Hydrolevel Company OS-200 Parts list manual

1
MODEL OS-200
Wireless
Outdoor Sensor
for Model 3200-Plus
Model 3250-Plus
Fuel Smart HydroStat Controls
Model 4200 HydroStat-IC
HydroStat Control
Installation Instructions
and Operating Manual
• Low Transmitter battery status indicator
on the Receiver
• Power and communication indicator lights
• Transmitter temperature range of -40°F
to 140°F (-40°C to 60°C)
• Long battery life (minimum 10 years)
with included 1.5V lithium AA batteries
• 5000 ft. (1500 m) open range
• 8 walls / 250 ft. (75 m) indoor range
• Transmits outdoor temperature every 10
minutes
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.
WARNING Frozen pipes/water damage. Central heating systems are prone to
shut down as a result of power or fuel outages, 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] • FAX [phone]
www.hydrolevel.com
The Hydrolevel Wireless
Outdoor Sensor OS-200
provides outdoor temperature
measurement in any
application without exterior
wiring. The transmitter and
receiver are sold pre-linked
and are installation-ready.
With exceptional range and
a 10-year battery life, the
Wireless Outdoor Sensor
OS-200 provides maximum
accuracy, convenience and
reliability.
Wireless Outdoor Sensor 087
Receiver
Communication
Power
Low Battery
Link
TRANSMITTER
(OUTDOOR)
RECEIVER

2
FCC ID: 2AHQR-10850A IC ID: 21247-10850A
FCC: This product has been tested and found to comply with FCC part 15 subpart C. Operation is
subject to the following two conditions: (1) this device may not cause Harmful interference, and (2)
this device must accept any interference received, including interference that may cause undesired
operation of the device. However, there is no guarantee that interference will not occur in a particular
installation. If this device does cause harmful interference to radio or television reception, which can
be determined by turning the equipment off and on. The user is encouraged to try to correct the
interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help
Warning: Changes or modifications not expressly approved by the party responsible for compliance
could void the user’s authority to operate the equipment.
Industry Canada
This Device complies with Industry Canada License-exempt RSS standard(s). Operation is subject
to the following two conditions: 1) this device may not cause interference, and 2) this device must
accept any interference, including interference that may cause undesired operation of the device
under Industry Canada regulations.
Le présent appareil est conforme aux CNR d’Industrie Canada applicables aux appareils radio
exempts de licence. L’exploitation est autorisée aux deux conditions suivantes: (1) l’appareil ne doit
pas produire de brouillage, et (2) l’utilisateur de l’appareil doit accepter tout brouillage radioélectrique
subi, même si le brouillage est susceptible d’en compromettre le fonctionnement.
Warning: FCC and IC Radiation Exposure Statement
This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment.
The antenna(s) used for this equipment must be installed to provide a separation distance of at least
8 inches (20 cm) from all persons.
Cet équipement est conforme à l’exposition aux radiations de FCC et d’Industrie Canada établies
pour un environnement non contrôlé. L’antenne (s) utilisé pour cet équipement doit être installé pour
fournir une distance d’au moins 20 cm à partir de toutes les personnes.
WARNING
To avoid serious personal injury and damage to the equipment:
It is your responsibility to ensure that this control is safely installed according to all
applicable codes and standards. Hydrolevel is not responsible for damages resulting
from improper installation and/or maintenance.
• Read manual and all product labels BEFORE using the equipment. Do not use unless
you know the safe and proper operation of this equipment.
• Keep this manual available for easy access by all users.
• Replacement manuals are available at hydrolevel.com
• Disconnect all power before opening the control.
• Do not attempt to service the control. There are no user serviceable parts inside the
control. Attempting to do so voids warranty.
This product is packaged with two AA lithium metal batteries and must be transported in
accordance with all relevant and international regulations. Contact your freight company for more
information. Hydrolevel is not responsible for damages resulting from improper transportation,
installation and/or maintenance.
This symbol identifies practices, actions, or failure to act which could result in
property damage or damage to the equipment.

3
STEP 1 – INSTALL RECEIVER
When choosing the location for the receiver unit, consider the following:
• Interior wall.
• Keep dry. Avoid potential leakage onto the unit.
• Relative humidity less than 90%. Non-condensing environment.
• No exposure to extreme temperatures beyond 32° to 122°F (0° - 50°C).
• Away from equipment, appliances, or other sources of electrical interference.
• Easy access for wiring.
• Approximately 5 feet (1.5 m) off the finished floor.
Grasp the front cover by the fingertip grips on the top and
bottom of the enclosure and pull the front cover off.
The enclosure is either mounted flush onto a wall or it can
be placed onto a 2" x 4" non-conductive electrical box. The
mounting holes in the enclosure accept #6 screws. Wiring to
the control enters the wiring chamber through the back or
bottom of the enclosure.

4
STEP 2 – PROVIDE POWER
Wiring to HydroStat Model 3200-Plus
(Gas applications)
The 3200-Plus provides a 24 volt power
supply in the thermostat terminal block
located at the top left hand corner of the
control. Make connections as shown
below.
Wiring to HydroStat Model 3250-Plus
(Oil applications)
The 3250-Plus is not equipped with a
24 VAC power supply. Locate an existing
24 volt power supply or add a transformer
(supplied by others) as shown below.
The receiver unit must be powered with 24 VAC
Batteries in the Transmitter unit
Remove the cover from the transmitter unit. Insert the
included batteries as marked on the battery holder.
1.5V lithium batteries are required to provide the
specified battery life and temperature range. Alkaline
batteries have short life spans and may fail during
cold weather.
Wiring to HydroStat-IC Model 4200
The modeal 4200 is not equipped with a
24 VAC power supply. Locate an existing
24 volt power supply or add a transformer
(supplied by others) as shown below.

5
STEP 3 – CONFIRM LINK
If the communication light is displayed on the control, the
transmitter is linked properly.
If the light is not on, the devices will need to be linked.
To link the transmitter and receiver, remove the cover on the
transmitter so that the button below the battery terminals
can be accessed. Press and hold both the button on the
transmitter and the button on the receiver simultaneously for
5 seconds and release. Upon release, the linkup process will
begin; the communication LED on the receiver will flash
8 times. Linking is successful when the communication LED is
steady on.
The link button on the receiver can also be used as a reset. If pushed, the receiver
will revert to a power-up condition; a temperature of 75°F (24°C) will be reported until
the first transmission is received (up to 10 minutes).
Communication
Power
Low Battery
Link
Wireless Outdoor Sensor 087
Receiver
Communication
Power
Low Battery
Link
Wireless Outdoor Sensor 087
Receiver
STEP 4 – INSTALL TRANSMITTER
The transmitter should be mounted on a northern exterior wall
away from direct sunlight. In order to prevent heat transmitted
through the wall from affecting the sensor reading, it may be
necessary to install an insulating barrier behind the enclosure.
• The OS-200 should not be exposed to heat sources such as
ventilation or window openings.
• The OS-200 should be installed at an elevation above the
ground that will prevent accidental damage or tampering.
• Do not install the transmitter on a conductive surface.
• The transmitter will send outdoor temperature data every
10 minutes.

6
STEP 5 – SENSOR TERMINAL WIRING
Connect 2-conductor wire between the HydroStat control and
the sensor terminals (3 and 4) on the receiver. This connection
is polarity sensitive. Wire the output Com terminal on the
receiver to the Cterminal on the HydroStat control. Wire the
output Sen terminal on the receiver to the OR (or WWSD)
terminal on the HydroStat control. At power-up the receiver will
report a temperature of 75°F (24°C) until the first temperature
transmission is received (up to 10 minutes). Wait up to 10
minutes to verify that the temperature at the control is accurate.
If the temperature displayed at the control is unreasonably hot
the wires may be reversed.
4
Output
Com Sen
3
To outdoor sensor terminals on
Hydrolevel control
Outdoor Sensor Terminals
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.
Outdoor Reset AND Warm Weather
Shutdown
Attach the spade connectors to the right and
center spade posts (OR and C) for full outdoor
reset functionality including warm weather
shutdown protection. Wiring this way overrides
the Thermal Targeting function of the HydroStat
control.
Warm Weather Shutdown Only (WWSD)
Connect the wire ends to the left and center
spade connectors (WWSD and C) to add warm
weather shutdown functionality only. When
wired this way, the HydroStat control will utilize
its internal Thermal Targeting function to reset
the boiler temperature.
Models 3200-Plus, 3250-Plus
Model 4200 HydroStat-IC
Location of terminals varies by model
STEP 6 – SETTING THE HYDROSTAT CONTROL
IMPORTANT: The OS-200 must be plugged in to the HydroStat prior to setting the
control.
SETTING WARM WEATHER SHUTDOWN
The warm weather shutdown feature prevents the boiler from providing space heating
when the outside temperature 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.

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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
RESET RATIO CHART
OUTDOOR DESIGN TEMPERATURE
BOILER TEMPERATURE
STEP 6 – SETTING THE HYDROSTAT CONTROL – continued
To set the desired warm weather shutdown temperature:
Press and hold the TEST/SETTING BUTTON and simultaneously adjust the
ECONOMY 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 ECONOMY dial fully counter-clockwise.
Release the TEST/SETTING BUTTON. Be sure to reset the ECONOMY 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 seconds), and OFF
(2 seconds).
SETTING THE OUTDOOR RESET
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 calculate and maintain the proper boiler temperature.
To 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 ECONOMY dial on the HydroStat control to the Reset Ratio
determined by the intersection of a. and b. above.
Example: For a house located in Springfield MA (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.
Refer to the HydroStat instructions for other control settings.

8
HOW THE OUTDOOR SENSOR WORKS
Outdoor Temperature Reset
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 Hydrolevel OS-100 or OS-200 is wired to the OR and C
spade connects on the HydroStat. When connected, Outdoor Reset overrides the Thermal
Targeting temperature reset method which is built into the 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.
Reset Ratio
The 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.
Thermal Boost
To insure that the heating system always satisfies a call for heat, the 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.

9
LOSS OF COMMUNICATION / TROUBLESHOOTING
If the Communication LED is not on, try the following:
1. Confirm that the receiver is powered with 24 VAC by observing that the green Power
LED is on.
2. Locate the transmitter. Remove the cover, and push the button located below the
battery terminals. The LED will flash once to indicate transmission. Locate the receiver,
and see if the Communication LED is on. If it does not come on, it may be one of
three problems:
• The transmitter may be out of range. Try moving the transmitter closer to the
receiver. Push the transmission button inside the transmitter and confirm that the
communication LED turns green.
• The battery life of the transmitter batteries may have expired. This is likely the
issue if the batteries have been in extended service. They can be replaced with
1.5V lithium batteries.
• The link may have been interrupted. Try re-linking the devices, as described on page 4.
3. If the communication LED remains off for over 30 minutes, please call Tech Support
at 203-776-0473.
LED OPERATION
LED Indicator Status Description
Power
Green Normal operation
Off No power. Check that the wires are securely
connected to the device.
Communication
Green Signal is good.
Off No signal. There is a loss of communication
or the Transmitter battery is dead, resulting in
an open circuit error on the control.
Flashing Signal is weak. Consider relocating a device
to obtain a stronger signal.

10
SENSOR RESISTANCE SETTINGS
Resistance Temperature
336095 -40°F (-40°C)
242426 -31°F (-35°C)
176801 -22°F (-30°C)
130307 -13°F (-25°C)
97007 -4°F (-20°C)
72910 5°F (-15°C)
55303 14°F (-10°C)
42316 23°F (-5°C)
32651 32°F (0°C)
25395 41°F (5°C)
19903 50°F (10°C)
15714 59°F (15°C)
12493 68°F (20°C)
10000 77°F (25°C)
8056 86°F (30°C)
6530 95°F (35°C)
5325 104°F (40°C)
4367 113°F (45°C)
3601 122°F (50°C)
2985 131°F (55°C)
2487 140°F (60°C)
10K Type 2 NTC Thermistor