STIEBEL ELTRON HydroShark 120NG Instruction Manual

OPERATION AND INSTALLATION
UTILISATION ET INSTALLATION
Condensing Gas Micro-boiler
»HydroShark120NG
»HydroShark120LP
Conforms to ANSI Z21.10.3/CSA 4.3
Conforme à la norme ANSI Z21.10.3/CSA 4.3

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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.
FEATURING
• EFFICIENCY: 93%
• TEMP RANGE: 99° - 140°F
• COMPACT, SPACE SAVING
• FLOW ACTIVATED: .75 GPM
• COMPUTERIZED SAFETY
• NO PILOT LIGHT
• Satisfies the 2012 SCAQMD Rule
1146.2 for Ultra-Low NOx Emissions
HydroShark 120 Condensing Gas Micro Boiler
Installation Manual and Owner’s Guide
If you have any questions,
please call or write to:
17 West St.
West Hatfield, MA 01088
Toll Free: 800.805.5384
The HydroShark 120 Condensing Gas
Micro-Boiler is a compact and powerful
residential unit with a versatile BTU modulating
range.
Please refer to local codes for space-heating
compliance.
Models
• HydroShark 120LP (Liquid propane)
• HydroShark 120NG (Natural Gas)
ANSI Z21.10.3 and CSA 4.3
If the information in these
instructions is not followed
exactly, a fire or explosion
may result causing property
damage, personal injury or
death.
WARNING

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Contents
CONTENTS
INSTALLATION MANUAL........................................................................3
SPECIFICATIONS .................................................................................................4
INTRODUCTION....................................................................................................5
SAFETY GUIDELINES ..........................................................................................6
INSTALLATION......................................................................................................7
-GENERAL-.................................................................................................................7
-INCLUDED ACCESSORIES-.....................................................................................9
-CLEARANCES-..........................................................................................................9
-VENTING INSTRUCTIONS- ....................................................................................10
-GAS SUPPLY AND GAS PIPE SIZING-...................................................................20
-CONDENSATE DRAIN- ...........................................................................................26
-ELECTRICAL CONNECTIONS-...............................................................................28
-HIGH-ALTITUDE INSTALLATIONS-.........................................................................29
-WATER CONNECTIONS-........................................................................................30
APPLICATIONS...................................................................................................31
-INITIAL OPERATION- ..............................................................................................33
OPTIONAL ITEMS...............................................................................................34
OWNER'S GUIDE.................................................................................40
OPERATING SAFETY.........................................................................................41
NORMAL OPERATION........................................................................................43
-DISPLAY OF THE CONTROLLER-..........................................................................43
-GENERAL-...............................................................................................................43
-TEMPERATURE TABLE OF THE CONTROLLER-..................................................43
-TEMPERATURE SETTINGS- ..................................................................................44
-ADDITIONAL FEATURES-.......................................................................................45
-FLOW-......................................................................................................................46
-FREEZE PROTECTION SYSTEM-..........................................................................46
-MAINTENANCE AND SERVICE-.............................................................................47
-UNIT DRAINING- .....................................................................................................47
TROUBLESHOOTING.........................................................................................48
-GENERAL-...............................................................................................................48
-ERROR CODES-......................................................................................................49
COMPONENTS DIAGRAM..................................................................................52
PARTS LIST.........................................................................................................56
OUTPUT TEMPERATURE CHART.....................................................................58
LIMITED WARRANTY..........................................................................................59

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CONGRATULATIONS
Installation Manual
Congratulations and thank you for choosing our condensing micro-boiler. Before use, we recommend
that you read through this safety manual carefully. Please refer to the back of the manual for details
about the warranty. Keep this manual for future reference.
If you lose the manual, contact the manufacturer or your local distributor. When you call, please tell us
the model number and the serial number of your unit written on the rating plate of the micro-boiler.

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Specifications
SPECIFICATIONS
* 40 psi (0.27 MPa) or above is recommended for maximum flow.
** The manifold pressure is the factory setting and 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.
The manufacturer reserves the right to discontinue, or change at any time, specifications or designs
without notice and without incurring obligation.
HydroShark Gas Condensing Micro-Boiler
Natural Gas Input
(Operating Range) BTU/h Min.: 15,000 Max.: 120,000
Propane Input
(Operating Range) BTU/h Min.: 15,000 Max.: 120,000
Gas Connection 1/2" NPT
Water Connection 3/4" NPT
Water Pressure* psi
(MPa) 15 - 150 (0.1 - 1.0)
Natural gas
Inlet Pressure inch W.C. (kPa) Min. 5.0 (1.2) Max. 10.5 (2.6)
Propane
Inlet Pressure inch W.C. (kPa) Min. 8.0 (2.0) Max. 14.0 (3.5)
Manifold
Pressure
**
Natural
Gas inch W.C. (Pa) 3.30 (820) 2.00 (500)
Propane inch W.C.
(Pa) 3.00 (750) 1.60 (400)
Weight lbs. (kg) 50 (22.5) 50 (22.5)
Dimension inch H 21-3/4 x W 14 x D 9-1/4
H 552 x W 352 x D 236
mm
Ignition Electric Ignition
Electric
Supply VAC / Hz 120 / 60
Consumption
Operation W / A 53.9 / 0.7
Standby W / A 3.2 / 0.05
Freeze-
Protection W / A 223.9 / 1.94

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• This manual provides information necessary for the installation,operation, and maintenance of the
micro-boiler.
• The model description is listed on the rating plate which is attached to the side panel of the micro-
boiler.
• Please read all installation instructions completely before installing this product.
• If you have any problems or questions regarding this equipment, consult the manufacturer or its
local representative.
• These hight efficiency models have a built-in secondary heat exchanger that absorbs latent heat
from the exhaust gas.
• The HydroShark 120 Condensing Gas Micro Boiler is only to be installed indoors.
• The principle behind condensing micro-boiler is simple:
INTRODUCTION
1. Your thermostat indicates a need for heat and turns on a circulator pump.
2. Fluid enters the heater.
3. The flow sensor detects the fluid 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. Fluid 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 fluid temperature.
8. Your room reaches desired temperature and the micro-boiler shuts off.
* This diagram illustrates condensing micro-boiler design concepts only and does not accurately
represent the micro-boiler's physical description.
Introduction
Burners
Exhaust
Secondary
heat exchanger
Primary
heat exchanger
Igniter
Gas valve
Fan motor
Flow sensor
Condensate
drain port
Gas inlet
Cold water inlet
Thermistor
Hot water outlet
Thermistor
Intake port
Exhaust
Thermistor
Water control
valve
Computer
board

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SAFETY GUIDELINES
Indicates an imminently hazardous situation which, if not avoided, could re-
sult in minor or moderate injury.
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 micro-boiler 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 micro-boiler. Please ensure:
• Your micro-boiler will have enough combustible air and proper ventilation.
• Locate your boiler where fluid leakage will not damage surrounding areas (refer to p. 9).
4. Check the rating plate for the correct GAS TYPE, GAS PRESSURE, FLUID PRESSURE and
ELECTRIC RATING.
*If this micro-boiler does not match your requirements, do not install and consult with the
manufacturer.
5. If any problem should occur, turn off all thermostats and turn off the gas. Then call a trained
technician or the Gas Company or the manufacturer.
Indicates an imminently hazardous situation which, if not avoided, could re-
sult in death or serious injury.
Indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
-Safety Definition-
-General-
• Do not store or use gasoline or other flammables, vapors, or liquids in the
vicinity of this appliance.
• Do not reverse the fluid and/or gas connections as this will damage the
gas valves and can cause severe injury or death. Follow the diagram in
the Applications section on p. 32 when installing your micro-boiler.
• Do not use this micro-boiler 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
micro-boiler if necessary.
• Do not disconnect the electrical supply if the ambient temperature will
drop below freezing. The Freeze Protection System only works if the
micro-boiler has electrical power. The heat exchanger will not be covered
under warranty if it is damaged due to freezing. Refer to "-FREEZE
PROTECTION SYSTEM-" on page 47 for more information.
Safety Guidelines
CAUTION
WARNING
WARNING
DANGER

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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.
2. All gas micro-boilers 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 micro-boiler so that it can be connected or removed
easily. Refer to the "Clearances" section on p. 10 for proper clearances.
5. The micro-boiler must be installed in a location where the proper amount of combustible air will be
available to it at all times without obstructions.
6. The electrical connection requires a means of disconnection, to terminate power to the micro-boiler
for servicing and safety purposes.
7. Do not install the micro-boiler 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 the "-Vent termination clearances-" section beginning on page 18).
8. Particles from flour, aerosols, clothes dryers and other airborne contaminants may clog the air
vent, build up and reduce the functions of the rotating fan, cause improper burning of the gas, or
cause damage to the micro-boiler. Regularly ensure that the area around the micro-boiler is dust-
or debris- free. Regular maintenance is recommended for these types of environments. Sealed
combustion is recommended too.
9. The HydroShark 120 micro-boiler is to be installed indoors only. The model is equipped with a
thermistor and hi-limit switch for the exhaust gas, detecting excess temperatures within the flue
and enabling the micro-boiler to safely stop operation if needed. These components are always
monitoring exhaust gas conditions in order to prevent heat damage to ABS, PVC, CPVC, or
Polypropylene (Plastic) venting if ABS, PVC, CPVC, or Polypropylene is used. If the exhaust gas
temperature exceeds 140°F (60°C) these components will enable the micro-boiler to safely stop
operation.
• The micro-boiler requires 3 inch, or 4 inch diameter intake air supply pipe. The intake pipe
must be sealed airtight.
• Air supply pipe can be made of aluminum flexible tube, ABS, PVC, CPVC, Polypropylene,
corrugated stainless steel, or Category III/IV stainless steel. Regarding exhaust pipe, please
refer to p. 12 for detailed information.
• Sidewall venting is recommended for this boiler. Vertical venting (roof termination) is
acceptable.
• The manufacturer recommends running the exhaust vent and the intake pipe as parallel as
possible.
-General-
INSTALLATION
Installation

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• Damage caused by water quality is not covered by the warranty.
• Only potable water or potable water / glycol mixtures can be used
with this micro-boiler. Do not introduce pool or spa water, or any
chemically treated water into the micro-boiler.
• 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 micro-boiler.
Hard water scaling must be avoided or controlled by proper water
treatment. Distilled water is recommended.
• Water pH levels must be between 6.5 and 8.5
• Well water must be treated.
• Do not install the micro-boiler where water, debris, or flammable vapors
may get into the flue terminal.
• Although the micro-boiler is designed to operate with minimal sound, the
manufacturer does not recommend installing the micro-boiler on
a wall adjacent to a bedroom, or a room that is intended for quiet
study or meditation, etc.
• Locate your boiler close to a drain where water leakage will not do
damage to surrounding areas. As with any fluid heating appliance, the
potential for leakage at some time in the life of a product does exist. The
manufacturer will not be responsible for any water damage that may
occur. If you install a drain pan under the micro-boiler, ensure that it will
not restrict the combustion air flow.
• Installation and service must be performed by a qualified installer (for
example, a licensed plumber or gas fitter), otherwise the warranty will be
void.
• The installer (licensed professional) is responsible for the correct
installation of the micro-boiler and for compliance with all national, state /
provincial, and local codes.
• The manufacturer does not recommend installing the micro-boiler 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 the micro-boiler next to any source of airborne debris, such
as a clothes dryer and a vent that can cause debris to be trapped inside
the combustion chamber, unless the system is direct-vented.
• The manufacturer does not recommend installing the micro-boiler in
an attic due to safety issues. If you install the micro-boiler in an attic:
• Make sure the micro-boiler will have enough combustion air and
proper ventilation.
• Keep the area around the micro-boiler clean. When dust collects on
the flame sensor, the micro-boiler will shut down on an error code.
• Place the micro-boiler in a location that provides easy access for
service and maintenance.
• A drain pan, or other means of protection against water damage, is
required to be installed under the micro-boiler in case of leaks.
• It is recommended to direct vent the heater.
Installation
CAUTION
WARNING

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Maintain all clearances
around the micro-boiler.
-CLEARANCES-
Check that these items below are included with the micro-boiler.
* For more information on optional items, please refer to "OPTIONAL ITEMS" section beginning on
page 35
Installation Manual
and Owner's Guide Bird Screen PVC Couplers
Model Top Bottom Front Back Sides
HydroShark 120LP
(Liquid propane) 12 in.
(305 mm) 12 in. (305 mm) 4 in. * (120 mm) 1 in. (25 mm) 3 in. (76 mm)
HydroShark 120NG
(Natural gas) 12 in.
(305 mm) 12 in. (305 mm) 4 in. * (120 mm) 1 in. (25 mm) 3 in. (76 mm)
* 24 inches recommended for maintenance
Installation
-INCLUDED ACCESSORIES-
Qty. 1 Qty. 2 Qty. 2
Top
Back
Side
Side
Front