STIEBEL ELTRON HydroShark 115NG, HydroShark 115LP, HydroShark 115 Installation Manual And Owner's Manual

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Page 1

OPERATION AND INSTALLATION UTILISATION ET INSTALLATION

Non-Condensing Gas Micro-boiler

»HydroShark 115NG »HydroShark 115LP

Conforms to ANSI Z21.10.3/CSA 4.3

Conforme à la norme ANSI Z21.10.3/CSA 4.3

Page 2

HydroShark 115 Gas Micro Boiler Installation Manual and Owner’s Guide

The HydroShark 115 Gas Micro Boiler is a compact and powerful residential unit with a versatile BTU modulating range.

Featuring

• Eﬃ ciency: 83 %

• Wall Hung

• Flow Activated: .75 GPM

• Copper Heat Exchanger

• Temperature Range: 99°-167° F*

• Freeze Protection

• Power Vent

• CAT III Stainless Steel Venting

*Max Water Temp of 167° F at 2.4 GPM

Models:

HydroShark 115NG HydroShark 115LP

Do not return. Damages or repairs call

800.805.5384

If the information in these instructions is not followed exactly, a ﬁ re or explosion may result causing property damage, personal injury or death.

-Do not store or use gasoline or other ﬂ 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 ﬁ re department.

-Installation and service must be performed by

a qualiﬁ ed installer, service agency or the gas supplier.

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CONTENTS

Installation Manual

SPECIFICATIONS..........................................................................................................4

INTRODUCTIONS..........................................................................................................5

SAFETY GUIDELINES...................................................................................................6

INSTALLATION...............................................................................................................7

General................................................................................................................7

Clearances...........................................................................................................9

Included accessories............................................................................................9

High-altitude installations....................................................................................10

Venting instructions.............................................................................................11

Gas supply and gas pipe sizing..........................................................................17

Water connections..............................................................................................19

Electrical connections.........................................................................................20

APPLICATIONS..................................................................................................22

INITIAL OPERATION..........................................................................................24

OWNER’S GUIDE

OPERATING SAFETY...................................................................................................26

NORMAL OPERATION.................................................................................................28

General..............................................................................................................28

Temperature Settings.........................................................................................29

Flow....................................................................................................................30

Freeze protection system...................................................................................30

Maintenance and service...................................................................................31

Unit draining and ﬁ lter cleaning..........................................................................31

TROUBLESHOOTING..................................................................................................32

General...............................................................................................................32

Error codes.........................................................................................................34

COMPONENTS DIAGRAM...........................................................................................37

PARTS LIST...................................................................................................................39

OUTPUT TEMPERATURE CHART...............................................................................41

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Installation Manual

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.

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Page 5

SPECIFICATIONS

Model

Natural Gas Input

(OperaƟng Range)

Propane Input (OperaƟng Range)

Gas ConnecƟon ¾” NPT

Water ConnecƟŽŶƐ

Water Pressure

Natural Gas

Inlet Pressure

Propane Inlet Pressure

Manifold Pressure**

Weight 33 lbs.

Dimensions

Natural

Propane 2.5” WC

HydroShark 115

Min: 19,500 Btu/h Max: 140,000 Btu/h

¾” NPT

15 - 150 psi*

Min. 5.0” WC

Max. 10.5” WC

Min. 8.0” WC

Max. 14.0” WC

2.0” WC

H20.5” x W13.8” x D6.7”

IgniƟon

Supply

Electric

OperaƟon

Standby

Freeze-

ConsumpƟon

ProtecƟon

Electric IgniƟon

120 VAC / 60 Hz

73.1 W / 0.61 A

6.2 W / 0.05 A

111 W / 0.93 A

*18-25 PSI is recommended for maximum ﬂ 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 speciﬁ cations.

• The manufacture reserves the right to discontinue, or change at any time, speciﬁ cations, or designs without notice and without incurring obligation.

*When using boiler in-conjunction with HydroShark DHW Integrator Panel, system pressure may be much higher on your domestic water side. Your space heating side should still reﬂ ect the recommended 18-25 PSI for system pressure.

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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 eﬃ ciently supply endless hot water for your needs. (Radiant Heating, or Domestic Water used in-conjunction with Radiant Heating) See DHW Integrator 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:

HydroShark 115

Secondary pump

Radiant heĂƟng

Water control valve

Pump controller

Primary pump

HeaƟng panel “Integrator”

Flow sensor

Burner

GAS

Gas valve

Thermistor

Air vent Expansion tank

Water supply

Check valve

Strainer

*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 ﬂ ows through the boiler.

3. The ﬂ ow sensor detects the water ﬂ 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 ﬂ 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 oﬀ and the boiler shuts down.

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SAFETY GUIDELINES

SAFETY DEFINITION

Indicates an imminently hazardous situation which, if not avoided, will result in

DANGER

WARNING

CAUTION

1. Follow all local codes , or in the absence of local codes, follow the current edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or 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 Canadian 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 micro boiler where water leakage will not damage surrounding areas.

4. Check the rating plate for the correct Gas Type, Gas Pressure, Water Pressure and Electric

Rating.

5. *If this unit does not match your requirements, do not install and consult with the manufacture.

6. If any problem should occur, turn oﬀ the unit and unplug the zone controls for the space heating and/or DHW Integrator Panel system zone controls and turn oﬀ the gas. Then call a trained technician or the Gas Company or the manufacture.

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

• Water temperature 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. If using micro boiler with HydroShark DHW Integrator Panel, always check the water temperature. Always verify

WARNING

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emitter water delivery temperature requirements to avoid damage.

• Do not store or use gasoline or other ﬂ ammables, vapors, or liquids in the vicinity of this appliance.

• Do not reverse the ﬂ uid and/or gas connections as this will damage the gas valves and can cause sever injury or death.

• 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 ﬁ tter, 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 protection system only works if the unit has electrical power. The warranty will not be covered if the heat exchanger is damaged due to freezing.

Page 8

INSTALLATION

GENERAL

1. Follow all local codes, or in the absence of local codes, follow the current edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or B149.1 Natural Gas, Propane Installation Code in Canada.

2. All gas micro boilers require careful and correct installation to ensure safe and eﬃ cient 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 for proper clearance.

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 connections requires a means of disconnections, to terminate power to the micro boiler for servicing and safety purposes.

7. Do not install the unit where the exhaust vent is pointing into any opening in the 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.

8. Particles from ﬂ our, aerosols, and other 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 unit is dust or debris free. Regular maintenance is recommended for these types of environment.

9. If you will be installing the micro boiler in a contaminated area with a high level of dust, sand , ﬂ our, aerosols or other contaminates/chemicals, they can become airborne and enter and build up within the fan and burner causing damage to the micro boiler.

10. For the HydroShark 115:

• This unit may be converted to a direct-vent appliance by installing a direct-vent conversion kit. (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 boiler is used as a direct vent appliance, the unit requires 3” combustible air supply pipe. The intake pipe must be sealed airtight. Air supply pope 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.

• Terminate the exhaust and intake on the same wall / surface is recommended. Terminating the same pressure zone allows for pressure balancing, which prevents nuisance shutdowns.

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WARNING

• Installation and service must be performed by a qualiﬁ ed installer (for example, a licensed plumber or gas ﬁ tter, otherwise the warranty will be void.

• The installer (licensed professional) is responsible for the correct installation for 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 next to any source of airborne debris, such as clothes dryer, 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:

-Keep the area around the micro boiler clean. When dust collects on the

ﬂ ame sensor, the micro boiler will shut down on an error code.

-Place the unit for easy access for service and maintenance.

-A drain pan, or other means of protection against water damage, is to be

installed under the micro boiler in case of leaks.

-Make sure the unit will have enough combustion air and proper ventilation.

NOTICE

• The warranty will not cover damage cause by water quality.

-Only distilled water or distilled water/glycol mixtures can be used with this

micro boiler, unless when used in-conjunction with Stiebel Eltron DHW Integrator Panel system. 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 applications or more than 4 grains per gallon (70 ppm) for all other types of applications/ Water hardness leads to scale formation and may aﬀ ect / damage the micro 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 no install the micro boiler where water, debris, or ﬂ ammable vapors may get into the ﬂ ue terminal.

• Although the micro boiler is designed to operate with minimal sound, the

manufacturer 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 boiler 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. 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 combustion air ﬂ ow.

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CLEARANCES

Maintain all clearances around the micro boiler. Failure to do so could cre-

WARNING

ate a ﬁ re hazard, potentially leading to death, serious injury, and/or property damage.

Model Top BoƩom Front Back Sides

12” HydroShark 115* 12” 24” 1” 2 “

*Standard indoor installĂƟŽns and direct-vent indoor instalůĂƟŽns have the same clearances.

INCLUDED ACCESSORIES

Check that these items below are included with the micro boiler.

Side

Front

BoƩom

Top

Back

Side

1. InstallaƟon Manual and Owner’s Guide

Qty: 1

Remote controller

900766605 (TK-RE02)

Qty: 1

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HIGH-ALTITUDE INSTALLATIONS

Check the elevation where your micro boiler is installed. Set DIPswitches shown in the table below depending on the altitude.

AůƟƚƵĚĞ

Swiƚch NŽ.3

WARNING

0 ƚŽ 2,000 Ō

(DEFAULT)

OFF OFF

࣭

࣮

࣯









ࣰ

ࣱ

ࣲ

2,000 ƚŽ 4,000 Ō

ࣳ

ࣴ

࣭









࣮

OFF

࣯

ࣰ

ࣱ

ࣲ

Th Ğ ĚĂƌk sqƵĂƌĞs ŝŶĚŝĐĂƚĞ ƚhĞ ĚiƌĞcƟŽn ƚhĞ ĚiƉƐǁŝƚĐŚĞƐ ƐŚŽƵůĚ bĞ sĞƚ ƚŽ

4,000 ƚŽ 6,000 Ō

ࣳ

ࣴ

࣭











OFF

࣮

OvĞr 6,000 Ō

ON Swiƚch NŽ.4

ࣳ

࣯

ࣰ

ࣴ

ࣱ

ࣲ

DipswiƚĐhĞs

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Page 12

VENTING INSTRUCTIONS

GENERAL

• Improper venting of this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death.

DANGER

CAUTION

This appliance must be vented in accordance with the section” Venting of Equipment” of the current edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the United States and/or Section 8 of the B149.1 Natural Gas and Propane Installation Code in Canada, as well as applicable local building codes. The manufacturer recommends NovaVENT or Z-Vent Category III, single wall, stainless steel venting.

The boiler can obtain its combustion air from the space that it is installed in or it can be direct vented using the direct vent conversion kit (TK-TV10). Ensure the location has suﬃ cient, clean combustion air.

General rules for venting micro boilers are:

• Improper installation can cause nausea or asphyxiation, severe injury or death from carbon monoxide and ﬂ ue gases poisoning. Improper installation will void product warranty.

When installing the vent system, all applicable national and local codes must be followed. If you install thimbles, ﬁ re stops or other protective devices and they penetrate any combustible or noncombustible construction, be sure to follow all applicable national and local codes.

• Place the micro boiler as close as possible to the vent termination.

• The vent collar of the micro boiler must be fastened directly to an unobstructed vent pipe.

• Do not weld the vent pipe to the micro boiler’s vent collar.

• Do not cut the vent collar of the unit.

• The vent must be easily removable from the top of the boiler for normal service and inspection of the unit.

• The micro boiler vent must not be connected to any other gas appliance or vent stack except an approved common venting system.

• Avoid using an oversized vent pope or using extremely long runs of the pope unless it is part of an approved common vent system.

• For rooftop venting, a rain cap or other from of termination that prevents rain water from entering into the micro boiler must be installed.

• Do not terminate vent into chimney. If the vent must go through the chimney, the vent must run all the way through the chimney with approved vent pipe.

General rules for vent terminations:

• Avoid locating the micro boiler vent termination near any air intake devices. These fans can pick up the exhaust ﬂ ue products from the micro boiler and return them to the building. This can create a health hazard.

• Locate the vent termination so that it cannot be blocked by any debris, at any time. Most codes require that the termination be at least 12 in. (305 mm) above grade, but the installer may determine if it should be higher depending on the job site condition and applicable codes.

• A proper sidewall termination is recommended when the micro boiler is vented through a sidewall.

• Be sure to check the clearance form the exhaust termination to the air inlet or opening in the vent termination clearances section.

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NOTICE

WARNING

Combustion Air Supply

• The guidelines in this section apply to installations within the United Sates. All U.S. installation must conform to the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 (current edition) and local codes.

• Canadian requirements diﬀ er from the guidelines in this section. In Canada, follow the requirements of B149.1 (Natural Gas and Propane Installation Code, current edition) as well as local and provincial codes. Contact your local code enforcement agency for direction.

This micro boiler requires an adequate source of clean air for combustion and ventilation. Without suﬃ cient air, your boiler may not operate properly and may emit excessive and abnormal amounts of carbon monoxide which may result in carbon monoxide poisoning or death.

Before installing the boiler, you must determine the amount of air needed to supply this boiler and an other gas appliances in the same area and provide adequate air for combustion and ventilation. Consult a qualiﬁ ed person if you’re unsure of the proper way to supply air to your boiler.

Check for Chemicals:

Air for combustion and ventilation must be clean and free of corrosive chemicals. If corrosive chemicals, such as sulfur, ﬂ ouring, or chlorine are present, the boiler must be direct vented. Failure due to these corrosive chemicals is not covered by the warranty.

WARNING!

In all cases, ensure that corrosive chemicals are not present at the air intake. Presence of such chemicals at the air intake could result in death, personal injury, or property damage. Examples of locations that require outside air due to chemicals include:

• Beauty salons

• Photo processing labs

• Indoor pools

• Laundry, hobby, or craft rooms

• Chemical storage areas

Products such as aerosol sprays, detergents, bleaches, cleaning solvents, gasoline, air fresheners, paint, varnish removers, and refrigerants should not be stored or used near the micro boiler.

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Exhaust Venting

This is a Category III appliance and must be vented accordingly. The vent system must be sealed airtight. All seams and joints without gaskets must be sealed with high heat resistant silicone sealant or UL listed aluminum adhesive tape having a minimum temperature rating of 350° F. For best results, a vent system should be as short and straight as possible.

• This boiler is a Category III appliance and must be vented accordingly with any 4” vent approved for use with Category III or Special BH type gas vent.

• Follow the vent pipe manufacturer’s instructions when installing vent pipe.

• Do not common vent this appliance with any other vented appliance. (Do not terminate vent

into a chimney. if the vent must go through the chimney, the vent must run all the way through the chimney with Category III approved or Special BH vent pipe.)

• When the horizontal vent run exceeds 5 ft. (1.5 m), support the vent run at 3 ft. (0.9 m) intervals with overhead hangers.

• When th event run exceeds 5 ft. (1.5 m), a condensate drain is recommended. It should be installed as close to the boiler as possible.

• The maximum length of exhaust vent piping must not exceed 50 ft. (15.2 m) (deducting 5 ft. (1.5 m) for each elbow used in the venting system.) Do not use more than 5 elbows.

Diameter Max. No. of Elbow Max. VerƟcal and Horizontal (Total) Vent Length

4” 5 50 Ō.

*For each elbow added, deduct 5 Ō. from max. Vent length.

No. of Elbows

0 50 Ō 1 45 Ō 2 40 Ō 5 25 Ō

Max. sĞƌƟĐĂů or Horizontal Length

Horizontal InstallaƟŽŶ Diagram

BackŇow Preventer*

VerƟcal CondensaƟon Drain**

Venting Illustrations

Wall

Sidewall Vent Terminator

BackŇow Preventer *

VerƟcal InstallaƟon Diagram

Rain Cap

Roof Flashing

Roof

sĞƌƟĐĂů CondensaƟon Drain**

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Venting Illustrations

Horizontal InstallaƟŽŶ Diagram (With direct-ǀĞŶƟŶŐͿ

BackŇow Preventer *

sĞƌƟĐĂů CondensaƟon Drain**

See the picture below for detailed connecƟon instrucƟons to the Direct-Vent Conversion Kit.

Wall

Sidewall Vent Terminator

sĞƌƟĐal InstĂůůĂƟŽŶ Diagram (With direct-venƟŶŐͿ

Rain Cap

Roof

BackŇow Preventer *

VerƟcal CondensaƟŽn Drain**

Roof Flashing

Fire stop

*BackŇow Preventer (Recommended for freezing weather condiƟons: 36°F and below) **VerƟcal CondensaƟon Drain must be installed accordance with local codes.

Horizontal /ŶƐƚĂůůĂƟŽŶ Diagram With Direct-Vent Concentric

InstallaƟon Di agram of Direct-Vent Conversion Kit

TerminaƟŽn

Wall

Plate of Direct-Vent Conversion Kit Direct-vent Concentric TerminaƟon

Intake port of Direct-Vent Conversion Kit

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Vent Termination Clearances

Canada U.S.A

Direct vent and

other than Direct

Vent

Clearance above grade, veranda, porch, deck,

A 1 foot 1 foot

or balcony.

Clearance to window or door that may be

opened.

Clearance to permanently closed window

C * *

VerƟcal clearance to veŶƟůĂted soĸt located above the vent terminator within a horizontal

distance of 2 feet (61cm) from the center line of the terminator.

E * * *

Clearance to unvenƟlated soĸt Clearance to outside corner

Clearance to inside corner

Clearance to each side of center line extended

above meter/regulator assembly Clearance to service regulator vent outlet.

Clearance to non-mechanical air supply inlet

to building or the combusƟon air inlet to any other appůŝĐĂƟon.

Clearance to mechanical air supply inlet.

Clearance above paved sidewalk or paved

driveway located on public property. Clearance under veranda, porch deck, or

balcony.

*For clearances not spĞĐŝĮĞĚ in ANSI Z223.1 / NFPA 54 or CAN/CSA-B149.1, please use clearances in accordance with local installaƟon codes and the requirements of the gas supplier.

3 feet 1 foot

* * *

** * ** *

3 feet 1 foot

6 feet 3 feet

Direct vent

* 3 feet *

*3 feet

* 7 feet 7 feet

* * 1 foot

Other than Direct Vent

4 feet from below or side

opening. 1 foot from

4 feet from below or side

opening. 1 foot from

1 foot

above opening.

3 feet

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Page 17

Please follow all local and naƟŽnal codes in regards to proper terminaƟŽŶ clearances. In the absence of such codes, the following clearances can be used as guidelines. Local

CAUTION

codes supersede these guidelines.

For sidewall terminaƟons

2Ō.

1Ō.

Inside corner

Exhaust terminaƟŽŶ

For ŵƵůƟƉle sidewall exhaust terminaƟons (e.g. mulƟ-unit systems), an exhaust terminaƟŽŶ must be at least 1 Ō. away from another exhaust teƌŵŝŶĂƟŽŶ An exhaust terminaƟon must also be at least 2 Ō away from an inside corner (if the adjacent wall is less than 2 Ō. of length, the minimum required distance away from the inside corner will be equal to the length of that adjacent wall).

ϯŌ.

3Ō.

Air supply inlet

For direct-vent sidewall terminĂƟŽŶƐ that use two separate penetraƟŽns for the intake and exhaust, distance the intake and exhaust terminĂƟŽŶƐ at least 3 Ō away from each other, no maƩer the orientaƟon.

2Ō.

ϭŌ.

1Ō.

Inside corner

Direct vent ƚĞƌŵŝŶĂƟŽŶ

For ŵƵůƟƉle-unit, direct-vent sidewall terminaƟons that combine the intake and exhaust into a single penetraƟon, space each direct-vent terŵŝŶĂƟŽŶ at least 1 Ō. away from each other, no maƩer the orientaƟon. A direct-vent terminaƟon must also be at least 2 Ō. away from an inside corner (if the adjacent wall is less than 2 Ō. of length, the minimum required distance away from the inside corner will be equal to the length of that adjacent wall).

2Ō.

Exhaust terminaƟon

Exhaust and/or direct-vent sidewall terminaƟŽŶƐ should be at least 2 Ō away from an opposite surface/wall. Do not place the terminaƟon directly in front of an opening into a building.

For roŽŌŽƉ terminaƟons

ϮŌ.

Air intake

Exhaust terŵŝŶĂƟon

A: In accordance with local codes

Exhaust terminaƟon

Air intake

For ŵƵůƟƉle-unit rooŌŽƉ teƌŵŝŶĂƟons (whether for standard indoor or direct-vent installĂƟons) space all exhaust and intake terminaƟons in accordance with local codes. An exhaust terminaƟon must be spaced from a wall or surface in accordance with local codes as well. In the absence of such a code, an exhaust terminaƟŽŶ must be a horizontal distance of at least 2 Ō. away from a wall or surface.

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Page 18

GAS SUPPLY AND GAS PIPING SIZE

• Check that the type of gas matches the rating plate ﬁ rst.

• Ensure that any and all gas regulators are operating properly and providing gas pressures withing the speciﬁ ed range shown below.

CAUTION

• The minimum and maximum inlet gas pressures are:

Excess gas inlet pressure may cause serious accidents.

• Conversion of this unit from natural gas to propane or vice versa will void all warranty. Contact your local distributor to get the correct unit for your gas type. The manufacturer is not liable for nay property and/or personal

damage resulting from gas conversions.

Gas type

Natural Gas Min. 5.0” WC – Max. 10.5” WC

Propane Min. 8.0” WC – Max. 14.0” WC

Inlet gas pressure

• Inlet gas pressures that fall outside the range of values listed above may adversely aﬀ ect the performance of the micro boiler. These pressures are measured when the micro boiler is in full operation.

• Inlet gas pressure must not exceed the above maximum values; gas pressure above the speciﬁ ed range will cause dangerous operating conditions a damages to the unit.

• Until testing of the main gas line supply pressure is completed, ensure the gas line to the micro boiler is disconnected to avoid any further damage.

Gas connections

1. Install a manual gas shutoﬀ valve between the micro boiler and the gas supply.

2. When the gas connections are completed, it is necessary to perform a gas leak test either by applying soapy water to all gas ﬁ ttings and observing for bubble or by using a gas leak detection device.

• The micro boiler and its individual shutoﬀ valve must be disconnected from the gas supply piping system during any pressure testing of that system at the test pressures in excess of 1/2 psi (3.5kPa).

• The micro boiler must be isolated from the gas supply piping system by closing its individual manual shutoﬀ valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa).

3. Always purge the gas line of any debris and/or water before connecting to the gas inlet.

Size the gas pipe appropriately to supply the necessary volume of gas required for

NOTICE

the micro boiler using ANSI Z223.1/NFPA 54 in the USA of B149.1 in Canada or local codes. Otherwise, ﬂ ow capabilities and output temperatures will be limited.

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Page 19

Natural Gas Supply Piping

Maximum delivery Capacity of Cubic Feet of Gas per Hour of IPS Pipe carrying Natural Gas with 0.60 Speciﬁ c Gravity Based on Pressure Drop of 0.5”W.C.

Based on Energy Content of 1,000 BTU/Cubic ft.: The micro boiler requires 140 Cubic ft./hr.

Unit: Cubic Feet per Hour

Pipe Size

Diameter 10’ 20’ 30’ 40’ 50’ 60’ 70’ 80’ 90’ 100’ 125’ 150’ 200’

¾” 363 249 200 171 152 138 127 118 111 104 93 84 72

1” 684 470 377 323 286 259 239 222 208 197 174 158 135 1 ¼” 1,404 965 775 663 588 532 490 456 428 404 358 324 278 1 ½” 2,103 1,445 1,161 993 880 798 734 683 641 605 536 486 416

2” 4,050 2,784 2,235 1,913 1,696 1,536 1,413 1,315 1,234 1,165 1,033 936 801

Length

Propane (LP) Supply Piping

Maximum Capacity of Propane (LP) Based on 11” W.C. supply pressure at 0.5” W.C. pressure drop.

Unit: kBTU per Hour

Pipe Size Diameter

10’ 20’ 30’ 40’ 50’ 60’ 70’ 80’ 90’ 100’ 125’ 150’ 200’ ¾” 567 393 315 267 237 217 196 185 173 162 146 132 112 1” 1,071 732 590 504 448 409 378 346 322 307 275 252 213 1 ¼” 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 440 1 ½” 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787 675 2” 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496 1,260

For more informaƟŽn, please see the below.

Length

Based on Energy Content of 1,000 BTU/Cubic ft. Divide each appliance’s BTU/h requirement by 1,000 BTU/ft³ to get the appliances ft³/h requirement.

Take into account the distance the appliance is from the gas meter, look in the above gas chart to properly size the line.

For sections of the gas line supplying gas to more than one appliance (Ex. Point A to Point B), add up the cubic ft. per hour requirements of the appliances that are being supplied by that section, and size to the farthest appliance.

For Example: The section from A to B supplies gas to the furnace, range and dryer. Adding up the BTU/h requirements and dividing by 1,000 yields a cubic ft. per hour requirements of 220 cubic ft. of gas per hour. The

5’ Le

ngth

1-1/4” Pipe Size

5’ Length

1-1/4” Pipe Size

Gas Meter

farthest appliance is the range, which is 50 ft. away form the meter. Looking at the above chart, and under column of 50 ft., Section A to B needs to be 1” in order to supply 220 cubic ft.

Micro Boiler

199,000BTU

10’ Length

3/4” Pipe Size

10’ Length

1” Pipe Size

Gas Sizing Example

(Natural Gas)

15’ Length

1” Pipe Size

10’ Length

3/4” Pipe Size

Furnace

120,000BTU

Dryer

35,000BTU

10’ Length

15’ Length

Range

65,000BTU

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Page 20

Measuring inlet gas pressure

1. Turn oﬀ all electric power to the micro boiler if service is to be performed.

2. Turn the manual gas valve located on the outside of the unit clockwise to the oﬀ position.

WARNING

3. Failure to follow these steps could lead to a ﬁ re or explosion, resulting in personal injury or death.

The micro boiler cannot perform properly without suﬃ cient inlet gas pressures. Below are instructions on how to check the inlet gas pressure.

THIS IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL.

1. Shut oﬀ the manual gas valve on the gas supply line.

2. Remove the screw for the pressure port located on the gas inlet of the micro boiler shown in the diagram on the right.

3. Connect the manometer to the pressure port.

4. Re-open the manual gas valve. Check to see that there are no gas leaks.

5. Check in inlet gas pressure. When the micro boiler is on maximum and minimum burn, the manometer should read from 5.0” W.C. to 10.5” W.C. (1.24 to 2.61 kPa) for Natural Gas, from 8.0” to 14.0” W.C. (1.99 to 3.48 kPa) for Propane.

Pressure port

WATER CONNECTIONS

Do not use the micro boiler if any part has been under water. Immediately contact a qualiﬁ ed installer or licensed professional to inspect the boiler to

WARNING

NOTICE

determine if it needs to be replaced.

Do not reverse the hot outlet and cold inlet connections to the micro boiler. This will not properly activate the micro boiler.

All pipes, pipe ﬁ ttings, valves and other components, including soldering materials, must be suitable for potable water systems (when using DHW Integrator Panel), or distilled water or distilled water/glycol mix.

1. A manual shutoﬀ valve must be installed on the cold water inlet to the micro boiler between the main water supply line and the micro boiler.

2. In addition, a manual shutoﬀ valve is also recommended on the hot water outlet of the unit. If the micro boiler is installed within, or subjected to, a closed loop system

As Close as

Possible

(recommended), a thermal expansion tank or code approved device to handle the thermal expansion must be installed.

3. Before installing the micro boiler, ﬂ ush the water line

Pressure Relief Valve

Hot

outlet

Cold inlet

Gas inlet

to remove all debris, and after installation is complete, purge the air from the line. Failure to do so may cause damage to the boiler.

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Page 21

Pressure relief valve

The micro boiler has a high-temperature shutoﬀ switch built in as a standard safety feature (called a Hi-Limit switch) therefore a “pressure only” relief valve is required.

• This unit does not come with an approved pressure relief valve.

• An approved pressure relief valve must be installed on the hot water outlet.

• The pressure relieve vale must conform to ANSI Z21.22 or Can 1-4.4 and installation must follow local codes.

• The discharge capacity must be at least 140,000 BTU/h.

• The pressure relief valve needs to be rated for a maximum of 150 psi (1 MPa).

• The discharge piping for the pressure relief valve must be directed so that the hot water cannot splash on anyone or on nearby equipment.

• Attach the discharge tube to the pressure relief valve and run the end of the tube to within 6 in.(152 mm) from the ﬂ oor. This discharge tube must allow free and complete drainage without any restrictions.

• If the pressure relive valve installed on the micro boiler discharges periodically, this may be due to a defective thermal expansion tank or defective pressure relief valve.

• The pressure relief valve must be manually operated periodically to check for correct operation.

• No valve must be placed between the relief valve and the micro boiler.

WARNING

ELECTRICAL CONNECTIONS

• Follow the electrical code requirements of the local authority having jurisdiction. In the absence of such requirements, follow the current edition of the National Electrical Code ANSI/NFPA 70 in the U.S. or the current edition of CSA C22.1 Canadian Electrical Code Part 1 in Canada.

• When servicing or replacing parts with the micro boiler, label all wires prior to disconnection to facilitate an easy and error-free reconnection. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

• Failure to observe these warnings could result in personal injury or loss of life.

This unit comes with a power plug instead of a junction box.

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Page 22

REMOTE CONTROLLER CONNECTIONS

1. Disconnect power supply from the micro boiler.

2. Take Žī the micro boiler front cover.

3. Locate the remote controller terminal, pictured below (located around the lower right-hand

side of the computer board).

4. Open the plasƟĐ cover of the remote controller, and then aƩach the two fork terminals to

connector base of the backside the remote controller with two screws. Make sure the terminals are Įrmly Įxed.

5. Pull the remote’s wires through the hole at the boƩom of the water heater’s casing.

6. Properly ĂƩĂĐŚ the remote’s wires to the remote controller terminal on the computer board.

(No polarity)

*Do NOT jump or short-circuit the wires or computer will be damaged.

7. Replace Front Cover securely.

8. Wires used for the remote controller connecƟon must be:

Minimum 18AWG wire (No polarity) Maximum 400 feet long

*For detailed ĐŽŶŶĞĐƟŽŶ instrucƟons to the remote controller, refer to the instrucƟons that are

packaged with the remote controller.

Remote controller terminal inside micro boiler

Connect to these terminals

Front of remote

9007666005

(TK-RE02)

Connect other end to these terminals

Back of remote

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Page 23

APPLICATIONS

Space Heating Applications

• In order to purge air in water pipes within a closed loop system, an air vent, air separator, and expansion tank should be installed in the system. (Hydro-

Shark pre-built space heating panels incorporate all of these features).

WARNING

HydroShark per-plumbed panels help make space heating easy and reliable. These panels are professionally engineered and use proven Primary/Secondary hydronic practices. Call Tech Support (800.805.5384) for assistance.

• Water temperature over 125° F (52° C) can cause sever burns instantly of death from scalding.

• Chemicals such as diluted Glycol can be used for radiant ﬂ oor, Hydro/fan coil air or Baseboard heating only. The diluted solution of glycol must contain between 25% and 55% of Glycol. Be aware that in a closed loop system, low pressure in the heat exchanger can cause low-temperature boiling, resulting in excessive noise and damage to the micro boiler. Consult with the glycol maker for speciﬁ cations prior to use.

HydroShark Pre-Built Space Heating Panels

Sample:

Master Panel Single:

For more information on HydroShark pre-plumbed panels and zoning options for this boiler please visit www.hydro-shark.com or call 800.805.5384

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Page 24

Dual-purpose hot water heating

(Domestic and Space Heating)

Insert a HydroShark DHW Integrator Panel to provide potable heated water and Hydronic Heating (with space heating panel(s)) with one heat source.

The HydroShark DHW Integrator Panel integrates with a wide variety of boilers and delivers “Priority” potable heated water with no storage tank and hydronic space heating in a small reliable package.

Follow all local codes, or in the absence of local codes, follow the most recent

NOTICE

edition of the National Standard Code, ANSI Z21.10.3.

For more information on HydroShark DHW Integrator Panels and integrating space heating and domestic water for this boiler please visit www.hydro-shark.com or call 800.805.5384.

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Page 25

INITIAL OPERATION

• Check the Gas and Water Connections for leaks before ﬁ ring the unit for the ﬁ rst time.

• Open the main gas supply valve to the unit using only your had to avoid and spark. Never use tools. If the knob will not sure by had, do not try to force it; call a qualiﬁ ed service technician. Forced repair may result in a ﬁ re or explosion due to gas leaks.

• Be sure to check for the presence of leaking gas toward the bottom of the unit because some gases are heavier than air and may settle towards the ﬂ oor.

• Check the Gas Pressure.

• Do not try to light the burner manually. It is equipped with an electric ignition device which automatically lights the burner.

• Check for proper venting and combustible air to the micro boiler.

• Purge the gas and water lines to remove any air pockets.

• Do not use this micro boiler if any part has been under water. Immediately call a qualiﬁ ed installer or service technician to inspect the micro boiler to determine if it needs replacement.

IF YOU SMELL GAS:

• Do not try to start the micro boiler.

• Do no touch any electric switches; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas

WARNING

supplier’s instructions.

• If you cannot reach your gas supplier, call the ﬁ re department.

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Page 26

Owner’s Guide

CONGRATULATIONS

Congratulations and thank you for choosing our micro boiler. Before

use, we recommend that you read through this owner’s guide 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.

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Page 27

OPERATING SAFETY

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a ﬁ re or explosion may result

causing property damage, personal injury or loss of life.

1. The micro boiler does not have a pilot. It is equipped with an ignition device that automatically lights the burner. Do NOT try to light the burner by hand.

2. Before operating smell all around the micro boiler area for evidence of leaking gas. Be sure to smell next to the ﬂ oor because some gas is heavier than air and will settle on the ﬂ oor.

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 suppliers instructions. If gas supplier cannot be reached, call ﬁ re dept.

3. Use only your hand to turn the gas shutoﬀ valve. Never use tools. If the valve will not turn by hand, don’t try to repair it, call a qualiﬁ ed service technician. Force or attempted repair may result in a ﬁ re or explosion.

4. Do not use this micro boiler if any part has been under water. Immediately call a qualiﬁ ed service technician to inspect the micro boiler and to replace the unit if needed.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above or in the Owner’s Manual.

2. Turn oﬀ all electric power to the micro boiler.

3. Do not attempt to light the burner by hand.

4. Turn the manual as valve located on the outside of the unit clockwise to the OFF position.

5. Wait ﬁ ve (5) minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas, go to next step.

6. Turn the manual gas valve located on the outside of the unit counterclockwise to the ON position.

7. Turn on all electrical power to the micro boiler.

8. If the micro boiler will not operate, follow the instructions “To turn oﬀ Gas to appliance” and call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1. Turn oﬀ all electric power to the micro boiler if service is to be performed.

2. Turn the manual gas valve located on the outside of the unit clockwise to the OFF position.

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Page 28

DANGER

Vapors from ﬂ ammable liquids will explode and catch ﬁ re causing death or sever burns.

Do not use or store ﬂ ammable products such as gasoline, solvents or adhesives in the same room or area near the micro boiler.

Flammable Vapors

Read and follow micro boiler warnings and instructions. If the owner’s manual is missing, contact the manufacturer.

Keep ﬂ ammable products: Vapors:

1. Far away from boiler.

2. In approved containers.

3. Tightly closed and out of reach of children.

4. Micro boiler has a main burner, which may come on at any time and will ignite ﬂ am-

1. Cannot be seen.

2. Are heavier than air.

3. Go a long way on the ﬂ oor.

4. Can be carried form other rooms to the main burner by air currents.

mable vapors.

DANGER

When using micro boiler with DHW Integrator Panel for Domestic Hot Water:

1. Water temperature over 125° F can cause severe burns instantly or death from scalds.

2. Children, disabled and elderly are at highest risk of being scalded

3. Feel water before bathing or showering.

4. Temperate limiting valves are available on the DHW Integrator Panel(s). Adjust these mixing valves accordingly.

5. The outlet temperature of the micro boiler is set at 120° F (50° C). If you require water temperatures below this setting, follow the instruction manual.

6. Test the boiler before bathing or showering. Do not leave children or an inﬁ rm person unsupervised.

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Page 29

NORMAL OPERATION

TEMPERATURE CONTROLLER AND REMOVE CONTROLLER

The illustration below shows an example of the controllers. The exact display may diﬀ er from examples.

GENERAL

• Water temperatures over 125° F (52° C) can cause sever burns instantly or death from scalding.

WARNING

NOTICE

• The outlet hot water temperature of the boiler is factory set at 120° F.

• Flow rate to active micro boiler: 0.75 gallon per minute at the default set temperature

• Flow rate to keep the micro boiler running: 0.4 gallon per minute.

OPERATION

1. Turn on the 120 VAC power supply to the micro boiler.

2. Press the "OPERATION" buƩon on the remote in order to turn the remote controller on. It shows the

set temperature on its display as shown the picture to the below.

3. Press the "HOT" bu

4. You can set the temperature from 99°F (38°C) to 167°F (75°C).

"INFOMATION" BuƩon

99 100

Ʃon or the "COLD" ďƵƩon to set the temperature seƫng of the unit.

"HOT" BuƩon

"OPERATION" BuƩon

"COLD" BuƩon

102 104 106 108 110 111 113 115 117 122 131 140 158 167

Temperature above 122°F (50°C) can cause severe burns or death from scalding. Children, disabled

CAUTION

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and the elderly are at high risk of being injured.

Page 30

TEMPERATURE SETTINGS

Set Temperature

-Without remote controller-

There are 4 temperatures that you can select from by changing the dipswitch seƫngs on the computer board without the remote controller. See the table below.

Temperatures available

113°F 122°F 131°F 140°F

For detailed dipswitch seƫngs for each temperature see below.

The temperature has been preset at the factory to 120°F (50°C).

If temperatures other than the ones listed above are required, the remote controller can provide several more temperature opƟons.

-Dipswitch seƫngs for each temperature on the computer board-

Temperature Seƫngs

࣭



ࣿࣥ







࣭࣭࣯ 

ࣰࣱࣤ

WARNING

࣮

ࣳ

࣯

ࣴ

ࣱ

ࣰ

ࣲ

࣭࣮࣮ 

ࣱࣤ࣬ ࣿࣥ

ࣽ

Turn oī the power supply to the micro boiler before changing the dipswitch seƫŶŐƐ

Only change the switches with the dark squares. The dark squares indicate which direĐƟŽŶ the dipswitch should be set to.

࣭

࣮









ࣳ

࣯

ࣴ

ࣰ

ࣱ

ࣲ

࣭࣯࣭ 

ࣱࣱࣤ

ࣿࣥ

࣭

࣮









ࣳ

࣯

ࣴ

ࣱ

ࣰ

ࣲ

ࣰ࣭࣬ 

ࣲࣤ࣬

ࣿࣥ

࣭

࣮











ࣳ

࣯

ࣴ

ࣰ

ࣱ

ࣲ

Dipswitches

30 | HYDROSHARK 115 WWW.HYDRO-SHARK.COM

Page 31

FLOW

• The ﬂ ow rate through the micro boiler is limited to a maximum of 6.6 GPM (38 L/min).

• The temperature setting, along with the supply temperature of the water will determine the ﬂ ow rate output of the unit.

FREEZE PROTECTION SYSTEM

• This unit comes equipped with heating blocks to protect it against damages associated with freezing.

• For this freeze protection system to operate, there has to be electrical power to the unit. Damage to the heat exchanger caused by freezing temperates due to a power loss is not covered under warranty. In cases where power losses can occur, consider the use of a backup power supply.

• The freeze protection system will activate when the surrounding and/or outside temperature drop below 36.5°F (2.5° C).

• It is the installer’s responsibility to be aware of freezing issues and take all preventive measures. The manufacture will not be responsible for any damage to the heat exchanger as a result of freezing.

• In any area subject to freezing temperatures, freezing issues can occur if cold air enters through the venting into the heat exchanger by either negative pressures within the installation location or by strong outside wind. The manufacturer highly recommends the use of a back ﬂ ow preventer (sold separately) to minimize the amount of cold air entering through the exhaust venting when the micro boiler is oﬀ .

• If you will not be using your boiler for a long period of time:

1. Completely drain the water out of the unit.

2. Disconnect power to your boiler.

This will keep your unit from freezing and being damaged.

Only pipes within the micro boiler are protected by the freeze protection system. Any water pipes (hot or cold) located outside the unit will no be protected. Properly

CAUTION

WWW.HYDRO-SHARK.COM HYDROSHARK 115| 31

protect and insulate these pipes from freezing.

Page 32

MAINTENANCE AND SERVICE

Turn oﬀ the electrical power supply and close the manual gas shutoﬀ valve and the manual water control valve before servicing.

WARNING

• Be sure that all openings for combustion and ventilation air are not blocked.

• The venting system should be checked annually for any leaks, corrosion, blockages or damage.

• The burner should be checked annually for dust, lint, grease or dirt.

• Keep the area around the micro boiler clear. Remove any combustible materials, gasoline or any ﬂ ammable vapors and liquids.

• In accordance with all local codes and common safety practices, water discharged from the pressure relief valve can cause severe burns instantly from scalding. DO NOT touch the pressure relief valve.

• If the relief valve discharges periodically, it may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation.

• Visual check of burner ﬂ ames (see below) through the burner window in the burner assembly located at the middle of the micro boiler.

Flame blowing up

Red or Yellow

The manufacturer recommends having the unit checked once a year or as necessary by a licensed technician. If repairs are needed, any repairs should be done by a licensed technician.

UNIT DRAINING

1. Close the manual gas shutoﬀ valve.

2. Turn oﬀ power to the unit and wait a couple of seconds.

Turn on again.

3. Wait 30 seconds, and then turn oﬀ power to the unit, yet again.

4. Close the water shut oﬀ valve.

5. Have a bucket or pan to catch the water from the unit’s drain plugs. Unscrew the two drain plugs (large and small) to drain all the water out of the unit.

6. Wait a few minutes to ensure all water has completely drained from the unit.

Drain Plug (Large)

Drain Plug (Small)

Gas Valve

Water Valve

32 | HYDROSHARK 115 WWW.HYDRO-SHARK.COM

Page 33

TROUBLESHOOTING

PROBLEM SOLUTIONS

General

It takes long ƟŵĞ to get hot water at the Įǆtures.

The water is not hot enough.

The water is too hot.

The hot water is not available when a Įǆture is opened.

•

The Ɵŵe it takes to deliver hot water froŵ the ŵŝĐƌŽ boiler to your Įǆtures depends on the length of piping between the two. The longer the ĚŝƐƚĂŶĐĞ or the bigger the pipes, the longer it will

• take to get hot water.

•

Žŵpare the Ňow and teŵperature.

•

CheĐŬ Đƌoss plƵŵbing between ĐŽůĚ water lines and hot water lines.

•

Is the gas supply valve fully open?

•

Is the gas line sized properly?

•

Is the gas supply pressure enough?

•

Is the set teŵperature set too low?

•

Is the set teŵperature set too high?

Make sure the unit has 120 VAC / 60 Hz power supply.

• If you are using the reŵote ĐŽntroller, is the power buƩon turned

• on?

•

Is the gas supply valve fully open?

•

Is the water supply valve fully open?

•

Is the hot water ĮǆƚƵre suĸĐiently open to draw at least 0.5 GPM through the ŵŝĐƌŽ boiler?

•

Is the unit frozen?

•

Is there enough gas in the tank / ĐǇlinder? (For Propane ŵŽĚels)

The hot water turns Đold and stays Đold.

-TEMPERATURE and AMOUNT OF HOT WATER-

FluĐtuaƟon in hot water teŵperature.

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•

Is the ŇŽw rate enough to keep the ŵŝĐƌŽ boiler running?

Does the ƌĞĐŝƌĐƵůĂƟŽŶ line have enough ĐŚeĐk valves?

•

Is the gas supply valve fully open?

•

Are the Įǆtures ĐůĞĂŶ of debris and obstruĐƟons?

•

CheĐŬ if the Ňow rate is too low.

•

Is the gas line sized properly?

•

Is the supply gas pressure ƐƵĸĐŝent?

•

CheĐŬ for Đƌoss ĐonneĐƟon between Đold water lines and hot

• water lines.

Page 34

Troubleshooting (Cont’d)

PROBLEM SOLUTIONS

Unit does not ignite when water goes through the unit.

The fan motor is sƟůů spinning aŌer operaƟon has stopped.

- Micro Boiler -

Unit sounds abnormaů ǁŚŝůe in opeƌĂƟon

Remote controůůer does not dispůĂǇ anything when the power buƩon is turned on.

An ERROR code is diƐƉůayed.

(OPTIONAL)-

-Remote controller-

Is the ŇŽǁ rate over 0.5 GPM?

Check for reverse connecƟŽŶ and cross coŶŶĞĐƟon.

If you use the remote contrŽůůer, is the power buƩon turned on?

Check if the ŝŶůĞƚ temperature is too high.

This is normaů AŌer opeƌĂƟon has stopped, the fan motor keeps running from 15 to 70 seconds in order to re-ignite quickůy, as weůů as purge aůů the exhaust gas out of the Ňue.

Contact Hydro-Shark at 800-805-5384.

Make sure the unit is suppůŝed with power.

Make sure the connecƟŽn to the unit is correct.

ZĞĨĞƌƚŽĨĂƵůƚĂŶĂůǇƐŝƐĐŽĚĞƐƚŽĚĞƚĞƌŵŝŶĞƚŚĞƉƌŽďůĞŵ

34 | HYDROSHARK 115 WWW.HYDRO-SHARK.COM

Page 35

ERROR CODES

• The units are self-diagnostic for safety and convenience when troubleshooting.

• If there is a problem with the installation or the unit, the error code will be displayed on the temperature controller and remote controller.

• Consult with the table on the following pages for the description of each error code.

Red LED

Error code on the computer board

Error code on the remote controller 9007666005 (TK-RE02)

Single unit installations

Example: if your unit has the “321” error code (which signiﬁ es an inlet thermistor failure)

• Indicator on the temperature controller or remote controller: “321” will be displayed on the screen in its entirety.

• Green LED on the computer board: The green LED on the computer board will be

blinking two times.

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Page 36

Fault Analysis of Error Codes

If the error code is displayed on the computer board of the micro boiler or remote controller and/or temperature controller, please check the following. After checking, Consult with the manufacturer.

One

Time

Five

Times

Three Times

Two

Times

Two

Times

Remote Red LED

MalfuncƟon

descripƟon

Incorrect dipswitch seƫng

Warning for the “991” error code

IgniƟon failure

Loss of ŇĂme

Outlet thermistor failure

Inlet thermistor failure

Air –fuel RaƟŽ Rod failure

Diagnosis

Check the dipswitch seƫngs on the PCB. (Part #701)

•

Check the gas type of the micro boiler.

• Check if there is any blockage in the intake air and/or

• exhaust. If the micro boiler is installed as a direct-vent system,

• check whether there is enough distance between the intake air terminal and the exhaust terminal. Check the alƟtude/elevĂƟon of area of where the

• micro boiler installed. Check if there is grease and/or dirt in the burner (Part

• #101) and the fan motor (Part #103), especially if the micro boiler has been installed in a contaminated area.

Check if the Hi-limit switch (Part #412) is properly

• funcƟŽning.

•

Check for connecƟŽŶbreakage of wires (Part #413, 708, 709, 710, 712), burn marks on the computer board (Part #701), and/or soot on the Ňame rod (Part #108). Check if there is a buzzing spark igniƟon sound coming

• from the burner (Part #101) when micro boiler prepares for combƵƐƟŽŶ Listen for the double “clunk” sound coming from gas

• valve assembly (Part #102) when micro boiler goes into combusƟŽŶ. Check if there is leaking from heat exchanger. (Part

• #401)

Check if the Hi-limit switch (Part #412) is properly

• funcƟŽning. Check for connecƟŽŶbreakage of wires (Part #413,

• 708, 709, 710, 712), burn marks on the computer

board (Part #701), and/or soot on the Ňame rod (Part #108). Check if there is leaking from heat exchanger. (Part

• #401)

•

••

Check for connecƟŽŶ/breakage of wires and/or debris on thermistor. (Part #407, 408)

Check for connecƟon/breakage of wires (Part #709)

• and/or soot on the AFR rod. (Part #108)

36 | HYDROSHARK 115 WWW.HYDRO-SHARK.COM

Page 37

Fault Analysis of Error Codes cont’d

Red LED Remote

Six

Times

Six

Times

Four 61

Times

One

Time

72 Six Times

N/A 74

Five

Times

MalfuncƟon

descripƟon

Abnormal Gas Solenoid Valve

Abnormal Main Gas Valve

Fan Motor Fault

Computer board Fault

False Flame DetecƟŽn

MiscommuniĐĂƟŽn between Micro boiler and remote controller

Imperfect coŵďƵƐƟŽŶ

Diagnosis

•

Check for connecƟon/breakage of wires (Part #708) and/or burn marks on the computer board (Part #701).

Check for connecƟŽŶbreakage of wires (Part #708)

• and/or burn marks on the computer board (Part

#701). Check for connecƟŽŶbreakage of wires, dust buildup

• in the fan motor (Part #103) and/or burn marks on the

computer board (Part #701). Check for frozen/corrosion of connectors (Part #103).

• Check for connecƟon/breakage of wires (Part #714)

• and/or burn marks on the computer board (Part #701).

•

Check the power supply of the micro boiler.

•

For indoor models, check if condensate drain is installed on the vent collar of the micro boiler.

•

Check if there is leaking from heat exchanger (Part #401).

Check the model type of the remote controller.

• Inspect the connecƟons between the micro boiler

• and remote controller.

•

Check the power supply of the micro boiler. Check the gas type of the micro boiler.

• Inspect the environment around the micro boiler.

• Determine how long the unit has been installed.

• Check the alƟtude/elevĂƟon of the area of where the

• micro boiler installed. Check if there is any blockage in the intake air and/or

• exhaust. If the micro boiler is installed as a direct-vent system,

• check whether there is enough distance between the intake air terminal and the exhaust terminal.

••

Check if there is grease and/or dirt in the burner (Part

•

# 101) and the fan motor (Part # 104), especially if the micro boiler has been installed in a contaminated

area.

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Page 38

COMPONENTS DIAGRAM

Case assembly

࣬࣬ࣳ

࣮࣬࣬

ࣱ࣭࣬

ࣱ࣬࣬

࣯࣬࣬

ࣱ࣮࣬

࣮ࣳ࣬

ࣱ࣮࣬

࣮࣭ࣳ

ࣱ࣮࣬

ࣰࣳ࣬

ࣱ࣮࣬

ࣰ࣬࣬

࣭࣬࣬

Temperature remote controller

࣮ࣳ࣬

Water way assembly

ࣰࣲ࣬

ࣰࣱࣲ

ࣰࣱࣳ

ࣰࣰ࣬

ࣾ

ࣰ࣮࣬

ࣰࣲ࣭

ࣰࣱࣴ

ࣰࣲ࣯

ࣰ࣭࣯

࣮࣮ࣳ

ࣰࣱ࣯

Computer board

Assembly

࣭ࣳ࣬

ࣳ࣬ࣴ

࣭࣯࣬

38 | HYDROSHARK 115 WWW.HYDRO-SHARK.COM

࣭ࣳ࣬

ࣰࣰ࣭࣬ࣳ࣬ࣴࣳࣵ

ࣰࣱ࣮

ࣲ࣯࣬

ࣰ࣭࣮

ࣰࣱ࣬

ࣰࣰ࣭

ࣰࣰࣱ

ࣰ࣬ࣳ

ࣰࣱ࣬

ࣱ࣮࣬

ࣰࣱ࣭

ࣰࣲ࣬

Water inlet seĐƟŽŶ

ࣰ࣭࣬

ࣰࣱࣲ

ࣿ

ࣳ࣬ࣳ

ࣳ࣬ࣵ

ࣰ࣭ࣳ

ࣰࣰ࣮࣮࣬࣬

ࣰࣲ࣬

ࣰ࣬ࣵ

ࣰࣰ࣭

ࣾ

ࣰࣱࣱ

ࣰ࣭࣬

ࣰࣰࣱ

ࣰ࣬ࣴ

ࣿ

ࣰࣲ࣬

ࣰࣱ࣭

Water Žutlet seĐƟŽŶ

Page 39

Burner assembly

ࣰࣳ࣬

ࣱࣳ࣬

ࣱ࣯࣬

࣭࣮࣭

ࣲ࣭࣭࣬࣬ࣳ

࣭࣬ࣵ

ࣱ࣯࣬

࣭࣭࣯

ࣰ࣭࣭

࣭࣭࣮

ࣱ࣭࣬

ࣰ࣭࣬

ࣰ࣭࣬

ࣱ࣬ࣵ

ࣱ࣮࣬

ࣱ࣬ࣵ

࣭࣯࣬

࣭࣭࣭࣭࣬࣬

࣭࣭࣬

ࣱࣲ࣬

ࣵࣵ࣬ࣳ࣬ࣳ

࣭࣭࣭࣭࣭࣭

ࣲࣳ࣬

࣯ࣳ࣬

ࣱ࣯࣬

࣭࣬ࣴ

࣭࣮ࣳ

ࣱ࣯࣬

࣭ࣳ࣬

ࣱ࣯࣬

࣭࣮࣬

ࣱ࣯࣬

࣭࣮ࣳ

ࣱ࣯࣬

ࣲ࣬ࣳ

࣭࣭ࣳ

ࣱࣱ࣬

ࣰ࣭ࣳ

ࣱ࣭࣬

ࣲ࣭࣬

ࣲ࣮࣬

ࣱࣱ࣬

ࣳ࣬ࣴ

Manifold assembly

࣭࣮࣬

࣭࣭ࣵ

ࣱ࣭࣭

࣭࣭ࣴ

ࣱ࣮࣬

ࣱ࣬ࣴ

࣭࣯ࣳ

ࣱ࣭࣭

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Page 40

PARTS LIST

Item# Part# DescripƟon

001 002 003 004 005 006 007

050 051 052 053 055

056 058 059 061 062 063 064 065 066 067

101 102

103 104 105 Burner gasket 106 107 108 109 110 111 112 113 114 115 118 119 120 121

150 151

Screw M4×12 (W/Washer) Screw M4×10 (W/Washer)

Pan screw M4x12 (W/Washer)

Tap Ɵght screw M4x12 FEZN

Manifold with gas valve assembly LP

Manifold with gas valve assembly NA

Case assembly

Front cover

Air blockage plate

Bracket

:ƵŶĐƟon box

JuncƟon box inner plate

Back guard panel

Screw M4×10 (Coated)

Screw M4x10

Hex head screw M4x8

Screw M4x10 Screw M3x10

Pan screw M4x10

Screw M3x6 Screw M4x6

Pan screw M4x8

Nylon clamp

Wire clamp 60

Burner assembly

Fan motor

Burner holder gasket

Burner window

Rod holder gasket

Flame rod

Igniter rod

Rod holder

Rod cap

Burner damper Manifold gasket A Manifold gasket B

Fan damper 319143-160

Gas inlet

Gas inlet ring

Igniter plate

Surge box plate

O-ring P18 NBR (Black) O-ring P20 NBR (Black)

319143-159 319143-163 319143-150 319143-184 319143-014 319143-128 319143-338

319143-025 319143-325 319143-026 319143-060 319143-063

319143-372 319143-327 319143-061 319143-201 319143-062 319143-087 319143-328 319143-059 319143-143 319143-048

319143-161 319143-169 319143-165 319143-347 319143-341 319143-031 319143-033 319143-034 319143-339 319143-373 319143-340 319143-038 319143-170 319143-044 319143-045

319143-050 319143-049 319143-051 319143-213

319143-350 319143-057

40 | HYDROSHARK 115 WWW.HYDRO-SHARK.COM

Page 41

Item# Part# DescripƟon

401 402 404 405 407 408 409 410 412 413 414 415

450 451 452 453 454 455 456 457 458 460 461 463

701 702 703 704 705 706 707 708 709 710 711 712 713 714 719 720 721 722

Heat exchanger assembly

Flow adjustment valve/Flow sensor

Water inlet

Inlet drain plug

Inlet thermistor

Outlet thermistor

Water outlet Outlet drain plug Hi-Limit switch

Overheat-cut-oī fuse

Heater

Inlet heater

Pipe heater ĮǆŝŶŐ plate

Heater ĮǆŝŶŐ plate 16

Fuse Įxing plate 18 Fuse Įxing plate 14

O-ring P4 FKM

O-ring P6 FKM O-ring P14 FKM O-ring P15 FKM O-ring P16 FKM

Fastener “14-22”

Fastener “16A”

Silicon ring

Computer board

Transformer

Surge box

AC120V wire

Transformer wire

AC120V Power ON-OFF switch

Switch wire

Gas valve wire

Flame rod wire

EH-IG wire

Igniter

High voltage igniter cable

Freeze protecƟŽŶ thermostat

ProporƟonal gas valve wire

Computer board cover

Rubber grommet

Cable strap

319143-162 319143-167 319143-193 319143-197 319143-214 319143-218 319143-194 319143-199 319143-228 319143-149 319143-200 319143-078

319143-088 319143-125 319143-066 319143-146 319143-082 319143-080 319143-100 319143-091 319143-083 319143-105 319143-226 319143-065

319143-164 319143-182 319143-168 319143-427 319143-155 319143-141 319143-154 319143-207 319143-171 319143-209 319143-052 319143-039 319143-185 319143-220 319143-212 319143-426 319143-425 319143-352Temperature remote controller

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Page 42

OUTPUT TEMPERATURE CHART

Chart is based on properly sizes gas line

Output Temperature vs. GPM (Max. 6.6 GPM) with Various Inlet Water Temperature

7.0

6.0

5.0

4.0

3.0

2.0

1.0

0.0

Out Put Hot Water GPM

40 F 50 F 60 F 70 F

3.8 3.5 3.3 3.1 2.9 2.7 2.5 2.4 2.3 1.92.1

4.6 4.2 3.8 3.5 3.3 3.1 2.9 2.7 2.5 2.12.3

5.7 5.1 4.6 4.2 3.8 3.5 3.3 3.1 2.9 2.32.5

6.6 6.6 5.7 5.1 4.6 4.2 3.8 3.5 3.3 2.52.9 2.4

105100 110 120115 125 135130 140 150 160 165

40 F 50 F

60 F 70 F

1.8

2.0

2.2

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Page 43

NOTES:

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Page 44

STIEBEL ELTRON, Inc. 17 West Street | West Hatﬁeld MA 01088 Tel. 800-805-5384 hydroshark@stiebel-eltron-usa.com www.hydro-shark.com

4<AMHCMO=bgibea>

Subject to errors and technical changes! | Sous réserve d‘erreurs et de modiﬁ cations techniques!

Subject to errors and technical changes!

331125-40419-9328