STIEBEL ELTRON HydroShark 199LP, HydroShark 199NG Operation And Installation

OPERATION AND INSTALLATION UTILISATION ET INSTALLATION
Condensing Gas Micro-boiler
»HydroShark 199NG »HydroShark 199LP
Conforms to ANSI Z21.10.3/CSA 4.3
Conforme à la norme ANSI Z21.10.3/CSA 4.3
HydroShark 199 Condensing Gas Micro Boiler Installation Manual and Owner’s Guide
Models:
HydroShark 199NG HydroShark 199LP
The HydroShark 199 Condensing Gas Micro Boiler is a compact and powerful residential unit with a versatile BTU modulating range.
Featuring
• Effi ciency: 95 %
• Wall Hung
Flow Activated: .5 GPM
Copper Heat Exchanger
Temperature Range: 80°-160° F*
• Freeze Protection
• Power Vent
• PVC Venting
*Up to 185 with optional control
Do not return. Damages or repairs call
HydroShark 800.805.5384
If the information in these instructions is not followed exactly, a fi re or explosion may result causing property damage, personal injury or death.
-Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of this or any other appliance.
-WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance
Do not touch any electric switch, do not use any phone in your building.
Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the re department.
-Installation and service must be performed by
a qualifi ed installer, service agency or the gas supplier.
CONTENTS
Installation Manual
SPECIFICATIONS..........................................................................................................4
INTRODUCTIONS..........................................................................................................5
SAFETY GUIDELINES...................................................................................................6
INSTALLATION...............................................................................................................7
General................................................................................................................7
Clearances...........................................................................................................9
Included accessories............................................................................................9
High-altitude installations....................................................................................10
Venting instructions.............................................................................................11
Gas supply and gas pipe sizing..........................................................................21
Water connections..............................................................................................23
Condensate drain...............................................................................................25
Electrical connections.........................................................................................26
APPLICATIONS..................................................................................................27
INITIAL OPERATION..........................................................................................29
OWNER’S GUIDE
OPERATING SAFETY...................................................................................................31
NORMAL OPERATION.................................................................................................33
Temperature controller and Remote controller...................................................33
General..............................................................................................................33
Temperature Settings.........................................................................................34
Temperate table of controller..............................................................................34
Additional features..............................................................................................35
Temperature setting on the PCB (without remote controller).............................36
Flow....................................................................................................................37
Freeze protection system...................................................................................37
Maintenance and service...................................................................................38
Unit draining and fi lter cleaning..........................................................................38
TROUBLESHOOTING..................................................................................................39
General...............................................................................................................39
Error codes.........................................................................................................41
COMPONENTS DIAGRAM...........................................................................................44
PARTS LIST...................................................................................................................48
OUTPUT TEMPERATURE CHART...............................................................................50
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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 installation manual
carefully. Keep this manual for future reference.
If you need an additional manual, contact the manufacturer or your local distributor. When you call, please tell us the product name and the serial
number of your unit written on the rating plate of the boiler.
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SPECIFICATIONS
HydroShark 199 Gas Condensing Micro-Boiler
Natural Gas Input
(Opera
Range)
Propane Input
(Opera
Range)
Gas
Water
Water Pressure* 15 - 150 (0.1 - 1)
Natural gas Inlet Pressure Propane Inlet Pressure
Natural
Manifold Pressure**
Gas
Propane
BTU/h
BTU/h
Max.: 199,000
Max.: 199,000
3/4" NPT
3/4" NPT
psi
(MPa)
inch W.C.
(kPa)
inch W.C.
(kPa)
Min. 5.0 (1.24)
Max. 10.5 (2.61)
Min. 8.0 (1.99)
Max. 14.0 (3.48)
inch W.C. 2.95
(Pa) (734)
inch W.C.
(Pa)
3.3
(821)
000,51 :.niM
000,31 :.niM
Weight lbs. (kg) 59 (26.8)
Dimensions
inch mm
H 22.4 x W 17.7 x D 10.7
H 570 x W 450 x D 272
Electric
Supply
Opera W / A 89.0 / 0.74
Standby W / A 4.2 / 0.04
Electric
Freeze-
Consump
Prot
VAC/Hz 120 / 60
W / A 175 / 1.5
*18-25 PSI is recommended for maximum fl ow (Space Heating) **The Manifold Pressure is the factory setting and generally should not need adjustment.
NOTE:
Check the rating plate to ensure this product matches your specifi cations.
The manufacture reserves the right to discontinue, or change at any time, specifi cations, or designs without notice and without incurring obligation.
*When using boiler in-conjunction with HydroShark DHW Integrator Panel, system pressure may be much higher on your domestic water side. Your space heating side should still refl ect the recommended 18-25 PSI for system pressure.
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INTRODUCTION
This manual provides information necessary for the installation, operation, and maintenance of the boiler.
The model description is listed on the rating plate which is attached to the side panel of the boiler.
Please read all instructions completely before installing this product.
If you have any problems or questions regarding this equipment, consult the manufacturer or its local representative.
This equipment is a condensing micro boiler designed to effi ciently supply endless hot water for your needs. (Radiant Heating, or Domestic Water used in-conjunction with Radiant Heating) See DHW Integrator Panel for more information on integrating domestic water with your radiant heat­ing system.
• These high ef ciency models have a built-in secondary heat exchanger that absorbs latent heat from the exhaust gas.
These boilers are only to be installed indoors.
The principle behind condensing micro boilers is easy:
Intake port
Exhaust thermistor
Thermistor
Bypass valve
Water control valve
Computer board
Thermistor
Hot water outlet
Thermistor
Exhaust
Secondary heat exchanger
Primary heat exchanger
Burners
Gas valves
Fan motor Flow sensor
Condensate drain port
Gas
Cold water inlet
*This diagram illustrates condensing micro boiler design concepts only and does not accurately repre­sent the boilers physical description.
1. Your thermostat indicates a need for heat and turns on the circulator pump(s).
2. Water fl ows through the boiler.
3. The fl ow sensor detects the water fl ow .
4. The computer initiates the fan motor and sends a signal to the igniter to create an ignition spark.
5. The gas ignites and fl ames appear within the burner chamber.
6. Water circulates through the heat exchanger and then gets hot.
7. Using thermistors to measure temperatures throughout the micro-boiler, the computer modulates the gas and water valves to ensure proper output water temperature.
8. When your room reaches desired temperature the pumps turn off and the boiler shuts down.
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SAFETY GUIDELINES
SAFETY DEFINITION
Indicates an imminently hazardous situation which, if not avoided, will result in
DANGER
WARNING
CAUTION
1. Follow all local codes , or in the absence of local codes, follow the current edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or B149.1 Natural Gas, Propane Installation Code in Canada.
2. Properly ground the unit in accordance with all local codes or in the absence of local codes, with the National Electrical Codes: ANSI/NFPA 70 in the USA or CSA standard C22.1 Canadian Electri­cal Code Part 1 in Canada.
3. Carefully plan where you intend to install the micro boiler. Please ensure:
•Your micro boiler will have enough combustible air and proper ventilation
•Locate your micro boiler where water leakage will not damage surrounding areas.
4. Check the rating plate for the correct Gas Type, Gas Pressure, Water Pressure and Electric
Rating.
5. *If this unit does not match your requirements, do not install and consult with the manufacture.
6. If any problem should occur, turn off the unit and unplug the zone controls for the space heating and/or DHW Integrator Panel system zone controls and turn off the gas. Then call a trained techni­cian or the Gas Company or the manufacture.
death or serious injury.
Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.
Indicates an imminently hazardous situation which, if not avoided, could result in minor or moderate injury.
GENERAL
Water temperature over 125°F (52°C) can cause severe burns instantly or death from scalding. The water temperature is set at 120°F (50°C) from the factory to minimize any scalding risk. If using micro boiler with HydroShark DHW Integrator Panel, always check the water temperature. Always verify
WARNING
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emitter water delivery temperature requirements to avoid damage.
Do not store or use gasoline or other fl ammables, vapors, or liquids in the vicinity of this appliance.
Do not reverse the fl uid and/or gas connections as this will damage the gas valves and can cause sever injury or death.
Do not use this appliance if any part has been in contact with or been im­mersed in water. Immediately call a licensed plumber, a licensed gas fi tter, or a professional service technician to inspect and/or service the unit if neces­sary.
Do not disconnect the electrical supply if the ambient temperature will drop below freezing. The freeze protection system only works if the unit has electri­cal power. The warranty will not be covered if the heat exchanger is damaged due to freezing.
INSTALLATION
GENERAL
1. Follow all local codes, or in the absence of local codes, follow the current edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the USA or B149.1 Natural Gas, Propane Installation Code in Canada.
2. All gas micro boilers require careful and correct installation to ensure safe and effi cient operation. This manual must be followed exactly. Read the “Safety Guidelines” section.
3. The manifold gas pressure is preset at the factory. It is computer controlled and should not need adjustment.
4. Maintain proper space for servicing. Install the unit so that it can be connected or removed easily. Refer to the “Clearances” section for proper clearance.
5. The micro boiler must be installed in a location where the proper amount of combustible air will be available to it at all times without obstructions.
6. The electrical connections requires a means of disconnections, to terminate power to the micro boiler for servicing and safety purposes.
7. Do not install the unit where the exhaust vent is pointing into any opening in the building or where the noise may disturb your neighbors. Make sure the vent termination meets the required distance by local code from any doorway or opening to prevent exhaust from entering a building.
8. Particles from fl our, aerosols, and other contaminants may clog the air vent, build up and reduce the functions of the rotating fan, cause improper burning of the gas, or cause damage to the micro boiler. Regularly ensure that the area around the unit is dust or debris free. Regular maintenance is recommended for these types of environment.
9. The HydroShark 199 condensing gas boiler is to be installed indoors only. This unit is equipped with thermistors and a hi-limit switch for the exhaust gas, detecting excess temperatures within the fl ue and enabling the unit to safely stop operations. 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 temperatures exceeds 140° F, these components will enable the unit to safely stop operations.
The micro-boiler requires 3” or 4” make-up intake air supply pipe. The intake pipe must be sealed airtight.
Air supply pipe can be made of ABS. PVC (solid core), CPVC (solid core), polypropylene, corru­gated stainless steel, or Category III/IV stainless steel. Regarding exhaust pipe refer to the “Ex­haust section” under venting instructions.
Sidewall venting is recommend 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 and service must be performed by a qualifi ed installer (for example, a licensed plumber or gas fi tter, otherwise the warranty will be void.
The installer (licensed professional) is responsible for the correct instal­lation for the micro boiler and for compliance with all national, state / provincial, and local codes.
The manufacturer does not recommend installing the micro boiler in a pit or location where gas and water can accumulate.
Do not have the vent terminal pointing toward any operating window, door, or opening into a building.
Do not install next to any source of airborne debris, such as clothes dryer, that can cause debris to be trapped inside the combustion chamber, unless the system is direct vented.
The manufacturer does not recommend installing the micro boiler in an attic due to safety issues. If you install the micro boiler in an attic:
-Keep the area around the micro boiler clean. When dust collects on the
fl ame sensor, the micro boiler will shut down on an error code.
-Place the unit for easy access for service and maintenance.
-A drain pan, or other means of protection against water damage, is to be
installed under the micro boiler in case of leaks.
-Make sure the unit will have enough combustion air and proper ventilation.
CAUTION
The warranty will not cover damage cause by water quality.
-Only distilled water or distilled water/glycol mixtures can be used with this
micro boiler, unless when used in-conjunction with Stiebel Eltron DHW Integra­tor Panel system. Do not introduce pool or spa water, or any chemically treated water into the micro boiler.
-Water hardness levels must not exceed 7 grains per gallon (120 ppm) for
single family applications or more than 4 grains per gallon (70 ppm) for all other types of applications/ Water hardness leads to scale formation and may affect / damage the micro boiler. Hard water scaling must be avoided or controlled by proper water treatment.
-Water pH levels must be between 6.5 and 8.5.
-Well water must be treated.
Do no install the micro boiler where water, debris, or fl ammable vapors may get into the fl ue terminal.
Although the micro boiler is designed to operate with minimal sound, the
manufacturer does not recommend installing the unit on a wall adjacent to a bedroom, or a room that is intended for quiet study or meditation, etc.
Locate your boiler close to a drain where water leakage will not do damage to surrounding areas. As with any water heating appliance, the potential for leak­age at some time in the life of the product does exist. The manufacturer will not be responsible for any water damage that may occur. If you install a drain pan under the unit, ensure that it will not restrict the combustion air fl ow.
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CLEARANCES
To p
Maintain all clearances around the micro-boiler.
Side
Front
Model Top Bo om Front Back Sides
HydroShark 199LP (Liquid propane)
HydroShark 199NG (Natural Gas)
*24 inches recommended for maintenance.
12 in.
(914 mm)
12 in.
(914 mm)
12 in.
(305 mm)
12 in.
(305 mm)
24 in.
(610 mm)
24 in.
(610 mm)
0.5 in.
(13 mm)
0.5 in.
(13 mm)
INCLUDED ACCESSORIES
Check that these items below are included with the micro boiler.
Back
Side
2 in.
(51 mm)
2 in.
(51 mm)
Installa manual and owner’s guide
1 :ytQ
Bird screen
Qty: 2
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HIGH-ALTITUDE INSTALLATIONS
Check the elevation where your micro boiler is installed. Set DIPswitches shown in the table below depending on the altitude.
DIPswitches
HydroShark 199 Boiler
(Lower bank of
DIPswitches)
0 (DEFAULT) Up to 2,500 Up to 5,000 Up to 7,500
123456
ON
OFF
No. 2 : OFF No. 3 : OFF No. 4 : OFF
123456
ON
OFF
No. 2 : OFF
No. 3 : ON
No. 4 : OFF
123456
ON
OFF
No. 2 : OFF No. 3 : OFF
No. 4 : ON
123456
ON
OFF
No. 2 : OFF
No. 3 : ON No. 4 : ON
Up to 10,100
123456
ON
OFF
No. 2 : ON No. 3 : ON No. 4 : ON
NOTE: The dark squares indicate the direction the DIPswitches should be set to.
Computer board
Lower bank of DIPswitches
DO NOT adjust any DIPswitches on the upper bank.
WARNING
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VENTING INSTRUCTIONS
GENERAL
Improper venting of this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death.
DANGER
CAUTION
This appliance must be vented in accordance with the section” Venting of Equipment” of the current edition of the National Fuel Gas Code: ANSI Z223.1/NFPA 54 in the United States and/or Section 8 of the B149.1 Natural Gas and Propane Installation Code in Canada, as well as applicable local building codes. The use of venting materials approved for Category III/IV appliances is recommended when­ever possible. However, this appliance may also be vented with plastic pipe materials such as ABS, PVC (solid core), CPVC (solid core), or polypropylene. For details, please refer toe the Exhaust Vent (ABS, PVC, CPVC, or Polypropylene Vent) Section. Vent installations in Canada which utilize plastic vent systems must use venting that complies with ULC S636.
Improper installation can cause nausea or asphyxiation, severe injury or death from carbon monoxide and fl ue gases poisoning. Improper installation will void product warranty.
When installing the vent system, all applicable national and local codes must be followed. If you install thimbles, fi re stops or other protective devices and they penetrate any combustible or noncombustible construction, be sure to follow all applicable national and local codes.
General rules for venting micro boilers 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 the vent collar of the unit.
The vent must be easily removable from the top of the boiler for normal service and inspection of the unit.
The micro boiler vent must not be connected to any other gas appliance or vent stack except an approved common venting system.
Avoid using an oversized vent pope or using extremely long runs of the pope unless it is part of an approved common vent system.
For rooftop venting, a rain cap or other from of termination that prevents rain water from entering into the micro boiler must be installed.
Do not terminate vent into chimney. If the vent must go through the chimney, the vent must run all the way through the chimney with approved vent pipe.
General rules for vent terminations:
Avoid locating the micro boiler vent termination near any air intake devices. These fans can pick up the exhaust fl ue products from the micro boiler and return them to the building. This can create a health hazard.
Locate the vent termination so that it cannot be blocked by any debris, at any time. Most codes re­quire that the termination be at least 12 in. (305 mm) above grade, but the installer may determine if it should be higher depending on the job site condition and applicable codes.
A proper sidewall termination is recommended when the micro boiler is vented through a sidewall.
Be sure to check the clearance form the exhaust termination to the air inlet or opening in the vent termination clearances section.
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DIPswitch settings for Vent length
<Two-pipe, direct-vent installation>
Set DIPswitches shown in the tables below depending on vent length.
3"
Vent length
5 to 20
(DEFAULT)
21 to 40
41 to 70
Vent length
5 to 50
(DEFAULT)
51 to 100
4"
(Upper bank of DIPswitches)
12345678
ON
OFF
No. 3 : ON
No. 4 : OFF
123456 78
ON
OFF
No. 3 : OFF No. 4 : OFF
123456 78
ON
OFF
No. 3 : ON No. 4 : ON
(Upper bank of DIPswitches)
12345678
ON
OFF
No. 3 : ON
No. 4 : OFF
123456 78
ON
OFF
No. 3 : OFF No. 4 : OFF
<Single pipe with room-air intake installation>
Set DIPswitches shown in the tables below depending on vent length.
Vent length
5 to 45
(DEFAULT)
46 to 70
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3"
(Upper bank of DIPswitches)
123456 78
ON
OFF
No. 3 : ON
No. 4 : OFF
12345678
ON
OFF
No. 3 : OFF No. 4 : OFF
Exhaust vent (ABS, PVC, CPVC, or polypropylene vent)
This appliance can be vented with ABS, PVC, CPVC, or polypropylene (temperature rated up to 149°F). Vent material certifi ed to ULC S636 standards is recommended in the USA. In Canada, plas- tic venting must be certifi ed to ULC S636 standards.
Item Material CanadaUnited States
Schedule 40 PVC ANSI/ASTM D1785
Exhaust pipe and
Fi
Pipe Cement/Primer
PVC-DWV
Schedule 40 CPVC ANSI/ASTM F441
Schedule 40 ABS-DWV ANSI/ASTM D2661
PVC ANSI/ASTM D2564
CPVC
ABS
NOTE: Do NOT Use Cellular Foam Core Pipe
ANSI/ASTM D2665
UL-1738Polypropylene
ANSI/ASTM F493
ANSI/ASTM D2235
ULC S636 Materials Only
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.
Diameter Max. No. of Elbows
53 in. (76 mm) 70 (21.3 m)
4 in. (102 mm) 100 (30.5 m)
5
Max. V cal and Horizontal (Total) Vent Length
*For each elbow added, deduct 5 ft. (1.5 m) from max vent length.
Max. V cal or Horizontal (Total) Vent Length
No. of Elbows 3" ven 4" ven
Up to 3,000
0
1
2
5
70 (21.3 m) 40 (12.2 m) 25 (7.6 m)
65 (19.8 m) 35 (10.7 m) 20 (6.1 m)
60 (18.3 m) 30 (19.1 m) 15 (4.6 m)
Up to 6,000
N/A45 (13.7 m) N/A 75 (22.9 m)
Up to 10,100
Up to 10,100
100 (30.5 m)
95 (29.0 m)
90 (27.4 m)
Excludes vent terminators, termination elbows, or rain caps.
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Two-pipe, direct vent illustrations
Typical installation using PVC. ABS, or polypropylene vent
Horizontal Installation Vertical Installation
Wall
Roof
Roof
Fire stop
Connect between exhaust vent collar and piping.
See the below.
For details of the optional items, refer to the installation manual for each optional item.
<How to install intake and exhaust venting (two-pipe, direct vent)
3” vent connection
1. Connect 3” couplings directly on the exhaust and intake vent collar of the micro boiler.
2. Connect 3” straight pipes to the couplings.
From 3” to 4” vent connection
1. Connect 3” x 4” increasers directly on the exhaust and intake vent collar of the micro boiler
2. Connect 4” straight pipes to the increasers.
3” straight pipe
3” coupling
Intake vent collar (Female)
4” straight pipe
3"x4" increaser
3” straight pipe
3” coupling
Exhaust vent collar (Female)
4” straight pipe
3"x4" increaser
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Intake vent collar (Female)
Exhaust vent collar (Female)
Single pipe with room-air intake illustrations
Typical installation using PVC. ABS, or polypropylene vent
Horizontal Installation Vertical Installation
Wall
Roof
Roof
Elbow
Connect between exhaust vent collar and piping. See the below.
For details of the optional items, refer to the installation manual for each optional item.
3” vent connection
1. Connect 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.
3. Connect a 3” straight pipe to the coupling.
Elbow
<How to install single vent>
3” elbow with bird screen
Intake vent collar (Female)
Fire stop
3” straight pipe
3” coupling
Exhaust vent collar (Female)
From 3” to 4” vent connection
1. Connect 3” elbow directly on the intake vent collar of the micro boiler.
2. Connect 3” x 4” increasers directly on the exhaust vent collar of the micro boiler
3. Connect a 4” straight pipe to the increasers.
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3” elbow with bird screen
Intake vent collar (Female)
4” straight pipe
3"x4" increaser
Exhaust vent collar (Female)
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” vent ap­proved for use with Category III/IV or Special BH type gas vent.
The manufacturer recommends the NovaVent line. However, the following are also UL listed man­ufactures: 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
54 in. (102 mm)
*For each elbow added, deduct 5 (1.5 m) from max. vent length.
No. of Elbows
0
1
2
5
Excludes vent terminators, termina elbows, or rain caps.
Max. V cal and Horizontal (Total) Vent Length
100
(30.5 m )
Max. V
cal or Horizontal Vent Length
100
(30.5 m)
95
(29.0 m)
(27.4 m)
90
(22.9 m)
75
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Direct-vent and single vent illustrations
Horizontal Installation Vertical Installation
Wall
Roof
Hanger
Hanger
Sidewall vent
Rain cap
Fire stop
The diagram above shows direct-vent installations. For single vent installation, connect a 4” elbow directly on the intake vent collar instead of a straight pipe. See the instructions below for the detail.
For details of the optional items, refer to the installation manual for each optional item.
Regarding the clearances from the exhaust terminal to the air inlet or opening, refer to next few pages.
Follow all vent system manufacturer’s instructions and all local codes.
Use 4” Category III/IV approved or Special BH, single or double wall stainless steel vent pipe.
<How to install single vent>
4” vent connection for direct vent installation
1. Connect 4” stainless steel vent straight pipes directly on the ex­haust/intake vent collar of the micro boiler.
4” vent connection for a single vent installation
1. Connect 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.
4" (102 mm) stainless steel vent straight pipe
Intake vent collar (Female)
4" (102 mm)elbow with bird screen
Intake vent collar (Female)
4" (102 mm) stainless steel vent straight pipe
Exhaust vent collar of the Indoor models (Female)
4” (102 mm) stainless steel vent straight pipe
Exhaust vent collar of the Indoor models (Female)
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Vent termination clearances
INSIDE CORNER DETAIL
Vent terminal
V
Air supply inlet
X
G
V
A
D
E
V
Area where is not permi ed
H
B
C
V
FIXED
L
Clearance above grade, veranda, porch, deck, or balcony
C Clearance to permanently closed window
V cal clearance to ven ated soĸƚ located above the vent terminator within a horizontal distance
D
of 2 feet (61cm) from the center line of the terminator
Clearance to each side of center line extended above meter/regulator assembly
Clearance to non-mechanical air supply inlet to
J
building or the combus air inlet to any other applica
Clearance above paved sidewalk or paved driveway located on public property
V
OSE
CL D
L
OPERAB E
V
F
B
B
B
OPERABLE
V
B
B
FIXED
OSED
CL
V
J
A
Canada U.S.A
than Direct-vent Direct-vent
1 foot 1 foot 1 footA
3 feet 1 foot B Clearance to window or door that may be opened
***
***
***E Clearance to unven ated soĸƚ ***F Clearance to outside corner ***G Clearance to inside corner
3 feetI Clearance to service regulator vent outlet
3 feet 1 foot
6 feet
V
M
I
X
Gas meter / regulator
Direct-
vent
**3 feetH
**
3 feetK Clearance to mechanical air supply inlet 3 feet
*7 feetL
*1 foot *M Clearance under veranda, porch deck, or balcony
Other than Direct-vent and other
4 feet from below or
side opening. 1 foot from above opening
4 feet from below or
side opening. 1 foot from above opening
7 feet
X
V
K
*For clearances not specifi ed in ANSI Z223.1/NFPZ 54 (US) or B149.1 (Canada), please use clear- ances in accordance with local installation codes and the requirements of the gas supplier.
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For sidewall terminations
Please follow all local and national codes in regards to proper termination clear­ances. In the absence of such codes, the clearances below can be used as guidelines. Local codes supersede these guidelines.
1 (305 mm)
min
1 (305 mm) min
Exhaust termina
1 (305 mm)
min
1 (305 mm) min
Combined intake and exhaust termina
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.
2 (610 mm) min
Inside corner
2 (610 mm) min
Inside corner
<Case 1>
For multiple sidewall exhaust terminations (e.g. Multi-unit Systems), an exhaust termination must be at least 1 ft. (305mm) away from another exhaust termination. An ex­haust termination must also be at least 2 ft. (610mm) away from an inside corner. (If the adjacent wall is less than 2 ft. (610mm) of length, the minimum required distance away from the inside corner will be equal to the length of that adjacent wall.)
For multiple-unit, direct-vent sidewall terminations that combine the intake and exhaust into a single penetration, space each direct-vent termination at least 1 ft. (305mm) away from each other, no matter the orientation. A direct vent termination must also be at least 2 ft. (610mm) away from an inside corner. (If the adjacent wall is less than 2 ft. (610mm) of length, the minimum required distance away from the inside corner will be equal to the length of that adjacent wall.)
Exhaust
Intake
1 (305 mm)
min
Exhaust
Intake
0.5
(159 mm)
min
0.5
(159 mm) min
<Case 2>
1 (305 mm) min
Exhaust
Intake
Exhaust
Intake
0.5
(159 mm) min
CAUTION
Exhaust and/or direct-vent sidewall terminations should be at least 2 ft. (610mm) away from an opposite surface/wall. Do not place the termination directly in front of an opening
2 (610 mm)
min
Exhaust termina
into a building.
For rooftop terminations
Please follow all local and national codes in regards to proper termination clear­ances. In the absence of such codes, the clearances below can be used as guidelines. Local codes supersede these guidelines.
Intake air
2 (610 mm) min
1 (305 mm) min
Exhaust gas
1 (305 mm) min
1 (305 mm) min
1 (305 mm) min
3 (914 mm) min
Intake air
Exhaust gas
1 (305 mm) min
Exhaust terminations must be at least 1 ft. (305 mm) away from any obstructions.
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GAS SUPPLY AND GAS PIPING SIZE
Check that the type of gas matches the rating plate fi rst.
Ensure that any and all gas regulators are operating properly and providing gas pressures withing the specifi ed range shown below.
CAUTION
The minimum and maximum inlet gas pressures are:
Excess gas inlet pressure may cause serious accidents.
Conversion of this unit from natural gas to propane or vice versa will void all warranty. Contact your local distributor to get the correct unit for your gas type. The manufacturer is not liable for nay property and/or personal
damage resulting from gas conversions.
Gas type Inlet gas pressure
Natural Gas
Propane
Min. 5.0” W.C. (1.24 kPa) – Max. 10.5” W.C. (2.61 kPa)
Min. 8.0” W.C. (1.99 kPa) – Max. 14.0” 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 a damages to the unit.
Until testing of the main gas line supply pressure is completed, ensure the gas line to the micro boiler is disconnected to avoid any further damage.
Gas connections
1. Install a manual gas shutoff valve between the micro boiler and the gas supply.
2. When the gas connections are completed, it is necessary to perform a gas leak test either by applying soapy water to all gas fi ttings and observing for bubble or by using a gas leak detection device.
The micro boiler and its individual shutoff valve must be disconnected from the gas supply pip­ing system during any pressure testing of that system at the test pressures in excess of 1/2 psi (3.5kPa).
The micro boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa).
3. Always purge the gas line of any debris and/or water before connecting to the gas inlet.
Size the gas pipe appropriately to supply the necessary volume of gas required for
NOTICE
the micro boiler using ANSI Z223.1/NFPA 54 in the USA of B149.1 in Canada or local codes. Otherwise, fl ow capabilities and output temperatures will be limited.
Natural Gas Supply Piping
Maximum delivery Capacity of Cubic Feet of Gas per Hour of IPS Pipe carrying Natural Gas with 0.60 Specifi c Gravity Based on Pressure Drop of 0.5”W.C.
Based on Energy Content of 1,000 BTU/Cubic ft.: The micro boiler requires 199 Cubic ft./hr.
Unit: Cubic feet per hour
Pipe Size Length
10' 20'Diameter 30' 40' 50' 60' 70' 80' 90' 100' 125' 150' 200'
3/4"
1" 684 470 377 323 286 259 239 222 208
1/4"
1
1/2"
1
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
363 249 200
1,404 965 775 663 588 532 490 456 428 404 358 324 278 2,103 1,445 1,161 993 880 798 734 683 641 605 536 486 416
Propane (LP) Supply Piping
Maximum Capacity of Propane (LP) Based on 11” W.C. supply pressure at 0.5” W.C. pressure drop.
Unit: kBTU per hour
LengthPipe Size
10'Diameter 20' 30' 40' 50' 60' 70' 80' 90' 100' 125' 150' 200'
3/4"
1" 1,071 732 590 504 448 409 378 346 322 307 275 252 213
1/4"
1/2"
1
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
567 393 315 267 237 217
2,2051
1,496 1,212 1,039 913 834 771 724 677 630 567 511 440
3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787 675
elpmaxe gnizis saG
(Natural Gas)
5' Length
1-1/4" Pipe size
5' Length 1-1/4" Pipe size
Gas meter
Based on Energy Content of 1,000 BTU/Cubic ft. Divide each appliance’s BTU/h requirement by 1,000 BTU/ft³ to get the appliances ft³/h requirement.
Take into account the distance the appliance is from the gas meter, look in the above gas chart to properly size the line. For sections of the gas line supplying gas to more than one appliance (Ex. Point A to Point B), add up the cubic ft. per
hour requirements of the appliances that are being supplied by that section, and size to the farthest appliance. For Example: The section from A to B supplies gas to the furnace, range and dryer. Adding up the BTU/h requirements
and dividing by 1,000 yields a cubic ft. per hour requirements of 220 cubic ft. of gas per hour. The farthest appliance is the range, which is 50 ft. away form the meter. Looking at the above chart, and under column of 50 ft., Section A to B needs to be 1” in order to supply 220 cubic ft.
Micro-
boiler
199,000 BTU/h
10' Length
3/4" Pipe size
A
10' Length
1" Pipe size
B
10' Length
3/4" Pipe size
Furnace
120,000 BTU/h
15' Length
1" Pipe size
Dryer
35,000 BTU/h
10' Length
1/2" Pipe size
15' Length
1/2" Pipe size
C
Range 65,000 BTU/h
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Measuring inlet gas pressure
1. Turn off all electric power to the micro boiler if service is to be performed.
2. Turn the manual gas valve located on the outside of the unit clockwise to the off position.
WARNING
The micro boiler cannot perform properly without suffi cient inlet gas pressures. Below are instructions on how to check the inlet gas pressure.
1. Shut off the manual gas valve on the gas supply line.
2. Remove the screw for the pressure port located on the gas inlet of the micro boiler shown in the diagram on the right.
3. Connect the manometer to the pressure port.
4. Re-open the manual gas valve. Check to see that there are no gas leaks.
5. Check in inlet gas pressure. When the micro boiler is on maximum and minimum burn, the manometer should read from 5.0” W.C. to 10.5” W.C. (1.24 to 2.61 kPa) for Natural Gas, from 8.0” to 14.0” W.C. (1.99 to 3.48 kPa) for Propane.
3. Failure to follow these steps could lead to a fi re or explosion, resulting in personal injury or death.
THIS IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL.
Pressure port
WATER CONNECTIONS
Do not use the micro boiler if any part has been under water. Immediately contact a qualifi ed installer or licensed professional to inspect the boiler to
WARNING
NOTICE
determine if it needs to be replaced. Do not reverse the hot outlet and cold inlet connections to the micro boiler.
This will not properly activate the micro boiler.
All pipes, pipe fi ttings, valves and other components, including soldering materials, must be suitable for potable water systems (when using DHW Integrator Panel), or distilled water or distilled water/gly­col mix.
1. A manual shutoff valve must be installed on the cold water inlet to the micro boiler between the main water supply line and the micro boiler.
2. In addition, a manual shutoff valve is also recommended on the hot water outlet of the unit. If the micro boiler is installed within, or subjected to, a closed loop system (recommended), a thermal expansion tank or code approved device to handle the thermal expansion must be installed.
3. Before installing the micro boiler, fl ush the water line to remove all debris, and after in­stallation is complete, purge the air from the line. Failure to do so may cause damage to the boiler.
As Close as
Possible
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Hot outlet
Cold inlet
Gas inlet
Pressure relief valve
Pressure relief valve
The micro boiler has a high-temperature shutoff switch built in as a standard safety feature (called a Hi-Limit switch) therefore a “pressure only” relief valve is required.
This unit does not come with an approved pressure relief valve.
An approved pressure relief valve must be installed on the hot water outlet.
The pressure relieve vale must conform to ANSI Z21.22 or Can 1-4.4 and installation must follow local codes.
The discharge capacity must be at least 199,000 BTU/h.
The pressure relief valve needs to be rated for a maximum of 150 psi (1 MPa).
The discharge piping for the pressure relief valve must be directed so that the hot water cannot splash on anyone or on nearby equipment.
Attach the discharge tube to the pressure relief valve and run the end of the tube to within 6 in.(152 mm) from the fl oor. This discharge tube must allow free and complete drainage without any restrictions.
If the pressure relive valve installed on the micro boiler discharges periodically, this may be due to a defective thermal expansion tank or defective pressure relief valve.
The pressure relief valve must be manually operated periodically to check for correct operation.
No valve must be placed between the relief valve and the micro boiler.
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, th manufacture 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 installa
Condensate drain port
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Condensate Drain Connections
Discharge condensate (acidic water) in accordance with all local codes
WARNING
The micro boiler is a high effi ciency condensing micro boiler 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 Adaptor 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 Adaptor. The manufacturer recommends the material of the condensate tube 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 a 1/2” FPT X 3/8” (or 1/2”) HB Adaptor to the condensate drain port at the bottom of the micro boiler.
2. Connect the Neutralizer to the 3/8” MPT connection of the adapters. 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.
and common safety practices.
Case A
1/2" FPT x 3/8" (or 1/2") HB
3/8" or 1/2" Condensate drain tube
Drain
Condensate drain port
Adequate space
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)
Drain
Condensate drain port
1/2" Condensate drain tube
Adequate space
26 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
WARNING
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.
WARNING
ELECTRICAL CONNECTIONS
Follow the electrical code requirements of the local authority having jurisdic­tion. In the absence of such requirements, follow the current edition of the Na­tional Electrical Code ANSI/NFPA 70 in the U.S. or the current edition of CSA C22.1 Canadian Electrical Code Part 1 in Canada.
When servicing or replacing parts with the micro boiler, label all wires prior to disconnection to facilitate an easy and error-free reconnection. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
Failure to observe these warnings could result in personal injury or loss of life.
This unit comes with a power plug instead of a junction box.
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APPLICATIONS
Space Heating Applications
In order to purge air in water pipes within a closed loop system, an air vent, air separator, and expansion tank should be installed in the system. (Hydro-
Shark pre-built space heating panels incorporate all of these features).
WARNING
HydroShark per-plumbed panels help make space heating easy and reliable. These panels are pro­fessionally engineered and use proven Primary/Secondary hydronic practices. Call Tech Support (800.805.5384) for assistance.
Water temperature over 125° F (52° C) can cause sever burns instantly of death from scalding.
Chemicals such as diluted Glycol can be used for radiant fl oor, Hydro/fan coil air or Baseboard heating only. The diluted solution of glycol must contain between 25% and 55% of Glycol. Be aware that in a closed loop system, low pressure in the heat exchanger can cause low-temperature boiling, resulting in excessive noise and damage to the micro boiler. Consult with the glycol maker for specifi cations prior to use.
HydroShark Pre-Built Space Heating Panels
Sample:
1 Zone Panel:
28 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
Dual-purpose hot water heating
(Domestic and Space Heating)
Insert a HydroShark DHW Integrator Panel to provide potable heated water and Hydronic Heating (with space heating panel(s)) with one heat source.
The HydroShark DHW Integrator Panel integrates with a wide variety of boilers and delivers “Priority” potable heated water with no storage tank and hydronic space heating in a small reliable package.
NOTICE
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.
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INITIAL OPERATION
Check the Gas and Water Connections for leaks before fi ring the unit for the fi rst time.
Open the main gas supply valve to the unit using only your had to avoid and spark. Never use tools. If the knob will not sure by had, do not try to force it; call a qualifi ed service technician. Forced repair may result in a fi re or explosion due to gas leaks.
Be sure to check for the presence of leaking gas toward the bottom of the unit because some gas­es are heavier than air and may settle towards the fl oor.
Check the Gas Pressure.
Do not try to light the burner manually. It is equipped with an electric ignition device which auto­matically lights the burner.
Check for proper venting and combustible air to the micro boiler.
Purge the gas and water lines to remove any air pockets.
Do not use this micro boiler if any part has been under water. Immediately call a qualifi ed installer or service technician to inspect the micro boiler to determine if it needs replacement.
IF YOU SMELL GAS:
Do not try to start the micro boiler.
Do no touch any electric switches; do not use any phone in your building.
Immediately call your gas supplier from a neighbor’s phone. Follow the gas
WARNING
supplier’s instructions.
If you cannot reach your gas supplier, call the fi re department.
Opera
Once the above checks have been completed, please clean
1.
Įůter of any debris.
Fully open the manual ǁater control valve on the ǁater
2.
supply line.
Turn on the thermostat and verify thĂƚŇƵŝĚŇŽǁƐ through your radiant system. Then tuƌŶŽīLJŽƵƌ
3.
thermostat.
Fully open the manual gas control valve installed.
4.
urn on the 120 VAC, 60 Hz poǁer supply to the ǁater
T
5.
heater.
EŽǁƚƵƌŶŽŶƚŚĞƚŚĞƌŵŽƐƚĂƚzŽƵĂƌĞƌĞĂĚLJƚŽĞŶũŽy hours
6.
of endless comfort.
30 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
Owner’s Guide
CONGRATULATIONS
Congratulations and thank you for choosing our condensing micro
boiler. Before use, we recommend that you read through this owner’s
guide carefully. Keep this manual for future reference.
If you need an additional manual, contact the manufacturer or your
local distributor. When you call, please tell us the product name and
the serial number of your unit written on the rating plate of the boiler.
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OPERATING SAFETY
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a re or explosion may result
causing property damage, personal injury or loss of life.
1. The micro boiler does not have a pilot. It is equipped with an ignition device that automatically lights the burner. Do NOT try to light the burner by hand.
2. Before operating smell all around the micro boiler area for evidence of leaking gas. Be sure to smell next to the fl oor because some gas is heavier than air and will settle on the fl oor .
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone.
• Follow the gas suppliers instructions. If gas supplier cannot be reached, call fi re dept.
3. Use only your hand to turn the gas shutoff valve. Never use tools. If the valve will not turn by hand, don’t try to repair it, call a qualifi ed service technician. Force or attempted repair may result in a re or explosion.
4. Do not use this micro boiler if any part has been under water. Immediately call a qualifi ed service technician to inspect the micro boiler and to replace the unit if needed.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above or in the Owner’s Manual.
2. Turn off all electric power to the micro boiler.
3. Do not attempt to light the burner by hand.
4. Turn the manual as valve located on the outside of the unit clockwise to the OFF position.
5. Wait fi ve (5) minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas, go to next step.
6. Turn the manual gas valve located on the outside of the unit counterclockwise to the ON position.
7. Turn on all electrical power to the micro boiler.
8. If the micro boiler will not operate, follow the instructions “To turn off Gas to appliance” and call your service technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Turn off all electric power to the micro boiler if service is to be performed.
2. Turn the manual gas valve located on the outside of the unit clockwise to the OFF position.
32 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
DANGER
Vapors from fl ammable liquids will explode and catch fi re causing death or sever burns.
Do not use or store fl ammable products such as gasoline, solvents or adhesives in the same room or area near the micro boiler.
Flammable Vapors
Read and follow micro boiler warnings and instructions. if the owner’s manual is miss­ing, contact the manufacturer.
Keep fl ammable products: V apors:
1. Far away from boiler.
2. In approved containers.
3. Tightly closed and out of reach of children.
4. Micro boiler has a main burner, which may come on at any time and will ignite fl am-
1. Cannot be seen.
2. Are heavier than air.
3. Go a long way on the fl oor.
4. Can be carried form other rooms to the main burner by air currents.
mable vapors.
DANGER
When using micro boiler with DHW Integrator Panel for Domestic Hot Water:
1. Water temperature over 125° F can cause severe burns instantly or death from scalds.
2. Children, disabled and elderly are at highest risk of being scalded
3. Feel water before bathing or showering.
4. Temperate limiting valves are available on the DHW Integrator Panel(s). Adjust these mixing valves accordingly.
5. The outlet temperature of the micro boiler is set at 120° F (50° C). If you require water tempera­tures below this setting, follow the instruction manual.
6. Test the boiler before bathing or showering. Do not leave children or an infrim person unsuper­vised.
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NORMAL OPERATION
TEMPERATURE CONTROLLER AND REMOVE CONTROLLER
The illustration below shows an example of the controllers. The exact display may differ from examples.
Built-in controller
Temperature Controller
Display for Temperature
When the STAND BY LED is ON, the hot water temperature will be displayed.
"HOT" BuƩon "COLD" ƵƩŽŶ
Press the "HOT" buƩon or the "COLD" buƩon to set the hot water temperature.
• When the remote controller is installed it will take priority over the built-in controller.
NOTICE
• dŚĞĐŽŶƚƌŽůůĞƌŚĂƐĂŶĞŶĞƌŐLJƐĂǀŝŶŐŵŽĚĞ&ŝǀĞŵŝŶƵƚĞƐĂŌĞƌƚŚĞǁĂƚĞƌŚĞĂƚĞƌƐƚŽƉƐ ŽƉĞƌĂƟŶŐƚŚĞďĂĐŬůŝŐht of the controller turns oī.
• The backlight of the remote will turn back on once the water heater begŝŶƐĮring again.
"INFO" ƵƩŽŶ
Each ƟŵĞ the buƩon is pressed, the operaƟŽŶ mode is selected in the sequence of the following.
Inlet water temperature
Outlet water temperature
Water Ňow
IN USE LED (Green)
The indicator lights during combusƟŽŶ
STAND BY LED (Orange)
The indicator is ON to show that power is ON.
"ON/OFF" ƵƩŽŶ
Press this buƩon to start or stop operaƟŽŶ
Remote controller
NOTICE
GENERAL
Flow rate to active micro boiler: 0.5 gallon per minute at the default set temperature
Flow rate to keep the micro boiler running: 0.4 gallon per minute.
The controllers have an energy saving mode. Five minutes after the micro boiler stops operating, the back-light of the controllers turn off.
The back-light of the controllers will turn back on once the micro boiler be­gins fi ring again.
34 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
TEMPERATURE SETTINGS
Set Temperature
OperaƟŽŶ
Turn on the 120 VAC power supply to the unit.
1.
Press the "ON/OFF" buƩon on the controller in order to
2.
turn the controller on.
When ON, the STAND BY LED is lit.
3.
It showsthe set temperature on its display as shown in
4.
the picture on the right. (EX.: 120 °F)
Press the "HOT" buƩon or the "COLD" buƩon to set the temperature seƫŶŐ of the unit.
creĂƐŝŶg temperature frŽm 120 °F (50 °C) tŽ 125 °F (52 °C) :
1. The micro boiler must be in Stand By to increase the temperature.
2. Press the "HOT" buƩon to set 120 °F (50 °C).
3. Press and hold the "INFO" buƩon and the "HOT"
buƩon for at least 3 seconds. The remote will emit a beep and change to 125 °F (52 °C).
4. Press the "HOT" buƩon to set up to 140 °F (60 °C).
5.
ScrĞĞŶ ŽŶ the cŽŶtrŽůůĞƌ
ƵŝůtͲŝŶ cŽŶtrŽůůĞƌ
RĞŵŽte cŽŶtrŽůůĞƌ
(EX.: 120 °F)
/ŶĐrĞĂƐŝŶŐ temperature abŽve 140 °F (60 °C)
1. The micro boiler must be in Stand By to increase the temperature.
2. Press the "HOT" buƩon to set 140 °F (60 °C).
3. Press and hold the "INFO" buƩon and the "HOT" buƩon for at least 3 seconds. The remote will emit a beep and change to 145 °F (63 °C).
4. Press the "HOT" buƩon to set up to 160 °F (70 °C).
TEMPERATURE TABLE OF CONTROLLER
°F 100 105 110 115 120* 125 130 135 140 145 150
°C
38 40 43 45 50* 52 55 57 60 63 65 68 70
*Factory seƫŶŐ (Default): 120 °F
155 160
165 175
75 80
185
85
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ADDITIONAL FEATURES
Information mode
You can get some information about the micro boiler condition by pressing “Info” button. For more information, follow the procedures below:
Screen on the controller
Opera
Temperature controller Remote controller
First of all, inlet water temperature will be displayed
1.
on the controller by pressing the "INFO" bu on.
Outlet water temperature will be displayed on the
2.
controller by pressing the "INFO" bu
And then, water ŇŽǁ will be displayed on the
3.
controller by pressing the "INFO" bu
Press the "INFO" bu on to ĮŶŝƐŚ informa mode.
4.
on.
on.
Inlet water temperature
(EX.: 60 °F)
Outlet water temperature
(EX.: 120 °F)
Water Ňow
(EX.: 3.5 GPM)
Unit Conversion Mode
The remote controller has a function that can change units of temperature and fl ow rate from °F to °C and from gallon per minute to liter per minute and vice versa, please follow the procedure below.
ScrĞĞŶ ŽŶ the cŽŶtrŽůůĞƌ
OperaƟŽŶ
Press the "ON/OFF" buƩon on the controller in
1.
order to turn the controller on.
ƵŝůtͲŝŶ cŽŶtrŽůůĞƌ
RĞŵŽte cŽŶtrŽůůĞƌ
When ON, the orange LED is lit.
2.
The previous set temperature will be displayed on
3.
the screen.
Press the "INFO" buƩons for at least 3 seconds.
4.
The set temperature should now be displayed in the
5.
alternate unit of measurement.
When the micro boiler is connected with the remote controller, the temperature controller will not operate temperate settings, as only work for the information mode.
36 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
(EX.: 100 °F)
(EX.: 38 °C)
TEMPERATURE SETTINGS ON THE PCB
(WITHOUT REMOTE CONTROLLER)
There are 2 preset DIPswitches (120° F (50° C) and 140° F (60° C)) that you can select from by changing the DIPswitch settings on the computer board without the remote controller. See the table below. When the remote controller is in normal operation, the set temperature of the remote controller is given priority over th set temperature of the DIPswitch settings.
The temperature has been preset at the factory to 120° F (50° C).
WARNING
(Lower bank of DIPswitches)
120 °F (49 °C)
DEFAULT
123456
ON
OFF
No. 5 : OFF No. 5 : ON
140 °F (60 °C)
12233445566
ON
OFF
Upper bank of DIPswitches
Lower bank of DIPswitches
Computer board
NOTE: Only change the switches with dark squares. The dark squares indicate the direction the DIPswitches should be set to.
• DO NOT adjust the upper bank of DIPswitches
Turn off the power supply to the micro boiler before changing the DIPswitch settings.
WWW.HYDRO-SHARK.COM HYDROSHARK 199 | 37
FLOW
• The fl ow rate through the micro boiler is limited to a maximum of 10.0 GPM (38 L/min).
The temperature setting, along with the supply temperature of the water will determine the fl ow rate output of the unit.
FREEZE PROTECTION SYSTEM
This unit comes equipped with heating blocks to protect it against damages associated with freez­ing.
For this freeze protection system to operate, there has to be electrical power to the unit. Damage to the heat exchanger caused by freezing temperates due to a power loss is not covered under warranty. In cases where power losses can occur, consider the use of a backup power supply.
The freeze protection system will activate when the surrounding and/or outside temperature drop.
It is the installer’s responsibility to be aware of freezing issues and take all preventive measures. The manufacture will not be responsible for any damage to the heat exchanger as a result of freezing.
In any area subject to freezing temperatures, freezing issues can occur if cold air enters through the venting into the heat exchanger by either negative pressures within the installation location or by strong outside wind. The manufacturer highly recommends the use of a back fl ow preventer (sold separately) to minimize the amount of cold air entering through the exhaust venting when the micro boiler is off.
It is the installer’s responsibility to be aware of freezing issues and take all preventive measures. The manufacture will not be responsible for any damage to the heat exchanger as a result of freezing.
If you will not be using your boiler for a long period of time:
1. Completely drain the water out of the unit.
2. Disconnect power to your boiler.
This will keep your unit from freezing and being damaged.
Only pipes within the micro boiler are protected by the freeze protection system. Any water pipes (hot or cold) located outside the unit will no be protected. Properly
CAUTION
38 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
protect and insulate these pipes from freezing.
MAINTENANCE AND SERVICE
Turn off the electrical power supply and close the manual gas shutoff valve and the manual water control valve before servicing.
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 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 lo- cated at the middle of the micro boiler.
Flame blowing up
Red or Yellow
The manufacturer recommends having the unit checked once a year or as necessary by a licensed technician. If repairs are needed, any repairs should be done by a licensed technician.
UNIT DRAINING
1. Close the manual gas shutoff valve.
2. Turn off power to the unit and wait a couple of seconds.
Turn on again.
3. Wait 30 seconds, and then turn off power to the unit, yet again.
4. Close the water shut off valve.
5. Have a bucket or pan to catch the water from the unit’s drain plugs. Unscrew the two drain plugs (large and small) to drain all the water out of the unit.
6. Wait a few minutes to ensure all water has completely drained from the unit.
Drain plug (Small)
Drain plug (Large)
Gas valve
Water valve
WWW.HYDRO-SHARK.COM HYDROSHARK 199 | 39
TROUBLESHOOTING
PROBLEM SOLUTIONS
General
The water is not hot enough.
The water is too hot. • Is the set temperature set too high? The hot water is not
available when there is a call for heat.
The hot water turns cold and stays cold.
Fluctua water temperature.
TEMPERATURE and AMOUNT OF HOT WATER
in hot
•Compare the Ňow and temperature.
• Check cross plumbing between cold water lines and hot water lines.
• Is the gas supply valve fully open?
• Is the gas line sized properly?
• Is the gas supply pressure suĸĐŝĞnt?
• Is the set temperature set too low?
• Make sure the unit has 120 VAC, 60 Hz power supply.
• If you are using the remote controller and/or temperature controller, is the power bu
• Is the gas supply valve fully open?
• Is the water supply valve fully open?
• Is the unit frozen?
• Is ther e enough gas in the t ank / cy linde r? (For Propane models)
• Is the Ňow rate enough to keep the micro-boiler running?
• Is the gas supply valve fully open?
•Are the Įxtures clean of debris and obs
•Check if the Ňow rate is too low.
• Is the gas line sized properly?
• Is the supply gas pressure suĸĐŝĞnt?
•Check for cross c
on turned on?
between cold water lines and hot water lines.
40 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
Troubleshooting (Cont’d)
PROBLEM SOLUTIONS
Unit does not ignite when water goes through the unit.
The fan motor is sƟůů spinning aŌer operaƟŽŶ has stopped.
WATER HEATER
Unit sounds abnor-
ŵĂů ǁŚŝůĞ in opera- ƟŽŶ
ContrŽůůĞƌ does not ĚŝƐƉůay anything
when the power buƩon is
turned on.
•Is the Ňow rate over 0.5 GPM (1.9 L/min)?
• Check for the Įůter on the cŽůĚ water ŝŶůet.
• Check for reverse cŽŶŶĞĐƟŽŶ and cross cŽŶŶĞĐƟŽŶ
• If you use the remote contrŽůůĞƌ and/or temperature contrŽůůĞr, is the power buƩon turned on?
•Check if the ŝŶůet temperature is too high. If it is too ĐůŽƐĞ to the set temperature, the water heater ǁŝůů not ĂĐƟvate.
•This is ŶŽƌŵĂů AŌer operaƟŽŶ has stopped, the fan motor keeps running from 15 to 70 seconds in order to re-ignite ƋƵŝĐŬůy, as wĞůů as purge Ăůů the exhaust gas out of the ŇƵĞ
• Contact the manufacturer at 1-763-331-3066
• Make sure the unit is ƐƵƉƉůŝĞĚ with power.
• Make sure the cŽŶŶĞĐƟŽŶ to the unit is correct. NOTICE: When the unit has not operated for Įve minutes or more, the ĚŝƐƉůay of the contrŽůůers turns oī to conserve energy.
Ƶŝůt-in contrŽůůĞƌ
When the contrŽůůĞƌƚƵƌŶĞĚ ON, STAND BY LED
ŝƐůŝƚ
REMOTE CONTROLLER
An ERROR code is ĚŝƐƉůayed.
BUILT-IN CONTROLLER AND
ůƚŚŽƵŐŚ the contrŽůůĞƌ of the parent unit ǁŝůů temperature at the Easy-Link System, the contrŽůůĞƌ of the ĐŚŝůĚ unit ǁŝůů not ĚŝƐƉůay the set temperature.
WůĞĂƐĞ see ƌƌŽƌŽĚĞ^ĞĐƟŽŶ
ĚŝƐƉůay the set
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ERROR CODES
The units are self-diagnostic for safety and convenience when troubleshooting.
If there is a problem with the installation or the unit, the error code will be displayed on the tem­perature controller and remote controller.
Consult with the table on the following pages for the description of each error code.
Error code indicator on the temperature controller
Error code indicator on the remote controller
Green LED
Single unit installations
Example: if your unit has the “321” error code (which signifi es an inlet thermistor failure)
Indicator on the temperature controller or remote controller: “321” will be displayed on the screen in its entirety.
Green LED on the computer board: The green LED on the computer board will be
blinking two times.
42 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
Fault Analysis of Error Codes
If the error code is displayed on the computer board of the micro boiler or remote controller and/or temperature controller, please check the following. After checking, Consult with the manufacturer.
Remote
031
101
111
121
Green
LED
One Time Incorrect DIPswitch
Five Times
Three Times failure
Three Times Loss of ŇĂŵĞ
descrip
se Warning for the
“991” error code
Diagnosis
• Check the DIPswitch se on the PCB (Part #701).
• Check the gas type of the micro-boiler.
• Check if there is any blockage in the intake air and/ or exhaust.
• If the micro-boiler is installed as a direct-vent system, check whether there is enough distance between the intake air terminal and the exhaust terminal.
•Check the micro-boiler is installed.
• Check if there is grease and/or dirt in the burner (Part #101) and the fan motor (Part #103), especially if the micro-boiler has been installed in a contaminated area.
• Check if the Hi-limit switch (Part #412) is properly
•Check for connec reakage of wires (Part #413, 708, 709, 710, 712), burn marks on the computer board (Part #701), and/or soot on the Ňame rod (Part #108).
• Check if there is a buzzing spark coming from the burner (Part #101) when micro-boiler prepares for combus
• Listen for the double “clunk” sound coming from gas valve assembly (Part #102) when micro-boiler goes into combus
• Check if there is leaking from heat exchanger (Part #401).
• Check if the Hi-limit switch (Part #412) is properly
/eleva of area of where the
sound
311
321
331
341
WWW.HYDRO-SHARK.COM HYDROSHARK 199 | 43
Two Times Heat exchanger
thermistor failure
Two Times
Two Times
Two Times
Inlet thermistor failure Outlet thermistor failure Exhaust thermistor
failure
•Check for c reakage of wires (Part #413, 708, 709, 710, 712), burn marks on the computer board (Part #701), and/or soot on the ŇĂŵĞ rod (Part #108).
• Check if there is leaking from heat exchanger (Part #401).
• Check for connec reakage of wires and/or debris on thermistor (Part #407, 408, 411, 715).
Remote
391
441
510
551
611
651
661
701 711
Green
LED
Two Times Air-fuel ra rod
Two Times
Six Times Abnormal main gas
Six Times Abnormal gas
Four Times Fan motor fault
Four Times Flow adjustment
Four Times Bypass valve fault
One Time One Time
descrip
failure Flow sensor failure
(Easy-Link System only)
solenoid valve
solenoid valve
valve fault (Easy­Link System only)
Computer board fault Gas solenoid valve
drive circuit failure
Diagnosis
•Check for c reakage of wires (Part #709)
and/or soot on the AFR rod (Part #108).
•Check for c reakage of wires and/or
debris on the Ňow sensor impeller (Part #402).
• Check for connec reakage of wires (Part #708)
and/or burn marks on the computer board (Part #701).
• Check for connec reakage of wires (Part #708)
and/or burn marks on the computer board (Part #701).
•Check for c reakage 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).
• Inspect the Ňow adjustment valve (Part #402), for
c reakage of wires, locked motor drive due to scale buildup, and/or water leakage.
• Inspect the bypass valve (Part #403), for c
breakage of wires, locked motor drive due to scale buildup, and/or water leakage.
•Check for c reakage of wires (Part #714).
• Refer to the 111 and 121 error codes.
721
741
751
761
941
991
Six Times
N/A Miscommunica
N/A
N/A Miscommunica
Five Times Abnormal exhaust
Five Times Imperfect
False Ňame det
between micro­boiler and remote controller
Miscommunica between micro-boiler and temperature controller
in Easy-Link System
temperature
combus
• Check if condensate drain is installed on the vent
collar of the micro-boiler.
• Check if there is leaking from heat exchanger (Part #401).
• Check the model type of the remote controller.
• Inspect the c between the micro-boiler
and remote controller.
• Check the power supply of the micro-boiler.
• Inspect the c between the micro-boiler
and temperature controller.
• Check the power supply of the micro-boiler.
• Check if the c
and the child units are correct.
• Check if the set temperature is higher than 140°F
(60°C) and the system is Recircula
• Check the gas type of the micro-boiler.
• Inspect the environment around the micro-boiler.
Determine how long the unit has been installed.
•Check the
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.
between the parent unit
eleva of the area of where
44 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
COMPONENTS DIAGRAM
Case assembly
052
003
007
052
713
052
004
004
002
050
050
Temperature
remote controller
717
724
052
008
001
702
704
Temperature controller
723
056
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722
Computer board assembly
701
709
711
708
714
403
715
721
716
707
713
103
402
402
715
722
46 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
Surge box assembly
703
703
706
053
121
709
713
063
Burner assembly
Burner assembly
709
110
062
Manifold assembly
108
053
107
109
053
102
106
111
711
114
115
104
112
053
101
113
401
116
053
117
103
105
065
708
121
711
055
707
062
WWW.HYDRO-SHARK.COM HYDROSHARK 199 | 47
063
150
057
719
117
714
055
054
119
151
118
051
Water Way assembly
418
451
458
415
467
462
458
458
412
058
462
064
E
462
F
473
458
468
468
064
458
473
453
451
B
413
452
472
418
471
718
E
F
401
470
053
415
459
454
153
152
540 ŵŽĚĞů
411
A
451
414
403
456
460
462
B
Bypass ƐĞĐƟŽŶ
D
466
240 ĂŶĚ 340 ŵŽĚĞůƐ
466
458
A
D
414
458
462
409
052
463
052
C
465
C
455
469
455
464
454
455
463
408
410
417
416
009
052
456
D
460
458
052
406
457
405
414
450
402
461
404
417
059
454
407
48 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
PARTS LIST
Item # Descrip
001
002 Front cover 003
004 005 006 007
008 009 050 051 052 053 054 055 056 057
058 059 060 061
062 063 064 065
101 102
103 EK109
Case assembly
Intak e Ăŝƌ port assembly Bracket
bodž Power supply cord assembly Back ŐƵĂrd panel
Chamber ĮdžŝŶŐ plate Condensate drĂŝŶ port Screw M4×12 (W/Washer) Screw M4×10 (W/Washer) Screw M4×10 (Coated) Screw DϰdžϭϬ Hedž head screw M4×12 (W/Washer) Hedž head screw Dϰdžϴ Pan screw DϰdžϮϬ Tap ht screw DϰdžϭϮ FEZN
Screw Dϯdžϲ Screw Dϰdžϲ Screw DϰdžϭϮ Screw Dϯdžϲ
Pan screw Dϰdžϴ re clamp 60 Screw DϰdžϭϬ Screw Dϯdžϲ SUS3
Burner assembly
DĂŶŝfold ǁŝƚŚ Őas valve assembly LP DĂŶŝfold ǁŝƚŚ Őas valve assembly NA
Fan motor
Part #
EK159
EK158 EK170 EK162 EK190 EK171 EK161
EK160
EKH23 EW000 EW001 EW002 EW003
EW004 EW005 EW018
EKK31
EW00A EW009
EKK37 EK191
EW00D
EM167
EK230
EW00B
EK192 EK181 EK182
104 105 106 107
108 109 110 111
112
113 114 115
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Burner Őasket Fan damper Burner ǁŝŶĚow Rod holder Őasket
Flame rod /ŐŶŝter rod Rod holder Rod cap
Burner damper LP Burner damper NA
DĂŶŝ fold Őasket A DĂŶŝfold Őasket B
Burner holder Őasket
EKK2X
EM381
EKK2V
EKK2W
EK193 EKK0F EKK32
EKN61
EK183 EK169 EKK2Y EKK2K
EKK0G
Item # Descrip
Part #
116 117 118 119 121
150 151
401
402 403 404 405
407 EK137 408
409 410 411
412 EKN34
413 414 415 EK210
416 417
418
450 451 452 453
454 455 456 457
458 459 460 461
Pressure port Combus chamber tube Gas inlet Gas inlet ring Surge box plate
O-ring P18 NBR (Black) O-ring P20 NBR (Black)
Primary heat exchanger
Flow adjustment valve / Flow sensor Bypass valve Water inlet Inlet drain plug
Inlet thermistor Outlet thermistor
Water outlet Outlet drain plug Heat exchanger thermistor
Hi-Limit switch
Overheat-cut-oī fuse Pipe heater Inlet heater
Drain tube EK231 Inlet heater
Secondary heat exchanger
Pipe heater ĮdžŝŶg plate Heater ĮdžŝŶŐ plate 16 Fuse ĮdžŝŶŐ plate 18 Fuse ĮdžŝŶŐ plate 14
O-ring P4 FKM O-ring P6 FKM O-ring P14 FKM O-ring P15 FKM
O-ring P16 FKM Fastener “4-11” Fastener “14-22” Fastener “16A”
EKK2D EX019 EK117 EX00D EK163
EZP18
EK042
EK250
EK129 EKD58 EKK1U EKK2B
EKK1A
EK208
EKK2E EKK2T
EK333 EK209
EK105 EK251
EKK27 EK031 EKK26 EK029
EZM04 EZM06 EZM14 EZM15
EZM16
EKH30 EKK24
EM192
50 | HYDROSHARK 199 WWW.HYDRO-SHARK.COM
Item # Descrip
Part #
462 463 464 465
466 EK220Cold pipe 467
468 469 470
471 472 473
701 EK176 702
703 704
706 707 708
709 711
713
714 715 716 717
718 719 721 722 723
724 ER014Temperature remote controller
Fastener “16-25A” Fastener “6-15” Flat heater Drain tube
Stainless heat exchanger out pipe Header c Drain port Thermistor ĮdžŝŶŐ plate
Exhaust thermistor gasket Hi-limit switch for exhaust Gasket
Computer board Rubber grommet
Surge box 120 VAC wire
120 VAC Power ON-OFF switch Remote controller wire Gas valve wire
Flame rod wire Igniter assembly
Switch wire with thermostat Pr gas valve wire
24V cables Computer board cover Cable clamp
Exhaust Remote ĮdžŝŶŐ plate Exhau st Hi-limit switch wire Temperature controller Fixing plate
thermistor
EKK39 EX12K EK217 EK218
EK222 EK226 EK228
EK13H
EK13L
EKH6G
EK229
EX00B EK280 EK146
EKK4V EK165 EK168
EK166 EK153
EK184
EM167
EK179
EKK1M
EX13C
EKH6E
EK152 EK180 EK173 EK178
Output Temperature vs. GPM (Max. 10.0 GPM) with Various Inlet Water Temperature
Output Hot Water GPM
*When the set temperature is 130 °F (55 °C) or higher, maximum Ňow rate is limited to 8.0 GPM.
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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
4<AMHCMO=bgibea>
Subject to errors and technical changes! | Sous réserve d‘erreurs et de modifi cations techniques!
Subject to errors and technical changes!
331127-40419-9328
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