STIEBEL ELTRON HydroShark 120NG, HydroShark 120LP, HydroShark 120 Operation And Installation

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OPERATION AND INSTALLATION UTILISATION ET INSTALLATION

Condensing Gas Micro-boiler

»HydroShark 120NG »HydroShark 120LP

Conforms to ANSI Z21.10.3/CSA 4.3

Conforme à la norme ANSI Z21.10.3/CSA 4.3

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HydroShark 120 Condensing Gas Micro Boiler Installation Manual and Owner’s Guide

ANSI Z21.10.3 and CSA 4.3

Models

• HydroShark 120LP (Liquid propane)

• HydroShark 120NG (Natural Gas)

If the information in these instructions is not followed exactly, a ﬁ re or explosion

WARNING

may result causing property damage, personal injury or death.

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.

FEATURING

• EFFICIENCY: 93%

• TEMP RANGE: 99° - 140°F

• COMPACT, SPACE SAVING

• FLOW ACTIVATED: .75 GPM

• COMPUTERIZED SAFETY

• NO PILOT LIGHT

• Satisﬁ es the 2012 SCAQMD Rule

1146.2 for Ultra-Low NOx Emissions

- 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.

If you have any questions,

please call or write to:

17 West St.

West Hatﬁ eld, MA 01088

Toll Free: 800.805.5384

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CONTENTS

INSTALLATION MANUAL ........................................................................3

SPECIFICA TIONS .................................................................................................4

INTRODUCTION ....................................................................................................5

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

INST ALLATION ......................................................................................................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

Contents

-WATER CONNECTIONS- ........................................................................................30

APPLICA TIONS ...................................................................................................31

-INITIAL OPERATION- ..............................................................................................33

OPTIONAL ITEMS ...............................................................................................34

OWNER'S GUIDE .................................................................................40

OPERATING SAFETY .........................................................................................41

NORMAL OPERATION ........................................................................................43

-DISPLAY OF THE CONTROLLER- ..........................................................................43

-GENERAL- ...............................................................................................................43

-TEMPERA TURE 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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Installation Manual

CONGRATULATIONS

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

HydroShark Gas Condensing Micro-Boiler

Speciﬁ cations

Natural Gas Input (Operating Range)

Propane Input (Operating Range)

BTU/h

Min.: 15,000

Max.: 120,000

Min.: 15,000

Max.: 120,000

Gas Connection 1/2" NPT Water Connection 3/4" NPT

Water Pressure* Natural gas

Inlet Pressure Propane

Inlet Pressure

Natural

Manifold

Gas

psi

(MPa)

inch W.C.

(kPa)

inch W.C.

(kPa)

inch W.C.

(Pa)

15 - 150 (0.1 - 1.0)

Min. 5.0 (1.2)

Max. 10.5 (2.6)

Min. 8.0 (2.0)

Max. 14.0 (3.5)

3.30

(820)

Pressure **

Propane

inch W.C.

(Pa)

3.00

(750)

2.00

(500)

1.60

(400)

Weight lbs. (kg) 50 (22.5) 50 (22.5)

inch

Dimension

H 21-3/4 x W 14 x D 9-1/4

H 552 x W 352 x D 236

Ignition Electric Ignition

Supply VAC / Hz 120 / 60

Operation W / A 53.9 / 0.7 Standby W / A 3.2 / 0.05

Freeze-

Electric

* 40 psi (0.27 MPa) or above is recommended for maximum ﬂ ow. ** The manifold pressure is the factory setting and should not need adjustment.

Note:

Check the rating plate to ensure this product matches your speciﬁ cations. 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, speciﬁ cations or designs without notice and without incurring obligation.

Protection

Consumption

W / A 223.9 / 1.94

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Introduction

INTRODUCTION

• 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 microboiler.

• 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 efﬁ ciency 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:

Intake port

Exhaust Thermistor

Exhaust

Secondary heat exchanger

Primary heat exchanger

Water control

Burners

Igniter

valve

Gas valve

Computer board

Fan motor

Flow sensor

Thermistor

Condensate drain port

Gas inlet

Hot water outlet

Cold water inlet

Thermistor

* This diagram illustrates condensing micro-boiler design concepts only and does not accurately represent the micro-boiler's physical description.

1. Your thermostat indicates a need for heat and turns on a circulator pump.

2. Fluid enters the heater.

3. The ﬂ ow sensor detects the ﬂ uid 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. 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 ﬂ uid temperature.

8. Your room reaches desired temperature and the micro-boiler shuts off.

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DANGER

WARNING

CAUTION

Safety Guidelines

SAFETY GUIDELINES

-Safety Deﬁ nition-

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

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 ﬂ uid 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.

• 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

WARNING

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 ﬁ tter, 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.

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Installation

INSTALLATION

-General-

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 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 ﬂ our, 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 dustor 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 ﬂ ue 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 ﬂ exible 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.

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WARNING

Installation

• 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 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 ﬂ ame 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.

CAUTION

• 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 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 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 ﬂ uid 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 ﬂ ow.

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-INCLUDED ACCESSORIES-

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

Installation

Installation Manual

and Owner's Guide

Qty. 1 Qty. 2 Qty. 2

* For more information on optional items, please refer to "OPTIONAL ITEMS" section beginning on page 35

Bird Screen PVC Couplers

-CLEARANCES-

Top

Maintain all clearances around the micro-boiler.

Back

Side

Model Top Bottom Front Back Sides

HydroShark 120LP

(Liquid propane)

HydroShark 120NG

(Natural gas)

* 24 inches recommended for maintenance

12 in.

(305 mm)

12 in.

(305 mm)

12 in.

Front

4 in. *

(120 mm)

4 in. *

(120 mm)

1 in.

(25 mm)

1 in.

(25 mm)

Side

3 in.

(76 mm)

3 in.

(76 mm)

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Installation - Venting

-VENTING INSTRUCTIONS-

For the HydroShark 120 Gas Condensing Micro Boiler

-GENERAL-

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

• Improper installation can cause nausea or asphyxiation, severe injury

DANGER

CAUTION

The micro-boiler must be vented in accordance with the section "Venting of Equipment" of the latest edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the United States and/or Section 7 of the CAN/CSA B149.1 Natural Gas and Propane Installation Code in Canada, as well as applicable local building codes. The use of venting materials approved for Category III/IV appliances is recommended whenever possible. However, the micro-boiler may also be vented with plastic pipe materials such as ABS, PVC, CPVC, or Polypropylene. For details, please refer to the Exhaust Vent (ABS, PVC, CPVC, or Polypropylene Vent) section on p. 12. Vent installations in Canada which utilize plastic vent systems must use venting that complies with ULC S636.

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.

General rules for venting micro-boiler are:

• 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 or alter the vent collar of the micro-boiler.

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

• Avoid using an oversized vent pipe or using extremely long runs of the pipe.

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

• Do not terminate the vent into a 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 inches (305mm) 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.

• Regarding the clearances from the exhaust termination to the air inlet or opening, refer to the "-Vent termination clearances-" section beginning on page 18.

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Installation - Venting

-Exhaust vent (ABS, PVC, CPVC, or Polypropylene vent)-

The micro-boiler can be vented with ABS, PVC, CPVC, or Polypropylene (temperature rated up to at least 149° F). Vent material certiﬁ ed to ULC S636 standards is recommended in the USA. In Canada, plastic venting must be certiﬁ ed to ULC S636 standards.

Item Material United States Canada

Schedule 40 PVC ANSI/ASTM D1785

PVC-DWV ANSI/ASTM D2665

Exhaust pipe and

Fittings

Schedule 40 CPVC ANSI/ASTM F441

Schedule 40 ABS-

DWV

ANSI/ASTM D2661

ULC S636 Certiﬁ ed

Materials Only

Polypropylene UL-1738

PVC ANSI/ASTM D2564

Pipe Cement / Primer

CPVC ANSI/ASTM F493

ABS ANSI/ASTM D2235

Note: Do NOT Use Cellular Foam Core Pipe

• The maximum length of exhaust vent piping must not exceed 70 ft. (21.3 m) for 3" venting, which depends on the elevation where the micro-boiler is installed, and 100 ft. (30.5 m) for 4" venting (deducting 5 ft. (1.5 m) for each elbow used in the venting system). Do not use more than 5 elbows. See the table below.

• 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.

-Max. Vertical or Horizontal (total) Vent Length-

No. of Elbow

2" venting 3" venting 4" venting

Up to 3,000 ft Up to 3,000 ft Up to 6,000 ft Up to 10,100 ft Up to 10,100 ft

0 6.5 ft. (2.0 m) 70 ft. (21.3 m) 40 ft. (12.2 m) 25 ft. (7.6 m) 100 ft. (30.5 m) 1 1.5 ft. (0.5 m) 65 ft. (19.8 m) 35 ft. (10.7 m) 20 ft. (6.1 m) 95 ft. (29.0 m) 2 N/A 60 ft. (18.3 m) 30 ft. (9.1 m) 15 ft. (4.6 m) 90 ft. (27.4 m) 3 N/A 55 ft. (16.8 m) 25 ft. (7.6 m) 10 ft. (3.0 m) 85 ft. (25.9 m) 4 N/A 50 ft. (15.2 m) 20 ft. (6.1 m) 5 ft. (1.5 m) 80 ft. (24.4 m) 5 N/A 45 ft. (13.7 m) N/A N/A 75 ft. (22.9 m)

- Excludes vent terminators, termination elbows, or rain caps.

- For details on the vent connection, refer to the "-Intake and Exhaust Venting Illustrations-" section beginning on page 14.

* For each elbow added, deduct 5 ft. (1.5 m) from max. vent length.

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Installation - Venting

-GENERAL-

Set DIPswitches shown in the tables below depending on the vent length. Only adjust switches with a black square. Black squares indicate the position of the switch.

2 inch venting

Vent length Single pipe

1 2 3 4 5 6 7 8 9 10

5 to 6.5 ft.

3 inch venting

OFF

No. 6 : ON No. 7 : ON

Vent length Two-pipe

1 2 3 4 5 6 7 8 9 10

5 to 20 ft.

(DEFAULT)

21 to 40 ft.

41 to 70 ft.

OFF

No. 6 : ON No. 7 : OFF

1 2 3 4 5 6 7 8 9 10

OFF

No. 6 : OFF No. 7 : OFF

1 2 3 4 5 6 7 8 9 10

OFF

No. 6 : ON No. 7 : ON

4 inch venting

Vent length Two-pipe and Single pipe

1 2 3 4 5 6 7 8 9 10

5 to 50 ft.

(DEFAULT)

OFF

No. 6 : ON No. 7 : OFF

Vent length Single pipe

1 2 3 4 5 6 7 8 9 10

5 to 45 ft.

(DEFAULT)

46 to 70 ft.

OFF

No. 6 : ON No. 7 : OFF

1 2 3 4 5 6 7 8 9 10

OFF

No. 6 : OFF No. 7 : OFF

51 to 100 ft.

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1 2 3 4 5 6 7 8 9 10

OFF

No. 6 : OFF No. 7 : OFF

Page 14

-Intake and Exhaust Venting Illustrations-

Typical installations using ABS, PVC, CPVC, or Polypropylene vent

2 inch venting installation

Installation - Venting

Vent connections for single pipe

2" straight pipe

* 3" elbow with bird screen

3"x2" reducer

Exhaust vent collar (Female)

Intake vent collar (Female)

* The micro-boiler came with a metal screen that will ﬁ t into a 3 inch elbow.

1. Connect a 3" elbow directly on the intake vent collar of the micro-boiler.

2. Connect a 3" x 2" reducer directly on the exhaust vent collar of the micro-boiler. Make sure the couplings engage the o-rings installed in the intake and exhaust vent collars.

3. Connect a 2" straight pipe to the reducer.

For details of the optional items, refer to "OPTIONAL ITEMS" section beginning on page 35.

Refer to "-Vent termination clearances-" section beginning on page 18 for

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Single pipe with room-air intake

Hanger

clearance information

Page 15

3 inch venting installation

Installation - Venting

Vent connections for two-pipe

3" straight pipe

3" coupling

Intake vent collar (Female)

3" straight pipe

3"coupling

Exhaust vent collar (Female)

1. Connect 3" couplings directly on the exhaust and intake vent collar of the micro-boiler. Make sure the couplings engage the o-rings installed in the intake and exhaust vent collars.

2. Connect 3" straight pipes to the couplings.

For details of the optional items, refer to "OPTIONAL ITEMS" on page 35.

Vent connections for single pipe

3" straight pipe

* 3" elbow with bird screen

Intake vent collar (Female)

* The micro-boiler came with a metal

screen that will ﬁ t into a 3 inch elbow.

3" coupling

Exhaust vent collar (Female)

1. Connect a 3" elbow directly on the intake vent collar of the micro-boiler.

2. Connect a 3" coupling directly on the exhaust vent collar of the micro-boiler. Make sure the couplings engage the o-rings installed in the intake and exhaust vent collars.

3. Connect a 3" straight pipe to the coupling.

4 inch venting installation

Vent connections for two-pipe

4" straight pipe

3"x4" increaser

Intake vent collar (Female)

1. Connect 3" x 4" increasers directly on the exhaust and intake vent collar of the micro-boiler. Make sure the couplings engage the o-rings installed in the intake and exhaust vent collars.

2. Connect 4" straight pipes to the increasers.

4" straight pipe

3"x4" increaser

Exhaust vent collar (Female)

Vent connections for single pipe

4" straight pipe

* 3" elbow with bird screen

Intake vent collar (Female)

* The micro-boiler came with a metal

screen that will ﬁ t into a 3 inch elbow.

3"x4" increaser

Exhaust vent collar (Female)

1. Connect a 3" elbow directly on the intake vent collar of the micro-boiler.

2. Connect a 3" x 4" increaser directly on the exhaust vent collar of the microboiler. Make sure the couplings engage the o-rings installed in the intake and exhaust vent collars.

3. Connect a 4" straight pipe to the increaser.

For details of the optional items, refer to "OPTIONAL ITEMS" on page 35.

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Examples of installation of 3 inch and 4 inch vent

Installation - Venting

Two-pipe, direct-vent

Hanger

Wall

Single pipe with room-air intake

Hanger

Wall

Roof

Fire stop

Refer to "-Vent termination clearances-" section beginning on page 18 for

clearance information

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Installation - Venting

-Exhaust vent (Stainless steel vent)-

This is a Category IV 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 160° F. For best results, a vent system should be as short and straight as possible.

• The micro-boiler is a Category IV appliance and must be vented accordingly with any 4 inch vent approved for use with Category III / IV or Special BH type gas vent.

• The manufacturer recommends the NovaVent (Z-Vent) line. However, the following are also UL listed manufacturers: ProTech Systems Inc. (FasNSeal), Metal-Fab Inc., and Heat-Fab Inc. (Saf-T Vent).

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

• The maximum length of exhaust vent piping must not exceed 100 ft. (30.5 m) (deducting 5 ft. (1.5 m) for each elbow used in the venting system). Do not use more than 5 elbows.

• 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.

Diameter Max. No. of Elbows Max. Vertical or Horizontal (Total) Vent Length

4 in. (102 mm) 5 100 ft. (30.5 m)

* For each elbow added, deduct 5 ft. (1.5 m) from max. vent length.

No. of Elbows Max. Vertical or Horizontal Vent Length

0 100 ft. (30.5 m) 1 95 ft. (29.0 m) 2 90 ft. (27.4 m) 3 85 ft. (25.9 m) 4 80 ft. (24.4 m) 5 75 ft. (22.9 m)

Excludes vent terminators, termination elbows, or rain caps.

Vent connections for two-pipe

4" stainless

4" stainless steel vent straight pipe

Intake vent collar (Female)

steel vent straight pipe

Exhaust vent collar (Female)

1. Connect 4" stainless steel vent straight pipes directly on the exhaust / intake vent collar of the micro-boiler.

Vent connections for single pipe

4" elbow with bird screen

Intake vent collar (Female)

4" stainless steel vent straight pipe

Exhaust vent collar (Female)

1. Connect a 4" stainless steel vent straight pipes directly on the exhaust vent collar of the micro-boiler.

2. Connect a 4" elbow directly on the intake vent collar of the micro-boiler.

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Page 18

-Vent termination clearances-

INSIDE CORNER DETAIL

Vent terminal

Air supply inlet

Installation - Venting

CLO

Gas meter / regulator

Canada U.S.A

Direct-vent and other

than Direct-vent

Clearance above grade, veranda, porch, deck, or

balcony.

Clearance to window or door that may be opened 3 foot 1 foot

Clearance to permanently closed window * * *

Vertical clearance to ventilated sofﬁ t located above the vent terminator within a horizontal distance of 2 feet

(61 cm) from the center line of the terminator Clearance to unventilated sofﬁ t * * *

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 3 feet * *

Clearance to non-mechanical air supply inlet to build-

ing or the combustion air inlet to any other application Clearance to mechanical air supply inlet 6 feet 3 feet 3 feet

Clearance above paved sidewalk or paved driveway

located on public property Clearance under veranda, porch deck, or balcony 1 foot * *

1 foot 1 foot 1 foot

* * *

3 feet * *

3 feet 1 foot

7 feet * 7 feet

Direct

- Vent

Other than

Direct -Vent

4 feet from below or

side opening. 1 foot

from above opening

4 feet from below or

side opening. 1 foot

from above opening

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

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Page 19

Exhaust

. (305 mm)

min.

(305 mm) min.

(610 mm ) min.

Inside corner

Installation - Venting

For multiple sidewall exhaust terminations, an exhaust termination must be at least 1 ft. (305 mm) away from another exhaust termination. An exhaust termination must also be at least 2 ft. (610 mm) away from an inside corner. (If the adjacent wall is less than 2 ft. (610 mm) of length, the minimum required distance away from the inside corner will be equal to the length of that adjacent wall.)

(610 mm) min.

(305 mm) min.

Inside

Combined intake and exhaust

. (305 mm)

min.

corner

-Case 1-

For direct-vent sidewall terminations that use two separate penetrations for the intake and exhaust, keep the termination clearances shown in the diagrams on the right.

For multiple, direct-vent sidewall terminations that combine the intake and exhaust into a single penetration, space each direct-vent termination at least 1 ft. (305 mm) away from each other, no matter the orientation. A directvent termination must also be a least 2 ft. (610 mm) away from an inside corner. (If the adjacent wall is less than 2 ft. (610 mm) of length, the minimum required distance away from the inside corner will be equal to the length of the adjacent wall.

Exhaust

Intake

min.

Exhaust

Intake

-Case 2-

A: 0.5ft. (159 mm) The clearance of A is recommended on the basis of the structure of the micro-boiler.

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Exhaust

Intake

(305 mm)

min.

Exhaust

Intake

* 3 inch and 4 inch vent installations only

Page 20

Exhaust

.(610 mm)

min

-For rooftop terminations-

Installation - Venting

Exhaust and/or direct-vent sidewall terminations should be at least 2 ft. (610 mm) away from an opposite surface / wall. Do not place the termination directly in front of an opening into a building.

Intake air

Exhaust

Gas

Exhaust gas

A: Exhaust terminations must be at least 1 ft. (305 mm) away from any obstructions. B: Intake terminations must be at least 1 ft. (305 mm) away from any obstructions.

Please follow all local and national codes in regards to proper termination clearances. In the absence of such codes, the clearances above can be used as guidelines. Local codes supersede these guidelines.

CAUTION

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Page 21

CAUTION

Installation - Gas

-GAS SUPPLY AND GAS PIPE SIZING-

-General-

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

• Ensure that any and all gas regulators used are operating properly and providing gas pressures within the speciﬁ ed range shown below. Excess gas inlet pressure may cause serious accidents.

• Conversion of this micro-boiler from natural to propane of 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 any property and/or personal damage resulting from gas conversion.

• INSTALLATION OF THIS GAS BOILER IS ONLY TO BE PERFORMED BY A LICENSED PROFESSIONAL.

• The minimum and maximum inlet gas pressures are:

Gas type Inlet gas pressures

Natural Gas Min. 5.0” W.C. (1.24 kPa) - Max. 10.5” W.C. (2.61 kPa)

Propane Min. 8.0” W.C. (1.99 kPa) - Max. 14” W.C. (3.48 kPa)

• Inlet gas pressures that fall outside the range of values listed above may adversely affect 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 and damage to the micro-boiler.

-Regulators-

The gas pressure delivered to this unit and other gas appliances needs to be constant and at the correct pressure. Regardless of what type of gas you have, the supply gas pressure can change. Depending on temperature LP (Liquid Propane) gas pressure inside a storage tank may be as low as 10psi in the cold of winter or as high as 200psi in the heat of summer. NG (Natural Gas) gas pressures can also very greatly depending on the geographic region, season, time of day and other reasons. The gas regulator must keep gas ﬂ owing to the boiler at a constant pressure even as the gas supply (LP storage tanks or NG gas mains) and the number of appliances consuming gas changes (as devices turn on and off in the home).

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Page 22

-Regulator Installation Example (Natural Gas)-

Installation - Gas

1. Gas Appliance Shutoff

or repair arises.

2. Drip Leg - a plumbing conﬁ guration that is used to remove debris from the gas line before it

enters the boiler. A drip leg consists of a black iron T ﬁ tting, a straight Black iron pipe (about 3-4”) and a cap.

3. Flexible Gas Line - the regulator should be a minimum of 3’ from the boiler. The ﬂ exible gas line

is an ideal solution, it reduces space and helps with alignment.

4. Regulator - needed to deliver constant pressure to the boiler. The NG supply after the meter is

about 2 psi and needs to be reduced to 5.0 - 10.5” W.C. (1.24 - 2.61 kPa) for the micro-boiler.

5. Gas Company Meter and Regulator

6. Incoming Gas Supply from utility company.

- required to shutoff the gas supply to the boiler if the need for service

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Page 23

-Regulator Installation Example (Liquid Propane)-

Installation - Gas

1. Gas Appliance Shutoff

or repair arises.

2. Drip Leg - a plumbing conﬁ guration that is used to remove debris from the gas line before it

enters the boiler. A drip leg consists of a black iron T ﬁ tting, a straight Black iron pipe (about 3-4”) and a cap.

3. Flexible Gas Line - the regulator should be a minimum of 3’ from the boiler. The ﬂ exible gas line

is an ideal solution, it reduces space and helps with alignment.

4. Line/Appliance Regulator - needed to deliver the precise gas pressure the micro-boiler needs.

It will drop the second stage regulator's 2 psi pressure down to inches of W.C.

5. Second stage regulator - brings gas pressure down to either 2 psi. or inches of W.C. The

micro-boiler operates on inches of W.C.(See Specs)

6. Propane Tank - gas pressures varies between 10 psi and 200 psi.

7. First stage regulator - brings tank gas pressure down to 10 psi. output, to high for the boiler.

8. Safety relief valve - relieves pressure in case the tank pressure build past the design

parameters.

9. Tank shutoff Valve - this valve will shut the supply to the whole house / system off.

10. Fuel Gauge - indicates the level of fuel in the tank.

- required to shutoff the gas supply to the boiler if the need for service

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Page 24

-Gas Connections-

NOTICE

Installation - Gas

1. Install a manual gas shutoff valve, drip leg, ﬂ exible gas line and regulator between the micro-boiler and the gas supply line as pictured. The gas supply line shall be checked for leaks using code approved methods.

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 bubbles 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 test pressures in excess of 1/2 psi (3.5 kPa).

• 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.

NOTICE

Size the gas pipe appropriately to supply the necessary volume of gas required for the micro-boiler using ANSI Z223.1/NFPA 54 in the USA or CAN/ CSA B149.1 in Canada or local codes. Otherwise, ﬂ ow capabilities and output temperatures will be limited. This unit is not equipped with a regulator. A gas regulator is required for all gas appliance installations. You should always check and follow local codes and regulations. THIS IS

ONLY TO BE INSTALLED BY A LICENSED PROFESSIONAL.

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Page 25

Installation - Gas

-Natural Gas (NG) 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 120 Cubic ft./hr

Unit: Cubic feet per hour

Pipe Size Length

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

1/2” 172 118 3/4” 363 249 200 171 152 138 127 118

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

HS120

Gas Meter

Micro-boiler

120,000 BTU/h

10' Length

1¼” Pipe Size

10' Length ½” Pipe Size

10' Length

1” Pipe Size

Furnace

120,000 BTU/h

10' Length ¾” Pipe Size

1” Pipe Size

15' Length

Dryer

35,000 BTU/h

10' Length

Range

65,000 BTU/h

15' Length ½” Pipe Size½” Pipe Size

Based on energy content of 1,000 BTU/Cubic ft: Divide each appliance’s BTU requirement by 1,000 BTH/h to get the appliances Cubic Ft. 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. 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 requirements and dividing by 1,000 yields a cubic ft. requirement of 220 cubic ft. of gas. The farthest appliance is the range, which is 50 ft. away from the meter. Looking at the above chart, and under the column of 50 ft., section A to B needs to be 1” in order to supply 220 cubic ft.

-Propane (LP) Supply Piping-

Unit: kBTU per hour

Pipe Size Length

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

1/2” 268 184 148 126 112 3/4” 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

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Page 26

Installation - Gas

-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 micro-boiler to the off position.

The micro-boiler cannot perform properly without sufﬁ cient inlet gas pressure. Below are instructions on how to check the inlet gas pressure. THIS IS ONLY TO BE DONE BY A LICENSED

PROFESSIONAL.

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

• Remove the screw from the pressure port located on the gas inlet of the micro-boiler shown in the diagram on the right.

• Connect the manometer to the pressure port.

• Re-open the manual gas valve. Check to see that there are no gas leaks. Take a reading of the gas pressure. Turn up a room thermostat to activate the boiler.

• Check the inlet gas pressure. Take another reading. When the micro-boiler is on maximum and minimum burn, the manometer should read from 5.0” to 10.5” W.C. (1.24 to 2.61 kPa) for Natural gas, or from 8.0” to 14.0” W.C. (1.99 to 3.48 kPa) for Propane. Verify that the pressure drop is acceptable.

Pressure Port





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Page 27

Installation

-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. If you are using HydroShark pre-built panels the pressure relief valve will be on the primary(boiler) loop of the Master Panel and an additional pressure relief valve may not be needed, check local codes.

• This micro-boiler does not come with an approved pressure relief valve.

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

• The pressure relief valve must conform to ANSI Z21.22 or CAN 1-4.4 and installation must follow local codes.

• The discharge capacity must be at least 120,000 BTH/h.

• The pressure relief valve needs to be rated for a maximum of 75 psi (0.5 MPa).

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

• If the pressure relief valve installed on the micro-boiler discharges periodically, this may be due to a defective thermal expansion tank, defective pressure relief valve, or it could be signs of internal scale build up.

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

• No valves may be placed between the relief valve and the micro-boiler.

-CONDENSATE DRAIN-

• The micro-boiler does not include a built-in condensate neutralizer cartridge for reducing the pH level of condensate water. If local codes dictate that condensate must be neutralized prior to drainage, a condensate neutralizer must be installed. An accessory Neutralizer assembly is sold separately.

• In the absence of applicable local codes and regulations, the manufacturer recommends that condensate be disposed of into a standard drain. Connect a drain tube from the condensate drain port (shown below) located on the bottom of the micro-boiler to a standard drain.

Follow all code requirements of the local authority on condensate neutralizers and whether or not they are required for the installation.

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Condensate drain port

Page 28

Installation

-Condensate Drain Connections-

Discharge condensate (acidic water) in accordance with all local codes and common safety practices.

WARNING

The micro-boiler is a high efﬁ ciency condensing model that produces condensate (acidic water). The acidic condensate generated in the secondary heat exchanger can be neutralized by the Neutralizer accessory.

Case A: If a neutralizer is not required

1. Connect a 1/2" FPT x 3/8" (or 1/2") HB Adapter to the condensate drain port at the bottom of the micro-boiler.

2. Connect a condensate drain tube to the 1/2" FPT x 3/8" (or 1/2") HB Adapter. The manufacturer recommends the material of the condensate tube to be either EPDM or PVC.

3. Leave an adequate amount of space between the end of the drain tube and the actual drain, to facilitate proper drainage.

Case B: If a neutralizer is required (installing the Neutralizer assembly)

1. Connect the 1/2" FPT x 3/8" MPT adapter to the condensate drain port at the bottom of the microboiler.

2. Connect the Neutralizer to the 3/8" MPT connection of the adapter. There is a ﬂ ow direction indicator on the neutralizer. Please orient the neutralizer in the proper direction.

3. Connect a 1/2" drain tube to the other end of neutralizer.

4. Leave an adequate amount of space between the end of the drain tube and the actual drain, to facilitate proper drainage.

Condensate drain port

Drain

Case A

1/2" FPT x 3/8" (or 1/2") HB

3/8" or 1/2" Condensate drain tube

Adequate space

Condensate drain port

Drain

Case B

1/2" FPT x 3/8" MPT (Included with Neutralizer accessory)

Neutralizer cartridge (Included with Neutralizer accessory)

3/8" MPT x 1/2" HB (Included with Neutralizer accessory)

1/2" Condensate drain tube

Adequate space

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Page 29

WARNING

Installation

• The condensate drain is at atmospheric pressure (non-pressurized) and therefore must be allowed to drain freely with gravity only. Please ensure that there are no blockages along the condensate drain tube. All portions of the condensate drain (neutralizer and drain tube) must be at a lower elevation than the micro-boiler to prevent condensate water from building up inside the heat exchanger.

• Condensate cannot be effectively neutralized if the neutralizer elements inside the Neutralizer accessory have been completely consumed. If this happens condensate will remain acidic and can possibly cause damage to items such as pipes, concrete, etc., if drained improperly.

• The Neutralizer cartridge is designed to last for 3 years before replacement. However, the actual life of the neutralizer may vary, depending on the application and usage. Please ensure that the cartridge is properly replaced before the neutralizer elements have been completely consumed.

• All preventive measures and safety practices must be adhered to when draining condensate. The manufacturer will not be responsible for any damage caused by condensate.

• A drain pan, or other means of protection against water damage, is required to be installed under the micro-boiler in case of leaks.

-ELECTRICAL CONNECTIONS-

Follow the electrical code requirements of the local authority having jurisdiction. In the absence of such requirements, follow the latest edition of

WARNING

CAUTION

All micro-boilers come with a power plug instead of a junction box.

the National Electrical Code ANSI/NFPA 70 in the U.S. or the latest edition of CSA C22.1 Canadian Electrical Code Part 1 in Canada.

When servicing or replacing parts within 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.

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Page 30

Installation

-HIGH-ALTITUDE INSTALLATIONS-

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

Altitude

0 to 2,000 ft.

(DEFAULT)

1 2 3 4 5 6 7 8 91010

OFF

2,000 to 3,000 ft.

1 2 3 4 5 6 7 8 91010

OFF

3,000 to 5,000 ft.

1 2 3 4 5 6 7 8 91010

OFF

5,000 to 7,500 ft.

1 2 3 4 5 6 7 8 91010

OFF

DIPswitches

No. 3 : OFF No. 4 : OFF No. 5 : OFF

NOTE: The dark squares indicate the direction the DIPswitches should be set to. Only adjust the necessary switches.

No. 3 : OFF

No. 4 : ON

No. 5 : OFF

No. 3 : OFF No. 4 : OFF

No. 5 : ON

No. 3 : OFF

No. 4 : ON No. 5 : ON

Computer board

7,500 to

10,100 ft.

1 2 3 4 5 6 7 8 91010

OFF

No. 3 : ON No. 4 : ON No. 5 : ON

30 | HYDROSHARK 120 WWW.HYDRO-SHARK.COM

Bank of DIPswitches

Page 31

Installation

-Water Connections-

• Do not use this micro-boiler if any part has been submersed under water. Immediately call a licensed professional to inspect the micro-boiler to replace any damaged parts.

CAUTION

• All pipes, pipe ﬁ ttings, valves and other components, including soldering materials, must be suitable for space heating systems.

• We recommend using an isolation valve set with hose bibs for serviceability. See maintenance and service section. Contact 800.805.5384 to order a isolation valve/service kit.

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

Isolation Valve / Service Kit

Product # 4443W

3/4" FPT ball v. Iso w/drains

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Boiler Supply

Boiler Return

Page 32

WARNING

Installation

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. The system must follow primary/secondary plumbing design speciﬁ cation. (Optional HydroShark pre-built space heating panels incorporate all these features and are located in the optional accessories section starting on p. 35.

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

• Chemicals such as diluted Glycol can be used for radiant ﬂ oor heating only. The diluted solution of glycol must contain between 25 and 50 % of Glycol. Be aware that in closed-loop glycol systems, 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.

• The micro-boiler manufacturer requires primary/ secondary plumbing conﬁ gurations for space heating applications. See description below.

-Hydraulic Separation-

The HydroShark panel systems operate on a principal of hydraulic separation between the boiler circuit and the emitter circuit (tubing, baseboard, ect.). This hydraulic separation creates the ability to adjust the ﬂ ow in the boiler circuit independently from the emitter circuit while still passing heat from the boiler to the emitters. Flow rate from boilers need to be adjusted to manufacturer's speciﬁ cations. Flow rate for emitters need be adjusted for heat output performance.

For more information on hydraulic separation visit this website:

www.calefﬁ .com/sites/default/ﬁ les/ﬁ le/hydraulicseparation-tr07.pdf

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Page 33

pressure relief valve

Primary Circulator

Stiebel Eltron or Gundfos

circulator w/

internal check valve

isolation flanges &

purge valve

-One zone plumbing example-

supply pressure/ temp gauge

air separators

HYDRO SMART

HydroShark 120

Installation

HydroShark 120

HS120 Modulating/ Condensing boiler

gas regulator

thermostat

secondary fitting

tubing in concrete

pump controller

primary/

balancing & sight flow valves

manifold station with

return pressure/temp gauge

diaphragm type expansion tank

y-strainer

Secondary Circulator Stiebel Eltron or Gundfos

circulator w/ internal check valve & isolation flanges

* This diagram illustrates tankless micro-boiler design concepts only and does not accurately represent to micro-boilers description.

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Page 34

Installation

- INITIAL OPERATION-

FOR YOUR SAFETY, READ BEFORE OPERATING

• Check the GAS and WATER CONNECTIONS for leaks before ﬁ ring unit for the ﬁ rst time.

• Open the main gas supply valve to the micro-boiler using only your hand to avoid any spark. Never use tools. If the knob will not turn by hand, 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 micro-boiler because some gases are heavier than air and may settle towards the ﬂ oor.

• Check the GAS PRESSURE. Refer to p. 26.

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

• Check for PROPER VENTING and COMBUSTION 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 submersed under water. Immediately call a qualiﬁ ed service technician to inspect the micro-boiler and to replace any damaged parts.

IF YOU SMELL GAS:

• Do not try to start the micro-boiler.

• Do not touch any electric switches; do not use any phone in your building.

WARNING

2. Fully open the manual gas control valve installed.

Turn on the thermostat and verify that ﬂ uid ﬂ ows through

your radiant system. Then turn off your thermostat.

Turn on the 120 Vac, 60 Hz power supply to the micro-

• 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.

OPERATION

boiler.

Now turn on the thermostat. You are ready to enjoy hours of

34 | HYDROSHARK 120 WWW.HYDRO-SHARK.COM

endless comfort.

Page 35

Optional Items

OPTIONAL ITEMS

ECM Pump Options for Panels are available.

# ITEM CATALOG #

1. 3- inch Concentric PVC Termination HS-CVent-3

2. 4- inch Backﬂ ow Preventer HS-2ZVB04

3. 3/4 in. Flexible Gas Pipe ConnGasFlex34

4. 1/2 in. Gas Regulator (LP and NG) RegGasLP12 / RegGasNG12

5. 3/4 in. Gas Regulator (LP and NG) RegGasLP34 / RegGasNG34

6. Master Pro One Zone Panel STBMP-1ZN190

7. Master Pro Integrator Panel - Zoning by Actuator STBMP-Actuator190

8. 24 Vac Actuator HSMANACT4W

9. Master Pro Integrator Panel - Zoning by Pump STBMP-Pump190

10. Master Pro Integrator Panel - Zoning by Zone Valve STBMP-Valve190

11. Zone Pro 2 Zone Panel - Zoning by Pump STBZP-2T2PMP

12. Zone Pro 3 Zone Panel - Zoning by Pump STBZP-2T3PMP

13. Zone Pro 4 Zone Panel - Zoning by Pump STBZP-2T4PMP

14. Zone Pro 2 Zone Panel - Zoning by Zone Valve STBMZP-2T2ZV

15. Zone Pro 3 Zone Panel - Zoning by Zone Valve STBMZP-2T3ZV

16. Dual Purpose Domestic and Space Heating Panel COMBI-180

-Venting Options-

Item #1: 3- inch Concentric PVC Termination - Used when terminating direct-vent (seal combustion) systems, with boilers that require a 3 in. (76 mm) intake and a 3 in. (76 mm) exhaust. This concentric termination provides the convenience of only having to make one penetration through a sidewall instead of two separate penetrations for the intake and exhaust piping. The termination includes a bird screen, restricting small animals, pests, and foreign objects from entering into the vent system.

Item #2: 4- inch Backﬂ ow Preventer - There are two functions available for this adapter, which can be connected with the micro-boiler and category III venting and prevents the back-ﬂ ow of air through the exhaust vent. This helps prevent harmful exhaust gases from entering the home, as well as helping to prevent the micro-boiler from freezing in areas where cold air can be blown or drawn into the exhaust system. Install this adapter in accordance with the installation instructions that are packaged with the adapter and any applicable codes.

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Page 36

-Gas Options-

Item #3: 3/4 in. Flexible Gas Pipe - This 1 inch OD, 3/4" ID, durable, corrosion-resistant stainless steel gas connector is conﬁ gured with 3/4" MIP x 3/4" FIP adapters and is 36 inches in length. Designed with safety in mind, this CSA approved gas connector is coated with an antimicrobial PVC for unmatched protection from weather and abuse. It is commonly used for the installation of appliances with a high BTU requirement.

Item #4 & #5: 1/2in. and 3/4 in. Gas Regulators(LP and NG) - These gas appliance and line pressure regulators are designed to supply precise regulating control to ﬂ ow of Liquid propane or Natural gas used in residential, commercial and industrial applications. In the absence of ﬂ ow, these regulators guarantee excellent control of the outlet pressure. These regulators have female NPT connections and a venting outlet of 3/8" NPT. They have a maximum inlet pressure of 2 PSIG with 300,000BTU/hr capacity, a spring range of 7 to 11 inches. These units have a spring set point of 11" W.C. for Liquid propane and 8" W.C. for Natural Gas.

Optional Items

-Pre-built Heating Panels Options-

HydroShark-Pre built Heating Panels -HydroShark micro-boilers require primary / secondary plumbing. Pre-built panels from HydroShark make installing you system easy. We do all the engineering and you just bolt it to the wall. HydroShark pre-built space heating panels: Call tech

support (1-763-331-3066) for order assistance.

Features: Master Panels

• 3/4" FPT boiler supply and return connections

• 1" Quick Connect (Pex or Copper) supply and return connections

• 120,000 btu capacity

• 3-spd circulator (0-19 FT HD, 0-17 GPM) with check valve on primary and secondary circuits

• Panel dimensions: 26.25 in. HT x 26 in. WD x 10 in. HT

• Max. Temperature: 155° F

• Max. Operating Pressure: 50 psi. Zoning Panels

• 1" Quick Connect (Pex or Copper) supply and return connections

• 3/4" FPT zone / emitter connections

• 190,000 btu capacity

• Zone Control Options: 3-spd circulator with check valve, 24 Vac Zone Valves, or 24 Vac Actuators

• Panel dimensions: 26 in. - 32.5 in. HT x 26 in. WD x 6.5 in. DP

• Max. Temperature: 190° F

• Max. Operating Pressure: 50 psi.

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Page 37

Optional Items

-One zone system-

Item #6: Master Panel Single - This Master One Zone Panel is utilized when 1 thermostat zone is required in the system.

The panel extracts the heated ﬂ uid from the boiler and processes the heated ﬂ uid to the emitter circuit. Boiler and emitter circuits have hydraulic separation for independent ﬂ ow adjustments.

-Multi zone by Actuator/Telestat system-

Item #7: Master Panel Actuator (Master Pro Integrator Panel - Zoning by Actuator) - This Master Zoning by

Hydronic Manifold - Always use a hydronic manifold

not a potable water manifold for your radiant heating system. Hydronic manifolds have ﬂ ow control valves and site ﬂ ow gauges. Ideal ﬂ ow rate of .5 to .8 GPM per loop/run. (Call 1-763-331-3066 for order assistance.)

Actuator Panel utilizes primary/secondary plumbing just like the one zone panels. This panel would be a great choice when you have multiple zones with emitters that have the same water delivery temperatures, less than 3600 sqft. total and can bring all the loops to 1 central manifold. Note: This

options requires 1 actuator( Item #8) for each loop/run of your system (12 Max.) Each zone must have min. of 600 sqft.

Item #8: Thermo-Electric Zoning Actuator - Actuators open and close when thermostats call for heat and can be grouped together for thermostatically controlled zones with more than 1 loop (there should always be a minimum of 2 loops per zone). These actuators have a control knob for manual opening, valve opening/closing indicator and a device for returning to automatic operation from the manual position.

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Page 38

Optional Items

-Multi zone by Pump system-

Item #9: Master Panel Pump (Master Pro Integrator Panel - Zoning by Pump) - This

Master Zoning by Pump Panel utilizes primary/ secondary plumbing. This panel would be a great choice when you have multiple zones and would like to maintain constant pressure on each zone. A pump panel system can handle up to 1800 sqft per zone and 3600 sqft for the total system. Note:

Each zone must have min. of 600 sqft.

11 12

Item #10, 11, 12: 2 Zone Panel, 3 Zone Panel, 4 Zone Panel - These Zoning Panels paired with the STBMP-Pump190 panel will supply heat to 2 - 4 thermostatically controlled zones. Each pump will handle from 600 sqft to 1800 sqft (Max. 3600 sqft) or 2 to 6 loops /runs of tubing (Max. 12 loops / runs) in concrete. The advantages of zoning by pumps is less variation in ﬂ ow rate and minimization of head loss. Please contact 800.805.5384 for technical assistance when ordering.

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Page 39

14 15 16

Optional Items

-Multi zone by Zone Valve system-

Item #13: Master Panel Valve (Master Pro Integrator Panel - Zoning by Zone Valve) -

This Master Zoning by Zone Valve Panel utilizes primary/secondary plumbing. This panels zoning is similar to Item #7. I would recommend this system when you choose to control your zone by the entire manifold and not by the individual loop. Note: Each zone must have min. of 600 sqft.

Item #14, 15, 16: 2 Zone Panel, 3 Zone Panel, 4 Zone Panel - These Zoning Panels paired with the STBMP-Valve190 panel will supply heat to 2 - 4 thermostatically controlled zones. Each zone valve

will handle from 600 sqft to 1800 sqft. (System Max. 3600 sqft) or 2 to 6 loops /runs of tubing (System Max.12 loops /runs) in concrete. The secondary circulator on the master panel supplies ﬂ ow to the emitters and the zone valves, controlled by a room thermostat determine which zone or area the ﬂ ow will go to. Please contact 800.805.5384 for technical assistance when ordering.

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Page 40

-Dual Purpose panel (Domestic and Space Heating)-

Item #17: DHW Integrator - Insert a HydroShark Dual Purpose Panel into your space heating system to provide potable

heated water. Call 800.805.5384 for sizing assistance.

Space Heating Supply

To Space Heating

Panel System

Space Heating Return

Follow all local codes, or in the absence of local codes, follow the most recent edition of the National Standard Code, ANSI Z21.10.3.

To Domestic Potable

Water System

Hot Potable Water Out

Cold Potable Water In

Boiler Supply

Boiler Return

To Boiler

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Page 41

Owner's Guide

CONGRATULATIONS

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Page 42

OPERATING SAFETY

-For your safety read before operating-

If you do not follow these instructions exactly, a ﬁ re or explosion may result causing property damage, personal injury or loss of life.

WARNING

A. This 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.

B. 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.

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

C. Use only your hand to turn the gas valve knob. Never use tools. If the knob will not turn by hand,

don't try to repair it. Call a qualiﬁ ed service technician. Forced or attempted repair may result in a ﬁ re or explosion.

D. 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 any damaged parts.

-Operating Instruction-

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 gas 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, information above on this page. 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.

STOP! Follow "B" in the safety

-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 43

Operating Safety

DANGER

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

Keep ﬂ ammable products

1. Far away from boiler

2. In approved containers

3. Tightly containers

4. Out of children's reach

1. Cannot be seen

2. Vapors are heavier than air

3. Go a long way on the ﬂ oor

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

Vapors:

WARNING: California Proposition 65 lists chemical substances known to the state to cause cancer,

birth defects, death, serious illness or other reproductive harm. This product may contain such

substances, be their origin from fuel combustion (gas, oil) or components of the product itself.

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Page 44

Normal Operation

NORMAL OPERATION

-Display of the controller-

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

"INFO"

Each the is pressed, the mode is selected in the following sequence.

Inlet water temperature

Outlet water temperature

Water

IN USE LED (Green)

This .

STANDBY LED(Orange)

The indicator turns on when the

• Flow rate to activate the micro-boiler: 0.5 gallon per minute at the default set temperature (1.9 L/min.).

• Flow rate to keep the micro-boiler running: 0.4 gallon per minute (1.5 L/min)

• The controllers have an energy saving mode. Five minutes after the microboiler stops operating, the back-light of the controller turns off.

• The back-light of the controller will turn back on once the micro-boiler begins ﬁ ring again.

Display for Temperature

When the STAND BY LED is ON, the hot water set temperature will be displayed.

"HOT"

"COLD"

"ON/OFF"

-General-

-Temperature table of the controller-

°F 100 105 110 115 120* 125 130 135 140

°C 38 40 43 45 50* 52 55 57 60

* Factory setting (Default)

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Page 45

Normal Operation

-TEMPERATURE SETTINGS-

OPERATION SCREEN ON THE CONTROLLER

Turn on the 120 VAC power supply to the

micro-boiler.

Press the "ON/OFF" button on the controller in

order to turn the controller on.

3. When ON, the STAND BY LED is lit.

It shows the set temperature on its display as

shown in the picture on the right. (EX.: 120° F)

Press the "HOT" button or the "COLD" button

to set the temperature setting of the unit.

Temperature setting above 120° F on Display

Press the "INFO" and the "HOT" buttons

down together and hold for 3-5 secs. Release

the buttons when the display begins to

ﬂ ash. Press the "HOT" button to raise the

temperature setting.

(EX.: 120° F)

-Temperature setting on the PCB-

Without Digital Display

There are 2 preset temperatures (120° F (49° C) and 140° F (60° C)) that you can select from by changing the DIPswitch settings on the computer board. See the table below. When the controller is in normal operation, the set temperature of the controller is given priority over the set temperature of the DIPswitch settings.

• The temperature has been preset at the factory to 120° F (49° C).

Computer board

120 °F (49 °C)

DEFAULT

12 34 56

OFF

No. 9 : OFF

NOTE: Only change the switches with dark squares. The dark squares indicate the direction the DIPswitches should be set to.

140 °F (60 °C)

12 34 56 78 9 10

OFF

No. 9 : ON

Bank of DIPswitches

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Page 46

Normal Operation

-ADDITIONAL FEATURES-

-Information mode-

You can get some information about the micro-boiler condition by pressing the "INFO" button. For more information, follow the procedures below:

OPERATION SCREEN ON THE CONTROLLER

Inlet water temperature will be displayed on

the controller by pressing the "INFO" button.

Outlet water temperature will be displayed on

the controller by pressing the "INFO" button.

Water ﬂ ow rate, in GPM, will be displayed on

the controller by pressing the "INFO" button.

Press the "INFO" button to ﬁ nish information

mode.

Inlet water temperature (EX.: 60° F)

Outlet water temperature (EX.: 120° F)

Water ﬂ ow (EX.: 3.5 GPM)

-Unit conversion mode-

The controller display information can be changed from English Units to S.I. / metric units. Please follow the procedures below:

OPERATION SCREEN ON THE CONTROLLER

Press the "ON/OFF" button on the controller

2. When ON, the orange LED is lit.

displayed in the alternate unit measurement.

46 | HYDROSHARK 120 WWW.HYDRO-SHARK.COM

in order to turn the controller on.

The previous set temperature will be

displayed on the screen.

Press the "INFO" buttons for at least 3

seconds.

The set temperature should now be

(EX.: 100° F)

(EX.: 38° C)

Page 47

Normal Operation

- FLOW-

• The ﬂ ow rate through the micro-boiler is limited to a maximum of 7.0 GPM (26.5 L/min.).

• The temperature setting, along with the return temperature of the water in the system will determine the ﬂ ow rate output of the micro-boiler.

- FREEZE PROTECTION SYSTEM-

• This micro-boiler comes equipped with heating blocks to protect it against damage associated with freezing.

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

• The freeze protection system will activate when the freeze protection thermostat senses temperatures at 36.5° F (2.5° C) or lower.

• It is the installer's responsibility to be aware of freezing issues and take all preventative measures. The manufacturer 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 wind. The manufacturer highly recommends the use of a backﬂ 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 micro-boiler. Refer to "-UNIT DRAINING-" on page 48.

2. Disconnect power to your boiler.

This will keep your micro-boiler 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 micro-boiler will not be protected. Properly protect and insulate these pipes from freezing.

CAUTION

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Page 48

Normal Operation

-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.

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

Flame

Blue

blowing up

Red or Yellow

- UNIT DRAINING-

1. Close the manual gas shutoff valve.

2. Turn off power to the micro-boiler and wait a couple of seconds. Turn on again.

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

4. Close the water shutoff valve.

5. Have a bucket or pan to catch the water from the microboiler's drain plugs. Unscrew the small drain plug ﬁ rst and unscrew the large drain plug next to drain all the water out of the micro-boiler.

6. Wait a few minutes to ensure all water has completely drained from the micro-boiler.

Drain plug (Small)

Drain plug (Large)

Gas valve

Water valve

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Page 49

Troubleshooting

TROUBLESHOOTING

-General-

PROBLEM SOLUTIONS

• Compare the ﬂ ow and temperature. See the chart on p. 59.

• Is the plumbing correct(primary/secondary, pump size, ect.)?

The water is not hot enough.

The water is too hot. • Is the set temperature set too high? (p. 44 to p. 46)

The hot water is not available when there is a call for heat.

• Is the gas supply valve fully open? (p. 34)

• Is the gas line sized properly? (p. 25)

• Is the gas supply pressure sufﬁ cient? (p. 21 and p. 26)

• Is the set temperature set too low? (p. 44 to p. 46)

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

• Is the temperature controller power button turned on?

• Is the gas supply valve fully open? (p. 34)

• Is the Y-strainer clean?

• Can the emitters sufﬁ ciently draw at least 0.5GPM (1.9 L/min) through the micro-boiler. (p. 44)

• Is the unit frozen? (p. 47)

• Is there enough gas in the tank/cylinder? (For Propane)

• Is it plumbed backwards with reverse plumbing?

• Is the ﬂ ow rate enough to keep the unit running? (p. 44)

The hot water turns cold and stays cold.

TEMPERATURE and AMOUNT OF HOT WATER

Fluctuation in hot water temperature.

Unit does not ignite when water goes through the unit.

The fan motor is still spinning after operation has stopped.

Micro Boiler

Abnormal sounds from the micro-boiler.

Unit sounds abnormal while in operation

Controller does not display anything when the power button is turned on.

REMOTE

CONTROLLER

An ERROR code is displayed. • Please see "-ERROR CODES-" on page 50.

• Is the gas supply valve fully open? (p. 34)

• Is the Y-strainer clean?

• Is the system clean of debris and obstructions?

• Is the gas line sized properly? (p. 25)

• Is the supply gas pressure sufﬁ cient? (p. 21 and p. 26)

• Is the plumbing correct?

• Is the power on the micro-boiler?

• Is the gas on?

• Is the ﬂ ow rate over 0.5GPM (1.9 L/min)? (p. 44)

• Is the system Y-strainer clean?

• Check for reverse connection and cross connection. (p. 31)

• Is the temperature controller power button on?(p. 44 & p. 45)

• Check if the system return temperature is to high?

• This is normal. After operation has stopped, the fan motor keeps running from 15 to 70 seconds in order to re-ignite quickly, as well as purge all the exhaust gas out of the ﬂ ue.

• Is the correct gas type of micro-boiler installed? (LP or NG)

• Are the DIPswitch settings for your altitude set correctly?(p. 30)

• Check the ﬂ ame quality. (p. 48)

• Is the intake or exhaust vent blocked? (p. 11)

• Is the vent length and diameter correct? (p. 12 to p. 17)

• Is the manifold pressure set correctly? (p. 5)

• Contact the manufacturer at 1-763-331-3066

• Make sure the micro-boiler is supplied with power.

• Make sure the connection to the micro-boiler is correct.

• Note: When the micro-boiler has not operated for ﬁ ve minutes or more, the display of the controller turns off to conserve energy.

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Page 50

Troubleshooting

-ERROR CODES-

-General-

• The micro-boiler has self-diagnostics for safety and convenience when troubleshooting.

• If there is a problem with the micro-boiler itself, or the installation of the unit, the error code will be displayed on the temperature controller.

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

Error code indicator on the temperature

Green LED

controller

Example: If your unit has the "321" error code (which signiﬁ es an inlet thermistor failure)

• Indicator on the 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.

Error code

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Page 51

Troubleshooting

-Fault Analysis of Error Codes-

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

Display

031

101

111

121

311 321 341

Green

LED

One Time

Five Times

Three Times

Two Times Two Times Inlet thermistor failure Two Times

Malfunction

Description

Incorrect DIPswitch setting

Warning for the "991" error code

Ignition failure

Loss of ﬂ ame

Outlet thermistor failure

Exhaust thermistor failure

Diagnosis

• Check the DIPswitch settings on the PCB (Part #701).

• Check if the gas type of the micro-boiler matches the gas supplied to it.

• 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 altitude/elevation of area where the microboiler is installed and match the appropriate DIPswitches.

• 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 DIPswitches match gas type of the microboiler.

• Check the manifold pressure at Max. and Min.

• Check combustion chamber tube (Part #117) to make sure it is clear and securely installed.

• Check if the Hi-limit switch (Part #411) is properly functioning.

• Check for connection/breakage of wires (Part #412,707,708,709,710), burn marks on the computer board (Part #701), and/or soot on the ﬂ ame rod (Part#108).

• Check if there is a buzzing spark ignition sound coming from the burner (Part #101) when micro-boiler prepares for combustion.

• Listen for the double "clunk" sound coming from gas valve assembly (Part #102) when the micro-boiler goes into combustion.

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

• Check that the gas is turned on.

• Check gas supply.

• Check if the Hi-limit switch (Part #411) is properly functioning.

• Check for connection/breakage of wires (Part #412,707,708,710), burn marks on the computer board (Part #701), and/or soot on the ﬂ ame rod (Part #108).

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

• Check gas supply.

• Check for connection/breakage of wires and/or debris on thermistor (Part #407,408,715).

• Check the resistance.

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Page 52

Troubleshooting

Display

391

510

551

611

701

711

721

751

941

991

Green

LED

Two Times

Six Times

Four Times

One Time

Six Times

N/A

Five Times

Malfunction Description

Air-Fuel ratio rad failure

Abnormal main gas solenoid valve

Abnormal gas solenoid valve

Fan motor fault

Computer board fault

Gas solenoid valve drive circuit failure

False ﬂ ame detection

Miscommunication between micro-boiler and temperature controller

Abnormal exhaust temperature

Imperfect combustion

Diagnosis

• Check for connection/breakage of wires (Part #708) and/or soot on the AFR rod (Part #108).

• Check for connection/breakage of wires (Part #707) and/or burn marks on the computer board (Part #701).

• Check for signs of vent corrosion.

• Check gas valve contacts and gas valve wire harness connections for signs of rust or corrosion.

• Check for connection/breakage of wires (Part #707) and/or burn marks on the computer board (Part #701).

• Check gas valve contacts and gas valve wire harness connections for signs of rust or corrosion.

• Check for connection/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 connection/breakage of wires (Part #711).

• Refer to the 111 and 121 error codes.

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

• Inspect the connections between the micro-boiler and temperature controller.

• Check the power supply of the micro-boiler.

• Check to see if the exhaust temperature is higher than 149°F (65°C).

• Check if the gas type of the micro-boiler matches the gas supplied to it.

• Inspect the environment around the micro-boiler. Determine how long the micro-boiler has been installed and match DIPswitches.

• Check the altitude/elevation of the area of where the micro-boiler is 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 #103), especially if the micro-boiler has been installed in a contaminated area.

• Check the DIPswitches match gas type of the microboiler.

• Check the manifold pressure at Max. and Min.

• Check combustion chamber tube (Part #117) to see if it is clear and securely installed.

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Page 53

COMPONENTS DIAGRAM

-Case assembly-

Components Diagram

003

007

050

002

714

052

704

702

052

004

001

052

-Temperature controller-

722

721

724

056

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Page 54

-Computer board assembly-

701

Components Diagram

709

713

707

711

716

408

407

706

060

-Surge box assembly-

710

103

708

402

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053

705

701

703

120

712

710

712

Page 55

708

053

108

Components Diagram

-Burner assembly-

Burner assembly

101

104

115

401

106

107

116

110

061

053

120

709

109

102

111

114

055 062

709

112 053

053 711

150

057

113

117

Manifold assembly

055

053

117

103

105

064

707

054

119

151

118

051

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Page 56

412

Components Diagram

-Water way assembly-

063

455

458

451

463

451

413

455

413

467

063

455

458

401

462

468

463

451

414

455

467

452

403

154

417

418

058

419 465

460

457

409

052

715

464

053

458

455

408

453

059

416

410

454

405

456

052

406

453

407

059

402

459

457

404

416

466 064

413

450

053

411

415

461

451

56 | HYDROSHARK 120 WWW.HYDRO-SHARK.COM

052

Page 57

Parts List

PARTS LIST

Item # Description Part #

001 Case assembly EK450 002 Front cover EK452 003

004 005 006 007

050 051 052 053

054 055 056 057

058 059 060

061 062 063 064

101 102

103 Fan motor EK109 104

105 106 107

108 109 110 111

112 113 114 115

116 117 118 119

120 Surge box plate EK466

Intake air port assembly Bracket Junction box Power supply cord assembly Back guard panel

Screw M4 x 12 (W / Washer) Screw M4 x 10 (W / Washer) Screw M4 x 10 (Coated) Screw M4 x 10

Hex head screw M4 x 12 (W / Washer) Hex head screw M4 x 8 Pan screw M4 x 20 Tap tight screw M4 x 12 FEZN

Screw M3 x 6 SUS Screw M4 x 6 Screw M3 x 6

Pan screw M4 x 8 Wire clamp 60 Screw M4 x 10 Screw M3 x 6 SUS3

Burner assembly Manifold with gas valve assembly LP Manifold with gas valve assembly NG

Burner gasket Fan damper Burner window Rod holder gasket

Flame rod Igniter rod Rod holder Rod cap

Burner damper Manifold gasket A Manifold gasket B Burner holder gasket

Pressure port Combustion chamber tube Gas inlet Gas inlet ring

EK454 EK455 EK190 EK456 EK457

EW000 EW001 EW002 EW003

EW004 EW005 EW018

EKK31

EW00A EW009

EK191

EW00D

EM167 EW00P EW00B

EK458 EK459 EK460

EKK2X

EK491

EKK2V

EKK2W

EK193 EK461

EKK32

EK462

EK463 EKK2Y EKK2K

EKK0G

EKK2D

EX019

EK465

EKK2Z

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Parts List

Item # Description Part #

150 151 154

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

EZP18

EK042 EKN50

401 Heat exchanger assembly EK467 402

403 404 405 406

Flow adjustment valve / Flow sensor Condensate drain port Water inlet Inlet drain plug Inlet water ﬁ lter

EK129 EKH23

EKK1U

EKK2B

EKK2C 407 Inlet thermistor EKK4J 408 Outlet thermistor EK207 409

410

Water outlet Outlet drain plug

EK104

EKK2E

411 Hi-Limit switch EM212

412 413

Overheat-cut-off fuse Pipe heater

EX02A

EK468 414 Inlet heater EK469 415

416

Drain tube Inlet heater

EK470

EK105 417 Secondary heat exchanger EK471 418

419 450

451 452

453 454 455 456 457

458 459

460 461

462 463

464 465

466 467 468

Secondary heat exchanger heater Heater ﬁ xing plate

Pipe heater ﬁ xing plate Heater ﬁ xing plate 16 Fuse ﬁ xing plate

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"

Fastener "16-25A" Flat heater

EK473

EK474

EK475

EK031

EK476

EZF04

EZF06

EZF14

EZF15

EZF16

EKK24

EM192

EKK39

EK217

Cold pipe for 140 model EK477 Header connection

Thermistor ﬁ xing plate Exhaust thermistor gasket

Hi-limit switch for exhaust Gasket Inlet pipe packing

EK478

EX13H

EX13L

EKH6G

EK229

EK479

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Parts List

Item # Description Part #

701 Computer board EK480 702

703 704

705 707

708 709

710 Freeze protection thermostat EKJ59 711

712 713 714

Rubber grommet Surge box 120 VAC wire

120 VAC Power ON-OFF switch Gas valve wire

Flame rod wire Igniter assembly

Proportional gas valve wire Nylon clamp FC6 Computer board cover Cable clamp

EX148 EK280 EK146

EKK4V

EK482 EK483

EK484

EK112

EX004

EKK1M

EX13C

715 716

721 722

Exhaust thermistor Exhaust Hi-limit switch wire

Temperature controller Fixing plate

OUTPUT TEMPERATURE CHART

Chart is based on properly sized gas line.

Boiler Temp vs Flow Rate with 70 Deg F Return Fluid

EKH6E

EK180 EK487

EK490

Boiler Flow-GPM

100 110 120 130 140

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DEG F

Page 60

Notes

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Notes

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Warranty

LIMITED WARRANTY

1. The manufacturer warrants this product against defects in materials or workmanship as described in this document if installed within the United States or Canada. The manufacturer or its authorized Service Representative will, at its sole discretion, repair or replace any failed or defective mechanical or electrical parts, or components thereof, or, if the manufacturer or its authorized Service Representative cannot replace said parts and repair is not commercially practicable, the manufacturer or its authorized Service Representative will refund the purchase price. The manufacturer or its authorized Service Representative may, at its sole discretion, use new, refurbished or reconditioned parts.

2. Warranty for all models:

Single Family Residential Heating 5 2 N/A

• All warranty claims must be authorized and approved by the manufacturer.

3. General terms of limited warranty:

• This limited warranty gives you speciﬁ c legal rights, and you may also have other rights which vary from State to State. The manufacturer will honor the warranty to the original retail buyer at the original location only, within the United States or Canada, and it is not transferable.

• THIS WARRANTY COVERS ONLY FAILED MECHANICAL AND ELECTRICAL PARTS DUE TO FACTORY DEFECTS UNDER NORMAL USAGE FOR THE PRODUCT'S INTENDED PURPOSES AND WITHIN THE APPLICABLE PERIOD SPECIFIED IN THE TABLES ABOVE. ONLY DIRECT DAMAGES SHALL BE RECOVERABLE BY A CLAIMANT UNDER THIS LIMITED WARRANTY AND, IN NO EVENT, WHETHER AS A RESULT OR BREACH OF CONTRACT, BREACH OF WARRANTY, TORT LIABILITY (INCLUDING NEGLIGENCE), STRICT LIABILITY, INDEMNITY OR OTHERWISE WILL BE LIABLE FOR ANY SPECIAL, INCIDENTAL, OR INDIRECT CONSEQUENTIAL DAMAGES INCLUDING PROPERTY DAMAGE, PERSONAL DAMAGES, LOSS OF USE, OR INCONVENIENCE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

4. Limitation on Duration of Implied Warranties:

• ANY IMPLIED WARRANTIES ARISING UNDER STATE LAW, INCLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY, SHALL IN NO EVENT EXTEND PAST THE EXPIRATION OF ANY WARRANTY PERIOD HEREUNDER. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

5. THIS WARRANTY WILL NOT COVER THE FOLLOWING:

• Any product that is not installed by a licensed plumber, gas installer, or contractor.

• Damages due to accidents, abuse, misuse, improper installation, misapplication, or incorrect sizing.

• Damages due to ﬁ res, ﬂ ooding, freezing, electrical surges, or any Acts of God.

• Damages due to unauthorized alterations, attachments, and/or repairs.

• Damages due to a lack of maintenance (e.g. Y-stainer, water treatment system, vent blockage, ect.).

• Any product installed in an improper environment (e.g. corrosive, dusty, chemically contaminated, excessive lint, etc.).

Application Type Heat Exchanger Parts Labor

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Warranty

• Freeze damage that occurs without taking proper preventive measures as described in the installation manual.

• Condensate damage due to improperly installed or lack of a condensate trap (drain).

• Any product not installed in compliance with all applicable local & provincial codes, ordinances, and good trade practices.

• Any product sold to or installed in areas outside of the ﬁ fty states (and the District of Columbia) of the United States of America and Canada.

• Any product installed in applications that cause the micro-boiler to activate more than 300 times per day. (This averages to an activation every 5 minutes in a 24-hour period.)

• Damages due to improper installation:

• Gas: incorrect gas pipe sizing, incorrect gas meter sizing, incorrect gas type, and/or gas pressures that fall outside the product's speciﬁ ed range.

• Water: incorrect water pipe sizing, water pressures that fall outside the product's speciﬁ ed range, recirculation ﬂ ow rates that fall outside the product's speciﬁ ed range (air removal), and/ or lack of proper methods of air removal in a closed-loop, circulation system. (See installation manual for details.)

• Electric: supply power voltages that fall outside the product's speciﬁ ed range.

• Damages due to water quality:

• Introduction of liquids other than water or water / glycol mixtures into the product.

• Introduction of pool water, spa water, or any chemically treated water into the product.

• Introduction of hard water measuring more than 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 into the product.

• Introduction of untreated or poorly treated well water into the product.

• Introduction of water with pH levels less than 6.5 and greater than 8.5 into the product.

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

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

Subject to errors and technical changes!

331126-40419-9328