 2.50 2.50
205 1.25 1.25 1.25 1.50 1.50 1.50 1.50 1.75 1.75 2.00 2.25 2.25 2.50 2.50 2.50 2.50 2.50 2.50
200 1.25 1.25 1.25 1.50 1.50 1.50 1.50 1.75 1.75 2.00 2.00 2.25 2.50 2.50 2.50 2.50 2.50 2.50
195 1.00 1.25 1.25 1.25 1.50 1.50 1.50 1.50 1.75 1.75 2.00 2.25 2.25 2.50 2.50 2.50 2.50 2.50
190 1.00 1.00 1.25 1.25 1.25 1.50 1.50 1.50 1.75 1.75 2.00 2.00 2.25 2.50 2.50 2.50 2.50 2.50
185 1.00 1.00 1.00 1.25 1.25 1.25 1.25 1.50 1.50 1.75 1.75 2.00 2.25 2.50 2.50 2.50 2.50 2.50
180 1.00 1.00 1.00 1.00 1.25 1.25 1.25 1.50 1.50 1.50 1.75 2.00 2.00 2.25 2.50 2.50 2.50 2.50
175 1.00 1.00 1.00 1.00 1.25 1.25 1.25 1.50 1.50 1.50 1.75 1.75 2.00 2.25 2.50 2.50 2.50 2.50
170 1.00 1.00 1.00 1.00 1.00 1.25 1.25 1.25 1.50 1.50 1.50 1.75 1.75 2.00 2.25 2.50 2.50 2.50
165 0.75 1.00 1.00 1.00 1.00 1.00 1.00 1.25 1.25 1.50 1.50 1.50 1.75 2.00 2.25 2.50 2.50 2.50
160 0.75 0.75 0.75 1.00 1.00 1.00 1.00 1.25 1.25 1.25 1.50 1.50 1.75 1.75 2.00 2.25 2.50 2.50
155 0.75 0.75 0.75 0.75 1.00 1.00 1.00 1.00 1.25 1.25 1.25 1.50 1.50 1.75 2.00 2.25 2.50 2.50
150 0.75 0.75 0.75 0.75 0.75 1.00 1.00 1.00 1.00 1.25 1.25 1.50 1.50 1.75 1.75 2.00 2.50 2.50
145 0.75 0.75 0.75 0.75 0.75 0.75 0.75 1.00 1.00 1.00 1.25 1.25 1.50 1.50 1.75 2.00 2.25 2.50
140 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 1.00 1.00 1.00 1.25 1.25 1.50 1.50 1.75 2.00 2.50
-40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45
Refer to the Fuel Smart HydroStat instructions for other control settings.
RESET RATIO CHART
OU DOOR DESIGN EMPERA URE
BOILER EMPERA URE

126 Bailey Road, North Haven, CT 06473 • Phone [phone] • FAX [phone] • www.hydrolevel.com
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LIMI ED MANUFAC URER’S WARRAN Y
We warrant products manufactured by Hydrolevel Company to be free from defects n
mater al and workmansh p for a per od of two years from the date of manufacture or
one year from the date of nstallat on, wh chever occurs f rst. In the event of any cla m
under th s warranty or otherw se w th respect to our products wh ch s made w th n
such per od, we w ll, at our opt on, repa r or replace such products or refund the pur-
chase pr ce pa d to us by you for such products. In no event shall Hydrolevel Company
be l able for any other loss or damage, whether d rect, nd rect, nc dental or conse-
quent al. Th s warranty s your EXCLUSIVE remedy and shall be IN PLACE OF any other
warranty or guarantee, express or mpl ed, nclud ng, w thout l m tat on, any warranty
of MERCHANTABILITY or f tness for a part cular purpose. Th s warranty may not be
ass gned or transferred and any unauthor zed transfer or ass gnment thereof shall be
vo d and of no force or effect.
HOW THE OUTDOOR SENSOR WORKS
OU DOOR EMPERA URE RESE
The outdoor reset feature monitors outdoor temperature to continuously adjust the boiler water to the minimum
temperature required to satisfy the heat demand. The feature is activated automatically when the sensor is wired to
the OR and C spade connects on the Fuel Smart HydroStat. When connected, Outdoor Reset overrides the
Thermal Targeting temperature reset method which is built into the Fuel Smart HydroStat. The display will toggle
between boiler temperature (8 seconds) and outdoor temperature (2 seconds). If the sensor becomes damaged or
disconnected, the control will automatically revert back to the Thermal Targeting reset method. The display will no
longer toggle outdoor temperature.
RESE RA IO
The Fuel Smart HydroStat control’s Outdoor Reset feature uses a reset ratio method to control the boiler
temperature. The reset ratio determines how much the boiler temperature is adjusted for changes in outdoor
temperature. A reset ratio of 2.0 means that for each 1 degree increase in outdoor temperature, the boiler
temperature will decrease 2 degrees. Conversely, for each 1 degree drop in outdoor temperature, the boiler
temperature will increase 2 degrees. The control adds 10 degrees to the calculated reset temperature and
provides a 20 degree differential for burner operation. So, if the control calculates a reset temperature of 150°F, it
will set a target temperature of 160°F. It will then allow the burner to fire up to 160°F and draw down to
140°F before re-firing. This operation will maintain the desired average temperature of 150°F. You can check the
current target temperature at any time, by pressing the Test/Settings button in 4 short intervals.
HERMAL BOOS
To insure that the heating system always satisfies a call for heat, the Fuel Smart HydroStat control is equipped
with a thermal boost feature. If the thermostat is not satisfied thirty minutes after the boiler reaches the reset
temperature, the control will boost the reset temperature by 10 degrees. It will continue to boost at 30 minute
intervals until the call is satisfied. Once the call is satisfied, the control reverts to normal operation, utilizing the
calculated reset temperature.
OS100 070218